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Univ.-Prof. Dr.-Ing. Peter GustChair of Engineering Design - University of Wuppertal June 23th 2016
VDI-GesellschaftMaterials Engineering
Newgeometricalproductspecifications(GPS*)androbustdesign
Univ.-Prof. Dr.-Ing. Peter Gust and M.Sc. Christoph Schluer
*MechanicalEngineeringworldwide,needsthejointoutputofthesestandards committeesmorethanever.
SourceISO/TC213
Univ.-Prof. Dr.-Ing. Peter GustChair of Engineering Design - University of Wuppertal June 23th 2016
VDI-GesellschaftMaterials Engineering Main Reserach
Univ.-Prof. Dr.-Ing. Peter GustChair of Engineering Design
Product-developmentand Innovation-Management „RobustDesign“
Tolerance-analysis and -management
Univ.-Prof. Dr.-Ing. Peter GustChair of Engineering Design - University of Wuppertal June 23th 2016
VDI-GesellschaftMaterials Engineering
Specificationinadequacy istheAchillesheelformanyof today’stechnologicallyadvancedcompanies.
Tightertolerancescanoftenprovephenomenally expensivetoapply
Quelle:http://auto-motor-tu
ning.blogsport.de
Anexample:chassisbearing
*SourceISO/TC213
TypicalDrawing DrawingwithGPSSpec‘s:
Univ.-Prof. Dr.-Ing. Peter GustChair of Engineering Design - University of Wuppertal June 23th 2016
VDI-GesellschaftMaterials Engineering
PrincipleofDuality
• Thedesign engineerisresponsible forthespecifications
• Production andQualityManagementareresponsibleforvalidation
PrincipleofIndependency
• SinceSeptember2011thenewstandardDINENISO8015appeared,theprincipleofindependencyisthestandardforgeometricaltolerancing insteadofthePrinciple ofEnvelope (Ⓔ)
• ...exceptifyouseethesymbolⒺ (ISO14405-1) fortheenvelope
Structuringallgeometricalstandardsthroughthe
• GPS-Matrix(attheendofeachdocument– tolocatetheposition ofthesinglestandardinthewholesystem)
...since201087newspecificationsinEuropa
NewStandards fromCEN/TC290
Univ.-Prof. Dr.-Ing. Peter GustChair of Engineering Design - University of Wuppertal June 23th 2016
VDI-GesellschaftMaterials Engineering
Moderne Produktionstechnik - Neue Anforderungen an die ProzessfähigkeitKonstruktion im Maschinenbau, Prof. Dr.-Ing. Peter Gust
IS THE WORLD PERFECT?
a a=f(µ,s)
DeterministicApproach StatisticalApproach„RobustDesign“
Univ.-Prof. Dr.-Ing. Peter GustChair of Engineering Design - University of Wuppertal June 23th 2016
VDI-GesellschaftMaterials Engineering
6
ForthereferencecaseaFEanalysisisperformedtoevaluatetheinfluenceoftheshapeanddimensionaltolerancesofpartsonthestressdistributionunderload
Flatplate,fixedbottomside000000
Contactregionincl.friction
Pistonguidance
LoadF=10kN
InhouseCatiaModule
Univ.-Prof. Dr.-Ing. Peter GustChair of Engineering Design - University of Wuppertal June 23th 2016
VDI-GesellschaftMaterials Engineering
7
Contactsurfacewithrandomlydeformedshape(insidethegiventolerance!)
ToleranceZonet=2mm
SurfaceProfile Tolerance(SPT)=2mmSPT=0,2mm
Univ.-Prof. Dr.-Ing. Peter GustChair of Engineering Design - University of Wuppertal June 23th 2016
VDI-GesellschaftMaterials Engineering
8
FirstResult
[MPa]
[MPa]
[MPa]
SPT=0,1mm
SPT=0,0mm“NominalValue”
SPT=0,2mm
Univ.-Prof. Dr.-Ing. Peter GustChair of Engineering Design - University of Wuppertal June 23th 2016
VDI-GesellschaftMaterials EngineeringRobusteKonstruktionen
BaugruppefürweiterführendeAnalysen
9
InvestigationofthestressesinanassemblywithtwocontactregionsandthepossibilityofexperimentalvalidationBracket-Bolt-Jointasastandardmachineelement
Univ.-Prof. Dr.-Ing. Peter GustChair of Engineering Design - University of Wuppertal June 23th 2016
VDI-GesellschaftMaterials EngineeringRobusteKonstruktionen
BerücksichtigungnichtidealerModelle
10
Univ.-Prof. Dr.-Ing. Peter GustChair of Engineering Design - University of Wuppertal June 23th 2016
VDI-GesellschaftMaterials EngineeringRobusteKonstruktionen
ErzeugungnichtidealerGeometrie
11
• Thenon-idealmodelwhichisrequiredforthesimulation,iscreatedintheCADsystem.• Dimensionalangeometrictolerancesaredefinedinadvance.• Thegeometrycreationworkswithparametricpointclouds,whichformthebasisforasurface
model.
Univ.-Prof. Dr.-Ing. Peter GustChair of Engineering Design - University of Wuppertal June 23th 2016
VDI-GesellschaftMaterials EngineeringRobusteKonstruktionen
ErzeugungnichtidealerGeometrie
12
Thegenerationofthedatapoints inthepredeterminedtolerancefieldiscarriedoutaccordingtodefinedrules.Amongotherthings,theadjacentdatapointsdeviatenotmorethan20%ofthepermissibletolerancezonefromeachotherà ensuringtogetarealisticcomponentsurface.
Part1withrestrictions
Part2without restrictions
Univ.-Prof. Dr.-Ing. Peter GustChair of Engineering Design - University of Wuppertal June 23th 2016
VDI-GesellschaftMaterials Engineering
13
ThenonidealComponentscausecomplexcontactbehavior withclearance• Bracketisfixedontheleftsideandtherodisloadedwith6300N. • Frictioninthecontactregionswithμ=0,1non-linearmaterialS235JR• Thetolerancesofthecomponents aretheinput• Thenormalstressdistribution intheboltistheoutput
F=6300N
Univ.-Prof. Dr.-Ing. Peter GustChair of Engineering Design - University of Wuppertal June 23th 2016
VDI-GesellschaftMaterials EngineeringRobusteKonstruktionen
SensitivitätsstudiefürdieBolzenbaugruppe
14
LatinHypercubeSamplingwith120designsshowstherelevantparameters(tolerances)withrespecttothenormalstressintheboltunderload
Univ.-Prof. Dr.-Ing. Peter GustChair of Engineering Design - University of Wuppertal June 23th 2016
VDI-GesellschaftMaterials EngineeringRobusteKonstruktionen
KlassifizierungnichtidealerGeometrievarianten
15
Univ.-Prof. Dr.-Ing. Peter GustChair of Engineering Design - University of Wuppertal June 23th 2016
VDI-GesellschaftMaterials EngineeringRobusteKonstruktionen
ErgebnissederseparatenVarianten
16
Idealpart
Non-idealvariants
Univ.-Prof. Dr.-Ing. Peter GustChair of Engineering Design - University of Wuppertal June 23th 2016
VDI-GesellschaftMaterials Engineering
17
1. Testspecimen2. Hydraulicpowerunit3. Mainframe4. Cooling fan5. Measurement
Hardware6. Graphicaluser
interface
Univ.-Prof. Dr.-Ing. Peter GustChair of Engineering Design - University of Wuppertal June 23th 2016
VDI-GesellschaftMaterials EngineeringRobusteKonstruktionen
BenutzerschnittstelledesMessprogramms
18
Univ.-Prof. Dr.-Ing. Peter GustChair of Engineering Design - University of Wuppertal June 23th 2016
VDI-GesellschaftMaterials EngineeringRobusteKonstruktionen
19
Afteraperiodofinitialtests,theidealassemblys weretested(blue)incomparisontothenon-idealvariants1(red)and2(green).Theverticallinesrepresentthemedianofrespectively10probes.
Loadcycles
Univ.-Prof. Dr.-Ing. Peter GustChair of Engineering Design - University of Wuppertal June 23th 2016
VDI-GesellschaftMaterials Engineering
ProcessSuitabilityCp:Istheprocesssuitable?
ProcessSuitabilityCpk:Istheprocesscontrollable?
withCp >1,33theprocessissuitable!...thecarfitsinyourgarage!
withCpk >1,33theprocessiscontrollable!...thecarstrikesinyourgarage!
withCpk <1,0theprocessisnot controllable!...thecardoes notstrikeinyourgarage
withCp <1,0theprocess isnot suitable!...thecardoes notfitinyourgarage!
Univ.-Prof. Dr.-Ing. Peter GustChair of Engineering Design - University of Wuppertal June 23th 2016
VDI-GesellschaftMaterials Engineering
WeneedrobustProcesses
1. Suitableprocess,
2. Controllableprocesses
3. Andnew:centered Processes
TheautomotiveworkingcommitteedefinedanewIndexCpr*:
• Itisavaluefortherobustness andwillbecalculatedthroughtheaveragequadraticfailure
• Itcanbeeasilycalculatedthrough4parameters
• Itissuitableforalldistributionshapes
• ItincludedCp undCpk.
*Quelle
SummerSchoolToleranzanalysen,UniErlangen,W
.R.Landschoff,VW
,2013
T: Tolerance=differenceOTG-UTG
m: MeanValueofthetolerance
μ: MeanValue
σ: Standarddeviation
Univ.-Prof. Dr.-Ing. Peter GustChair of Engineering Design - University of Wuppertal June 23th 2016
VDI-GesellschaftMaterials Engineering
• Cpr-IndexisonhiswaytobecomeafuturepartoftheVDA
• Thereforexisting„ok“partscould bedefectivepartsinfuture
• Butthemountingprocesses ismore„robust“withlessdefectiveassemblies
Univ.-Prof. Dr.-Ing. Peter GustChair of Engineering Design - University of Wuppertal June 23th 2016
VDI-GesellschaftMaterials Engineering
Idea: TheconsequentusageofTolerance-Managementiscapableforasignificantcostreduction
AndHow? • UsageoftheprincipleofIndependency,(Envelopeonlyforfunctionalrequirements(Ⓔ ISO14405-1)
• UsageofRobustDesigns(OptimizationandValidation)andTolerance-Management
• Reductionoffailureexpensesthroughdefinitionofrightreferencesandcleardimensions
• Consistent levelofcompetencethroughtrainingandinstallationofinternalGPSCoaches
EngineeringDesign
Production, Tooling
QualityManagement
Univ.-Prof. Dr.-Ing. Peter GustChair of Engineering Design - University of Wuppertal June 23th 2016
VDI-GesellschaftMaterials Engineering
24
Contact
Univ.-Prof.Dr.-Ing.PeterGust
Chair of EngineeringDesign)Universityof Wuppertal,GermanyFaculty Mechanical and Safety EngineeringGaußstrasse 20- Germany42119WuppertalPostfach42097,Tel.:+492024392046,Mobile:+491787170467eMail:[email protected]://konstruktion.mbau.uni-wuppertal.de
