Virtual and experimental tolerance analysis of deviated assembly groups

该研究项目的目的是通过提供所需的方法和工具，实现面向过程的公差，该公差考虑了所有几何偏差及其各种来源以及测量不确定性。为实现这一目标，重点解决了面向过程公差规范的最佳实践、公差仿真模型中各种几何偏差的集成以及利用公差仿真结果优化公差分配和工艺设计等方面的研究挑战。研究单位第二个资助期的研究项目重点是在考虑使用过程中的磨损行为的情况下，扩展跨学科过程导向的公差分配。在这里，整个预期的产品使用都通过公差管理工具进行了虚拟验证，不仅考虑了产品开发期间的工艺变化，而且还在仿真模型中虚拟地映射了运行期间的磨损影响。为了验证所建立的仿真模型，在研究单位的试验台上进行了实验公差分析，并与虚拟结果进行了比较。此外，为了在产品生命周期内满足规定的质量目标，同时确保与生产和测量过程相关的限制得到遵守，应进行公差优化。除了开发用于公差分析及其验证的虚拟工具外，还提供了集成和整体公差管理的方法和最佳实践，这些方法和实践考虑了计算机辅助工程工具的特点，并将与研究单位的合作伙伴一起进行检查。因此，该研究项目的主要好处是一个面向过程的公差程序，它允许在产品开发过程中对各种类型和来源的几何偏差进行整体考虑，并确定相关的过程和操作参数。在此基础上，可以系统地优化制造和检验流程，节省成本，缩短上市时间。

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.