Flexible Tools for Specifying Design Variation

This paper describes flexible tools for specifying design variations that are based on nonuniform profile tolerance definitions. These tools specify bounds of design performance that can be used for negotiation among engineers in a collaborative design process. These specification methods allow for the capture of many different design functions that are not easily described with current tool designs. In addition, these specification methods lend themselves to efficient verification methods. Profile tolerance definitions provide the most general variation controls for complex mechanical surfaces. Common design practices and engineering standards for profile tolerances exhibit many weaknesses and limitations. We present a rationale for a complete specification approach using B-splines [1, 2] for profile tolerances, and illustrate the approach with examples. B-splines can be used to specify both uniform and nonuniform profile tolerance boundaries. Subsequently, algorithms for the evaluation of actual feature deviations and reporting methodologies for such tolerance zones are presented

Methodology for automatic recovering of 3D partitions from unstitched faces of non-manifold CAD models

Data exchanges between different software are currently used in industry to speed up the preparation of digital prototypes for Finite Element Analysis (FEA). Unfortunately, due to data loss, the yield of the transfer of manifold models rarely reaches 1. In the case of non-manifold models, the transfer results are even less satisfactory. This is particularly true for partitioned 3D models: during the data transfer based on the well-known exchange formats, all 3D partitions are generally lost. Partitions are mainly used for preparing mesh models required for advanced FEA: mapped meshing, material separation, definition of specific boundary conditions, etc. This paper sets up a methodology to automatically recover 3D partitions from exported non-manifold CAD models in order to increase the yield of the data exchange. Our fully automatic approach is based on three steps. First, starting from a set of potentially disconnected faces, the CAD model is stitched. Then, the shells used to create the 3D partitions are recovered using an iterative propagation strategy which starts from the so-called manifold vertices. Finally, using the identified closed shells, the 3D partitions can be reconstructed. The proposed methodology has been validated on academic as well as industrial examples.This work has been carried out under a research contract between the Research and Development Direction of the EDF Group and the Arts et Métiers ParisTech Aix-en-Provence

A statistical tolerance analysis approach for over-constrained mechanism based on optimization and Monte Carlo simulation

Tolerancing decisions can profoundly impact the quality and cost of the mechanism. To evaluate the impact of tolerance on mechanism quality, designers need to simulate the influences of tolerances with respect to the functional requirements. This paper proposes a mathematical formulation of tolerance analysis which integrates the notion of quantifier: ‘‘For all acceptable deviations (deviations which are inside tolerances), there exists a gap configuration such as the assembly requirements and the behavior constraints are verified’’ & ‘‘For all acceptable deviations (deviations which are inside tolerances), and for all admissible gap configurations, the assembly and functional requirements and the behavior constraints are verified’’. The quantifiers provide a univocal expression of the condition corresponding to a geometrical product requirement. This opens a wide area for research in tolerance analysis. To solve the mechanical problem, an approach based on optimization is proposed. Monte Carlo simulation is implemented for the statistical analysis. The proposed approach is tested on an over-constrained mechanism

A new approach to tolerance analysis

Journal ArticleTolerance analysis is seen as part of a more general problem, namely handling data with uncertainty. Uncertain geometric data arises when interpreting measured data, but also in solid modeling where floating point approximations are common, when representing design tolerances, or when dealing with limited manufacturing precision. The common question is whether parts with uncertain shape fulfill certain functional specification. The question is expressed as geometrical relationship between toleranced objects. Unfortunately, tolerance based relations are often inconsistent, unlike relations between exactly represented objects. In this paper we survey current tolerance representation and analysis methods. We then derive our method of intuitionistic tolerance handling from a method developed for robust solid modeling. A new representational framework is proposed, which serves as the basis for robust geometric modeling and tolerance analysis. We illustrate the framework with examples of assembly design

The role of automatic shape and position recognitionin streamlining manufacturing

The main features of most components consist of simple basic functional geometries: planes, cylinders, spheres and cones. Shape and position recognition of these geometries is essential for dimensional characterization of components, and represent an important contribution in the life cycle of the product, concerning in particular the manufacturing and inspection processes of the final product. This work aims to establish an algorithm to automatically recognize such geometries, without operator intervention. Using differential geometry large volumes of data can be treated and the basic functional geometries to be dealt recognized. The original data can be obtained by rapid acquisition methods, such as 3D survey or photography, and then converted into Cartesian coordinates. The satisfaction of intrinsic decision conditions allows different geometries to be fast identified, without operator intervention. Since inspection is generally a time consuming task, this method reduces operator intervention in the process. The algorithm was first tested using geometric data generated in MATLAB and then through a set of data points acquired by measuring with a coordinate measuring machine and a 3D scan on real physical surfaces. Comparison time spent in measuring is presented to show the advantage of the method. The results validated the suitability and potential of the algorithm hereby proposedCMAT, the Research Centre of Mathematics of the University of Minho with the Portuguese Funds from the “Fundação para a Ciência e a Tecnologia”, through the Project PEstOE/MAT/UI0013/2014; MEtRICs – (Mechanical Engineering and Resource Sustainability Center); CGIT - Centro de Gestão Industrial e da Tecnologi

Application feature model for geometrical specification of assemblies

The work begins with the description of a Domain Meta-Model for collaborative and integrated product development based on a Feature Model that aggregates all Application Features required to support domain specific reasoning. These Application Features are conceived as an aggregation of several Object Features containing all the knowledge about the structure and geometric interface that are the solution for a certain function. Afterwards, the Specification Feature, as a specialisation of the previous feature, is presented. This contains information about geometry, nominal and with defects, as well as about the relations established between them in the dimensional and geometrical specification process of an assembly, as established by GPS standard. Finally, the Specification Assembly Model is shown, an assembly model based on the Specification Feature and on the description of specifications using the Geospelling language