Models for Computer Aided Tolerancing in Design and Manufacturing

Transcription

1 Models for Computer Aided Tolerancing in Design and Manufacturing

2 Models for Computer Aided Tolerancing in Design and Manufacturing Selected Conference Papers from the 9th CIRP International Seminar on Computer-Aided Tolerancing, held at Arizona State University, Tempe, Arizona, USA, April, 2005 Edited by Joseph K. Davidson Design Automation Laboratory Department of Mechanical and Aerospace Engineering Ira A. Fulton School of Engineering Arizona State University Tempe, Arizona, USA

3 A C.I.P. Catalogue record for this book is available from the Library of Congress. ISBN (HB) ISBN (HB) ISBN (e-book) ISBN ( e-book) Published by Springer, P.O. Box 17, 3300 AA Dordrecht, The Netherlands. Printed on acid-free paper All Rights Reserved 2007 Springer No part of this work may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, microfilming, recording or otherwise, without written permission from the Publisher, with the exception of any material supplied specifically for the purpose of being entered and executed on a computer system, for exclusive use by the purchaser of the work.

4 The 9th CIRP International Seminar on Computer-Aided Tolerancing Arizona State University, Tempe, Arizona , USA April 10-12, 2005 Sponsored by CIRP (International Institution for Production Engineering Research) Arizona State University International Program Committee P. Bourdet (France) K. Chase (USA) A. Clément (France) J. K. Davidson (USA) A. Desrochers (Canada) H. Elmaraghy (Canada) C. Fortin (Canada) F.J.A.M. van Houten (Netherlands) L. Joskowicz (Israel) L. Laperrière (Canada) L. Mathieu (France) E. Morse (USA) J. Shah (USA) V. Srinivasan (USA) J.-C. Tsai (Taiwan) A. Weckenmann (Germany) R.G. Wilhelm (USA) E. Zussman (Israel)

5 vi The 9th CIRP International Seminar National Organizing Committee J. K. Davidson (Chair) L. Mathieu (Co-chair) J. Shah (Co-chair) R.G. Wilhelm (Co-chair) G. Ameta Z. Shen R. Salinas C. Standiford L. Mata-Hauksson Additional Reviewers M. Giordano T. Kurfess J.-M. Linares E. Pairel A. Rivière R. Söderberg J.-M. Sprauel F. Villeneuve

6 Pref ace Computer Aided Tolerancing (CAT) is an important topic in any field of design and production where parts move relative to one another and/or are assembled together. Geometric variations from specified dimensions and form always occur when parts are manufactured. Improvements in production systems only mean that the amounts of the variations become smaller, but their presence does not disappear. Clearances nearly always are the measures used to predict how consistently the relative motion will occur and also to ensure that parts will assemble together in a mass-production environment. But clearances, which are attributes of pairs of parts, must be converted to tolerances, which are attributes of individual parts and dimensions. It is this process that CAT is intended to fulfill, all the while being sensitive to the impact of manufacturability, interchangeability, and maintainability on parts and product being designed. To shorten the time from concept to market of a product, it has been increasingly important to take clearances and the tolerancing of manufacturing variations into consideration right from the beginning, at the stage of design. Hence, geometric models are defined that represent both the complete array of geometric variations possible during manufacture and also the influence of geometry on the function of individual parts and on assemblies of them. The subject of this book, Models for Computer Aided Tolerancing in Design and Manufacturing, focuses on mathematical and computer models and their application to the design and manufacture of machinery and other products. Current CAT systems work for simple problems in which the geometry is not very elaborate. However, for many practical applications, consistent results can be obtained only by those who are expert in both solid modeling and tolerance standards, and sometimes also expert in the computational methods and machinery for quality control measurements. The software for these three fields are not well integrated, and the standards for each were derived from different communities and different premises. Some time ago ISO experts around the world realized how important the integration of these three fields is. Each new standard in these fields improves the integration. The ultimate goal, and the motivation for much of the work described in this book, is to provide CAT systems which are comprehensive enough that ordinary designers can achieve acceptable and consistent results when assigning tolerances to dimensions and features. In 1996, ISO created a new technical committee, the ISO/TC213, in charge of the standards on geometrical product specification. This committee followed the JHG ISO/TC which coordinated the technical committees ISO/TC3 adjustment, ISO/TC57 Metrology and properties of surfaces and the subcommittee ISO/TC10/SC5 Specification and tolerance. The aim of this committee is to provide industrialists with complete and vii

7 viii Preface coherent standards in the field of specification and geometrical inspection of products (GPS). In 1996, ISO also published the technical report FD CR ISO/TR to establish the array of standards to be created or to revised in the future. In order to achieve this ambitious goal, it is no longer possible to create or develop standards based only on engineers and experts knowledge and practice. Now it is necessary to have a global and theoretical approach of the geometrical specification and verification problem. On the basis of French research results, called GEOSPELLING, a model to describe the micro and macro geometry has been developed. The basic concepts are described in the document ISO/TR that was published in The model is distinct because of its declarative method describing the process of tolerance specification and the process of tolerance verification in inspection. The contents of this book originate from a collection of selected papers presented at the 9th CIRP International Seminar on Computer Aided Tolerancing (CAT), organized by the Design Automation Laboratory and the Department of Mechanical and Aerospace Engineering of the Ira A. Fulton School of Engineering, Arizona State University, USA from April 10-12, The CIRP (Collège International pour la Recherche en Production or International Institution for Production Engineering Research) plans this seminar every two years. The Seminar presentations in Arizona in 2005 began with the keynote address (page 1) by Daniel Whitney from the Massachusetts Institute of Technology. In it he points out specific needs for improvement for CAD and CAT software. Current design practice does not make a clear distinction between creation of a competent nominal design (that is, one that is as close as practical to properly constrained or one in which the designer deliberately inserts desired over-constraint and takes it into account) and performance of a variation analysis (too often called tolerance analysis). Existing CAD systems do not support this distinction or yet provide sufficiently adequate tools for addressing each kind of design. Since the content of his address was taken from the references on page 2, only the abstract of it appears in this book. This book focuses in particular on the Models for Computer Aided Tolerancing in Design and Manufacturing since accurate and comprehensive models are the basis of the algorithms in software for CAT. Also included are other developments in the field and present applications. Models for Computer Aided Tolerancing in Design and Manufacturing provides an excellent resource to anyone interested in computer aided tolerancing. The book is intended for a wide audience including:

8 Preface ix Researchers in the fields of product design, Computer Aided Process Planning (CAPP), precision engineering, inspection, quality control, and dimensional and geometrical tolerancing, Technicians of standardization who are interested in the evolving ISO standards for tolerancing in mechanical design, manufacturing, and inspection, Practitioners of design, design engineers, manufacturing engineers, staff in R&D and production departments at industries that make mechanical components and machines, Software developers for CAD/CAM/CAX and computer aided tolerancing (CAT) application packages, Instructors and students of courses in design that are offered either for degrees by universities and technical schools, or for professional development through commercial short-courses, and Individuals interested in design, assembly, manufacturing, precision engineering, inspection, and CAD/CAM/CAQ. The book is organized into seven parts, the papers in each one corresponding to a principal topic. The first, Models for Tolerance Representation and Specification, deals with the role that models play in overcoming some of the shortcomings to CAT. Part 2, Tolerance Analysis, is a traditional activity of tolerancing in which values for geometric functional conditions are computationally simulated from tolerance-values that are imposed on dimensions and features of the parts of a mechanism or assembly. Part 3, Tolerance Synthesis, is about determining the part specifications required to comply with the geometric functional conditions of the mechanism. Part 4, Computational Metrology and Verification, concerns the measurements of features and the computational reduction of these to simple values for comparison to the specified tolerances. Part 5, Tolerances in Manufacturing, deals with the quality of part handling within the processes of manufacturing and the simulation of manufacturing processes. Part 6, Applications to Machinery, is about the use of new models and methods to solve specific problems of tolerancing in mechanical systems. Part 7, Incorporating Elasticity in Tolerance Models, shows progress for interfacing models for computer-aided tolerancing in design and manufacturing with the mechanics of elastic deformation. Several of these papers highlight applications for parts made from sheet metal, such as automotive panels and aircraft components. As Editor, I wish to express my sincere thanks to the authors for their contributions, to the members of the international program committee and the organizing committee, to the additional reviewers, and in particular to Mr. G. Ameta, Mr. N. Joshi, Mr. R. Salinas, Ms. C. Standiford, and Ms. L. Mata-Hauksson for their efforts in getting this book published. Joseph DAVIDSON

9 Table of Contents Preface... vii Keynote abstract A Unified Approach to Design of Assemblies Integrating Nominal and Variation Design D. E. WHITNEY (MASSACHUSETTS INST. OF TECHNOLOGY, USA)... 1 Tolerance Representation and Specification Virtual Gauge Representation for Geometric Tolerances in CAD-CAM Systems E. PAIREL, P. HERNANDEZ, M. GIORDANO (UNIV. DE SAVOIE, FRANCE)...3 Modal Expression of Form Defects F. FORMOSA, S. SAMPER (UNIV. DE SAVOIE, FRANCE)...13 Dependence and Independence of Variations of a Geometric Object P. SERRÉ, A. RIVIÈRE, A. CLÉMENT (CESTI, ST. OUEN, DASSAULT SYSTÈMES, FRANCE) A Model for a Coherent and Complete Tolerancing Process L. MATHIEU, A. BALLU (LURPA ENS DE CACHAN, LMP BORDEAUX, FRANCE)...35 Tolerance-Maps Applied to the Straightness and Orientation of an Axis S. BHIDE, G. AMETA, J. K. DAVIDSON, J. J. SHAH (UGS THE PLM COMPANY, ARIZONA STATE UNIV., USA) Tolerance Analysis Information Modeling to Manage Tolerances during Product and Process Design J. -Y. DANTAN, T. LANDMANN, A. SIADAT, P. MARTIN (ENSAM, METZ, FRANCE)...55 Relative Positioning of Planar Parts in Toleranced Assemblies Y. OSTROVSKY-BERMAN, L. JOSKOWICZ (HEBREW UNIV. OF JERUSALEM, ISRAEL)...65 Geometrical Variations Management in a Multi-Disciplinary Environment with the Jacobian-Torsor Model A. DESROCHERS (UNIV. DE SHERBROOKE, CANADA) Tolerance Analysis and Synthesis by Means of Deviation Domains, Axi-Symmetric Cases M. GIORDANO, S. SAMPER, J. P. PETIT (UNIV. DE SAVOIE, FRANCE)...85 Re-Design of Mechanical Assemblies using the Unified Jacobian Torsor Model for Tolerance Analysis W. GHIE, L. LAPERRIÈRE, A. DESROCHERS (UNIV. DU QUÉBEC À TROIS-RIVIÈRES, UNIVERSITÉ DE SHERBROOKE, CANADA)...95 xi

10 xii Table of Contents Tolerance Synthesis Complex Mechanical Structure Tolerancing by Means of Hyper-graphs M. GIORDANO, E. PAIREL, P. HERNANDEZ (UNIV. DE SAVOIE, FRANCE) An Efficient Solution to the Discrete Least-Cost Tolerance Allocation Problem with General Loss Functions J. LÖÖF, T. HERMANSSON, R. SÖDERBERG (CHALMERS UNIV., SWEDEN) Computational Metrology and Verification Monitoring Coordinate Measuring Machines by User-Defined Calibrated Parts A. WECKENMANN, S. BEETZ, J. LORZ (UNIV. ERLANGEN-NUREMBERG, ERLANGEN) Evaluation of Geometric Deviations in Sculptured Surfaces Using Probability Density Estimation A. BARARI, H. A. ELMARAGHY, G. K. KNOPF (UNIV. OF WESTERN ONTARIO, UNIV. OF WINDSOR, CANADA) How to Automate the Geometrical Tolerances Inspection: A Reverse Engineering Approach M. GERMANI, F. MANDORLI (POLYTECHNIC UNIV. OF MARCHE, ITALY) A New Algorithm to Assess Revolute Surfaces through Theory of Surface Continuous Symmetry W. POLINI, U. PRISCO, G. GIORLEO (UNIV. DI CASSINO, UNIV. DEGLI STUDI DI NAPOLI, ITALY) Statistical Modelling of Geometrical Invariant Sampled Sets P. CHIABERT, M. DE MADDIS (POLITECNICO DI TORINO, ITALY) Tolerances in Manufacturing Simulation of the Manufacturing Process in a Tolerancing Point of View: Generic Resolution of the Positioning Problem F. VILLENEUVE, F. VIGNAT (UNIV. OF GRENOBLE, FRANCE) Surface Best Fit: Generated Distribution of the Real Manufacturing Process S. ARANDA, J. M. LINARES, J. M. SPRAUEL, P. BOURDET (EA (MS) 2, I.U.T., LURPA - ENS DE CACHAN, FRANCE) Position Deviation of a Holes Pattern Due to Six-Point Locating Principle W. POLINI, G. MORONI (UNIV. DI CASSINO, POLITECNICO DI MILANO, ITALY) Tolerance Assignment Using Genetic Algorithm for Production Planning H. SONG, Y. D. YANG, Y. ZHOU, Y. K. RONG (WORCESTER POLYTECHNIC INST., USA) Applications to Machinery Impact of Geometric Uncertainties Onto the Operating Performance of a Mechanical System J. M. LINARES, J. M. SPRAUEL, S. ARANDA, P. BOURDET (EA (MS) 2, I.U.T., LURPA - ENS DE CACHAN, FRANCE)...225

11 Table of Contents xiii Influence of the Standard Components Integration on the Tolerancing Activity J. DUFAURE, D. TEISSANDIER, G. DEBARBOUILLE (OPEN CASCADE SA, UNIV. DE BORDEAUX, FRANCE) Surfaces Seam Analysis J.-P. PETIT, S. SAMPER, I. PERPOLI (UNIV. DE SAVOIE, FRANCE) Statistical Tolerance Analysis of Gears by Tooth Contact Analysis J. BRUYERE, J.-Y. DANTAN, R. BIGOT, P. MARTIN (ENSAM DE METZ, FRANCE) Tolerance Analysis and Allocation Using Tolerance-Maps for a Power Saw Assembly A. D. JIAN, G. AMETA, J. K. DAVIDSON, J. J. SHAH (ARIZONA STATE UNIV., USA) Error Analysis of a NanoMechanical Drill A. BRYAN, J. CAMELIO, S. J. HU, N. JOSHI, A. MALSHE (UNIV. OF MICHIGAN, UNIV. OF ARKANSAS, USA) Tolerance Synthesis of Higher Kinematic Pairs M.-H. KYUNG, E. SACKS (PURDUE UNIV., USA) Incorporating Elasticity in Tolerance Models Geometrical Study of Assembly Behaviour, Taking Into Accounts Rigid Components Deviations, Actual Geometric Variations and Deformations G. CID, F. THIEBAUT, P. BOURDET, H. FALGARONE (LURPA ENS DE CACHAN, LURPA, IUT DE CACHAN, EADS CCR, FRANCE) Practical Implications in Tolerance Analysis of Sheet Metal Assemblies: Experiences from an Automotive Application S. DAHLSTRÖM, L. LINDKVIST, R. SÖDERBERG (VOLVO CAR CORP., CHALMERS UNIV., SWEDEN) Predicting Deformation of Compliant Assemblies Using Covariant Statistical Tolerance Analysis M. R. TONKS, K. W. CHASE, C. C. SMITH (BRIGHAM YOUNG UNIV., USA) Elastic Clearance Domain and Use Rate Concept Applications to Ball Bearings and Gears S. SAMPER, J.-P. PETIT, M. GIORDANO (UNIV. DE SAVOIE, FRANCE) Tolerance Verification for Sheet Metal Bending: Factors Influencing Dimensional Accuracy of Bent Parts T. H. M. NGUYEN, J. R. DUFLOU, J.-P. KRUTH, I. STOUTEN, J. VAN HECKE, A. VAN BAEL (KATHOLIEKE UNIV. LEUVEN, XIOS HOGESCHOOL LIMBURG, BELGIUM) Author Index Keyword Index...353