Computational implementation of part stiffness on tolerance specification based on the functional performance of assembl
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ORIGINAL ARTICLE
Computational implementation of part stiffness on tolerance specification based on the functional performance of assemblies Andreas Mavridis-Tourgelis 1 & Christos Vakouftsis 1 & Georgios Kaisarlis 1 & Vaios G. Arampatzis 1 & Christopher G. Provatidis 1 & Vasilios Spitas 1 Received: 1 September 2020 / Accepted: 22 September 2020 / Published online: 28 September 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract One of the most critical tasks within the scope of Design for Manufacturing (DfM) is to define the set of Geometrical Product Specifications (GPS) in the 3D model or in the engineering drawing that ensures the functionality and the interchangeability of parts, as well as the intended functional performance of an assembly. Several methodologies have been proposed for the optimal designation of such specifications; however, the majority of them do not effectively take into account the deformations that are inevitably induced during assembly and operation for the vast majority of mechanical components. Motivated by the widely accepted tolerancing practice for sheet metal parts in the automotive industry, where the distinction between free state and constrained state is considered, the paper investigates the influence of the deformations induced during assembly and operation on GPS. The effect of part stiffness in the resultant functional GPS of the assembly/component is explored, through CAD surfacing and non-linear numerical finite element analysis tools including the contact problem. The current stage of development of a novel, performance-based methodology for the GD&T design procedure is presented. The methodology is applied on a realworld mechanical assembly that is derived from tolerance stack up-related literature. This study illustrated is that for an unpredictably wide range of mechanical components the default, free-state GPS scheme should only be assigned after rigorous analysis of their compliance behaviour. The proposed approach will lead to deduce the correlation between production cost and performance through a further development in future study. Keywords Stiffness . Tolerancing . Free state . ISO GPS standards . Quality control and inspection . Computational geometry/ CAD
1 Introduction Tolerancing has always been a non-trivial task and traditionally a major concern in precision manufacturing. However, globalized supply chain in modern industrial environment imposed the transition from bespoke assembly to the manufacture of parts made in different places all over the world that fit together with a high degree of repeatability. Therefore, tolerance assignment, i.e. the type and range of acceptable geometrical variation, has become a critical step for the majority of
* Georgios Kaisarlis [email protected] 1
Section of Mechanical Design and Automatic Control, School of Mechanical Engineering, National Technical University of Athens, Heroon Polytechniou 9, Zografou, 15780 Athens, Greece
mechanical engineering design projects. The global need for comp
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