Models for Computer Aided Tolerancing in Design and Manufacturing: Selected Conference Papers from the 9th CIRP International Seminar on Computer-Aided ... Tempe, Arizona, USA, 10-12 April, 2005

364 Pages·2006·13.32 MB·English

by  Joseph K. Davidson

(cid:77)(cid:111)(cid:100)(cid:101)(cid:108)(cid:115)(cid:32)(cid:102)(cid:111)(cid:114)(cid:32)(cid:67)(cid:111)(cid:109)(cid:112)(cid:117)(cid:116)(cid:101)(cid:114)(cid:32)(cid:65)(cid:105)(cid:100)(cid:101)(cid:100)(cid:32)(cid:84)(cid:111)(cid:108)(cid:101)(cid:114)(cid:97)(cid:110)(cid:99)(cid:105)(cid:110)(cid:103)(cid:32)(cid:105)(cid:110)(cid:32)(cid:68)(cid:101)(cid:115)(cid:105)(cid:103)(cid:110)(cid:32)(cid:97)(cid:110)(cid:100)(cid:32)(cid:77)(cid:97)(cid:110)(cid:117)(cid:102)(cid:97)(cid:99)(cid:116)(cid:117)(cid:114)(cid:105)(cid:110)(cid:103)
(cid:77)(cid:111)(cid:100)(cid:101)(cid:108)(cid:115)(cid:32)(cid:102)(cid:111)(cid:114)(cid:32)(cid:67)(cid:111)(cid:109)(cid:112)(cid:117)(cid:116)(cid:101)(cid:114)(cid:32)(cid:65)(cid:105)(cid:100)(cid:101)(cid:100)(cid:32)
(cid:84)(cid:111)(cid:108)(cid:101)(cid:114)(cid:97)(cid:110)(cid:99)(cid:105)(cid:110)(cid:103)(cid:32)(cid:105)(cid:110)(cid:32)(cid:68)(cid:101)(cid:115)(cid:105)(cid:103)(cid:110)
(cid:32)(cid:97)(cid:110)(cid:100) (cid:77)(cid:97)(cid:110)(cid:117)(cid:102)(cid:97)(cid:99)(cid:116)(cid:117)(cid:114)(cid:105)(cid:110)(cid:103)
(cid:83)(cid:101)(cid:108)(cid:101)(cid:99)(cid:116)(cid:101)(cid:100)(cid:32)(cid:67)(cid:111)(cid:110)(cid:102)(cid:101)(cid:114)(cid:101)(cid:110)(cid:99)(cid:101)(cid:32)(cid:80)(cid:97)(cid:112)(cid:101)(cid:114)(cid:115)(cid:32)(cid:102)(cid:114)(cid:111)(cid:109)(cid:32)(cid:116)(cid:104)(cid:101)(cid:32)(cid:57)(cid:116)(cid:104)(cid:32)(cid:67)(cid:73)(cid:82)(cid:80)
(cid:73)(cid:110)(cid:116)(cid:101)(cid:114)(cid:110)(cid:97)(cid:116)(cid:105)(cid:111)(cid:110)(cid:97)(cid:108)(cid:32)(cid:83)(cid:101)(cid:109)(cid:105)(cid:110)(cid:97)(cid:114)(cid:32)(cid:111)(cid:110)(cid:32)(cid:67)(cid:111)(cid:109)(cid:112)(cid:117)(cid:116)(cid:101)(cid:114)(cid:45)(cid:65)(cid:105)(cid:100)(cid:101)(cid:100)(cid:32)(cid:84)(cid:111)(cid:108)(cid:101)(cid:114)(cid:97)(cid:110)(cid:99)(cid:105)(cid:110)(cid:103)(cid:44)
(cid:104)(cid:101)(cid:108)(cid:100)(cid:32)(cid:97)(cid:116)(cid:32)(cid:65)(cid:114)(cid:105)(cid:122)(cid:111)(cid:110)(cid:97)(cid:32)(cid:83)(cid:116)(cid:97)(cid:116)(cid:101)(cid:32)(cid:85)(cid:110)(cid:105)(cid:118)(cid:101)(cid:114)(cid:115)(cid:105)(cid:116)(cid:121)(cid:44)(cid:32)(cid:84)(cid:101)(cid:109)(cid:112)(cid:101)(cid:44)(cid:32)(cid:65)(cid:114)(cid:105)(cid:122)(cid:111)(cid:110)(cid:97)(cid:44)(cid:32)(cid:85)(cid:83)(cid:65)(cid:44)
(cid:49)(cid:48)(cid:45)(cid:49)(cid:50)(cid:32)(cid:65)(cid:112)(cid:114)(cid:105)(cid:108)(cid:44)(cid:32)(cid:50)(cid:48)(cid:48)(cid:53)
(cid:69)(cid:100)(cid:105)(cid:116)(cid:101)(cid:100)(cid:32)(cid:98)(cid:121)
(cid:74)(cid:111)(cid:115)(cid:101)(cid:112)(cid:104)(cid:32)(cid:75)(cid:46)(cid:32)(cid:68)(cid:97)(cid:118)(cid:105)(cid:100)(cid:115)(cid:111)(cid:110)
(cid:68)(cid:101)(cid:115)(cid:105)(cid:103)(cid:110)(cid:32)(cid:65)(cid:117)(cid:116)(cid:111)(cid:109)(cid:97)(cid:116)(cid:105)(cid:111)(cid:110)(cid:32)(cid:76)(cid:97)(cid:98)(cid:111)(cid:114)(cid:97)(cid:116)(cid:111)(cid:114)(cid:121)
(cid:68)(cid:101)(cid:112)(cid:97)(cid:114)(cid:116)(cid:109)(cid:101)(cid:110)(cid:116)(cid:32)(cid:111)(cid:102)(cid:32)(cid:77)(cid:101)(cid:99)(cid:104)(cid:97)(cid:110)(cid:105)(cid:99)(cid:97)(cid:108)(cid:32)(cid:97)(cid:110)(cid:100)(cid:32)(cid:65)(cid:101)(cid:114)(cid:111)(cid:115)(cid:112)(cid:97)(cid:99)(cid:101)(cid:32)(cid:69)(cid:110)(cid:103)(cid:105)(cid:110)(cid:101)(cid:101)(cid:114)(cid:105)(cid:110)(cid:103)
(cid:73)(cid:114)(cid:97)(cid:32)(cid:65)(cid:46)(cid:32)(cid:70)(cid:117)(cid:108)(cid:116)(cid:111)(cid:110)(cid:32)(cid:83)(cid:99)(cid:104)(cid:111)(cid:111)(cid:108)(cid:32)(cid:111)(cid:102)(cid:32)(cid:69)(cid:110)(cid:103)(cid:105)(cid:110)(cid:101)(cid:101)(cid:114)(cid:105)(cid:110)(cid:103)
(cid:65)(cid:114)(cid:105)(cid:122)(cid:111)(cid:110)(cid:97)(cid:32)(cid:83)(cid:116)(cid:97)(cid:116)(cid:101)(cid:32)(cid:85)(cid:110)(cid:105)(cid:118)(cid:101)(cid:114)(cid:115)(cid:105)(cid:116)(cid:121)
(cid:84)(cid:101)(cid:109)(cid:112)(cid:101)(cid:44)(cid:32)(cid:65)(cid:114)(cid:105)(cid:122)(cid:111)(cid:110)(cid:97)(cid:44)(cid:32)(cid:85)(cid:83)(cid:65)
AC.I.P. Catalogue record for this book is available from the Library of Congress.
(cid:73)(cid:83)(cid:66)(cid:78)(cid:45)(cid:49)(cid:48)(cid:32)(cid:32)(cid:49)(cid:45)(cid:52)(cid:48)(cid:50)(cid:48)(cid:45)(cid:53)(cid:52)(cid:51)(cid:55)(cid:45)(cid:56)(cid:32)(cid:40)(cid:72)(cid:66)(cid:41)
(cid:73)(cid:83)(cid:66)(cid:78)(cid:45)(cid:49)(cid:51)(cid:32)(cid:32)(cid:57)(cid:55)(cid:56)(cid:45)(cid:49)(cid:45)(cid:52)(cid:48)(cid:50)(cid:48)(cid:45)(cid:53)(cid:52)(cid:51)(cid:55)(cid:45)(cid:50)(cid:32)(cid:40)(cid:72)(cid:66)(cid:41)
(cid:73)(cid:83)(cid:66)(cid:78)(cid:45)(cid:49)(cid:48)(cid:32)(cid:32)(cid:49)(cid:45)(cid:52)(cid:48)(cid:50)(cid:48)(cid:45)(cid:53)(cid:52)(cid:51)(cid:56)(cid:45)(cid:54)(cid:32)(cid:40)(cid:101)(cid:45)(cid:98)(cid:111)(cid:111)(cid:107)(cid:41)
(cid:73)(cid:83)(cid:66)(cid:78)(cid:45)(cid:49)(cid:51)(cid:32)(cid:32)(cid:57)(cid:55)(cid:56)(cid:45)(cid:49)(cid:45)(cid:52)(cid:48)(cid:50)(cid:48)(cid:45)(cid:53)(cid:52)(cid:51)(cid:56)(cid:45)(cid:57)(cid:32)(cid:40)(cid:32)(cid:101)(cid:45)(cid:98)(cid:111)(cid:111)(cid:107)(cid:41)
Published by Springer,
P.O. Box 17, 3300 AADordrecht, The Netherlands.
www.springer.com
Printed on acid-free paper
All Rights Reserved
© 2007 Springer
No part of this work may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying, microfilming, recording
or otherwise, without written permission from the Publisher, with the exception
of any material supplied specifically for the purpose of being entered
and executed on a computer system, for exclusive use by the purchaser of the work.
The 9th CIRP International Seminar on Computer-Aided Tolerancing

Arizona State University, Tempe, Arizona 85287-6016, USA
April 10-12, 2005
Sponsored by
CIRP (International Institution for Production Engineering Research)
Arizona State University
International Program Committee
P. Bourdet (France)
K. Chase (USA)
A. Clément (France)
J. K. Davidson (USA)
A. Desrochers (Canada)
H. Elmaraghy (Canada)
C. Fortin (Canada)
F.J.A.M. van Houten (Netherlands)
L. Joskowicz (Israel)
L. Laperrière (Canada)
L. Mathieu (France)
E. Morse (USA)
J. Shah (USA)
V. Srinivasan (USA)
J.-C. Tsai (Taiwan)
A. Weckenmann (Germany)
R.G. Wilhelm (USA)
E. Zussman (Israel)
vi The 9th CIRP International Seminar
National Organizing Committee
J. K. Davidson (Chair)
L. Mathieu (Co-chair)
J. Shah (Co-chair)
R.G. Wilhelm (Co-chair)
G. Ameta
Z. Shen
R. Salinas – C. Standiford – L. Mata-Hauksson
Additional Reviewers
M. Giordano
T. Kurfess
J.-M. Linares
E. Pairel
A. Rivière
R. Söderberg
J.-M. Sprauel
F. Villeneuve
Pref ac e

Computer Aided Tolerancing (CAT) is an important topic in any field of design and
production where parts move relative to one another and/or are assembled together.
Geometric variations from specified dimensions and form always occur when parts are
manufactured. Improvements in production systems only mean that the amounts of the
variations become smaller, but their presence does not disappear. Clearances nearly always
are the measures used to predict how consistently the relative motion will occur and also to
ensure that parts will assemble together in a mass-production environment. But clearances,
which are attributes of pairs of parts, must be converted to tolerances, which are attributes
of individual parts and dimensions. It is this process that CAT is intended to fulfill, all the
while being sensitive to the impact of manufacturability, interchangeability, and
maintainability on parts and product being designed.

To shorten the time from concept to market of a product, it has been increasingly important
to take clearances and the tolerancing of manufacturing variations into consideration right
from the beginning, at the stage of design. Hence, geometric models are defined that
represent both the complete array of geometric variations possible during manufacture and
also the influence of geometry on the function of individual parts and on assemblies of
them. The subject of this book, Models for Computer Aided Tolerancing in Design and
Manufacturing, focuses on mathematical and computer models and their application to the
design and manufacture of machinery and other products. Current CAT systems work for
simple problems in which the geometry is not very elaborate. However, for many practical
applications, consistent results can be obtained only by those who are expert in both solid
modeling and tolerance standards, and sometimes also expert in the computational methods
and machinery for quality control measurements. The software for these three fields are
not well integrated, and the standards for each were derived from different communities
and different premises. Some time ago ISO experts around the world realized how
important the integration of these three fields is. Each new standard in these fields
improves the integration. The ultimate goal, and the motivation for much of the work
described in this book, is to provide CAT systems which are comprehensive enough that
ordinary designers can achieve acceptable and consistent results when assigning tolerances
to dimensions and features.

In 1996, ISO created a new technical committee, the ISO/TC213, in charge of the standards
on geometrical product specification. This committee followed the JHG ISO/TC 3-10-57
which coordinated the technical committees ISO/TC3 “adjustment”, ISO/TC57 “Metrology
and properties of surfaces” and the subcommittee ISO/TC10/SC5 “Specification and
tolerance”. The aim of this committee is to provide industrialists with complete and
vii
viii Preface
coherent standards in the field of specification and geometrical inspection of products
(GPS). In 1996, ISO also published the technical report FD CR ISO/TR 14638 to establish
the array of standards to be created or to revised in the future.

In order to achieve this ambitious goal, it is no longer possible to create or develop
standards based only on engineers’ and experts’ knowledge and practice. Now it is
necessary to have a global and theoretical approach of the geometrical specification and
verification problem. On the basis of French research results, called GEOSPELLING, a
model to describe the micro and macro geometry has been developed. The basic concepts
are described in the document ISO/TR 17450-1 that was published in 2005. The model is
distinct because of its declarative method describing the process of tolerance specification
and the process of tolerance verification in inspection.

The contents of this book originate from a collection of selected papers presented at the 9th
CIRP International Seminar on Computer Aided Tolerancing (CAT), organized by the
Design Automation Laboratory and the Department of Mechanical and Aerospace
Engineering of the Ira A. Fulton School of Engineering, Arizona State University, USA
from April 10-12, 2005. The CIRP (Collège International pour la Recherche en Production
or International Institution for Production Engineering Research) plans this seminar every
two years.

The Seminar presentations in Arizona in 2005 began with the keynote address (page 1) by
Daniel Whitney from the Massachusetts Institute of Technology. In it he points out
specific needs for improvement for CAD and CAT software. Current design practice does
not make a clear distinction between creation of a competent nominal design (that is, one
that is as close as practical to properly constrained or one in which the designer deliberately
inserts desired over-constraint and takes it into account) and performance of a variation
analysis (too often called tolerance analysis). Existing CAD systems do not support this
distinction or yet provide sufficiently adequate tools for addressing each kind of design.
Since the content of his address was taken from the references on page 2, only the abstract
of it appears in this book.

This book focuses in particular on the Models for Computer Aided Tolerancing in Design
and Manufacturing since accurate and comprehensive models are the basis of the
algorithms in software for CAT. Also included are other developments in the field and
present applications.

Models for Computer Aided Tolerancing in Design and Manufacturing provides an
excellent resource to anyone interested in computer aided tolerancing. The book is intended
for a wide audience including:
Preface ix
• Researchers in the fields of product design, Computer Aided Process Planning
(CAPP), precision engineering, inspection, quality control, and dimensional and
geometrical tolerancing,
• Technicians of standardization who are interested in the evolving ISO standards for
tolerancing in mechanical design, manufacturing, and inspection,
• Practitioners of design, design engineers, manufacturing engineers, staff in R&D and
production departments at industries that make mechanical components and machines,
• Software developers for CAD/CAM/CAX and computer aided tolerancing (CAT)
application packages,
• Instructors and students of courses in design that are offered either for degrees by
universities and technical schools, or for professional development through
commercial short-courses, and
• Individuals interested in design, assembly, manufacturing, precision engineering,
inspection, and CAD/CAM/CAQ.

The book is organized into seven parts, the papers in each one corresponding to a principal
topic. The first, Models for Tolerance Representation and Specification, deals with the role
that models play in overcoming some of the shortcomings to CAT. Part 2, Tolerance Ana-
lysis, is a traditional activity of tolerancing in which values for geometric functional condi-
tions are computationally simulated from tolerance-values that are imposed on dimensions
and features of the parts of a mechanism or assembly. Part 3, Tolerance Synthesis, is about
determining the part specifications required to comply with the geometric functional
conditions of the mechanism. Part 4, Computational Metrology and Verification, concerns
the measurements of features and the computational reduction of these to simple values for
comparison to the specified tolerances. Part 5, Tolerances in Manufacturing, deals with the
quality of part handling within the processes of manufacturing and the simulation of
manufacturing processes. Part 6, Applications to Machinery, is about the use of new mo-
dels and methods to solve specific problems of tolerancing in mechanical systems. Part 7,
Incorporating Elasticity in Tolerance Models, shows progress for interfacing models for
computer-aided tolerancing in design and manufacturing with the mechanics of elastic
deformation. Several of these papers highlight applications for parts made from sheet
metal, such as automotive panels and aircraft components.

As Editor, I wish to express my sincere thanks to the authors for their contributions, to the
members of the international program committee and the organizing committee, to the
additional reviewers, and in particular to Mr. G. Ameta, Mr. N. Joshi, Mr. R. Salinas, Ms.
C. Standiford, and Ms. L. Mata-Hauksson for their efforts in getting this book published.

Joseph DAVIDSON
Table of Contents

Preface................................................................................................................................vii

Keynote abstract

A Unified Approach to Design of Assemblies Integrating Nominal and Variation Design
D. E. WHITNEY (MASSACHUSETTS INST. OF TECHNOLOGY, USA)......................................................................1

Tolerance Representation and Specification

Virtual Gauge Representation for Geometric Tolerances in CAD-CAM Systems
E. PAIREL, P. HERNANDEZ, M. GIORDANO (UNIV. DE SAVOIE, FRANCE)..............................................3

Modal Expression of Form Defects
F. FORMOSA, S. SAMPER (UNIV. DE SAVOIE, FRANCE)............................................................................13

Dependence and Independence of Variations of a Geometric Object
P. SERRÉ, A. RIVIÈRE, A. CLÉMENT (CESTI, ST. OUEN, DASSAULT SYSTÈMES, FRANCE).......................23

A Model for a Coherent and Complete Tolerancing Process
L. MATHIEU, A. BALLU (LURPA ENS DE CACHAN, LMP BORDEAUX, FRANCE)......................................35

Tolerance-Maps Applied to the Straightness and Orientation of an Axis
S. BHIDE, G. AMETA, J. K. DAVIDSON, J. J. SHAH (UGS THE PLM
COMPANY, ARIZONA STATE UNIV., USA).................................................................................................................45

Tolerance Analysis

Information Modeling to Manage Tolerances during Product and Process Design
J.- Y. DANTAN, T. LANDMANN, A. SIADAT, P. MARTIN (ENSAM, METZ, FRANCE)...........................55

Relative Positioning of Planar Parts in Toleranced Assemblies
Y. OSTROVSKY-BERMAN, L. JOSKOWICZ (HEBREW UNIV. OF JERUSALEM, ISRAEL)..........................65

Geometrical Variations Management in a Multi-Disciplinary Environment with the Jacobian-Torsor
Model
A. DESROCHERS (UNIV. DE SHERBROOKE, CANADA)........................................................................... .....75

Tolerance Analysis and Synthesis by Means of Deviation Domains, Axi-Symmetric Cases
M. GIORDANO, S. SAMPER, J. P. PETIT (UNIV. DE SAVOIE, FRANCE)....................................................85

Re-Design of Mechanical Assemblies using the Unified Jacobian – Torsor Model for Tolerance
Analysis
W. GHIE, L. LAPERRIÈRE, A. DESROCHERS (UNIV. DU QUÉBEC À TROIS-RIVIÈRES,
UNIVERSITÉ DE SHERBROOKE , CANADA)......................................................................................................95

xi
xii Table of Contents
Tolerance Synthesis

Complex Mechanical Structure Tolerancing by Means of Hyper-graphs
M. GIORDANO, E. PAIREL, P. HERNANDEZ (UNIV. DE SAVOIE, FRANCE)..........................................105

An Efficient Solution to the Discrete Least-Cost Tolerance Allocation Problem with General
Loss Functions
J. LÖÖF, T. HERMANSSON, R. SÖDERBERG (CHALMERS UNIV., SWEDEN)........................................115

Computational Metrology and Verification

Monitoring Coordinate Measuring Machines by User-Defined Calibrated Parts
A. WECKENMANN, S. BEETZ, J. LORZ (UNIV. ERLANGEN-NUREMBERG, ERLANGEN)........................125

Evaluation of Geometric Deviations in Sculptured Surfaces Using Probability Density Estimation
A. BARARI, H. A. ELMARAGHY, G. K. KNOPF (UNIV. OF WESTERN ONTARIO, UNIV. OF
WINDSOR, CANADA)....................................................................................................................................135

How to Automate the Geometrical Tolerances Inspection: A Reverse Engineering Approach
M. GERMANI, F. MANDORLI (POLYTECHNIC UNIV. OF MARCHE, ITALY)..............................................147

A New Algorithm to Assess Revolute Surfaces through Theory of Surface Continuous Symmetry
W. POLINI, U. PRISCO, G. GIORLEO (UNIV. DI CASSINO, UNIV. DEGLI STUDI DI
NAPOLI, ITALY)...........................................................................................................................................157

Statistical Modelling of Geometrical Invariant Sampled Sets
P. CHIABERT, M. DE MADDIS (POLITECNICO DI TORINO, ITALY).........................................................169

Tolerances in Manufacturing

Simulation of the Manufacturing Process in a Tolerancing Point of View: Generic Resolution
of the Positioning Problem
F. VILLENEUVE, F. VIGNAT (UNIV. OF GRENOBLE, FRANCE)...............................................................179

Surface Best Fit: Generated Distribution of the Real Manufacturing Process
S. ARANDA, J. M. LINARES, J. M. SPRAUEL, P. BOURDET (EA (MS)2, I.U.T., LURPA - ENS DE
CACHAN, FRANCE)......................................................................................................................................191

Position Deviation of a Holes Pattern Due to Six-Point Locating Principle
W. POLINI, G. MORONI (UNIV. DI CASSINO, POLITECNICO DI MILANO, ITALY).....................................201

Tolerance Assignment Using Genetic Algorithm for Production Planning
H. SONG, Y. D. YANG, Y. ZHOU, Y. K. RONG (WORCESTER POLYTECHNIC INST., USA)....................213

Applications to Machinery

Impact of Geometric Uncertainties Onto the Operating Performance of a Mechanical System
J. M. LINARES, J. M. SPRAUEL, S. ARANDA, P. BOURDET (EA (MS)2, I.U.T., LURPA - ENS
DE CACHAN, FRANCE).................................................................................................................................225