An assembly deviation calculation method based on surface deviation modeling for circumferential grinding plane

Performance of mechanical product is highly influenced by assembly deviation. Due to manufacturing errors, the real part surface is machined with morphology deviations, which would cause mating surface deviating from ideal position in assembly behavior, consequently leading to assembly deviation. Meanwhile, the random variation of relative position and orientation between two non-ideal parts also affects the assembly deviation. To efficiently obtain the maximum assembly deviation considering the comprehensive influence of two factors above for circumferential grinding plane, an assembly deviation calculation method based on surface deviation modeling is proposed in this paper. In this method, morphology deviations models of part surfaces are firstly established from the deviation function. The randomness of two factors are represented by a multivariate group with randomness containing deviation function coefficients and three deflected parameters. Then based on surface deviation modeling method, differential evolution algorithm is applied to search the maximum assembly deviation, which involves the construction of fitness function by implementing optimized progressive contact method and iterative operations of mutation, crossover and selection. Finally, the effectiveness of this method is illustrated by an assembly in the end.