The Use of Kinematic Model To Analyze Positional Tolerances in

3D functional tolerancing
for Helicopter Rotor

WP 1.5.1
Forum 1 Warwick - September 20-21, 2005
Introduction of tolerancing issues and

stakes for tolerance management
VIVACE FORUM 1 - Warwick
2004 VIVACE Consortium Members.

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Page: 1
Hugo FALGARONE
September 20-21, 2005
Benoit FRICERO
Outlines
Introduction
Aerospace Tolerancing issues
Tolerancing tools : State of the Art
Comparison
Methodology specifications
Conclusions

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Page: 2
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 ?

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Page: 3
Introduction
Functional tolerancing Vs Traditional dimensioning

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Page: 4
Aerospace Tolerancing Issues

Manufacturing cost analysis for an aircraft structure :
Assembly
55%
Manufacturing
Materials
25%
20%
Improve product assemblability

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

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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


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Assembly sequence impact :
C
C
D
Nominal Model
Model with deviations
C
D
B
A
Sequence A->D->B ->C
Sequence A->B->C->D
Sequence is chosen regarding to product main functions

Tolerance annotations include implicitly assembly sequence

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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

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Page: 8
Tolerancing tools State of the art

Different tools for different goals
Kinematic tolerancing
Objective
When
Data needed
Feature tolerancing
Objective
When
Data needed
: Validate assembly of toleranced parts

: Design validation
: Complete geometry with GD&T, assembly sequence
Flexible tolerancing
Objective
When
Data needed
: Validate design concepts and define frontier tolerances

: early design stage
: Rought geometry, Manufacturing capabilities, building philosophy (kinematic scheme)
: Simulate realistic assembly process

: Design validation
: FEM, DMU with GD&T, assembly sequence
Tolerance edition
Objective
When
: Edit Geometrical Dimensional and Tolerancing annotations on DMU

: DMU Publication (drawings)

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Tolerancing tools : State of the art

Kinematic tolerancing
Mecamaster
AnaTole
Mecamaster SARL
EADS CCR
Feature tolerancing
3DCS
CeTOL6 Sigma
Tolerance Manager
eMTolMate
DCS
SigMetrix
PCO Technologies
PCT
Flexible tolerancing
CATIA V5 TAA
Dassault Systemes
Tolerance edition
CATIA V5 FTA & PFTA

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Dassault Systemes
Page: 10
Helicopter case study

Rotor case study
Mast
End Plate
Ring
Scissors
Objective : Check the continous non-contact between the

ring and the end plate

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Page: 11
Helicopter case study
Nominal Position
Worst Case Position
Plane Contact
End Plate
Ball Joint
Mast
Scissors
Measure
Ring
Currently, this computation is done with simplified 1D stack chain.

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Page: 12
Case study
To simplify the demonstration, lets use a demo case study easier to handle.
Demo case study presentation
a
U1
U3
U2
c
d
e
Variations
Measures
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Page: 13

Mecamaster
Technical Description
Kinematic modelling with liaison

Catia V5 VB integration
Worst case & statistical computation
Variations are included in liaison
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

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Page: 14

Mecamaster
Modeling
Measures
a
a
c
b&
d
Positioning link

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Page: 15

AnaTole

Catia V5 CAA integration
Variations are included in liaison
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

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Page: 16

Anatole
Modeling
Positioning link
Measures

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Page: 17

CeTol 6sigma

Assembly graph modelling
Take into account of geometrical
tolerances
Remarks
Friendly graphic user interface

Features based modeling ( DMU necessary)
over-constraints systems visualisation
lack of visualization of the model over the product

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Page: 18

CeTol 6sigma
Tolerance
Positioning link
This graph shows the degrees of

freedom of each part and link
It becomes hard to handle with
complex assembly as rotor of
helicopter
Measures

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Page: 19

Complex assemblies are not well managed by Cetol.
Product
A complex assembly (CATProduct) is

composed of assemblies (CATProduct)
and parts (CATPart).
Each assembly of the product must NOT
have over constraints issues in order to
perform a Cetol study.
But this is often the case when designing
an helicopter.

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Page: 20

3DCS
Modelling based on moves

Statistical computation only
Takes into account of
geometrical tolerances (FTA &
PFTA)
Moves
sequence
Remarks
Point & Features based modeling

( no DMU necessary)
Moves characteristics difficult to handle
Computation is only based on Monte Carlo algorithms

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Page: 21

3DCS
Rotor modelisation

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Page: 22

Results
Correct
Results
MECAMASTER
ANATOLE
CETOL
WC
0.54
0.53
0.47
0.48
Stat
0.3
0.26
0.19
0.3
WC
0.39
0.42
0.39
0.36
Stat
0.27
0.23
0.17
0.27
WC
0.29
0.31
0.31
0.25
Stat
0.18
0.19
0.15
0.18
MEASURES
U1
U2
U3
WC : Worst Case computation
Stat : Statistical computation

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Page: 23
Comparison
Results differences come from :
Different computing algorithm
Different modeling approach
State of the art of tolerancing tools :

Tool evaluation. Computed results
Functions available regarding to users requirements
Modeling principle
Tolerance annotations are the result of an assembly model performed
with a tool.
This model need to be managed with PLM.
This model need to be independent from the tool chosen

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Page: 24
Methodology improvements
New method is necessary with a associated modeling.
This model shouldnt be dependent with the choosen tool.
1.Functional
analysis
Functions
Requirements
New tolerancing Methodology, based on new

design parametric methodology
2. Assembly
Modeling
Geometrical
Requirements
Kinematic scheme
Assembly sequence
3. Geometric
Modeling
Geometrical
functional
skeleton
4.Tolerance
analysis
3D stack chain
Annotations

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Page: 25
5.Impact
analysis
Geometrical and functional Skeleton
Minimum geometry needed to perform functional tolerance

analysis.

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Page: 26
Structural and functional modelling
Assembly sequence modelling

Systemic analysis of assembly
Positioning datum choice
formalisation
Geometrical variation propagation
representation Datum Flow Chain
Geometrical and Dimensional
Tolerancing management

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Page: 27
Methodology specifications
Tool specifications :
Solve overconstraint system
As in Anatole
Use assembly graphs
As in CeTol
Take into account Tolerance annotation
As in CeTol
Display 3d variation in order to validate
modeling
As in 3DCS
Use schematic modeling for structural

and functional analysis.
As in GAIA

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Page: 28
Conclusions
Tolerance analysis are performed by experts but its

based on multidisciplinary models.
Tolerance analysis is part of a product-process approach.
Tolerance models should be available for all users of
toleranced drawings (design office, Manufacturing,
Quality control, suppliers,)
Tolerance models shall be managed within the virtual
Product, and during all the lifecycle.

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Page: 29
Questions ?
Thank you for your attention
hugo.falgarone@eads.net

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Page: 30

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3D functional tolerancing

for Helicopter Rotor

Forum 1 Warwick - September 20-21, 2005

Introduction of tolerancing issues and

2004 VIVACE Consortium Members.

VIVACE FORUM 1 - Warwick

2004 VIVACE Consortium Members.

September 20-21, 2005

Assembly simulation with

Manufacturing capability requirement :

How to define these tolerances ?

2004 VIVACE Consortium Members.

September 20-21, 2005

Functional tolerancing Vs Traditional dimensioning

VIVACE FORUM 1 - Warwick

2004 VIVACE Consortium Members.

September 20-21, 2005

Aerospace Tolerancing Issues

Improve product assemblability

VIVACE FORUM 1 - Warwick

2004 VIVACE Consortium Members.

September 20-21, 2005

Aerospace Tolerancing Issues

Technical data managed for tolerance analysis :

Tolerance management is a multidisciplinary process

2004 VIVACE Consortium Members.

September 20-21, 2005

Aerospace Tolerancing Issues

Model with deviations

Sequence A->D->B ->C

Sequence is chosen regarding to product main functions

2004 VIVACE Consortium Members.

September 20-21, 2005

Aerospace Tolerancing Issues

Tolerance impact analysis :

VIVACE use Case : Non conformity

VIVACE FORUM 1 - Warwick

2004 VIVACE Consortium Members.

September 20-21, 2005

Tolerancing tools State of the art

: Validate assembly of toleranced parts

: Validate design concepts and define frontier tolerances

: Simulate realistic assembly process

VIVACE FORUM 1 - Warwick

: Edit Geometrical Dimensional and Tolerancing annotations on DMU

2004 VIVACE Consortium Members.

September 20-21, 2005

Tolerancing tools : State of the art

VIVACE FORUM 1 - Warwick

2004 VIVACE Consortium Members.

September 20-21, 2005

Helicopter case study

Objective : Check the continous non-contact between the

2004 VIVACE Consortium Members.

September 20-21, 2005

Helicopter case study

Worst Case Position

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

VIVACE FORUM 1 - Warwick

2004 VIVACE Consortium Members.

September 20-21, 2005

Demo case study presentation

September 20-21, 2005