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    Stephen Werst Tolerance Stack

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    vikeshm
    This document discusses how engineering simulations of tolerance analysis can help predict production quality and performance. It provides benefits over traditional methods like reducing prototypes, providing a more thorough understanding of capabilities, and ensuring customer expectations are met. Simulations allow "learning opportunities" to be virtual. Examples show how simulations account for more sources of variation than simple spreadsheet analysis to give more accurate predictions of assembly fit and defect rates. Close collaboration between engineering and manufacturing is important to validate simulation assumptions reflect reality.

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    Stephen Werst Tolerance Stack

    Uploaded by

    vikeshm
    42 views23 pages
    This document discusses how engineering simulations of tolerance analysis can help predict production quality and performance. It provides benefits over traditional methods like reducing prototypes, providing a more thorough understanding of capabilities, and ensuring customer expectations are met. Simulations allow "learning opportunities" to be virtual. Examples show how simulations account for more sources of variation than simple spreadsheet analysis to give more accurate predictions of assembly fit and defect rates. Close collaboration between engineering and manufacturing is important to validate simulation assumptions reflect reality.

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    This document discusses how engineering simulations of tolerance analysis can help predict production quality and performance. It provides benefits over traditional methods like reducing prototypes, providing a more thorough understanding of capabilities, and ensuring customer expectations are met. Simulations allow "learning opportunities" to be virtual. Examples show how simulations account for more sources of variation than simple spreadsheet analysis to give more accurate predictions of assembly fit and defect rates. Close collaboration between engineering and manufacturing is important to validate simulation assumptions reflect reality.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    42 views23 pages

    Stephen Werst Tolerance Stack

    Uploaded by

    vikeshm
    This document discusses how engineering simulations of tolerance analysis can help predict production quality and performance. It provides benefits over traditional methods like reducing prototypes, providing a more thorough understanding of capabilities, and ensuring customer expectations are met. Simulations allow "learning opportunities" to be virtual. Examples show how simulations account for more sources of variation than simple spreadsheet analysis to give more accurate predictions of assembly fit and defect rates. Close collaboration between engineering and manufacturing is important to validate simulation assumptions reflect reality.

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    Tolerance Analysis –

    An Engineering Simulation of Production


    and Performance Quality

    Stephen Werst, Senior Product Strategist, Sigmetrix, LLC.

    PRESENTED BY
    The Motivation for Simulation
    The Real Motivation
    • Reduce number of prototypes
    • More thorough and accurate understanding of product capabilities 
    and limitations in less time
    • More efficient transition to production
    • Predictable results
    • “Learning opportunities” are virtual
    • Ensure product will perform as expected by customers when it’s in 
    their hands
    • Greater profitability
    Achieving Product Targets

    Pequin, Reid and Prouty, Kevin - Aberdeen Group. The Value of Virtual Simulation Versus Traditional Methods. 2014.
    Impact on New Product Development & Introduction

    Pequin, Reid and Prouty, Kevin - Aberdeen Group. The Value of Virtual Simulation Versus Traditional Methods. 2014.
    Example – Flight Simulator
    Questions Answered by Engineering Simulations
    • Will it break during operation?
    • Will it overheat during operation?
    • Will it last as long as expected by the customer?
    • Could there be resonance?
    •…

    Structural Thermal Fatigue


    Tolerance Analysis ‐
    A Simulation of Dimensional Variation
    • Will the parts fit together?
    • Will the assembly work as expected?
    • Will manufacturing be able to assess new vendors, processes, etc. 
    based on the design package?
    • Is manufacturing monitoring the right things to ensure a quality 
    product to the customer?
    • Will the product be profitable?
    Pitfalls of 1D Analysis Assumptions
    Name: Hub with Cap
    Description: Axial clearance between hub and cap

    Part Dimension Description Nominal Tolerance


    Hub large DIA face to shim mount 1.100 ± 0.010
    Shim thickness 0.050 ± 0.002
    Cap shim mount to top 1.150 ± 0.007
    Cap top to bottom ‐2.200 ± 0.010
    0.1 ± 0.029
    Total Variation Nominal Worst‐Case
    What to Consider? 
    (Sources of Dimensional Variation)
    • Process variation during part creation (setup, positioning errors, tool 
    deflection, casting and molding errors from mold or shrinkage, etc.)
    • Supplementary processing (plating, painting, etc.)
    • Assembly process (sequence, fixture, joining methods, clearances 
    between parts, etc.)
    • Operational Environment (thermal expansion, deflection under load, 
    vibration, etc.)
    Case Study ‐ Vestas
    Case Study – Cover Redesign
    • Spinner Cover Redesigned in OCT 2014
    • The two components typically assembled for the first time in the field 
    on the top of a 100m pole
    Spinner 
    Cover 
    Nacelle
    on HUB
    Case Study – Problem with Prototype
    • Prototype to check fit of Hub and Nacelle
    Case Study – Initial Analysis with Spreadsheet
    Case Study – First Update with Clearance
    Case Study – Assembly Method
    • The spinner cover is  Spinner 
    assembled to the hub with  Cover
    both in the vertical position 
    as shown. 
    • Gravity pulls the cover 
    downward during assembly.
    • This bias is in the direction of 
    the Nacelle when assembled 
    thus minimizing the gap.
    Hub
    (machined  Assembly 
    casting) brackets
    Case Study – Analysis Reflecting Reality
    Closing the Loop with Manufacturing
    • Like all simulations validating the assumptions is critical
    • If Engineering and Manufacturing aren’t aligned the actual results 
    may be significantly different from what was predicted
    • Garbage In, Garbage Out
    Example – One‐way Clutch

    Hub = 69.25%
    of variation
    Example – Analysis Updated with MFG Data
    Ring ID:

    Hub axis to flat:

    ! By machining to maximum material to permit rework manufacturing is changing assembly defect rate from 
    predicted 2.1% to actual 97.5%
    Example – After MFG Changes Targets
    Ring ID:

    Hub axis to flat:

    ! Changing setup target to tolerance midpoint results in new predicted defect rate of .0182%.
    Key Takeaways
    1. Engineering simulations offer quantifiable business benefits vs. 
    hand calculations and prototyping.
    2. Tolerance analysis, like other engineering simulations, is intended to 
    predict many characteristics of the design.
    3. Traditional approaches with simple tools like spreadsheets can 
    often lead to predicting less variation than what will actually occur.
    4. The best predictions of real‐world performance require considering 
    many aspects beyond tolerances on part drawings.
    Questions?

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