Tolerance Aware Product Development Using an Enriched Hybrid Digital Mock Up

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Abstract: Current practice in three-dimensional (3D) part constructionand product assembly definition within a digital mock-up (DMU) is basedon the nominal sizing of geometry. This approach does not reflect realpart dimensions when they are manufactured or the assembly conditions asthey come together during the final build. The value of virtual assemblyplanning (VAP) using clash and gap detection is therefore limited tomodelling error identification within the computer-aided design (CAD)domain for nominal conditions only. VAP could become a significantlymore powerful tool if the 3D representation of components within the DMUwere more representative of 'as manufactured' dimensions. This paperpresents the evolution and validation of an enriched digital mock-up(EDMU) introducing the concept of the hybrid assembly. This enables therepresentation of components in sizes which can range between upper andlower dimensional limits in addition to the nominally defined form. Theresulting capability has been exploited to perform early stage toleranceanalysis within CAD. The approach enables better informed toleranceconsideration earlier in the design process as DMU evolves. This has thepotential to reduce the time, effort and computational load associatedwith the application of statistical tolerance analysis methods later inthe design cycle.
Original languageEnglish
JournalCIRP Journal of Manufacturing Science and Technology
Publication statusAccepted - 24 Apr 2020



  • Computer-aided design; Variational geometry; Tolerance

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