In this research, we describe a computer-aided approach to geometric tolerance analysis for assemblies and mechanisms. A series of as-manufactured component models are generated within a NURBS-based solid modeling environment. These models reflect errors in component geometry that are characteristic of the manufacturing processes used to produce the components. The effects of different manufacturing process errors on product function are tested by simulating the assembly of imperfect-form component models and by measuring geometric attributes of the assembly that correspond to product functionality. A tolerance analysis model is constructed by generating and testing component variants that represent different manufacturing precision levels. The application of this approach to tolerance analysis is demonstrated using a case study that is based on a high-speed stapling mechanism.

Issue Section:
Research Papers
Keywords:
CAD, mechanical engineering computing, solid modelling, tolerance analysis
Topics:
Errors, Manufacturing, Rotation, Tolerance analysis, Geometry, Simulation
1.
Dimensioning and Tolerancing: ASME Y14.5M—1994
,
American Society of Mechanical Engineers
,
New York, NY
, 1995.
2.
Allen
,
G.
, 1993, “
Tolerances and Assemblies in CAD\CAM Systems
,”
Manuf. Rev.
0896-1611,
6
, pp.
320
–
328
.
3.
Chase
,
K. W.
,
Gao
,
J.
,
Magleby
,
S. P.
, and
Sorensen
,
C. D.
, 1996, “
Including Geometric Feature Variations in Tolerance Analysis of Mechanical Assemblies
,”
IIE Trans.
0740-817X,
1996
, pp.
795
–
807
.
4.
Zou
,
Z.
, and
Morse
,
E. P.
, 2003, “
Applications of the GapSpace Model for Multidimensional Mechanical Assemblies
,”
ASME J. Comput. Inf. Sci. Eng.
1530-9827,
3
, pp.
22
–
30
.
Crossref
Search ADS
 
5.
Cvetko
,
R.
,
Chase
,
K. W.
, and
Magleby
,
S. P.
, 1998, “
New Metrics for Evaluating Monte Carlo Tolerance Analysis of Assemblies
,”
Association for the Development of Computer-Aided Tolerancing Systems (ADCATS)
,
ADCATS Publication 98-2
, http://adcats.et.byu.edu/WWW/Publication/98-2/CvP1-2col_6=30=98.pdfhttp://adcats.et.byu.edu/WWW/Publication/98-2/CvP1-2col_6=30=98.pdf
6.
LaPerriere
,
L.
, and
Kabore
,
T.
, 2001, “
Monte Carlo Simulation of Tolerance Synthesis Equations
,”
Int. J. Prod. Res.
0020-7543,
39
(
11
), pp.
2395
–
2406
.
Crossref
Search ADS
 
7.
Pandit
,
V.
, and
Starkey
,
J. M.
, 1988, “
Mechanical Tolerance Analysis Using a Statistical Generate-and-Test Procedure
,”
ASME International Computers in Engineering Conference
, pp.
29
–
34
.
8.
Oppenheim
,
A. V.
, and
Schafer
,
R. W.
, 1989,
Discreet-Time Signal Processing
,
Prentice-Hall
,
Englewood Cliffs, NJ
, pp.
84
–
85
.
9.
Kline
,
W. A.
,
DeVor
,
R. E.
, and
Shareef
,
I. A.
, 1982, “
The Prediction of Surface Accuracy in End Milling
,”
ASME J. Eng. Ind.
0022-0817,
104
, pp.
272
–
278
.
Crossref
Search ADS
 
10.
Pierce
,
S.
, 2003, “
A Method for Integrating Form Errors Into Tolerance Analysis
,” Ph.D. thesis, School of Mechanical Engineering, Georgia Institute of Technology.
11.
Pierce
,
S.
, and
Rosen
,
D. W.
, 2005, “
Simulation of Mating Between Non-Analytic Surfaces Using a Mathematical Programming Formulation
,”
Proceedings of the 2005 ASME Computers in Information and Engineering Conference
,
Long Beach, CA
, Paper No. DETC2005-84232.
12.
Turner
,
J. U.
, 1990, “
Relative Positioning of Parts in Assemblies Using Mathematical Programming
,”
Comput.-Aided Des.
0010-4485,
22
(
7
), pp.
394
–
400
.
Crossref
Search ADS
 
13.
“Accuracy of Milled Surfaces: Arbor Type Cutters vs. End Mills,”
Metal Cuttings
, January, 1962,
The National Twist Drill and Tool Company
,
Rochester, MI
.
14.
Gu
,
F.
,
Melkote
,
S. N.
,
Kapoor
,
S. G.
, and
DeVor
,
R. E.
, 1994, “
A Model for the Prediction of Surface Flatness in Face Milling
,”
Materials Issues in Machining-II and the Physics of Machining Processes-II
,
ASME
,
New York, NY
.
15.
EMSIM End-Milling Simulation Software Testbed, The Machine Tool Agile Manufacturing Research Institute (http://mtamri.me.uiuc.edu/http://mtamri.me.uiuc.edu/).
16.
Bhote
,
K. R.
, 1998,
World Class Quality: Design of Experiments Made Easier, More Cost Effective Than SPC
American Management Association
,
New York
.
Copyright © 2008
 by American Society of Mechanical Engineers
You do not currently have access to this content.