Tolerance-based process plan evaluation using Monte Carlo simulation

International Journal of Production Research

Volumn 42, Issue 23, 2004, Pages 4871-4891

  Huang, Samuel H ^a   Liu, Qiu ^b   Musa, Rami ^a  

^a 705 Engineering Research Center   (United States)

^b MCNEESE STATE UNIVERSITY   (United States)

Author keywords

[No Author keywords available]

Indexed keywords

COMPUTATIONAL GEOMETRY; DECISION MAKING; ENGINEERS; ERROR ANALYSIS; EVALUATION; MACHINING; MONTE CARLO METHODS; PLANNING; PROCESS CONTROL; QUALITY CONTROL;

ERROR PROPAGATION; ERROR SOURCES; PROCESS PLANNING; STATISTICAL QUALITY CONTROL (SPC);

FITS AND TOLERANCES;

EID: 9944253311     PISSN: 00207543     EISSN: None     Source Type: Journal    
DOI: 10.1080/0020754042000264608     Document Type: Article

References (61)

1. ABDOU, G. and CHENG, R., 1993, TVCAPP, tolerance verification in computer-aided process planning. International Journal of Production Research, 31, 393-411.
2. AHLUWALIA, R. S. and KAROLIN, A. V., 1986, CATC: a computer aided tolerance control system. Journal of Manufacturing Systems, 3, 153-160.
3. ANSI Y14.5-1994. Dimensioning and Tolerancing, 1995 (American Society of Mechanical Engineers: New York).
4. BRITTON, G. A. and WHYBREW, K., 1997, CATCH: computer-aided tolerance charting. In H.-C. Zhang (ed), Advanced Tolerance Techniques (New York: Wiley), pp. 461-489.
5. CHEN, J.-S., 1996, A study of thermally induced machine tool errors in real cutting conditions. International Journal of Machine Tools and Manufacture, 36, 1401-1411.
6. CHEN, X. B., GEDDAM, A. and YUAN, Z. J., 1997, Accuracy improvement of three-axis CNC machining centers by quasi-static error compensation. Journal of Manufacturing Systems, 16, 323-336.
7. CHOUDHURI, S. A. and DE METER, E. C., 1999, Tolerance analysis of machining fixture locators. Journal of Manufacturing Science and Engineering, 121, 273-281.
8. DIMLA, D. E., 2000, Sensor signals for tool-wear monitoring in metal cutting operations: a review of methods. International Journal of Machine Tools and Manufacture, 40, 1073-1098.
9. DONG, Z. and Hu, W., 1991, Optimal process sequence identification and optimal process tolerance assignment in computer-aided process planning. Computers in Industry, 17, 19-32.
10. FENG, S. C. and HOPP, T. H., 1991, A review of current geometric tolerancing theories and inspection data analysis algorithms. NISTIR-4509. National Institute of Standards and Technology.
11. FRATICELLI, B. M. P., LEHTIHET, E. A. and CAVALIER, T. M., 1999. Tool-wear effect compensation under sequential tolerance control. International Journal of Production Research, 37, 639-651.
12. GAO, J., CHASE, K. and MAGLEBY, S., 1998, Generalized 3-D tolerance analysis of mechanical assemblies with small kinematic adjustments. IIE Transactions, 30, 367-377.
13. HALEVI, G. and WEILL, R. D., 1995, Principles of Process Planning: A Logical Approach, (London: Chapman & Hall).
14. 2 discrepancies of some plane sets. Monatsh. Mathematics, 73, 316-328.
15. HAMMERSLEY, J. M., 1960, Monte Carlo methods for solving multivariable problems. Annals of the New York Academy of Sciences, 86, 844-874.
16. HOCKENBERGER, M. J. and DE METER, E. C., 1996, The application of meta functions to the quasi-static analysis of workpiece displacement within a machining fixture. Journal of Manufacturing Science and Engineering, 118, 325-331.
17. HONG, M. and EHMANN, K., 1995, Generation of engineered surfaces by the surface-shaping system. International Journal of Machine Tools and Manufacture, 35, 1269-1290.
18. HUANG, Q., ZHOU, S. and SHI, J., 2002, Diagnosis of multi-operational machining processes by using virtual machining. Robotics and Computer-Integrated Manufacturing, 18, 233-239.
19. JI, P., 1993, A linear programming model for tolerance assignment in a tolerance chart. International Journal of Production Research, 31, 739-751.
20. JI, P., 1996, Determining dimensions for process planning: a backward derivation approach. International Journal of Advanced Manufacturing Technology, 11, 52-58.
21. JI, P., KE, M. and AHLUWALIA, R. S., 1995, Computer-aided operational dimensioning for process planning. International Journal of Machine Tools and Manufacture, 35, 1353-1362.
22. KIM, S. H., Ko, T. J. and AHN, J. H., 2002, Elimination of settling error due to clamping forces in on-machine measurement. International Journal of Advanced Manufacturing Technology, 19, 573-578.
23. KONAKALLA, S. and GAVANKAR, P., 1997, An object-oriented system for tolerance charting. Journal of Intelligent Manufacturing, 8, 239-250.
24. KRISHNAKUMAR, K. and MELKOTE, S., 2000, Machining fixture layout optimization using the genetic algorithm. International Journal of Machine Tools and Manufacture, 40, 579-598.
25. LEE, G., MOU, J. and SHEN, Y., 1997, Sampling strategy design for dimensional measurement of geometric features using coordinate measuring machine. International Journal of Machine Tools and Manufacture, 37, 917-934.
26. LEE, Y.-C. and WEI, C.-C., 1998, Process capability-based tolerance design to minimise manufacturing loss. International Journal of Advanced Manufacturing Technology, 14, 33-37.
27. LI, J. K. and ZHANG, C., 1989, Operational dimensions and tolerances calculation in CAPP systems for precision manufacturing. Annals of the CIRP, 38, 403-406.
28. LI, S., ZHANG, Y. and ZHANG, G., 1997, A study of pre-compensation for thermal errors of NC machine tools. International Journal of Machine Tools and Manufacture, 37, 1715-1719.
29. Li, X. Q., WONG, Y. S. and NEE, A. Y. C., 1997. Tool wear and chatter detection using the coherence function of two crossed accelerations. International Journal of Machine Tools and Manufacture, 1, 425-435.
30. LIN, A. C., LIN, M.-Y. and Ho, H.-B., 1999, CAPP and its integration with tolerance charts for machining of aircraft component. Computers in Industry, 38, 263-283.
31. LIN, S., WANG, H. P. and ZHANG, C., 1997, Statistical tolerance analysis based on beta distribution. Journal of Manufacturing Systems, 16, 150-158.
32. LIU, Q., 2003, Manufacturing error analysis and Monte Carlo simulation for proactive tolerance control in process planning. Ph.D. Dissertation, Department of Mechanical. Industrial, and Manufacturing Engineering, University of Toledo.
33. LIU, Q. and HUANG, S. H., 2001, Structured process plan information modeling for tolerance prediction. In 5th International Conference on Engineering Design and Automation, Las Vegas, NV, August 5-8.
34. LIU, Q., ZHANG, C. and WANG, H.-P. B., 1997, Form accuracy analysis and prediction in computer-integrated manufacturing. International Journal of Machine Tools and Manufacture, 7, 237-248.
35. MENQ, C.-H., YAU, H.-T., LAI, G.-Y. and MILLER, R. A., 1990, Statistical evaluation of form tolerances using discrete measurement data. Advanced in Integrated Product Design and Manufacturing, PED-37, 135-149.
36. MITTAL, R. O., IRANI, S. A. and LEHTIHET, E. A., 1990, Tolerance control in the machining of discrete components. Journal of Manufacturing Systems. 9, 233-246.
37. MIZE, C. and ZIRGERT, J., 2000, Neural network thermal error compensation of a machining center. Precision Engineering, 24, 338-346.
38. MUSA, R., SHULTES, B. C. and HUANG, S. H., 2004, Simulation-based manufacturing error synthesis: input analysis and validation. Transactions of the North American Manufacturing Research Institution/SME, 32, pp. 311-318.
39. NGOI, B. K. A., AGARWAL, M. and CHUA, C. S., 1998, The noded approach to stack analysis. International Journal of Advanced Manufacturing Technology, 14, 343-349.
40. NGOI, B. K. A. and FANG, S. L., 1994, Computer-aided tolerance charting. International Journal of Production Research, 32, 1939-1954.
41. NGOI, B. K. A., LIM, L. E. N., ONG, A. S. and LIM, B. H., 1999, Applying the coordinate tolerance system to tolerance stack analysis involving position tolerance. International Journal of Advanced Manufacturing Technology, 15, 404-408.
42. NGOI, B. K. A. and ONG, C. T., 1993, Process sequence determination for tolerance charting. International Journal of Production Research, 31, 2387-2401.
43. NGOI, B. K. A. and SEOW, M. S., 1996, Tolerance control for dimensional and geometric specifications. International Journal of Advanced Manufacturing Technology, 11, 34-42.
44. OKAFOR, A. C. and ERTEKIN, Y. M., 2000, Derivation of machine tool error models and error compensation procedure for three axes vertical machining center using rigid body kinematics. International Journal of Machine Tools and Manufacture, 40, 1199-1213.
45. RAMESH, R., MANNAN, M. A. and POO, A. N., 2000a, Error compensation in machine tools - A review, Part I: GEOMETRIC, cutting-force induced and fixture dependent errors. International Journal of Machine Tools and Manufacture, 40, 1235-1256.
46. RAMESH, R., MANNAN, M. A. and POO, A. N., 2000b, Error compensation in machine tools - A review, Part II: Thermal errors. International Journal of Machine Tools and Manufacture, 40, 1257-1284.
47. RAMESH, R., MANNAN, M. A. and POO, A. N., 2002, AI-based classification methodologies for modeling machine tool thermal error. Transactions of the North American Manufacturing Research Institution/SME, 30, 239-246.
48. RONG, Y., Hu, W., KANG, Y., ZHANG, Y. and YEN, D., 2001, Locating error analysis and tolerance assignment for computer-aided fixture design. International Journal of Production Research, 39, 3529-3545.
49. RONG, Y., Li, W. and BAI, Y., 1995, Locating error analysis for fixturing accuracy verification. In ASME Computers in Engineering, 1995, Boston, MA. 17-21 September, pp. 825-832.
50. SATYANARAYANA, S. and MELKOTE, S., 2002, Determination of clamping force based on minimization of workpiece elastic deformation. Transactions of the North American Manufacturing Research Institution/SME, 30, 597-604.
51. SCHMITZ, T. and ZIEGERT, J., 1999, Examination of surface location error due to phasing of cutter vibration. Precision Engineering, 23, 51-62.
52. TETI, R., 1995, A review of tool condition monitoring literature database. Annals of the CIRP, 44, 659-666.
53. WADE, O. R., 1983, Tolerance control. In Tool and Manufacturing Engineers Handbook, Vol. 1: Machining (SME: Dearborn, MI), pp. 2-1 to 2-60.
54. WANG, Y., ZHANG, G., MOON, K. S. and SUTHERLAND, J. W., 1998, Compensation for the thermal error of a multi-axis machining center. Journal of Materials Processing Technology, 75, 45-53.
55. WECKENMANN, A., HEINRICHOWSKI, M. and MORDHORST, H., 1991, Design of gauges and multipoint measuring systems using coordinate-measuring-machine data and computer simulation. Precision Engineering. 13, 203-207.
56. WEILL, R., DAREL, I. and LALOUM, M., 1991, The influence of fixture positioning errors on the geometric accuracy of mechanical parts. In Proceedings of CIRP Conference on PE and MS, Tianjin, China, Tianjin University Press, pp. 215-225.
57. WOO, T. C., LIANG, R., HSIEH, C. C. and LEE, N. K., 1995, Efficient sampling for surface measurement. Journal of Manufacturing Systems, 14, 345-354.
58. XIAOQING, T. and DAVIES, B. J., 1988, Computer aided dimensional planning. International Journal of Production Research, 26, 283-297.
59. YANG, M. and LEE, J., 1998, Measurement and prediction of thermal errors of a CNC machining center using two spherical balls. Journal of Materials Processing Technology, 75, 180-189.
60. ZHANG, J., HUANG, Y., HUANG, G. and CHEN, C., 2000, The Monte-Carlo method for solving the dimensional chain positive problem. Journal of Materials Processing Technology, 103, 189-193.
61. ZHANG, Y. F., NEE, A. Y. C., FUH, J. Y. H., NEO, K. S. and LOY, H. K., 1996, A neural network approach to determining optimal inspection sampling size for CMM. Computer Integrated Manufacturing Systems, 9, 161-169.