Variation modeling is used in design to predict and
diagnose potential quality problems. Most variation modeling
assumes the parts are rigidly assembled. However, in some
cases, this assumption is invalid. For example, when hydraulic
tubes are assembled into aircraft structures, the compliance of
the tube facilitates assembly. If the tubes were rigid, they
cannot be assembled, i.e., the variations of the tubes and
structures are too great. Despite the importance of compliance
in assembly, it is typically not explicitly modeled during
design. This paper proposes a new method to directly predict
the assemblability of any tube design with minimal dependence
CAD/FEM modeling and simulation. The model includes a
variation model for the tubes and aircraft, compliance model
and assembly model. It can be used during design to improve
yields
