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Three-Dimensional Tolerance Analysis Modelling of Variation Propagation in Multi-stage Machining Processes for General Shape Workpieces

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Abstract

The quality control of general shape workpieces has become one of research hotspots because of the increasing diversity of products. The theory of stream of variation (SoV) for machining processes is a successful method in researching variation propagation rule. However, with the consideration of all key elements in manufacturing system, there is no unified and integrated model for workpieces in different kinds of shapes. In this paper, a new variation propagation model in multi-stage machining processes for general shape workpieces is established. It visually demonstrates the variation propagation chain and expands the universality of current SoV models. The connection of all key elements in manufacturing system is defined as an assembly chain, in which the variations are defined and propagated by modified three-dimensional tolerance analysis method. The equivalent conversion of the connection between workpiece and fixture realizes the modelling of general shape workpiece regardless of its machining method and locating scheme. Real experiments validate the effectiveness and accuracy of the new SoV model for different shape workpieces. This model has great potential to be applied toward multi-scale variation modelling, process control, and fault diagnosis for general shape workpieces.

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Acknowledgements

This work is supported by the National Natural Science Foundation of China (Grant Nos. 51535007, 51775343). All experiments were performed at Shanghai Automotive Industry Corporation General Motors Wuling Company (SGMW) in Liuzhou, China, we are grateful to SGMW engineers for their experimental support.

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Authors and Affiliations

  1. Department of Industrial Engineering and Management, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai, People’s Republic of China

    Kun Wang, Shichang Du & Lifeng Xi

  2. State Key Lab of Mechanical System and Vibration, Shanghai Jiao Tong University, Shanghai, People’s Republic of China

    Shichang Du & Lifeng Xi

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  1. Kun Wang
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  2. Shichang Du
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  3. Lifeng Xi
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Correspondence to Shichang Du.

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Wang, K., Du, S. & Xi, L. Three-Dimensional Tolerance Analysis Modelling of Variation Propagation in Multi-stage Machining Processes for General Shape Workpieces. Int. J. Precis. Eng. Manuf. 21, 31–44 (2020). https://doi.org/10.1007/s12541-019-00202-0

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  • DOI: https://doi.org/10.1007/s12541-019-00202-0

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