Automating GD&T Schema for Mechanical Assemblies

abstract: Parts are always manufactured with deviations from their nominal geometry due to many reasons such as inherent inaccuracies in the machine tools and environmental conditions. It is a designer job to devise a proper tolerance scheme to allow reasonable freedom to a manufacturer for imperfections without compromising performance. It takes years of experience and strong practical knowledge of the device function, manufacturing process and GD&T standards for a designer to create a good tolerance scheme. There is almost no theoretical resource to help designers in GD&T synthesis. As a result, designers often create inconsistent and incomplete tolerance schemes that lead to high assembly scrap rates. Auto-Tolerancing project was started in the Design Automation Lab (DAL) to investigate the degree to which tolerance synthesis can be automated. Tolerance synthesis includes tolerance schema generation (sans tolerance values) and tolerance value allocation. This thesis aims to address the tolerance schema generation. To develop an automated tolerance schema synthesis toolset, to-be-toleranced features need to be identified, required tolerance types should be determined, a scheme for computer representation of the GD&T information need to be developed, sequence of control should be identified, and a procedure for creating datum reference frames (DRFs) should be developed. The first three steps define the architecture of the tolerance schema generation module while the last two steps setup a base to create a proper tolerance scheme with the help of GD&T good practice rules obtained from experts. The GD&T scheme recommended by this module is used by the tolerance value allocation/analysis module to complete the process of automated tolerance synthesis. Various test cases are studied to verify the suitability of this module. The results show that software-generated schemas are proper enough to address the assemblability issues (first order tolerancing). Since this novel technology is at its initial stage of development, performing further researches and case studies will definitely help to improve the software for making more comprehensive tolerance schemas that cover design intent (second order tolerancing) and cost optimization (third order tolerancing).Dissertation/ThesisMasters Thesis Mechanical Engineering 201

A numerical approach for 3D manufacturing tolerances synthesis

Making a product conform to the functional requirements indicated by the customer suppose to be able to manage the manufacturing process chosen to realise the parts. A simulation step is generally performed to verify that the expected generated deviations fit with these requirements. It is then necessary to assess the actual deviations of the process in progress. This is usually done by the verification of the conformity of the workpiece to manufacturing tolerances at the end of each set-up. It is thus necessary to determine these manufacturing tolerances. This step is called "manufacturing tolerance synthesis". In this paper, a numerical method is proposed to perform 3D manufacturing tolerances synthesis. This method uses the result of the numerical analysis of tolerances to determine influent mall displacement of surfaces. These displacements are described by small displacements torsors. An algorithm is then proposed to determine suitable ISO manufacturing tolerances

Tolerance analysis by static analogy on 2D assemblies with fits and fasteners

In tolerance analysis, the effect of clearance fits is especially difficult to estimate because the mating parts are not necessarily in actual contact and can take an infinite number of relative positions. The treatment of these situations is allowed in most of the available methods, possibly introducing additional elements in the dimension chains with appropriate statistical assumptions. The paper provides a similar extension for the static analogy, a previously proposed method that converts the tolerance analysis problem into an equivalent problem of force analysis. The procedure represents each fit, possibly between patterns of features (e.g., fasteners and holes), with a proper constraint in the equivalent static model. The ability of the constraint to transmit forces and torques is determined according to the types and directions of misalignments allowed by the joint clearance. With simple rules, this avoids complications in the static model, which must include only the constraint between parts rather than the geometric details of the mating features. The extended method, currently limited to 2D dimension chains, is demonstrated on examples involving both dimensional and geometric tolerances. The comparison with existing methods shows the correctness of the proposed procedure. The simplicity of the workflow confirms the possibility, already demonstrated for the static analogy, of avoiding numerical simulations or even the use of computer-based tools

An approach to collaborative assembly design modification and assembly planning

Ph.DDOCTOR OF PHILOSOPH

Intégration de modèles de caractéristiques (features) à une modélisation géométrique pour supporter l'analyse métiers

Ingénierie simultanée -- Conception de produit -- Approche par feature -- Problématiques -- Démarche et objectifs de recherche -- Définition des modèles géométriques -- L'organisation des données topologiques -- Le formalisme NIAM -- Date structure applied to product lifecycle -- Représentations des données métier -- Assiting designer using feature modeling for lifecycle

Tolerance analysis — Form defects modeling and simulation by modal decomposition and optimization

Tolerance analysis aims on checking whether specified tolerances enable functional and assembly requirements. The tolerance analysis approaches discussed in literature are generally assumed without the consideration of parts’ form defects. This paper presents a new model to consider the form defects in an assembly simulation. A Metric Modal Decomposition (MMD) method is henceforth, developed to model the form defects of various parts in a mechanism. The assemblies including form defects are further assessed using mathematical optimization. The optimization involves two models of surfaces: real model and difference surface-base method, and introduces the concept of signed distance. The optimization algorithms are then compared in terms of time consumption and accuracy. To illustrate the methods and their respective applications, a simplified over-constrained industrial mechanism in three dimensions is also used as a case study

An intelligent knowledge based cost modelling system for innovative product development

This research work aims to develop an intelligent knowledge-based system for product cost modelling and design for automation at an early design stage of the product development cycle, that would enable designers/manufacturing planners to make more accurate estimates of the product cost. Consequently, a quicker response to customers’ expectations. The main objectives of the research are to: (1) develop a prototype system that assists an inexperienced designer to estimate the manufacturing cost of the product, (2) advise designers on how to eliminate design and manufacturing related conflicts that may arise during the product development process, (3) recommend the most economic assembly technique for the product in order to consider this technique during the design process and provide design improvement suggestions to simplify the assembly operations (i.e. to provide an opportunity for designers to design for assembly (DFA)), (4) apply a fuzzy logic approach to certain cases, and (5) evaluate the developed prototype system through five case studies. The developed system for cost modelling comprises of a CAD solid modelling system, a material selection module, knowledge-based system (KBS), process optimisation module, design for assembly module, cost estimation technique module, and a user interface. In addition, the system encompasses two types of databases, permanent (static) and temporary (dynamic). These databases are categorised into five separate groups of database, Feature database, Material database, Machinability database, Machine database, and Mould database. The system development process has passed through four major steps: firstly, constructing the knowledge-based and process optimisation system, secondly developing a design for assembly module. Thirdly, integrating the KBS with both material selection database and a CAD system. Finally, developing and implementing a ii fuzzy logic approach to generate reliable estimation of cost and to handle the uncertainty in cost estimation model that cannot be addressed by traditional analytical methods. The developed system has, besides estimating the total cost of a product, the capability to: (1) select a material as well as the machining processes, their sequence and machining parameters based on a set of design and production parameters that the user provides to the system, and (2) recommend the most economic assembly technique for a product and provide design improvement suggestion, in the early stages of the design process, based on a design feasibility technique. It provides recommendations when a design cannot be manufactured with the available manufacturing resources and capabilities. In addition, a feature-by-feature cost estimation report was generated using the system to highlight the features of high manufacturing cost. The system can be applied without the need for detailed design information, so that it can be implemented at an early design stage and consequently cost redesign, and longer lead-time can be avoided. One of the tangible advantages of this system is that it warns users of features that are costly and difficult to manufacture. In addition, the system is developed in such a way that, users can modify the product design at any stage of the design processes. This research dealt with cost modelling of both machined components and injection moulded components. The developed cost effective design environment was evaluated on real products, including a scientific calculator, a telephone handset, and two machined components. Conclusions drawn from the system indicated that the developed prototype system could help companies reducing product cost and lead time by estimating the total product cost throughout the entire product development cycle including assembly cost. Case studies demonstrated that designing a product using the developed system is more cost effective than using traditional systems. The cost estimated for a number of products used in the case studies was almost 10 to 15% less than cost estimated by the traditional system since the latter does not take into consideration process optimisation, design alternatives, nor design for assembly issue

Functional and Behavioral Product Information Representation and Consistency Validation for Collaboration in Product Lifecycle Activities

Information models that represent the function, assembly and behavior of artifacts are critical in the conceptual development of a product and its evaluation. Much research has been conducted in this area; however, existing models do not relate function, behavior and structure in a comprehensive and consistent way. In this work, NIST\u27s Core Product Model (CPM) and the Open Assembly Model (OAM) are extended to integrate product information including function and behavior, with an emphasis on assembly, throughout all phases of product development. For function and flow classification, the NIST functional taxonomy is used to maintain consistency with the literature. The consistency validation of product information, and the verification of modified product information are discussed; these processes ensure that the product information has no contradictions and allows tracing through associations without any deficiency or disconnection. In other words, the information model has to be complete in terms of traceability of function, behavior, spatial relationships, etc., in order to support all information exchange activities. The product information representation provides a mechanism for capturing product information and storing it in a database. This representation schema also provides necessary information for any future decision making activities in the End of Life (EOL) environment, such as the replacement or reuse of any part or subassembly. When there is a need to replace one artifact with another, one must consider all of the associations of the existing artifact with other artifacts and the environment, not just functional and space requirements, and the relevant modification(s) of the associated objects has to verified. So one can manage product lifecycle activities in different perspectives by knowing how the product information is interconnected in various domains and how its characteristics affect each other