Three-Dimensional Synthesis of Manufacturing Tolerances Based on Analysis Using the Ascending Approach

The present paper develops a new approach for manufacturing tolerances synthesis to allow the distribution of these tolerances over the different phases concerned in machining processes using relationships written in the tolerance analysis phase that have been well developed in our previous works. The novelty of the proposed approach is that the treatment of non-conventional surfaces does not pose a particular problem, since the toleranced surface is discretized. Thus, it is possible to study the feasibility of a single critical requirement as an example. During the present approach, we only look for variables that influence the requirements and the others are noted F (Free). These variables can be perfectly identified on the machine, which can be applied for known and unknown machining fixtures; this can be the base for proposing a normalized ISO specification used in the different machining phases of a mechanical part. The synthesis of machining tolerances takes place in three steps: (1) Analysis of the relationship’s terms, which include the influence of three main defects; the deviation on the machined surface, defects in the machining set-up, and the influence of positioning dispersions; then (2) optimization of machining tolerance through a precise evaluation of these effects; and finally (3) the optimization of the precision of the workpiece fixture, which will give the dimensioning of the machining assembly for the tooling and will allow the machining assembly to be qualified. The approach used proved its efficiency in the end by presenting the optimal machining process drawing that explains the ordered phases needed to process the workpiece object of the case study.

Blade Envelopes Part I: Concept and Methodology

Blades manufactured through flank and point milling will likely exhibit geometric variability. Gauging the aerodynamic repercussions of such variability, prior to manufacturing a component, is challenging enough, let alone trying to predict what the amplified impact of any in-service degradation will be. While rules of thumb that govern the tolerance band can be devised based on expected boundary layer characteristics at known regions and levels of degradation, it remains a challenge to translate these insights into quantitative bounds for manufacturing. In this work, we tackle this challenge by leveraging ideas from dimension reduction to construct low-dimensional representations of aerodynamic performance metrics. These low-dimensional models can identify a subspace which contains designs that are invariant in performance -- the inactive subspace. By sampling within this subspace, we design techniques for drafting manufacturing tolerances and for quantifying whether a scanned component should be used or scrapped. We introduce the blade envelope as a computational manufacturing guide for a blade. In this paper, the first of two parts, we discuss its underlying concept and detail its computational methodology, assuming one is interested only in the single objective of ensuring that the loss of all manufactured blades remains constant. To demonstrate the utility of our ideas we devise a series of computational experiments with the Von Karman Institute's LS89 turbine blade.

Automatic Tolerance Analysis of Permanent Magnet Machines with Encapsuled FEM Models Using Digital-Twin-Distiller

Tolerance analysis is crucial in every manufacturing process, such as electrical machine design, because tight tolerances lead to high manufacturing costs. A FEM-based solution of the tolerance analysis of an electrical machine can easily lead to a computationally expensive problem. Many papers have proposed the design of experiments, surrogate-model-based methodologies, to reduce the computational demand of this problem. However, these papers did not focus on the information loss and the limitations of the applied methodologies. Regardless, the absolute value of the calculated tolerance and the numerical error of the applied numerical methods can be in the same order of magnitude. In this paper, the tolerance and the sensitivity of BLDC machines’ cogging torque are analysed using different methodologies. The results show that the manufacturing tolerances can have a significant effect on the calculated parameters, and that the mean value of the calculated cogging torque increases. The design of the experiment-based methodologies significantly reduced the calculation time, and shows that the encapsulated FEM model can be invoked from an external system-level optimization to examine the design from different aspects.

A novel approach for identification of sensor devices through Acoustic PUF

The supply chain traceability of components from a production facility to deployment and maintenance depends upon its irrefutable identity. There are two well-known methods for identification which includes an identity code stored in the memory and embedding a custom identification hardware. While storing the identity code is susceptible to malicious and unintentional attacks, the approach of embedding a custom identification hardware is infeasible for sensor nodes assembled with Commercially-Off-the-Shelf (COTS) devices. We propose a novel identifier - Acoustic PUF based on the innate properties of the sensor node. Acoustic PUF combines the uniqueness component and the position component of the sensor device signature. The uniqueness component is derived by exploiting the manufacturing tolerances, thus making the signature unclonable. The position component is derived through acoustic fingerprinting, thus giving a sticky identity to the sensor device. We evaluate Acoustic PUF for Uniqueness, Repeatability and Position identity with a deployment spanning several weeks. Through our experimental evaluation and further numerical analysis, we prove that Acoustic PUF can uniquely identify thousands of devices with 99% accuracy while simultaneously detecting the change in position.

Influence of manufacturing errors of bearing components on rotational accuracy of cylindrical roller bearings

Understanding the influence of bearing component manufacturing errors and roller number on the rotational accuracy of rolling bearings is crucial in the design of high precision bearings. The rotational accuracy of an assembled bearing is dependent upon roller number and manufacturing error of the bearing components. We propose a model for calculating the rotational accuracy of a cylindrical roller bearing; we experimentally verified the effectiveness of the model in predicting the radial run-out of the inner ring proposed in the previous paper in this series. We sought to define the key contributing factors to the rotational accuracy by studying both the influence of the coupling effect of the roller number and the influence of the manufacturing errors in the inner raceway, outer raceway, and rollers on the motion error. The model and results will help engineers choose reasonable manufacturing tolerances for bearing components to achieve the required rotational accuracy.