A New Approach for Synthesis of 3D Tolerances with Consideration of Flatness Defects in Mechanical Assembly Using Jacobian Torsor Model
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DOI: https://doi.org/10.15866/irea.v12i3.23557
Abstract
This research introduces a novel and practical approach to statistical tolerance synthesis in mechanical assemblies that adheres to ISO/ASME standards. The approach combines the unified Jacobian torsor model with Monte Carlo simulation and integrates flatness defects, dimensional, and geometric tolerances. The model is built using the Functional Requirements (FR) of an assembly and the starting tolerance values of the Functional Elements (FE) that make up the tolerance chain. While the model initially produces deterministic results, Monte Carlo simulation transforms it into a statistical model. Iterative simulations are conducted to evaluate the model. Random values for the torsor components corresponding to the functional elements are employed in each simulation until the predetermined maximum number of iterations is reached. Then, a set of values that represents the components of the Functional Requirement (FR) torsor is generated by repeatedly multiplying the model. A percentage that indicates the contribution of each Functional Element (FE) to the total Functional Requirement (FR) is calculated. This percentage aids in identifying the critical tolerance value that requires modification to ensure that the calculated functional requirement equals the desired functional requirement value. The significance of tolerances for flatness defects in ensuring the quality and precision of manufactured parts is emphasized in ISO/ASME standards. However, statistical studies on geometric tolerances often overlook these defects, leading to a decrease in tolerance analysis accuracy. The proposed approach employs additional torsors to model flatness defects and uses small displacement torsors to model tolerance zones. To demonstrate the application of this approach, an example of positioning and holding a milling part assembly is provided. This novel approach is expected to offer a practical and efficient solution for tolerance redesign, particularly in complex engineering systems where the performance of the entire system is reliant on the interplay between different components.
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