Computer Aided Tolerancing (CAT) platform for the design of assemblies under external and internal forces

Due to the stochastic nature of manufacturing processes, the functionality of mechanical assemblies is subject to variation defined by tolerances and manufacturing process characteristics. In many assemblies, functionality is also dependent on external and internal forces. Numerous Computer Aided Tolerancing (CAT) tools have been proposed that address tolerance analysis problems in complex mechanical assemblies; however current tools do not accommodate a general class of problem where the functionality of a design is fundamentally dependent on the effects of external and internal forces. This research addresses the limitation of CAT tools to accommodate assemblies under loading by developing a tolerance analysis platform which integrates CAD, CAE and statistical analysis tools using Process Integration and Design Optimisation (PIDO) software capabilities. The platform extends the capabilities of traditional CAT tools by enabling tolerance analysis of assemblies in which assembly characteristics are dependent on external and internal forces. To demonstrate the capabilities of the developed platform, examples of tolerance analysis problems involving external forces (compliance) and internal forces (multi-body dynamics) are presented.     

装配配合约束自动获取技术研究

装配配合约束获取对于装配设计、装配工艺规划等多个领域的研究具有重要意义;现有的装配配合约束获取方法容易产生约束的遗漏和约束无效性;通过对自动获取配合约束技术进行研究,在充分利用CAD模型几何拓扑信息的基础上。提出了几何约束识别和配合验证相结合的装配配合约束自动获取箅法;实践证明,该方法可以显著地提高约束信息的获取效率、正确性和有效性。     

Generation of functional tolerancing based on positioning features

The aim behind applying functional tolerancing to a mechanism is to widen the tolerances used in parts manufacturing according to the effective functional properties of the product. This step may be performed using CAD systems and geometrical specifications defined by ISO standards. The present paper will describe the complete process involved in functional tolerancing. The CLIC tolerancing method has been implemented within an Excel software environment. CAD models for parts have been imported via a STEP interface. According to this approach, the designer describes the assembly process; the CLIC system then determines the functional requirements corresponding to the joints between parts and generates all datum reference frames and tolerancing of set-up surfaces in compliance with ISO standards. CLIC also determines both the geometrical conditions of minimum distances in order to avoid interference between parts and the conditions for assembling small standard components. The designer next adds other functional requirements. For each such requirement, a tolerancing process creates location and orientation specifications for influential parts using datum reference frames derived during the previous stage. Excel formulae focusing on the sum of tolerances are generated using a three-dimensional statistical approach. Moreover, the tolerance database allows optimizing the tolerances and nominal dimensions of parts.     

Integration of the STEP-based assembly model and XML schema with the fuzzy analytic hierarchy process (FAHP) for muti-agent based assembly evaluation

Assemblability analysis and evaluation plays a key role in assembly design, operation analysis and planning. In this paper, we propose an integrated intelligent approach and framework for evaluation of assemblability and assembly sequence for electro-mechanical assemblies (EMAs). The approach integrates the STEP (STandard for the Exchange of Product model data, officially ISO 10303)-based assembly model and XML schema with the fuzzy analytic hierarchy process for assembly evaluation. The evaluation structure covers not only the geometric and physical characteristics of the assembly parts but also the assembly operation data necessary to assemble the parts. The realization of the integration system is implemented through a multi-agent framework. Through integration with the STEP-based product modeling agent system, CAD agent system and assembly planning agent system, the developed assembly evaluation agent system can effectively incorporate, exchange, and share concurrent engineering knowledge into the preliminary design process so as to provide users with suggestions for improving a design and also helping obtain better design ideas. The applications show that the proposed approach and system are feasible. Received: July 2004 / Accepted: January 2006     

A generic deviation-based approach for synthesis of tolerances

In this paper, a generic model for the synthesis of tolerances for manufactured parts is presented. The model uses a method of transforming traditional tolerance specifications (as defined in ASME Y14.5M) to a generalized coordinate system (hereinafter referred to as deviation space). Small displacement torsors (SDTs) have been used for representing the deviations. The tolerance synthesis method is formulated as a constrained nonlinear optimization process. Three different types of constraints have been considered for the optimization process: 1) representation of assemblability; 2) mapping of tolerance specification to deviations; and 3) functional requirements. A new deviation-based cost of manufacturing model has been proposed. A working module of the scheme has been implemented and the process has been elaborated with two examples. The possibility of extension of the model and scope for further generalization have been discussed. Note to Practitioners-This paper presents an optimization method for finding tolerance values for different features of an assembly of manufactured parts. Determination of different types of tolerances and their exact values for critical features of any part has been an ad-hoc process; it has been mostly experience-based till recent time. In this paper, efforts have been made to establish a strong mathematically oriented method for synthesis of tolerances. The procedure attempts to minimize cost of manufacturing while the functionality and assemblability are satisfied. It is a generalized method and could be applied for designing rigid manufacture parts. For practical usage, this method should be integrated with three-dimensional computer-aided design packages as a tolerance synthesis module for integrated tolerance design.     

Interference checking approach with tolerance based on assembly dimension chain

CAD model with nominal dimension is implemented in interference checking of assembly simulation of aircraft complex parts at present,which causes inadequate availability.In order to address this challenging issue,interference checking method with tolerance based on assembly dimension chain was proposed.Worst case and maximum error probability of tolerance of composing loop were used,and CAD models were respectively re-constructed and inserted into simulation system.Before dynamic interference checking,engineering semantic interference condition was set to assembly requirements.Finally,the interface checking result was a basis for reasonability of assembly process and tolerance.A prototype system was developed based on the above research.     

Solid modeling

Solid modeling deals with the representation, design, visualization. and analysis of models of 3D parts. While the embodiment of solid modeling technology in contemporary commercial CAD systems is finally beginning to fulfil the old promise of providing major improvements in the productivity of the manufacturing industry, solid modeling research remains in its infancy. Recent developments focus on advanced design paradigms, topological and geometric extensions of the domain and the performance and reliability of the fundamental algorithms. The current trend follows two paths: capitalizing on the concepts of features, constraints, and model parameterization, which provide a more intuitive and suitable design vocabulary than the traditional edges, faces, or Boolean operations; and incorporating information about the tolerances, assembly relations, and mechanical properties of parts and assemblies, which provides a suitable product database for the development of analysis and planning applications. We selected the articles in the special issue carefully, choosing from among the papers presented at the 1993 ACM/IEEE Second Symposium on Solid Modeling and Applications     

基于模板的自顶向下并行装配设计

在分析产品设计系统的装配功能的基础上,提出了一个并行装配设计模式及装配模板与模板实例化的概念;在处理装配约束的虚拟表示与实例表示概念,使得系统具有了支持自顶向下和自底向上２种设计方法的能力。该方法已被成功地应用于参数化特征造型系统ＺＤ－ＭＣＡＤＩＩ中,证明了基于装配模板基础上的装配设计方法法能在零件设计级上有效地支持并行设计。     

Coupling experimental design—digital simulation of junctions for the development of complex tolerance chains

This paper presents a new functional tolerancing method developed for analyzing tri-dimensional variations of mechanical assemblies. The behavior of a junction is simulated with Microsoft EXCEL to quantify the influence of geometrical variations of a given part on a functional requirement. The solver determines the critical situation of the mechanism with respect to the contact constraints and the location and orientation tolerances. The result of this stage is introduced into an experimental design so as to define a relationship between the variation of the functional requirement and the geometric tolerances specified for the surfaces of the parts. The complete inequality ensuring tolerance synthesis is obtained by adding the defects of all junctions forming the vector loop.     

Design of object-oriented database for the definition of machining operation sequences of 3D workpieces

This paper describes the activities of Object-Oriented (OO) analysis that were implemented in order to obtain a high part representation level and to give sets of structured and hierarchical data to the Computer Aided Process Planning (CAPP) system. The OO modeling activities were carried out by using the Object-Oriented System Analysis (OOSA) method which allows careful specification of all the information contained inside the system. All the models used by this method have been described in detail to show how the OO database is defined and how it can be used by a generative CAPP system. The feature model proposed is defined by taking all the part information that can be recognized and extracted from the Computer Aided Design (CAD) model into account. The result is the design of an OO database which allows the CAPP system to use manufacturing features to define machining operation sequences of 3D workpieces. The approach proposed is generic enough to integrate any geometrical forms which can be recognized and identified from the CAD system. Hole geometry is taken as an example to show the link between the step of OO analysis and the step of knowledge representation in the Expert System which has been used to generate machining cycles. The OO database presented makes up a real solution of CAD/CAPP/CAM integration by using feature modeling.     

Engineering knowledge formalization and proposition for informatics development towards a CAD-integrated DfX system for product design

Target design methodologies (DfX) were developed to cope with specific engineering design issues such as cost-effectiveness, manufacturability, assemblability, maintainability, among others. However, DfX methodologies are undergoing the lack of real integration with 3D CAD systems. Their principles are currently applied downstream of the 3D modelling by following the well-known rules available from the literature and engineers’ know-how (tacit internal knowledge).This paper provides a method to formalize complex DfX engineering knowledge into explicit knowledge that can be reused for Advanced Engineering Informatics to aid designers and engineers in developing mechanical products. This research work wants to define a general method (ontology) able to couple DfX design guidelines (engineering knowledge) with geometrical product features of a product 3D model (engineering parametric data). A common layer for all DfX methods (horizontal) and dedicated layers for each DfX method (vertical) allow creating the suitable ontology for the systematic collection of the DfX rules considering each target. Moreover, the proposed framework is the first step for developing (future work) a software tool to assist engineers and designers during product development (3D CAD modelling).A design for assembly (DfA) case study shows how to collect assembly rules in the given framework. It demonstrates the applicability of the CAD-integrated DfX system in the mechanical design of a jig-crane. Several benefits are recognized: (i) systematic collection of DfA rules for informatics development, (ii) identification of assembly issues in the product development process, and (iii) reduction of effort and time during the design review.     

Stacked tolerance analysis and allocation using assembly models

Allocation of appropriate tolerances is critical to ensure that components fit right and function satisfactorily in an assembly involving stacked components. There are numerous techniques available today to model assemblies on a computer. What is lacking is a common platform to make use of these computer models in order to perform tolerance analysis and allocation. This paper describes a technique to automate tolerance analysis and allocation of an assembly involving components stacked one on another represented in the boundary form. An algorithm is developed to track dimension loops in the stacked assembly. Statistical tolerance analysis and allocation is then performed on these interrelating dimensions and tolerances encompassed by a dimension loop. Advantages and limitations of this technique are compared against the manual method to conduct tolerance analysis and allocation.     

基于虚拟原型的机械多体系统建模可视化

针对虚拟样机意义下的机械多体系统性能分析,提出一种直接从产品虚拟原型中的零件设计模型和装配模型获取多体系统物理性能属性和空间拓扑结构的理论和方法.将设计模型按照多体系统空间拓扑结构描述,直接映射为抽象的可视模型,并以此向求解模型过渡,从而最终获得对多体系统运动学和动力学的求解,使虚拟样机过程能在短时间内得以成功实施,达到整机动态性能分析的目的,获得满意的结果.最后,通过一个典型的机车车辆模型验证了文中方法的可行性.     

Simultaneous optimal selection of design and manufacturing tolerances with alternative manufacturing process selection

Tolerance specification is an important part of mechanical design. Design tolerances strongly influence the functional performance and manufacturing cost of a mechanical product. Tighter tolerances normally produce superior components, better performing mechanical systems and good assemblability with assured exchangeability at the assembly line. However, unnecessarily tight tolerances lead to excessive manufacturing costs for a given application. The balancing of performance and manufacturing cost through identification of optimal design tolerances is a major concern in modern design. Traditionally, design tolerances are specified based on the designer’s experience. Computer-aided (or software-based) tolerance synthesis and alternative manufacturing process selection programs allow a designer to verify the relations between all design tolerances to produce a consistent and feasible design. In this paper, a general new methodology using intelligent algorithms viz., Elitist Non-dominated Sorting Genetic Algorithm (NSGA-II) and Multi Objective Particle Swarm Optimization (MOPSO) for simultaneous optimal selection of design and manufacturing tolerances with alternative manufacturing process selection is presented. The problem has a multi-criterion character in which 3 objective functions, 3 constraints and 5 variables are considered. The average fitness factor method and normalized weighted objective functions method are separately used to select the best optimal solution from Pareto optimal fronts. Two multi-objective performance measures namely solution spread measure and ratio of non-dominated individuals are used to evaluate the strength of Pareto optimal fronts. Two more multi-objective performance measures namely optimiser overhead and algorithm effort are used to find the computational effort of NSGA-II and MOPSO algorithms. The Pareto optimal fronts and results obtained from various techniques are compared and analysed.     

Quality- and cost-driven assembly technique selection and geometrical tolerance allocation for mechanical structure assembly

The assembly process planning has been the subject of extensive scientific work, mainly due to the multiple aspects involved from geometrical matters to operational research concerns. However, very few issues about assembly technique selection are addressed. The aim of this paper is to propose a method to select an assembly technique for each joint of a product and to allocate geometrical tolerances accordingly. This is achieved by solving a multi-objective optimization problem to minimize the cost and the non-conformity associated with the assembly plan. The potential benefits of the method are illustrated on a case study representing the assembly of a simple mechanical structure.     

An automated interface between CAD and CAM

The interface between CAD and CAM is an important phase in CAE (Computer Aided Engineering). There are many systems such as CAPP (Computer Aided Process Planning) that can solve this problem. But CAPP needs recognition of the features of a solid model that result from a complex procedure. This paper describes a new highly efficient method to link CAD and CAM from solid models to machinable models.     

A model-based approach to form tolerance evaluation using non-uniform rational B-splines

Tolerance evaluation is critical to quality assurance in modern manufacturing. In contrast to traditional measurement which relies on specific hard gauges, coordinate measuring machines provide more flexibility for dimensional measurement and tolerance evaluations. To fully automate CMM inspection and tolerance evaluation, CAD/CMM integration is an important key. Although the subject of CAD-directed inspection has been widely researched, CAD model-based tolerance evaluation has received less attention. This paper presents a CAD model-based approach for evaluating general form tolerances using non-uniform rational B-splines. Unlike classical methods which construct substitute geometric features from the measurement data, this method evaluates form tolerances by comparing the measurement data with a nominal CAD model. Non-uniform rational B-spline (NURBS) is used to represent general form features since NURBS offers a common format for modeling different form features. With this unified database, a general best-fit algorithm is developed that can be applied to the evaluation of various form tolerances. Computer simulations have been performed on different form features to study the robustness and efficiency of the algorithm. Application to the profile analysis of turbo charger housing and turbine blade die segments are also presented.     

The affect of contact force sensations on user performance in virtual assembly tasks

The development of a realistic virtual assembly environment is challenging because of the complexity of the physical processes and the limitation of available VR technology. Many research activities in this domain primarily focused on particular aspects of the assembly task such as the feasibility of assembly operations in terms of interference between the manipulated parts. The virtual assembly environment reported in this research is focused on mechanical part assembly. The approach presented addresses the problem of part-to-part contacts during the mating phase of assembly tasks. The system described calculates contact force sensations by making their intensity dependent on the depth of penetration. However the penetration is not visible to the user who sees a separate model, which does not intersect the mating part model. The two 3D models of the part, the off-screen rendered model and the on-screen rendered model are connected by a spring-dumper arrangement. The force calculated is felt by the operator through the haptic interface when parts come in contact during the mating phase of the assembly task. An evaluation study investigating the effect of contact force sensation on user performance during part-to-part interface was conducted. The results showed statistically significant effect of contact force sensation on user performance in terms of task completion time. The subjective evaluation based on feedback from users confirmed that contact force sensation is a useful cue for the operator to find the relative positions of components in the final assembly state.