IPDM and Tolerancing

Bob Campbell9780824788902, 0-8247-8890-7

This text discusses how to eliminate costly trial-and-error approaches and deliver economically viable products.

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Table of contents :
Integrated Product Design and Manufacturing Using Geometric Dimensioning and Tolerance……Page 1
FOREWORD……Page 4
PREFACE……Page 7
ACKNOWLEDGMENTS……Page 11
CONTENTS……Page 13
INTRODUCTION……Page 20
CONTENTS……Page 0
CHAPTER 2: WHAT ARE THE TECHNIQUES?……Page 25
2.2 PRODUCT DEFINITION……Page 26
2.3 THE LANGUAGE OF CONCURRENT ENGINEERING — Y14.5M……Page 29
2.4 CONCURRENT ENGINEERING……Page 31
2.5 SUMMARY……Page 40
REFERENCES……Page 41
3.1 INTRODUCTION……Page 42
3.2.1 DATUM REFERENCE FRAMES……Page 43
3.2.2 TOOLING AND GAGE DATUM ELEMENTS……Page 50
3.2.3 INTERRELATED AND INTERCHANGEABLE FEATURES……Page 53
3.2.4 BOUNDARY AND AXIAL CONCEPTS……Page 54
3.2.5 TAYLOR’S PRINCIPLE……Page 57
3.2.6 REFINEMENT OF CONTROLS……Page 60
3.3 APPLICATION CONSIDERATIONS……Page 61
3.3.2 DATUM ACCURACY……Page 62
3.3.4 VERIFIABLE CONTROLS……Page 63
3.3.5 MATERIAL MODI.ERS……Page 64
3.3.6 BASIC INTERCHANGEABILITY GAGES……Page 68
3.4 SUMMARY……Page 70
REFERENCES……Page 71
4.2 PRODUCT ARCHITECTURE……Page 72
4.3 THE SIX-STEP METHODOLOGY……Page 75
4.3.1 DESIGN LAYOUT……Page 76
4.3.2 IDENTIFICATION AND REMOVAL OF CRITICAL CHARACTERISTICS……Page 78
4.3.3 MECHANICAL SIMULATION……Page 82
4.3.4 CONSIDERATION OF DFA……Page 83
4.3.5 DESIGN OF EXPERIMENTS……Page 84
4.3.6 PHYSICAL PROTOTYPING……Page 86
4.3.7 METROLOGY AND PRODUCT DEVELOPMENT……Page 87
REFERENCES……Page 89
5.1 INTRODUCTION……Page 90
5.2 STEP ONE: THE DATUM REFERENCE FRAME……Page 92
5.3 STEP TWO: THE FIXTURE LAYOUT……Page 95
5.4 STEP THREE: GAGING AND MEASUREMENT……Page 100
5.5 STEP FOUR: FIXTURE CONTROLS……Page 102
5.6 STEP FIVE: TOOLING PACKAGE……Page 105
5.7 STEP SIX: ENGINEERING CHANGES……Page 107
REFERENCE……Page 108
6.1 INTRODUCTION……Page 109
6.2.1 DATUM SPECI.CATION……Page 111
6.2.4 DATUM QUALIFICATION……Page 112
6.2.5 DATUM IDENTICATION……Page 113
6.3 SINGLE-DATUM REFERENCE FRAME DIMENSIONING……Page 115
6.4 TOLERANCING……Page 116
6.4.2 THE ZERO POSITIONAL CONTROL……Page 117
6.5 PHANTOM-GAGE DIMENSIONING……Page 118
6.5.1 DESIGN LAYOUT……Page 119
6.5.2 PART/ GAGE DESIGN PARAMETERS……Page 120
6.5.3 DEFINING FUNCTIONAL GAGES FROM THE DESIGN LAYOUT……Page 121
6.6 APPLICATIONS OF PHANTOM GAGING……Page 123
6.7 CONCLUSIONS……Page 124
7.1 INTRODUCTION……Page 125
7.2.2 TRUE VALUE……Page 126
7.2.4 PRECISION AND ACCURACY……Page 130
7.2.5 PRECISION, BIAS, ACCURACY — AN ILLUSTRATION……Page 131
7.3.1 STATISTICAL CONCEPTS……Page 133
7.3.2 RANDOM UNCERTAINTIES……Page 136
7.3.3 SYSTEMATIC UNCERTAINTY……Page 138
7.3.5 AVERAGES AND INDIVIDUALS — AN EXAMPLE……Page 139
7.4.1 FUNCTIONAL REPRESENTATION/ DESIGN INTENT……Page 144
7.4.2 DERIVED GEOMETRY……Page 146
7.4.3 CONFORMANCE……Page 145
7.4.5 LINK TO SYSTEM OF UNITS……Page 147
7.5 SUMMARY……Page 148
REFERENCES……Page 149
8.1 INTRODUCTION……Page 150
8.2.1 PROCESS VARIATION……Page 151
8.2.2 MEASUREMENT QUALITY……Page 155
8.2.3 PLAN CONTENT……Page 156
8.3 INSPECTION PROCESS UNCERTAINTY……Page 158
8.4 TOLERANCE CHARACTERISTICS AND MODELING……Page 159
8.5.1 DATUM PLANES……Page 162
8.5.3 AXIS ANGULARITY……Page 163
8.6 TEMPERATURE CHANGES……Page 165
8.7 EQUIPMENT INACCURACIES……Page 166
8.8.1 BIAS……Page 168
8.9 FREE-STATE VARIATION……Page 169
8.10.1 RECORDING SETUP……Page 170
8.11 CONCLUSION……Page 172
REFERENCES……Page 173
9.1 INTRODUCTION……Page 174
9.2 FUNCTIONAL GAGING PRINCIPLES……Page 176
9.3.1 INTERNAL FEATURE PATTERNS……Page 177
9.3.2 EXTERNAL FEATURE PATTERNS……Page 184
9.4.1 CRITICAL (RFS) PART DATUM FEATURES……Page 187
9.4.2 CRITICAL (MMC) PART DATUM FEATURES……Page 191
9.4.3 INDEPENDENT HOLE PATTERNS……Page 194
9.4.4 TWO CRITICAL DATUM FEATURES……Page 195
9.4.5 MULTIPLE DATUM FEATURES, WITH INDEPENDENT HOLE PATTERN……Page 197
9.4.6 DATUM FEATURES RELATED TO PRIMARY DATUM PLANE……Page 199
9.4.7 THREE-HOLE PATTERN AND EXTERNAL DATUM FEATURE……Page 201
9.4.8 THREE-HOLE PATTERN AND INTERNAL DATUM FEATURE……Page 202
9.4.9 CYLINDRICAL PART WITH TWO-PIN PATTERNS……Page 203
9.4.10 TWO RADIAL PATTERNS OF PINS AND SLOTS……Page 205
9.5 REVIEW OF PRINCIPLES AND APPLICATIONS……Page 206
10.1 INTRODUCTION……Page 208
10.2 GAGING ELEMENT SIZE AND MATERIAL MODIFIERS……Page 209
10.3 WORKPIECE EXAMPLE……Page 210
10.4 ZERO POSITIONAL TOLERANCE AT LMC……Page 212
10.4.2 MMC GAGE PIN AT TRUE POSITION……Page 213
10.4.3 MMC GAGE PIN WITH MAXIMUM POSITIONAL ERROR……Page 214
10.5 RESULTS……Page 215
10.6 ALTERNATE FORM OF ANALYSIS……Page 217
10.8.1 MACHINE TOOL CAPABILITIES……Page 219
10.8.2 SINGLE-SETUP GAGE FEATURE MANUFACTURE……Page 221
10.8.3 GAGE ASSEMBLY OPERATIONS……Page 223
10.9 SUMMARY……Page 224
REFERENCES……Page 225
A10.1.2 SECOND TRIAL……Page 226
A10.2.3 GAGE PIN AT LMC AND MAXIMUM POSITIONAL ERROR……Page 229
A10.3.1 LMC GAGE PIN AT TRUE POSITION……Page 230
A10.3.3 LMC GAGE PIN AND MAXIMUM POSITIONAL ERROR……Page 231
A10.4 DIAMETRAL ANALYSIS — ZERO AT MMC GAGE……Page 232
11.1 INTRODUCTION……Page 233
11.2.1 GAGING POSITIONAL TOLERANCES……Page 234
11.2.2 GAGING FORM AND ORIENTATION TOLERANCES……Page 238
11.3 FUNCTIONAL GAGING WITH COORDINATE MEASURING MACHINES……Page 240
11.3.1 FUNCTIONAL CMM PROGRAMMING……Page 241
11.3.2 HYPOTHETICAL CONVERSION……Page 242
11.3.3 EXAMPLES……Page 243
11.4 FUNCTIONAL GAGING WITH OPTICAL COMPARATORS……Page 246
11.4.2 PROFILE TOLERANCING……Page 247
11.5 PAPER LAYOUT GAGING……Page 250
11.5.1 APPLICATION……Page 251
11.5.2 PARTS THAT CAN BE PAPER-GAGED……Page 253
11.5.3 PAPER GAGING PROCEDURE……Page 254
11.5.4 INSPECTION RESULTS LAYOUT……Page 255
11.5.5 TOLERANCE LAYOUT……Page 257
11.5.6 COMBINING LAYOUTS……Page 258
11.5.7 ALLOWANCE FACTORS……Page 259
11.5.8 ANALYZING RESULTS……Page 261
11.5.9 PAPER GAGES COMPARED TO OTHER FUNCTIONAL GAGES……Page 262
REFERENCES……Page 263
12.1 INTRODUCTION……Page 264
12.3 FUNCTIONAL FIXTURING PRINCIPLES……Page 266
12.4 FIXTURE DESIGN CONCEPTS……Page 267
12.5.1 FUNCTIONAL VERSUS PROCESS FRAME……Page 273
12.5.2 NUMBER OF DRFS……Page 274
12.5.3 LOCATION OF THE FIXTURE……Page 276
12.5.4 DESIGN OF DATUM FEATURE SIMULATORS……Page 277
12.6 APPLICATION ISSUES……Page 280
12.7 A PRACTICAL EXAMPLE……Page 281
12.7.1 TRADITIONAL PROCESSING OF PART……Page 283
12.7.2 SINGLE-SETUP PROCESSING OF PART*……Page 289
12.8 SUMMARY……Page 292
REFERENCES……Page 293
13.1 INTRODUCTION……Page 294
13.2 THE INITIAL SITUATION……Page 295
13.3 COMPONENT DEFINITION……Page 298
13.4 THE SIX-STEP PROCESS……Page 299
13.5 THE RESULTS……Page 307
14.1 INTRODUCTION……Page 309
14.2.2 COMMUNICATION……Page 310
14.2.4 PROBLEM SOLVING……Page 311
14.2.5 A BENCHMARK……Page 312
14.3.1 AUDIT EXISTING DESIGN PROCESS……Page 313
14.3.2 EDUCATION IN DOCUMENTATION PRINCIPLES……Page 315
14.3.3 SENIOR MANAGEMENT’S SUPPORT……Page 316
14.3.6 TRAINING ISSUES……Page 317
14.3.7 IDENTIFICATION OF AN ADVOCATE……Page 318
14.3.8 MANAGEMENT SUPPORT……Page 319
14.3.9 CONTROLLED IMPLEMENTATION……Page 320
14.3.10 UPGRADE METROLOGY/ INSPECTION CAPABILITIES……Page 321
14.3.11 REVIEW AND CRITIQUE……Page 322
14.3.12 EXPAND TRAINING……Page 324
14.4 CONCLUSION……Page 325
REFERENCES……Page 327