Parts Tolerance Allocation Based on Assembly Clearance Analysis and Product Functional Parameters

Abstract:

Geometric tolerances are assigned to avoid parts rejection in a manufacturing process while ensuring fulfillment of intended function. Selection of tolerance value is an important task which affects the overall product cost and performance both. The significance of tolerance value is more evident in case of mating parts where the dimension of more than one parts share responsibility of successful assembly and design. The objective of this research is to determine appropriate tolerance value based on assembly clearance analysis which takes into account relationship between assembly clearance and product performance parameters. The study is conducted through CAD-CAE integrated finite element analysis (FEA) simulations of the product process model. The results output help in distinguishing different tolerance levels which can be further probed for optimal, using available manufacturing resource capability data. The research output is a more practical tolerance value achieved based on product performance analysis as well as available resources and appropriate cost. The results obtained validate the utility of the approach presented in this paper.

• Periodical: Applied Mechanics and Materials (Volume 163)
• Pages: 116-120
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.163.116
• Online since: April 2012
• Authors: Ahmad Zia, Li Hong Qiao
• Keywords: Assembly Clearance Analysis, CAD/CAE, Engineering Design, Finite Element Analysis (FEA), Geometric Tolerance, Tolerance Allocation

References

[1] S. Lee and C. Yi, Statistical tolerance and clearance analysis for assembly. Proceedings of IEEE/RSJ International Conference on Intelligent Robots and Systems. (1996) IROS 96: 688-695.

DOI: 10.1109/iros.1996.571038

[2] S. Jin, C. Zheng, K. Yu and X. Lai, Tolerance design optimization on cost – quality trade-off using the Shapley value method. J. of Manufac. Sys., 29(4) (2011) 142-150.

DOI: 10.1016/j.jmsy.2011.01.003

[3] K. Sivakumar, C. Balamurugan and S. Ramabalan, Simultaneous optimal selection of design and manufacturing tolerances with alternative manufacturing process selection. Comput. Aided Des. 43(2) 207-218. Elsevier Ltd. doi: 10. 1016/j. cad. 2010. 10. 001.

DOI: 10.1016/j.cad.2010.10.001

[4] M. Mansuy, M. Giordano and P. Hernandez, A new calculation method for the worst case tolerance analysis and synthesis in stack-type assemblies. Comput. Aided Des. 43(9) (2011) 1118-11125.

DOI: 10.1016/j.cad.2011.04.010

[5] T. Y. Lin and C. C. Cheng, A novel opto-mechanical tolerance analysis method for precision lens systems. Precis. Eng. 35(3) (2011) 447-454.

DOI: 10.1016/j.precisioneng.2011.02.001

[6] E. Pearce, A. Parkinson and K. Chase, Tolerance analysis and design of nesting forces for exactly constrained mechanical assemblies. Res. in Eng. Des. 15(2004) 182-191.

DOI: 10.1007/s00163-004-0053-9

[7] H. P. Peng, X. Q. Jiang and X. J. Liu, Concurrent optimal allocation of design and process tolerances for mechanical assemblies with interrelated dimension chains. Int. J. of Prod. Res. 46 (24) (2008) 6963–6979.

DOI: 10.1080/00207540701427037

[8] D. I. D. You, Tolerance analysis: Preparing your model for the real world. Parametric Technology Corporation (PTC) (2009). www. creo. uk. com/articles_tolerance_analysis. html.

[9] J. J. Shah, G. Ameta, Z. Shen and J. K. Davidson, Navigating the tolerance analysis maze. Comput. Aided Des. & Appl. 4(5) (2007) 705–718. http: /cadanda. com/CAD_4_5_13. PDF.

DOI: 10.1080/16864360.2007.10738504

[10] L. Guowei, Z. Weimin and C. Can, Tolerance analysis considering the impact of working conditions on product performance. 2nd International Conference on Industrial Mechatronics and Automation (ICIMA 2010).

DOI: 10.1109/icindma.2010.5538102

[11] A. Asha, S. M. Kannan and V. Jayabalan, Optimization of clearance variation in selective assembly for components with multiple characteristics, Int. J. of Adv. Manufac. Technol. (2008) 1026-1044.

DOI: 10.1007/s00170-007-1136-3

[12] K. Kappaganthu and C. Nataraj, Nonlinear modeling and analysis of a rolling element bearing with a clearance. Commun. in Nonlinear Sci. and Num. Sim. 16(10) (2011) 4134-4145.

DOI: 10.1016/j.cnsns.2011.02.001

[13] H. Marjamaki and J. Makinen, Modeling a telescopic boom – the 3D case: Part II. Comput. and Struct. 84 (29-30) (2006) 2001–(2015).

[14] G. Kelly, S. Hallstro, Bearing strength of carbon fiber/epoxy laminates: effects of bolt-hole clearance. Composites Part B: Eng. 35(4) (2004) 331–343.

DOI: 10.1016/j.compositesb.2003.11.001

[15] L. Tong, Bearing failure of composite bolted joints with non-uniform bolt-to-washer clearance. Composites Part A: Appl. Sci. and Manufac. 31(6) (2000) 609-615.

DOI: 10.1016/s1359-835x(99)00090-1

[16] B. G. Kiral, Effect of the clearance and interference-fit on failure of the pin-loaded composites. Materials and Des. 31(1) (2010) 85-93.

DOI: 10.1016/j.matdes.2009.07.009