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Tolerance optimization method based on flatness error distribution

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Abstract

In conventional shape tolerance design, allowable ranges are given for the assembly joint surfaces. The conventional method does not restrict the distribution form of the actual errors of surfaces, resulting in a large deviation in the prediction of assembly performance (i.e., geometric accuracy and mechanical property) from those of actual state. In order to obtain the best performance of product, appropriate tolerance should be allocated for each feature during design stage. The design method of optimum shape tolerance based on the error model of part and assembly is proposed. This method constructs error models of part and assembly considering the error distribution of flatness caused by machining or active design, evaluates performances; and after optimization, obtains the best magnitude and distribution form of flatness error, and assembly force as the requirements for manufacturing and assembling. Finally, the tolerance design of the flatness of a flange is selected to demonstrate the method proposed in this article, the optimum magnitude and distribution form of flatness error and assembly force are obtained based on the analysis results.

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Funding

This work received financial support from the National Natural Science Foundation (No. U1737207) and the Ministry of Industry and Information Technology (No. JSZL2016204B102) of the People’s Republic of China.

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Authors and Affiliations

  1. School of Mechanical Engineering, Beijing Institute of Technology, Beijing, 100081, China

    Huan Guo, Zhijing Zhang, Muzheng Xiao & Qirong Zhang

  2. State Key Laboratory of Laser Propulsion and Application, Beijing Power Machinery Institute, Beijing, 100074, China

    Heng Liu

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  1. Huan Guo
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  2. Zhijing Zhang
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  3. Muzheng Xiao
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  4. Heng Liu
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  5. Qirong Zhang
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Correspondence to Zhijing Zhang.

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The research does not involve human participants or animals and the authors warrant that the paper fulfills the ethical standards of the journal. This manuscript has not been published or presented elsewhere in part or in entirety and is not under consideration by another journal.

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Authors’ contributions

Huan Guo designed and conducted the experiments, analyzed the results, and wrote the article. Zhijing Zhang proposed the basic idea of the article, and contributed the materials and measuring instruments. Muzheng Xiao modified the structure of the article, and analyzed the data. Heng Liu contributed the materials and analyzed the data. Qirong Zhang conducted the experiment, and performed the finite element analysis.

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Cite this article

Guo, H., Zhang, Z., Xiao, M. et al. Tolerance optimization method based on flatness error distribution. Int J Adv Manuf Technol 113, 279–293 (2021). https://doi.org/10.1007/s00170-020-06501-5

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  • DOI: https://doi.org/10.1007/s00170-020-06501-5

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