relationship of product function with dimensional tolerance student : irfan anjum manarvi...

Relationship of Product function with Dimensional tolerance

Student : Irfan Anjum Manarvi

Supervisor: Prof. Neal Juster

Presentation sequence

• Nature and scope of research

• Experimental

• Finite Element Simulations

• Analysis of results

• Primary conclusions

• Future direction

Nature and scope of research

• Experimental•Theoretical based on FE

simulations

• Selection of application

ABS plastics deformation under ABS plastics deformation under tolerancetolerance

• Design & Manufacture of test rig for application

• Validity of test rig design• Conduct of experiments

Test Rig and Coordinate measuring Test Rig and Coordinate measuring machinemachine

• Data collection • Analysis of results

Experimental

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Length x 10mm

Def

orm

atio

n (

mm

)

0.2mm 0.4mm 0.6mm 0.8mm 1.0mm 1.2mm

Fig 1.0 Specimen thickness 0.9mm, tolerance pin diameter 1.0mm

Experimental results

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0.2mm 0.4mm 0.6mm 0.8mm 1.0mm 1.2mm

Tolerance value (mm)

Defo

rmati

on

mm

1 mm 10 mm 50 mm 100 mm 150 mm 168 mm

Experimental results

Fig 2.0 Comparison of deformation at specific tolerance for 0.9mm thickness specimen with 1.0mm dia pin

FE Simulation

• Model design• Boundary conditions • Mesh formation• Product deformation • Deformation measurement at

specific path

Model Design and Boundary Conditions

Boundary conditions

Mesh generation for analysisElement size 2mm

No. of elements over 5500

Deformation results

Deformation results by FE simulations

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0.0

1.0

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Nodes along X -axis

Def

orm

atio

n (

mm

)

0.2mm 0.47mm 0.82mm

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0

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Distance along X-axis X 10 (mm)

Def

orm

atio

n (m

m)

FE at 0.2mm FE at 0.47mm FE at 0.82mm

Exp at 0.2mm Exp at 0.4mm Exp at 0.8mm

Analysis of Experimental and FE results at

0.2mm, 0.4mm and 0.8mm tolerance

Primary conclusions• Product function has definite

relationship with dimensional tolerances.

• Research is limited due to requirements of extra ordinary resources for experimentation and data analysis

• FE simulation can be used successfully for simulation of relationship between product function and dimensional tolerances.

• Improve upon existing FE model• To carry out more FE simulations and

analyse results on the bases of experimental data

• Establish sources of errors and minimise differences.

• Move from simple to complex applications

• Evolve strategy for using FE simulations to establish relationship between product function and dimensional tolerances

Future direction of research