relating engineering design and dimensional metrology · relating engineering design and...

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


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


Design Make Support

1. Diverse and Complex Products

Single Trent 1000

20,000 unique components


2. The Unmeasurables

Process

People

Product

Context

Globalisation & Formality

Specialist &

Maturing

Workforce

Coping with

Concurrency

Nominal

v.

‘Reality’

Unmeasurable

Features

BS8888: 2011


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


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?


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


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”


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


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)


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


8. Adding Value through Standards

Impact Knowledge Industry

‘good

practice’

Company

guidelines

Centre of expertise

International standards

New

products &

processes

Thank you for

your attention

The Arnolfini Portrait, Jan van Eyck, 1434

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