3d functional tolerancing for helicopter rotor wp 1.5 ... – catia v5 caa integration –...

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  • Page: 1 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved

    VIVACE FORUM 1 - Warwick Hugo FALGARONE

    Benoit FRICERO

    3D functional 3D functional tolerancingtolerancing for Helicopter Rotorfor Helicopter Rotor

    WP 1.5.1WP 1.5.1

    Introduction of tolerancing issues and stakes for tolerance management

    Forum 1 – Warwick - September 20-21, 2005

  • Page: 2 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved

    VIVACE FORUM 1 - Warwick

    Outlines

    • Introduction

    • Aerospace Tolerancing issues

    • Tolerancing tools : State of the Art

    • Comparison

    • Methodology specifications

    • Conclusions

  • Page: 3 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved

    VIVACE FORUM 1 - Warwick

    Introduction

    Tolerance analysis = Assembly simulation with manufactured parts, ie parts with geometric variations.

    Manufacturing capability requirement : Continous trade off between cheap manufacturing process and high quality product

    Features relationship : Garantee Product functions and assembly

    How to define these tolerances ?

    How to ensure tracability between function requirement and tolerance specification ?

  • Page: 4 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved

    VIVACE FORUM 1 - Warwick

    Introduction

    Functional tolerancing Vs Traditional dimensioning

  • Page: 5 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved

    VIVACE FORUM 1 - Warwick

    Aerospace Tolerancing Issues

    Manufacturing cost analysis for an aircraft structure :

    Assembly

    Manufacturing

    Materials

    55%

    25%

    20%

    Improve product assemblability

    Improve manufacturing capabilities Improve tolerance management methodologies from design offices to manufacturing Quality. Use tools to support these methodologies

  • Page: 6 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved

    VIVACE FORUM 1 - Warwick

    Aerospace Tolerancing Issues

    Technical data managed for tolerance analysis :

    Design requirements: Aerodynamic,Weight, … • Product functions • Key characteristics • Assembly constraints

    Product geometrical definition : Digital Mock Up

    Manufacturing capabilities

    Assembly sequence or kinematic model of assembly process

    3D stack chain : List of contributing features for each requirement

    Tolerance management is a multidisciplinary process

  • Page: 7 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved

    VIVACE FORUM 1 - Warwick

    Aerospace Tolerancing Issues

    A

    B

    C

    D

    Nominal Model

    A

    B

    C

    Model with deviations

    D

    B

    C

    D

    A

    Sequence A->B->C->D

    C

    B

    Sequence A->D->B ->C

    A

    D

    Assembly sequence impact :

    Tolerance annotations include implicitly assembly sequence

    Sequence is chosen regarding to product main functions

  • Page: 8 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved

    VIVACE FORUM 1 - Warwick

    Aerospace Tolerancing Issues

    Tolerance impact analysis : – How to understand specification for downstream

    tolerance users : Manufacturing – How to impact design change on tolerance

    specification ?

    VIVACE use Case : Non conformity One dimension of a manufacturd part is out of tolerance

    How to status on the associated risk ? • Re-build tolerance analysis to find out

    justification of tolerance specification. • Deal with non conformity process even without

    Digital Mock Up ; Case of old programs still in production

  • Page: 9 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved

    VIVACE FORUM 1 - Warwick

    Tolerancing tools State of the art

    • Kinematic tolerancing Objective : Validate design concepts and define frontier tolerances When : early design stage Data needed : Rought geometry, Manufacturing capabilities, building philosophy (kinematic scheme)

    • Feature tolerancing Objective : Validate assembly of toleranced parts When : Design validation Data needed : Complete geometry with GD&T, assembly sequence

    • Flexible tolerancing Objective : Simulate realistic assembly process When : Design validation Data needed : FEM, DMU with GD&T, assembly sequence

    • Tolerance edition Objective : Edit Geometrical Dimensional and Tolerancing annotations on DMU When : DMU Publication (drawings)

    Different tools for different goals

  • Page: 10 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved

    VIVACE FORUM 1 - Warwick

    Tolerancing tools : State of the art

    • Kinematic tolerancing Mecamaster Mecamaster SARL AnaTole EADS CCR

    • Feature tolerancing 3DCS DCS CeTOL6 Sigma SigMetrix Tolerance Manager PCO Technologies eMTolMate PCT

    • Flexible tolerancing CATIA V5 – TAA Dassault Systemes

    • Tolerance edition CATIA V5 – FTA & PFTA Dassault Systemes

  • Page: 11 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved

    VIVACE FORUM 1 - Warwick

    Helicopter case study

    Rotor case study Mast

    Scissors

    End Plate

    Ring

    Objective : Check the continous non-contact between the ring and the end plate

  • Page: 12 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved

    VIVACE FORUM 1 - Warwick

    Helicopter case study

    • Nominal Position

    Plane Contact

    Ball JointMast

    Scissors

    End Plate

    • Worst Case Position

    Measure

    Currently, this computation is done with simplified 1D stack chain.

    Ring

  • Page: 13 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved

    VIVACE FORUM 1 - Warwick

    Case study

    Demo case study presentation

    To simplify the demonstration, let’s use a demo case study easier to handle.

    c

    e

    b

    a

    d

    f

    U1

    U3 U2

    Variations Measures

  • Page: 14 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved

    VIVACE FORUM 1 - Warwick

    Tolerancing tools : State of the art

    • Technical Description – Kinematic modelling with liaison – Catia V5 VB integration – Worst case & statistical computation – Variations are included in liaison

    Mecamaster

    • Remarks – Point based modeling ( no DMU necessary) – No dynamic link with DMU – No translation of Tolerance annotation – Statistical computation very limited – Well adapted for early tolerance analysis

  • Page: 15 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved

    VIVACE FORUM 1 - Warwick

    Tolerancing tools : State of the art

    • Modeling

    Mecamaster

    a a

    b & d

    f

    e

    c

    Measures

    Positioning link

  • Page: 16 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved

    VIVACE FORUM 1 - Warwick

    Tolerancing tools : State of the art

    • Technical Description – Kinematic modelling with liaison – Catia V5 CAA integration – Worst case & statistical computation – Variations are included in liaison

    AnaTole

    • Remarks – Point based modeling ( no DMU necessary) – No dynamic link with DMU – No translation of Tolerance annotation – Good over constraints systems analysis – Statistical computation – Well adapted for early tolerance analysis

  • Page: 17 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved

    VIVACE FORUM 1 - Warwick

    Tolerancing tools : State of the art

    • Modeling

    Anatole

    Measures

    Positioning link

  • Page: 18 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved

    VIVACE FORUM 1 - Warwick

    Tolerancing tools : State of the art

    • Technical Description – Kinematic modelling with liaison – Assembly graph modelling – Catia V5 CAA integration – Worst case & statistical computation – Take into account of geometrical

    tolerances

    CeTol 6sigma

    • Remarks – Friendly graphic user interface – Features based modeling ( DMU necessary) – over-constraints systems visualisation – lack of visualization of the model over the product

  • Page: 19 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved

    VIVACE FORUM 1 - Warwick

    Tolerancing tools : State of the art

    CeTol 6sigma

    Measures

    Positioning link

    Tolerance

    – This graph shows the degrees of freedom of each part and link

    – It becomes hard to handle with complex assembly as rotor of helicopter

  • Page: 20 September 20-21, 2005© 2004 VIVACE Consortium Members. All rights reserved

    VIVACE FORUM 1 - Warwick

    Tolerancing tools : State of the art

    – Complex a