Shape aware Computer Aided Tolerancing: A new methodical and computational framework for the assembly and mobility simulation based on Skin Model Shapes (ShapeCAN)

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Geometric deviations are inevitably observable on every manufactured workpiece due to the axiom of manufacturing imprecision. These deviations hugely affect the quality and function of mechanical products, which leads to preventable consumptions of natural resources as well as safety damages. However, the management of geometric variations for complex assemblies and products is a major challenge even for innovative companies because of the far impact of tolerancing decisions on the manufacturing and inspection costs, the assemblability, and the product behavior during usage. In order to consider these various aspects during tolerancing in product development, models based on a coherent and complete language for the geometric product specification and verification are required, which enable the integration of simulation and measurement results from the various stages of the computer aided design and manufacturing processes.The main contribution of the proposed research project can be found in the developed methods and tools for the generation, assembly, and kinematic analysis of detailed virtual part representatives denoted as Skin Model Shapes, which are to be used for computer aided tolerancing. These methods and tools will enable a continuous transfer of geometric specifications considering all the different facets of design, manufacturing, inspection, assembly, and usage along the product life-cycle. Moreover, the developed algorithms and practices will allow the implementation of computer aided tools for the application in the design of complex systems and products. Based thereon, the potentials of a coherent and complete computer aided tolerancing process can be exploited, which leads to a reduced consumption of natural resources and an increased product safety and reliability.