Geometric Variations Management: New Challenges and Opportunities

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1 Geometric Variations Management: New Challenges and Opportunities Prof. Nabil Anwer LURPA, Paris-Sud Univ. & ENS Paris-Saclay ROBUST DESIGN DAY, RDD 17 Nov. 08th 2017, DTU, Denmark Laboratoire Universitaire de Recherche en Production Automatisée 61 avenue du Président Wilson Cachan Cedex - France -

2 Agenda Introduction Research on Tolerancing Challenges, Open, Future issues Conclusions and Outlook

3 Introduction 3

4 The Ubiquity of Geometric Variations SPECIFICATION Process Planning Manufacturing requirements Manufacturing specifications Geometrical specifications Deviations Variability Geometrical requirements Assembly process Functional requirements Inspection Process Planning Real part Uncertainty VERIFICATION

Geometric Variations Management Parts/Assemblies are specified with geometrical deviations, variability and uncertainties Functional Requirements are mapped

Uncertainty Axiom) There is an urgent need of Model that covers all the Product Lifecycle Representation and Computational Theories Integration with actual

5 Geometric Variations Management Parts/Assemblies are specified with geometrical deviations, variability and uncertainties Functional Requirements are mapped to admissible geometrical and dimensional deviations Part-to-part variability (Manufacturing Imprecision Axiom) Deviations/Variability assessment (Measurement Uncertainty Axiom) There is an urgent need of Model that covers all the Product Lifecycle Representation and Computational Theories Integration with actual CAX tools Standardization Benefits Improve product quality, Decrease the manufacturing cost, Reduce scrap in production (eco-aware), and product recalls (Toyota).

Geometrical Product Specification and Verification (GPS)

geometry specifications covering dimensional and

related verification principles, measuring equipment and

the ambiguity (description of the Function,

basic layout and explanation of drawing indications

6 Geometrical Product Specification and Verification (GPS) "Chain of standards" in the field of macro and micro geometry specifications covering dimensional and geometrical tolerancing, surface properties and the related verification principles, measuring equipment and calibration requirements Extended Uncertainty to describe the ambiguity (description of the Function, Specification) and Measurement Uncertainty Cover the basic layout and explanation of drawing indications (GD&T). Features and Operations Harmonize specification with verification of product tolerances. 6

7 Research on Tolerancing 7

Research on Tolerancing Tolerance analysis has been the most popular research topics in recent decades Geometric variations interaction and accumulation Mathematical

Transfer Tolerance Specification Tolerance Verification Keyword analysis of CIRP CAT proceedings (1989-2012)* * O. Rique Garaizar, N. Anwer, L. Mathieu, L.

8 Research on Tolerancing Tolerance analysis has been the most popular research topics in recent decades Geometric variations interaction and accumulation Mathematical representation of deviations and interfaces Spatial tolerance propagation Tolerance Representation Tolerance Analysis Tolerance Scheme ± GD&T Tolerance Synthesis Tolerance Transfer Tolerance Specification Tolerance Verification Keyword analysis of CIRP CAT proceedings ( )* * O. Rique Garaizar, N. Anwer, L. Mathieu, L. Qiao Exploring the proceedings of CAT CIRP Seminars and Conferences: A scientometric analysis (Keynote paper) 13th CIRP Conference on Computer Aided Tolerancing (CAT 2014), Hangzhou, China, May 11-14,

9 Evolution of Research Many methods and mathematical models Vectorial/Matrix models Substituted surfaces Models (no form errors) TTRS, SDT, Polytopes, Domains and Tolerance maps Shapes and their Statistics Few holistic approaches Vectorial Tolerancing TTRS/SDT Tolerance Maps Skin Model Shapes Various Research Efforts in Tolerance Analysis Conformance (ISO, ASME) Dimensionality (1D, 2D, 3D) Method (Worst case, Statistical) Kinematics/DOF (iso-constrained, over-constrained) Accumulation/Propagation (deviations, tolerances) Scale (Micro, Macro) Solution(Mathematical model, Computer Simulation) 9

10 Existing CAT Systems Integration with CAD (PMI/MBD/STEP) Semantic Tolerancing Advisor Visualization capabilities Retrofitted for CAD/Solid Modelling Rely on established tolerancing methods (90s) Conformance to ISO/ASME standards Consideration of form tolerances, datum precedence, No benchmark set for the evaluation/comparison of CAT systems Poor Tolerance Specification and Synthesis capabilities Proprietary systems 10

Tolerancing and the CIRP A permanent and important research issue in the long history of CIRP Interest to undertake

Assessment of form deviations In 1989, Prof.

700 authors* Important research achievements Tolerancing research Heat map (1989-2012)* G σ2 σ8' σ2 σ4' C σ7 σ4 σ7

plane ìrx U ü ï ï = íry U ý ï ï îu tzþ Nominal surface * O. Rique Garaizar, N. Anwer, L. Mathieu, L.

11 Tolerancing and the CIRP A permanent and important research issue in the long history of CIRP Interest to undertake cooperative projects on: Tolerancing for function Tolerancing for production Tolerance technologies for CAD/CAM Assessment of form deviations In 1989, Prof. Weill organized the first seminar on CAT Since then, every two years, the CIRP CAT held 14 times > 600 papers* / > 700 authors* Important research achievements Tolerancing research Heat map ( )* G σ2 σ8' σ2 σ4' C σ7 σ4 σ7 z E σ8' A H C x σ1 D F t p σ4 σ3 y B σ3 σ4' dy B σ1 q' s dx Associated surface Real surface Z tz ry Y Vi O rx X T plane ìrx U ü ï ï = íry U ý ï ï îu tzþ Nominal surface * O. Rique Garaizar, N. Anwer, L. Mathieu, L. Qiao Exploring the proceedings of CAT CIRP Seminars and Conferences: A scientometric analysis (Keynote paper) 13th CIRP Conference on Computer Aided Tolerancing (CAT 2014), Hangzhou, China, May 11-14,

12 An overview of Tolerancing in France (GRT*) > seminars 2 days 2 times a year 2 European seminars E-GRT (FAU Erlangen Nuremberg, Chalmers Univ., Poli Milano) 10 French laboratories About 50 researchers GRT: Groupe de Recherche en Tolérancement

13 Important contribution Small Displacement Torsor (SDT) (Bourdet, Clément) GAIA, ANATOLE (AIRBUS) Torsors as a model for small displacements of the associate surfaces of real parts 3D Simulation of an assembled product considering surfaces and links deviations tz Z O Associated surface ry rx Y X Nominal surface Hypothesis Vi Real surface T plane ìrx ï = íry ï îu The displacements of a rigid body or a surface, except for the degrees of freedom, are supposed small The rotations are small enough that can be linearized U ü ï U ý tzï þ Part 2 T + c1, c5 = -T1,c1 - TR,1 + TR,5 T5,c5 e Deviation torsor a b ìrx tx { } T cylinder Link Torsor T b1, b2 ï = íry ï îu g T 2, b2 ü ï ty ý U ï w þ

14 Important contribution Domains and Polytopes (Giordano, Duret, Teissandier) PolitoCAT/Politopix (GNU LGPL license) 3D Simulation of the feasibility and quality of an assembly using variations domains. Deviation Domain [D] The Deviation Domain represents the limits of a Deviation Torsor Joint Domain [J] The Joint Domain represents the limits of a Link Torsor h

15 General theory of dimensioning (TTRS) Important Contribution (Clément) ISO GPS, CATIA Æ Æ20 Nominal model Dimensional parameters

16 Important Contribution GEOSPELLING (Ballu, Mathieu) ISO GPS, CATIA d = AM n " M Î (S1) Max(d) t

geometry researches Holistic approach for integrating design, engineering, manufacturing and

17 Important Contribution Skin Model Shapes (Anwer, Schleich) Growing community (CN) New computational framework for tolerancing Ground on shape discretization and digital/computational geometry researches Holistic approach for integrating design, engineering, manufacturing and inspection from geometric variations and tolerancing perspective Coherent and complete tolerancing process based on GPS

18 Our contribution Industrie 4.0 Operationalization Concepts Skin Model (1993) Assembly Physical Modeling Skin Model Representation (2012) SMS for AM (2016) Skin Model Shapes (SMS) (2014) Actual Contour O P': r( q) q M å Dr( q) P: r0 ( q) SMS for DT (2017) Nominal Contour D r( q) = a + [ a cos( kq) + b sin ( kq)] -r ( q)+ eq 0 k k 0 k = 1 AM: Additive Manufacturing In-plane deviation + Out-of-plane deviation = Total geometric deviation DT: Digital Twin

19 Research on Tolerancing: Challenges and Opportunities 19

20 From Functional Requirements to ISO Specifications CAD Assembly 1- Set-Up 2 Chain/ Loop Manufacturing 4 Tolerance values + Geometry 3 Tolerance Synthesis (automatic) Consideration of other Geometric and non-geometric Functional Requirements

21 Complex Geometries // C C I 1 J J I K L 0.3 >< A[G] // C 0.2 // C L 1 K 0.12 >< A[G] // C 0.6 A[G] B 0.1 A[G] B I 1 L and J 1 K 0.3 CZ // C R3 ± /8 >< A // C 0.1 A[G] B 2 A[SL] B 0.05 CZ 0.1 A[G] A C B Specification, Simulation and Verification of complex shapes

constraints Geometrical requirement Functional tolerance Kinematics Detailed

22 Conceptual Design Conceptual Design Requirement Tolerancing process Function Function, structure Decomposed Function Behavior Form / Structure Geometrical constraints Geometrical requirement Functional tolerance Kinematics Detailed Design Geometry Tolerance Geometric Variations Management Early in the Design Process

23 Manufacturing considerations Phase 12 1 Phase 30 Phase 11: Casting Phase 12: Milling Phase 30: Braze welding Phase 40: Milling 2 2 Phase 21: Casting Phase 22: Milling Phase Specification/tolerance Transfer

of syntax and semantics based on relevant standards (ISO GPS, ASME Y14.

24 Product Manufacturing Information (PMI) & Model Based Definition (MBD) Presentation Representation From 2D Drawings to 3D Models Exchange of Product data with guarantee of syntax and semantics based on relevant standards (ISO GPS, ASME Y14.5), STEP related (AP 242) Integration/Interoperability with CAX tools Data Model and Representation

Lifecycle issues Concept Assembly Skeleton Functional

detailed design, manufacturing, assembly and inspection?

production (3D statistical tolerancing vs 3D worst case

25 Lifecycle issues Concept Assembly Skeleton Functional surfaces Solid How to identify the different key characteristics? How to build consistent 3D models for conceptual design, detailed design, manufacturing, assembly and inspection? How to integrate the 3D stochastic behavior of production (3D statistical tolerancing vs 3D worst case tolerancing)? How to extract the knowlege and reuse it for similar products (machine learning, transfer learning)

26 Form errors considerations Generation & Assessment Nominal Model Skin Model Shape Generation Assembly Modelling Skin Model Shapes Skin Model Shape Preparation SMS Preparation Partition of SMS using GeoSpelling operations 2 1 Assembly Process Definition Assembly Simulation Model Relative Positioning Assembly Position 1. 34,1% 2. 27,8% 3. 19,5% 4. 12% Result Visualization Contact Quality & KC Evaluation Evaluation Relative Positioning Constrained registration approaches for the relative positioning of Skin Model Shapes

27 Geometric Variations and Industrie 4.0

28 Digital Twin The Digital Twin refers to an entangled relation between a physical artefact and the set of its virtual models. Its Reference Model is based on the scientific fundamentals of GPS standards through a set of Properties ans Operations First theoretical and conceptual framework. Twinning Observation Digital Twin Physical Twin TWINNING Physical Operations Operations - - Conversion Composition Decomposition Evaluation Conversion Composition Decomposition Evaluation Prediction

Additive Manufacturing Accomodating geometry with

for free Complex Freeform Shapes with varying

Shapes/Features Internal Features Process-driven

thickness Support structure Scan direction and

29 Additive Manufacturing Accomodating geometry with material and manufacturing processes Complexity not for free Complex Freeform Shapes with varying thickness and tolerances Topology-Optimized Shapes/Features Internal Features Process-driven Specification Build direction and location Layer thickness Support structure Scan direction and Strategy Functionnaly Graded Materials UF 3 A B C 0,5 CZ / SØ50 0,05 / Ø4 V 29

Some recent efforts in Tolerancing for AM

representation Tolerance representation and

acceptable variation of the Solid of an additive

From Geometric to Physical Tolerancing considering

30 Some recent efforts in Tolerancing for AM Voxel-based Tolerancing Voxel based volumetric representation Tolerance representation and verification To specify a tolerance of the acceptable variation of the Solid of an additive manufactured component Multi-Physical Tolerancing From Geometric to Physical Tolerancing considering Simulation and Measurement data Variability Modeling PMI/MBD ASME Y14.46 (Product Definition for Additive Manufacturing) Extension of AMF to support features and tolerances 30

Education/Training Geometrical Product Specification and Verification as toolbox to meet up-to-date technical requirements EU funded project (Erasmus+ 2015-1-PL01- KA202-016875), 2015-2018 Partners:

31 Education/Training Geometrical Product Specification and Verification as toolbox to meet up-to-date technical requirements EU funded project (Erasmus PL01- KA ), Partners: University of Bielsko-Biala (Poland), Warsaw University of Technology (Poland), Friedrich-Alexander-Universitat Erlangen Nurnberg (Germany), Universita Degli Studi di Padova (Italy), Universitatea Tehnica Cluj- Napoca (Romania), University of Huddersfield (UK), Interstaatliche Hochschule fur Technik Buchs NTB (Switzerland), Volkswagen AG (Germany) Topics: Geometrical Product Specification and Verification, e-learning, web-based access, vocational training and lifelong learning of mechanical engineers.

Conclusions Ubiquity of Development. Geometric variations in Product Geometric Tolerancing is evolving and consider more simulation and measurement during the whole Product lifecycle.

32 Conclusions Ubiquity of Development. Geometric variations in Product Geometric Tolerancing is evolving and consider more simulation and measurement during the whole Product lifecycle. Lack of digital tools to support tolerance specification, simulation, verification and education. Digital Thread, Industrie 4.0, data Analytics and Additive Manufacturing are developing as new applications Questions: What are the most important applications of tolerances in your domain and business? What new requirements or processes are challenging the ability of traditional approaches to adequately ensure product quality?

33 Thank you Questions? Comments? Laboratoire Universitaire de Recherche en Production Automatisée 61 avenue du Président Wilson Cachan Cedex - France

Available online at ScienceDirect. Procedia CIRP 27 (2015 ) th CIRP conference on Computer Aided Tolerancing

Available online at ScienceDirect. Procedia CIRP 27 (2015 ) th CIRP conference on Computer Aided Tolerancing Available online at www.sciencedirect.com ScienceDirect Procedia CIRP 27 (2015 ) 16 22 13th CIRP conference on Computer Aided Tolerancing ISO specifications of complex surfaces: Application on aerodynamic