relating engineering design and dimensional metrology · relating engineering design and...
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Relating Engineering Design and Dimensional Metrology A Manufacturing Systems Perspective
Industrial Doctorate Centre & Rolls-Royce plc. Per Saunders Supervisors: Nick Orchard Neil Tatman Prof. Paul Maropoulos Prof. Andrew Graves
© Rolls-Royce plc 2013
© Rolls-Royce plc 2013
Relating Engineering Design and Dimensional Metrology
Defining the Problem
1. Introduction
2. The Unmeasurables and Scope
3. Product Lifecycle Management
Methodology
4. Research Approach
Results and Work-in-Progress
5. Modelling Measurement Capability
6. Building an Integration Framework
7. Developing Integrated Standards
Conclusions
8. Implications and Summary
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Design Make Support
1. Diverse and Complex Products
Single Trent 1000
20,000 unique components
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2. The Unmeasurables
Process
People
Product
Context
Globalisation & Formality
Specialist &
Maturing
Workforce
Coping with
Concurrency
Nominal
v.
‘Reality’
Unmeasurable
Features
BS8888: 2011
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Middle of LifeBeginning of Life End Of Life
Conceptual Design
Detailed Design
Procurement
Part Manufacturing
Logistics
Use / Maintenance
Assembly
RemanufacturingLife Cycle Planning
Disposal
Adapted from Jun et al (2007)
2. EngD Scope
Adapted from Jun et al (2007)
Aerospace Components Coordinate Measuring Machines
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3. Product Lifecycle Management (PLM)
Current Capability
• Fully Associative Master Model driven Technical Package
• Supports complex NC processes • Promotes Data Re-Use
`
Inspection Plan
Probing Macros
Equipment & Fixtures
Execution
Program Validation
Technical artefacts are developed concurrently and managed within the PLM environment
Desired Capability
• Enhanced support for verification
Desired Capability • Enhanced support for verification
CAM Process
Verification
Post Processor
Tool Path
Machine Setup
Spindle Tooling
Fixturing Stage Operation
Master Model
How feasible is it, using available technology, to fully plan
dimensional measurement processes in a digital environment
without conducting physical trials?
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4. Research Approach
Stakeholder Requirements
Prevent ‘Unmeasurables’
Systems Solution
Integrated standards that relate
engineering design and dimensional metrology
Enabling Technology
Integration of measurement processes within
Product Lifecycle Management (PLM)
Fundamental Knowledge
Modelling measurement capability
Needs How
How
How Needs
Needs
A
B
C
Adapted from NSF ERC Strategy Framework and Bristol Research Framework
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5. Modelling Measurement Capability (Fundamental Knowledge)
Uncertainty Evaluating
Software
Machine Environment
Task-specific
uncertainty
Probe System
Nominal
geometry
Geometric
tolerances
Sampling
strategy
Fitting
algorithms
I want to know, for each dimensional
characteristic, how much of my
tolerance band will be consumed by
measurement variation?
Uncertainty contributors
Form error
Monte-Carlo based algorithms
116+ uncertainty contributors are listed
in ISO14253-2: 2011 “Non-Exhaustive”
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5. Modelling Measurement Capability (Fundamental Knowledge)
Geometry exchange is tricky ... especially for ‘Product & Manufacturing Information’
Measuring machines are critical resources that exist in a ‘real’ and changing world
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6. Building an Integration Framework (Enabling Technology)
Component
Design
PMI* Assignment
Verification and Process
Planning
Measurement Planning
Measurement Programming
Measurement Execution
Measurement Results Analysis
Component Variation Analysis
How closely was
the specification met?
How did reality
differ from design?
Did the execution
go to plan?
CAD
CAD + PMI
QMPlan (High Level)
QMPlan (Low Level)
QMExecution
QMStats
QMResults
* PMI = Product and Manufacturing Information (e.g. size, position, flatness etc.)
QM = Quality Management (see www.qifstandards.org)
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QMPlan (High Level)
Component
Design
PMI* Assignment
Verification and Process
Planning
Measurement Planning
Measurement Programming
Measurement Execution
Measurement Results Analysis
Component Variation Analysis
How closely was
the specification met?
How did reality
differ from design?
Did the execution
go to plan?
CAD
CAD + PMI
QMPlan (Low Level)
QMExecution
QMStats
QMResults
* PMI = Product and Manufacturing Information (e.g. size, position, flatness etc.)
QM = Quality Management (see www.qifstandards.org)
7. Developing Integrated Standards (Systems Solution)
Uncertainty Evaluation
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8. Adding Value through Standards
Impact Knowledge Industry
‘good
practice’
Company
guidelines
Centre of expertise
International standards
New
products &
processes