Numerical study on predicting and correcting assembly deformation of a large fuselage panel during digital assembly

Purpose – The deformation of a large fuselage panel is unavoidable due to its weak-stiffness and low-rigidity. Sometimes, the assembly accuracy of the panel is out of tolerance. The purpose of this paper is to propose a method to predict and correct the assembly deformation of a large fuselage panel during digital assembly by using a finite element (FE) analysis and partial least squares regression (PLSR) method. Design/methodology/approach – A FE model is proposed to optimize the layout of load-transmitting devices to reduce panel deformation after the process of hoisting and supporting. Furthermore, another FE model is established to investigate the deformation behavior of the panel. By orthogonal simulations, the position error data of measurement points representing the precision of the panel are obtained. Then, a mathematical model of the relationship between the position errors of measurement points on the panel and the displacements of numerical control positioners is developed based on the PLSR method. Findings – The case study shows that the model has a high level of computing accuracy and that the proposed method is an efficient way to correct the panel deformation in digital assembly. Originality/value – The results of this study will enhance the understanding of the deformation behavior of a panel in aircraft digital assembly and help to improve the assembly precision systematically and efficiently.