Virtual and experimental tolerance analysis of deviated assembly groups

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The aim of the research project is to enable a process-oriented tolerancing, which considers all geometric deviations and their various sources as well as measurement uncertainties, by providing the required methods and tools. In order to achieve this goal, particularly the research challenges regarding the best practice for process-oriented tolerance specification, regarding the integration of various kinds of geometric deviations in tolerance simulation models and regarding the use of tolerance simulation results for optimized tolerance allocation and process design are answered. The focus of the research project in the second funding period of the research unit is on the extension of the interdisciplinary process-oriented tolerance allocation with regard to the consideration of wear behavior during use. Here, the entire intended product use is virtually validated with tolerance management tools by not only taking into account process variations during product development, but also virtually mapping wear influences during operation in the simulation models. In order to validate the novel simulation models developed, experimental tolerance analysis are carried out on the test stand of the research unit, the results from which are compared with the virtual results. In addition, a tolerance optimization is to be carried out in order to meet specified quality targets over the product lifecycle while at the same time ensuring that production and measuring process-related restrictions are observed.Beside the development of virtual tools for the tolerance analysis and their validation, methods and best practices for the integrated and holistic tolerance management are provided, which consider the characteristic features of computer-aided engineering tools and which will be checked in cooperation with the partners of the research unit. Thus, the main benefit of the research project is a procedure for process-oriented tolerancing, which allows the holistic consideration of various kinds and sources of geometric deviations already during product development as well as the identification of relevant process and operating parameters. Based thereon, manufacturing and inspection processes can be systematically optimized, costs can be saved and the time-to-market can be shortened.