Computer Aided Tolerancing (CAT) platform for the design of assemblies under external and internal forces

Due to the stochastic nature of manufacturing processes, the functionality of mechanical assemblies is subject to variation defined by tolerances and manufacturing process characteristics. In many assemblies, functionality is also dependent on external and internal forces. Numerous Computer Aided Tolerancing (CAT) tools have been proposed that address tolerance analysis problems in complex mechanical assemblies; however current tools do not accommodate a general class of problem where the functionality of a design is fundamentally dependent on the effects of external and internal forces. This research addresses the limitation of CAT tools to accommodate assemblies under loading by developing a tolerance analysis platform which integrates CAD, CAE and statistical analysis tools using Process Integration and Design Optimisation (PIDO) software capabilities. The platform extends the capabilities of traditional CAT tools by enabling tolerance analysis of assemblies in which assembly characteristics are dependent on external and internal forces. To demonstrate the capabilities of the developed platform, examples of tolerance analysis problems involving external forces (compliance) and internal forces (multi-body dynamics) are presented.

► The functionality of many assemblies is dependent on external and internal forces.
► Current tolerance analysis tools do not readily accommodate assemblies under loading.
► A tolerance analysis platform integrating CAD, CAE and statistical tools is shown.
► The platform enables tolerance analysis of assemblies under general loading.
► Tolerance analysis test cases involving compliance and dynamics are presented.