3d functional tolerancing for helicopter rotor wp 1.5 · pdf file3d functional tolerancing for...
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Page: 1 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved
VIVACE FORUM 1 - WarwickHugo FALGARONE
Benoit FRICERO
3D functional 3D functional tolerancingtolerancingfor Helicopter Rotorfor Helicopter Rotor
WP 1.5.1WP 1.5.1
Introduction of tolerancing issues andstakes for tolerance management
Forum 1 – Warwick - September 20-21, 2005
Page: 2 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved
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Outlines
• Introduction
• Aerospace Tolerancing issues
• Tolerancing tools : State of the Art
• Comparison
• Methodology specifications
• Conclusions
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Introduction
Tolerance analysis = Assembly simulation withmanufactured parts, ie parts with geometric variations.
Manufacturing capability requirement : Continous trade off between cheap manufacturingprocess and high quality product
Features relationship : Garantee Product functionsand assembly
How to define these tolerances ?
How to ensure tracability between function requirement and tolerance specification ?
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Introduction
Functional tolerancing Vs Traditional dimensioning
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Aerospace Tolerancing Issues
Manufacturing cost analysis for an aircraft structure :
Assembly
Manufacturing
Materials
55%
25%
20%
Improve product assemblability
Improve manufacturing capabilitiesImprove tolerance management methodologiesfrom design offices to manufacturing Quality.Use tools to support these methodologies
Page: 6 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved
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Aerospace Tolerancing Issues
Technical data managed for tolerance analysis :
Design requirements: Aerodynamic,Weight, …• Product functions• Key characteristics• Assembly constraints
Product geometrical definition : Digital Mock Up
Manufacturing capabilities
Assembly sequence or kinematic model of assembly process
3D stack chain : List of contributing features for each requirement
Tolerance management is a multidisciplinary process
Page: 7 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved
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Aerospace Tolerancing Issues
A
B
C
D
Nominal Model
A
B
C
Model with deviations
D
B
C
D
A
Sequence A->B->C->D
C
B
Sequence A->D->B ->C
A
D
Assembly sequence impact :
Tolerance annotations include implicitly assembly sequence
Sequence is chosen regarding to product main functions
Page: 8 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved
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Aerospace Tolerancing Issues
Tolerance impact analysis :– How to understand specification for downstream
tolerance users : Manufacturing– How to impact design change on tolerance
specification ?
VIVACE use Case : Non conformityOne dimension of a manufacturd part is out of tolerance
How to status on the associated risk ?• Re-build tolerance analysis to find out
justification of tolerance specification.• Deal with non conformity process even without
Digital Mock Up ; Case of old programs still in production
Page: 9 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved
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Tolerancing tools State of the art
• Kinematic tolerancingObjective : Validate design concepts and define frontier tolerancesWhen : early design stageData needed : Rought geometry, Manufacturing capabilities, building philosophy (kinematic scheme)
• Feature tolerancingObjective : Validate assembly of toleranced parts When : Design validationData needed : Complete geometry with GD&T, assembly sequence
• Flexible tolerancingObjective : Simulate realistic assembly process When : Design validationData needed : FEM, DMU with GD&T, assembly sequence
• Tolerance editionObjective : Edit Geometrical Dimensional and Tolerancing annotations on DMUWhen : DMU Publication (drawings)
Different tools for different goals
Page: 10 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved
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Tolerancing tools : State of the art
• Kinematic tolerancingMecamaster Mecamaster SARLAnaTole EADS CCR
• Feature tolerancing3DCS DCSCeTOL6 Sigma SigMetrixTolerance Manager PCO TechnologieseMTolMate PCT
• Flexible tolerancingCATIA V5 – TAA Dassault Systemes
• Tolerance editionCATIA V5 – FTA & PFTA Dassault Systemes
Page: 11 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved
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Helicopter case study
Rotor case studyMast
Scissors
End Plate
Ring
Objective : Check the continous non-contact between thering and the end plate
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Helicopter case study
• Nominal Position
Plane Contact
Ball JointMast
Scissors
End Plate
• Worst Case Position
Measure
Currently, this computation is done with simplified 1D stack chain.
Ring
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Case study
Demo case study presentation
To simplify the demonstration, let’s use a demo case study easier to handle.
c
e
b
a
d
f
U1
U3 U2
Variations Measures
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Tolerancing tools : State of the art
• Technical Description– Kinematic modelling with liaison– Catia V5 VB integration– Worst case & statistical computation– Variations are included in liaison
Mecamaster
• Remarks– Point based modeling ( no DMU necessary)– No dynamic link with DMU– No translation of Tolerance annotation– Statistical computation very limited– Well adapted for early tolerance analysis
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Tolerancing tools : State of the art
• Modeling
Mecamaster
aa
b & d
f
e
c
Measures
Positioning link
Page: 16 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved
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Tolerancing tools : State of the art
• Technical Description– Kinematic modelling with liaison– Catia V5 CAA integration– Worst case & statistical computation– Variations are included in liaison
AnaTole
• Remarks– Point based modeling ( no DMU necessary)– No dynamic link with DMU– No translation of Tolerance annotation– Good over constraints systems analysis– Statistical computation – Well adapted for early tolerance analysis
Page: 17 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved
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Tolerancing tools : State of the art
• Modeling
Anatole
Measures
Positioning link
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Tolerancing tools : State of the art
• Technical Description– Kinematic modelling with liaison– Assembly graph modelling– Catia V5 CAA integration– Worst case & statistical computation– Take into account of geometrical
tolerances
CeTol 6sigma
• Remarks– Friendly graphic user interface– Features based modeling ( DMU necessary)– over-constraints systems visualisation– lack of visualization of the model over the product
Page: 19 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved
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Tolerancing tools : State of the art
CeTol 6sigma
Measures
Positioning link
Tolerance
– This graph shows the degrees offreedom of each part and link
– It becomes hard to handle withcomplex assembly as rotor ofhelicopter
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Tolerancing tools : State of the art
– Complex assemblies are not well managed by Cetol.
A complex assembly (CATProduct) is composed of assemblies (CATProduct) and parts (CATPart).
Each assembly of the product must NOT have over constraints issues in order to perform a Cetol study.
But this is often the case when designing an helicopter.
Product
Page: 21 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved
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Tolerancing tools : State of the art
• Technical Description– Modelling based on moves– Catia V5 CAA integration– Statistical computation only– Takes into account of
geometrical tolerances (FTA & PFTA)
3DCS
• Remarks– Point & Features based modeling( no DMU necessary)– Moves characteristics difficult to handle– Computation is only based on Monte Carlo algorithms
Movessequence
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Tolerancing tools : State of the art
• Rotor modelisation
3DCS
Page: 23 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved
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Tolerancing tools : State of the art
Results
Stat
0.180.150.190.18Stat
0.250.310.310.29WC
U3
0.270.170.230.27Stat
0.360.390.420.39WC
U2
0.30.190.260.3
0.480.470.530.54WC
U1
CETOLANATOLEMECAMASTERCorrectResults
MEASURES
WC : Worst Case computationStat : Statistical computation
Page: 24 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved
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Comparison
Results differences come from :• Different computing algorithm• Different modeling approach
State of the art of tolerancing tools : • Tool evaluation. Computed results• Functions available regarding to user’s requirements• Modeling principle
Tolerance annotations are the result of an assembly model performed with a tool.
This model need to be managed with PLM.
This model need to be independent from the tool chosen
Page: 25 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved
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Methodology improvements
5.Impact analysis
1.Functionalanalysis
3. GeometricModeling
4.Tolerance analysis
FunctionsRequirements
Geometricalfunctionalskeleton
3D stack chain
Annotations
New tolerancing Methodology, based on new design parametric methodology
2. AssemblyModeling
GeometricalRequirementsKinematic schemeAssembly sequence
New method is necessary with a associated modeling. This model shouldn’t be dependent with the choosen tool.
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Geometrical and functional Skeleton
Minimum geometry needed to perform functional tolerance analysis.
Methodology improvements
Page: 27 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved
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Methodology improvements
Structural and functional modelling
Assembly sequence modellingSystemic analysis of assembly Positioning datum choice
formalisationGeometrical variation propagation
representation – Datum Flow ChainGeometrical and Dimensional
Tolerancing management
Page: 28 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved
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Methodology specifications
Tool specifications :
As in 3DCS …Display 3d variation in order to validatemodeling
As in GAIA …Use schematic modeling for structural and functional analysis.
As in CeTol …Take into account Tolerance annotation
As in CeTol …Use assembly graphs
As in Anatole …Solve overconstraint system
Page: 29 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved
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Conclusions
• Tolerance analysis are performed by experts but it’s based on multidisciplinary models.
• Tolerance analysis is part of a product-process approach.
• Tolerance models should be available for all users oftoleranced drawings (design office, Manufacturing, Quality control, suppliers,…)
• Tolerance models shall be managed within the virtualProduct, and during all the lifecycle.
Page: 30 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved
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Questions ?
Thank you for your attention