Abstract: Due to the weak rigidity and large manufacturing deviations of thin-walled composite structural components, geometric deviations, excessive internal stresses, and assembly damage are prone to occur during assembly. The current assembly modes mostly consider the satisfaction of geometric accuracy, and pay less attention to the distribution of internal stresses and damages between components. The highly uncertain assembly stresses and damages packaged into service will affect structural stability directly. Firstly, the types and characteristics of assembly geometry deviations, the generation of internal stresses in assembly, and the formation mechanism of assembly damage were analyzed. Then a correlation model between assembly geometry physics service assembly performance was proposed, and it demonstrated the bidirectional relationship between assembly geometry and physical performance on service performance. Secondly, the dynamic changes of initial assembly geometry deviation, internal stress, and damage state during service, as well as their impact on mechanical properties such as aircraft structural strength and fatigue life were analyzed, and basic theoretical guidance for the correlation analysis between assembly process and service performance indicators would be provided. Finally, key technologies such as assembly geometry and physical performance modeling, assembly service performance prediction, virtual simulation testing of assembly performance and service performance, and reverse engineering of assembly process parameters for service performance assurance were analyzed. And how to construct an assembly process model transformation for service performance assurance was discussed.

Key words: Aircraft assembly, geometric deviation, assembly stress, structural damage, service performance