Ce travail de recherche traite un problème qui joue un rôle très important pour le succès desprogrammes de fabrication : le tolérancement tridimensionnel, essentiel pour définir la géométried'une pièce mécanique assurant sa meilleure fonctionnalité dans un assemblage avec uneprécision optimale.Une méthode des chaînes de cotes angulaires tridimensionnelles a été développée. Cette méthodepermet d’une part l’optimisation du calcul des dispersions angulaires tridimensionnelles etd’autre part de valider la gamme de fabrication par la vérification du respect des tolérancesimposées par le bureau d’études en tenant compte des précisions des procédés utilisés.Cette étude est basée sur l’analyse de deux fonctions paramétrées qui sont étudiées pourdéterminer le défaut fabriqué : le défaut angulaire et la longueur projetée. Le défaut angulairereprésente le cumul des défauts angulaires générés par le processus de fabrication de la pièce. Lesdéfauts angulaires sont déterminés en fonction de la précision des machines outils. La longueurprojetée de la surface tolérancée est une caractéristique qui dépend uniquement de la forme de lasurface.Ensuite, à partir de ces deux fonctions paramétrées, le défaut fabriqué est déterminé puiscomparé avec la condition fonctionnelle afin de vérifier si la gamme choisie permet en fin duprocessus de fabrication de donner une pièce conforme. / To verify the capacity of a manufacturing process to make the corresponding parts it is necessaryto simulate the defects that it generates and to analyze the correspondence of produced parts withthe functional tolerances. In order to check the capability of a manufacturing process to carry outsuitable parts, it is necessary to analyze each functional tolerance.The main objective of our work is to define a methodology of tolerancing analysis. Thedeveloped method allows to determine the manufacturing tolerances in the case of angular chainsof dimensions and to check its correspondence with the functional tolerances.The objective of this work is to analyze two parameterized functions: the angular defect and theprojected length of the toleranced surface. The angular defect represents the angular defectgenerated by the manufacturing process. It is determined according to the machine toolsprecision. We consider only the geometrical defects, making the assumption that the form defectsare negligible. The projected length of toleranced surface is a characteristic which depends onlyon the form of surface.The manufactured defect is determined from these two parameterized functions. Then it will becompared with the functional condition in order to check if the selected machining range allows,at end of the manufacturing process, to give a suitable part.

Dans le cadre de la conception et de la fabrication des produits industriels, on retrouve principalement les étapes de conception, fabrication et contrôle. Le concepteur défini un tolérancement fonctionnel des pièces en lien étroit avec les procédés de fabrication. L’étape du contrôle des pièces est alors l’étape primordiale permettant la validation du produit fabriqué vis-à-vis des besoins du concepteur. Le sujet de recherche se place dans une optique d’optimisation du processus de contrôle des pièces. Cette étude d’optimisation du processus de contrôle devra se faire à plusieurs niveaux : - Au niveau des coûts liés à l’opération de mesure : lorsqu’un opérateur définit sa gamme de contrôle, il valide si possible l’ensemble de la pièce sur un unique moyen de mesure, même si le moyen de mesure choisi n’est pas le plus adapté. Cette partie de l’étude concerne les concepts de capabilité des moyens de mesures, tant matériels que logiciels. Elle permettra de définir les limites de chaque appareil. L’analyse poussée de l’adéquation entre le tolérancement et les matériels de mesure permet également au contrôleur de définir une stratégie économique de mesure (temps, matériel, …). - Au niveau des innovations techniques à prendre en compte : l’utilisation couplée d’un logiciel de calcul par éléments finis : Abaqus (permettant de modéliser les déformations des pièces lors de leur conformation sur le montage de contrôle), et d’un logiciel de traitement du tolérancement : 3DCS (permettant de valider les effets des dispersions des moyens de contrôle sur le résultat de la mesure : incertitude de mesure). / As part of the design and manufacturing of industrial products, we mainly find the steps of design, manufacture and control. The designer choose functional tolerancing values and specification for a part closely with manufacturing processes. The step of the control of parts is then an essential stage of the validation of the product made with respect to the needs of the designer. The research subject is placed in order to optimize process control parts. This optimization should be done at several levels: - In terms of costs to the measurement process: when an operator sets its control methodology, he validates if possible the entire piece on a unique way to measure it, even if the measurement device selected is not the most appropriate. This part of the study concerns the concepts of capability of measuring devices and calculation methods. It will define the limits of each machine. The analysis of the adequacy between the tolerancing specifications and the measurement tools also allows the controller to define a strategy for economic measurement (time, equipment, ...). - In terms of technical innovations to be taken into account: we will use simultaneously a finite element software, (Abaqus, for modeling the deformations of parts during the control process) and a software for tolerances analysis, (3DCS, to validate the effects of the dispersions of the measurement device over the validity of the result of the measure : measurement uncertainty).

In the age where quick turn around time and high speed manufacturing methods are becoming more important, quality assurance is a consistent bottleneck in production. With the development of cheap and fast computer hardware, it has become viable to use machine vision for the collection of data points from a machined part. The generation of these large sample points have necessitated a need for a comprehensive algorithm that will be able to provide accurate results while being computationally efficient. Current established methods are least-squares (LSQ) and non-linear programming (NLP). The LSQ method is often deemed too inaccurate and is prone to providing bad results, while the NLP method is computationally taxing. A novel method of using support vector regression (SVR) to solve the NP-hard problem of cylindricity of machined parts is proposed. This method was evaluated against LSQ and NLP in both accuracy and CPU processing time. An open-source, user-modifiable programming package was developed to test the model. Analysis of test results show the novel SVR algorithm to be a viable alternative in exploring different methods of cylindricity in real-world manufacturing.

Aspheric and freeform surfaces are becoming more common as optical designs become more sophisticated and new generations of fabrication tools reduce cost. Unlike spherical surfaces, these surfaces are fabricated with processes that leave a signature or "structure" that is primarily in the mid-spatial frequency region. Tolerancing aspheric and freeform surfaces requires attention to both surface form and structured mid-spatial frequency fabrication errors. These structured surface errors are shown to create image artifacts such as ghosts, and ripples in the MTF profile. Spatial frequencies beyond "form" errors are often ignored or are modeled with statistical descriptors, which do not account for structured errors.This work explores and develops the theory to describe these errors without statistical assumptions. The analytic source of these artifacts in the image Point Spread Function and the Modulation Transfer Function are compared with computational models. The magnitudes of the image artifacts arising from structured surface errors are shown to be non-linear with surface height. It is also shown that multiple structured surface frequencies mix to create sum and difference diffraction orders that are not present in statistical models.An algorithm is developed that enables an optical designer to determine the important spatial frequencies and magnitudes of allowable errors given an MTF performance budget.

abstract: There is very little in the way of prescriptive procedures to guide designers in tolerance specification. This shortcoming motivated the group at Design Automation Lab to automate tolerancing of mechanical assemblies. GD&T data generated by the Auto-Tolerancing software is semantically represented using a neutral Constraint Tolerance Feature (CTF) graph file format that is consistent with the ASME Y14.5 standard and the ISO STEP Part 21 file. The primary objective of this research is to communicate GD&T information from the CTF file to a neutral machine readable format. The latest STEP AP 242 (ISO 10303-242) “Managed model based 3D engineering“ aims to support smart manufacturing by capturing semantic Product Manufacturing Information (PMI) within the 3D model and also helping with long-term archiving of the product information. In line with the recommended practices published by CAx Implementor Forum, this research discusses the implementation of CTF to AP 242 translator. The input geometry available in STEP AP 203 format is pre-processed using STEP-NC DLL and 3D InterOp. While the former is initially used to attach persistent IDs to the topological entities in STEP, the latter retains the IDs during translation to ACIS entities for consumption by other modules in the Auto-tolerancing module. The associativity of GD&T available in CTF file to the input geometry is through persistent IDs. C++ libraries used for the translation to STEP AP 242 is provided by StepTools Inc through the STEP-NC DLL. Finally, the output STEP file is tested using available AP 242 readers and shows full conformance with the STEP standard. Using the output AP 242 file, semantic GDT data can now be automatically consumed by downstream applications such as Computer Aided Process Planning (CAPP), Computer Aided Inspection (CAI), Computer Aided Tolerance Systems (CATS) and Coordinate Measuring Machines (CMM). / Dissertation/Thesis / Masters Thesis Mechanical Engineering 2016

abstract: This thesis concerns the role of geometric imperfections on assemblies in which the location of a target part is dependent on supports at two features. In some applications, such as a turbo-machine rotor that is supported by a series of parts at each bearing, it is the interference or clearance at a functional target feature, such as at the blades that must be controlled. The first part of this thesis relates the limits of location for the target part to geometric imperfections of other parts when stacked-up in parallel paths. In this section parts are considered to be rigid (non-deformable). By understanding how much of variation from the supporting parts contribute to variations of the target feature, a designer can better utilize the tolerance budget when assigning values to individual tolerances. In this work, the T-Map®, a spatial math model is used to model the tolerance accumulation in parallel assemblies. In other applications where parts are flexible, deformations are induced when parts in parallel are clamped together during assembly. Presuming that perfectly manufactured parts have been designed to fit perfectly together and produce zero deformations, the clamping-induced deformations result entirely from the imperfect geometry that is produced during manufacture. The magnitudes and types of these deformations are a function of part dimensions and material stiffnesses, and they are limited by design tolerances that control manufacturing variations. These manufacturing variations, if uncontrolled, may produce high enough stresses when the parts are assembled that premature failure can occur before the design life. The last part of the thesis relates the limits on the largest von Mises stress in one part to functional tolerance limits that must be set at the beginning of a tolerance analysis of parts in such an assembly. / Dissertation/Thesis / M.S. Mechanical Engineering 2012

No description available.

L’objectif de l’étude est d’identifier le comportement des liaisons d’un mécanisme du point de vue des déplacements en fonction des défauts de forme et des jeux. Le sujet est abordé selon une approche théorique et une approche expérimentale.La partie théorique montre la dualité entre les deux concepts utilisés : le domaine jeu et la surface convexe des différences. Elle montre également la typologie des domaines et l’influence des incertitudes de forme sur ces domaines.En parallèle, un dispositif expérimental est développé. Il permet, non seulement, de réaliser la mesure des déplacements dans la liaison avec l’exactitude nécessaire, mais aussi, de valider les résultats par une simulation de l’assemblage à partir de la mesure 3D des surfaces en contact. L’expérimentation porte sur plusieurs couples de surfaces comportant des défauts de forme de différents types. L'influence d'un chargement mécanique est étudiée afin de quantifier les déformations locales de surfaces de contact et l'évolution des écarts de position entre les pièces. / The aim of the study is to identify, in terms of displacements, the joint behavior of a mechanism in function of form defects and gaps. Two approaches are proposed : a theoretical approach and an experimental one.The theoretical part presents the duality between the two concepts used in the experimental approach : gap hull and convex difference surface. It outlines also the typology of gap hulls and the influence of the form uncertainties on gap hulls.In parallel, an experimental device is developed. It allows, not only, to carry out the measure of displacements in the joint with the necessary accuracy, but also, to validate the results by an assembly simulation from the 3D measurement of the surfaces in contact. The experimentation involves several pairs of surfaces with different types of form defects. The influence of mechanical loads is studied in order to quantify the local deformation of the surfaces in contact and the evolution of location deviations between these surfaces.

La géométrie d'une pièce fabriquée réelle diffère de la pièce virtuelle de CAO (Conception Assistée par Ordinateur. Cette différence est due à la somme des écarts inhérents à la fabrication. L'objectif de ce travail est d’introduire des pièces virtuelles ayant des défauts de forme (Skin Model Shape) dans les applications d'ingénierie afin de répondre aux exigences croissantes de l'industrie en matière de gestion de la qualité de la géométrie des produits. Les travaux traitent de divers aspects, particulièrement de la génération de défauts de forme, de la simulation d'assemblage et de la métrologie virtuelle.Les méthodes permettant de générer des défauts de forme sur des surfaces simples sont analysés et classées. En raison des défauts de forme, la combinaison de surfaces simples pour générer une pièce entière induit une incohérence géométrique au niveau des arêtes. Une méthode globale basée sur les éléments finis et une méthode locale basée sur le lissage local de maillage sont utilisées pour résoudre ce problème.Pour prédire l'écart des caractéristiques fonctionnelles, la simulation d'assemblage est effectuée en utilisant des surfaces avec défauts de forme. Une approche est développée sur la base de la condition de complémentarité linéaire et du torseur de petits déplacements pour prendre en compte les conditions aux limites de l'assemblage, telles que les déplacements et les charges.Des méthodes pour évaluer les écarts sur les modèles de surfaces avec défauts de forme sont également étudiées. Les spécifications sur le produit sont exprimées avec GeoSpelling et évaluées à l'aide du torseur de petits déplacements. Les méthodes développées sont intégrées dans un laboratoire virtuel pour l'apprentissage en ligne.Les études susmentionnées complètent et étendent les méthodes de gestion des tolérances basées sur GeoSpelling et le « skin » modèle. / The geometry of a real manufactured part differs from the virtual workpieces designed in Computer Aided Design (CAD) systems. This difference is due to the accumulation of unavoidable manufacturing deviations. The objective of this work is to implement virtual workpieces with form defects (Skin Model Shape) in engineering applications to meet the industry’s increasing demands in product geometry quality management. Various aspects are covered here, in particular form defect generation, assembly simulation and virtual metrology.Methods to generate form defects on simple surfaces are reviewed and classified. Due to form defects, the combination of simple surfaces to generate a whole part led to inconsistency on the edges. A global FEA-based method and a local mesh smoothing based method are used to overcome this issue.To predict the deviation of functional characteristics, assembly simulation is conducted using skin model shapes. An approach is developed based on the Linear Complementarity Condition and the Small Displacement Torsor to take into account assembly boundary conditions, such as displacements and loads.Methods to evaluate deviation values on skin model shapes are also studied. Product specifications are expressed with GeoSpelling, and evaluated using the Small Displacement Torsor method. The developed methods are integrated into an online Virtual Laboratory for e-learning.The above-mentioned studies complement and extend the tolerance management methods based on GeoSpelling and skin models.

Product tolerancing decisions made in product design have a significant effect on manufacturing environmental and cost performances by strongly influencing both the selection and operation of processing machinery. These decisions however are typically made without quantitative knowledge of their effects in manufacturing. With estimates of environmental and cost performances of manufacturing processes required to achieve specific part designs earlier in the product design cycle, designers may make more informed, and potentially better, design decisions with respect to manufacturing environmental and cost performance goals. In this thesis a method for quantifiably relating product tolerancing decisions to environmental and cost performances in manufacturing in order to provide decision support for cost and environmentally conscious design for manufacturing is developed. The method is instantiated as an Excel-based tool and exercised by two illustrative examples of increasing complexity, as well as a study of the manufacture of automotive transmission pinion gears with differing tolerance requirements. Uncertainty analysis is performed through the use of @RISK software; the uncertainty of parameters associated with manufacturing operations and machinery is captured through the use of probability density functions and Monte Carlo simulation is performed. Simulation results provide insight into the uncertainty of performance estimates and the risks associated with ensuing decision making. This method may be useful to product designers, as well as process planners, to support decision making efforts related to cost and environmental consciousness in the manufacturing phase of the product life cycle.