Collaborative Research: Quantitative Roundness Design and Quality Assurance for Ultra-Precision Assemblies with Significant Error-Scaling Problems

合作研究：具有重大误差尺度问题的超精密组件的定量圆度设计和质量保证

• 批准号: 0355125
• 负责人: Arnold Sweet
• 金额: $ 8.24万
• 依托单位: Purdue University
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2004
• 资助国家: 美国
• 起止时间: 2004-06-01 至 2007-05-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=0355125&HistoricalAwards=false
• 关键词: Collaborative; Research; Quantitative; Roundness; Design

The objective of the project is to reveal new and fundamental insights into the error-scaling problem for ultra-precision applications in design and manufacturing and answer long-standing questions about quantitative design of geometric tolerances in roundness. This error-scaling problem arises when the uncertainty of precision becomes unacceptably large as the size of the critical features approaches in magnitude the size of the repeatability achieved during manufacturing. A collaboration is formed to develop a quantitative technology for designing and achieving quality assurance for manufacturing precision round components and assemblies, such as fuel injectors and spindles. Although engineers are now better trained in assigning proper size tolerance, at present there does not exist a quantitative methodology for assigning geometric tolerances such as roundness. Furthermore, the error-scaling problem that is critical to the manufacture of small scale (meso, micro, and nano) devices. As a result, fundamental definitions of quality assurance indices will be revisited via a new probability analysis considering truncated and skewed distributions in the region of significant error-scaling problems. These improved indices can then be incorporated into successful quality assurance approaches such as TQM and Six-Sigma. Roundness issues have great economic and social impacts. The development of low-emission diesel engines requires clean diesel fuel, electronically controlled fuel injection, and high injection pressure. Achieving a high injection pressure (over 30 ksi) requires a very precise control of fit conditions between the nozzle and the injector plunger, which in turn depends critically on the roundness of the plunger and nozzle bore. The proposed roundness technology is also critical for miniaturization techniques in imaging, in telecommunication, in lithography, and in many other fields.

该项目的目标是揭示在设计和制造中超精密应用的误差缩放问题的新的和基本的见解，并回答关于圆度几何公差定量设计的长期问题。当关键特征的尺寸接近制造过程中实现的可重复性尺寸时，精度的不确定性变得不可接受的大时，就会出现这种误差缩放问题。合作形成了一种定量技术，用于设计和实现制造精密圆形部件和组件的质量保证，如喷油器和主轴。虽然工程师们现在在分配适当的尺寸公差方面得到了更好的训练，但目前还没有一种定量的方法来分配圆度等几何公差。此外，误差缩放问题是制造小规模（中、微、纳米）器件的关键。因此，质量保证指数的基本定义将通过一种新的概率分析来重新审视，该分析考虑了显著误差标度问题区域的截断和偏态分布。这些改进的指标可以被纳入成功的质量保证方法，如全面质量管理和六西格玛。圆度问题具有巨大的经济和社会影响。低排放柴油机的发展需要清洁的柴油燃料、电控燃油喷射、高喷射压力。实现高喷射压力（超过30 ksi）需要非常精确地控制喷嘴和注入柱塞之间的配合条件，这反过来又取决于柱塞和喷嘴孔的圆度。提出的圆度技术对于成像、电信、光刻和许多其他领域的小型化技术也至关重要。