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Solid rocket motors (SRMs) are widely used as propulsion devices in the aerospace industry. The SRM nozzle and combustion chamber are connected with a plugged-in structure, which makes it difficult to use the existing technology to investigate the internal conditions of the SRM during docking and assembly. The unknown deformation of the O-ring inside the groove caused by different assembly conditions will prevent the engine assembly quality from being accurately predicted. Algorithms such as machine learning can be used to fit mechanical simulation data to create a model that can be used to make predictions during assembly. In this paper, the prediction method uses the sampled parameters as boundary conditions and applies the finite element method (FEM) to calculate the stresses and strains of the O-ring under different assembly conditions. The simulation data are fitted using the gradient-enhanced Kriging (GEK) model, which is more suitable for high-dimensional data than the ordinary Kriging model. A genetic algorithm (GA) and conditional tabular generative adversarial networks (CTGAN) are used to optimize the prediction model and improve its accuracy as new data are incorporated. The proposed method is not only accurate but also efficient, allowing for a significant reduction in assembly time. The use of the surrogate model and FEM makes it possible to predict the stresses and strains of the O-ring in real-time, making the assembly process smoother and more efficient. In conclusion, the proposed method provides a promising solution to the challenges associated with the assembly process of SRM in the aerospace industry.