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Visualisation Methods for Tolerance Stack-up Analysis

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Visualisation Methods for Tolerance Stack-up Analysis

Summary
Tolerance analysis is a key stage in the Topic Lifecycle Management (PLM) process. The relationship between quality and cost saving can only be optimised by the appropriate assignment of tolerances during the design stage of a products development. Software packages exist that perform this type of tolerance analysis but they rely on graphs and tables to represent the results. While this allows the user to view the results accurately, it can be difficult to interpret these results. This is why visualisation is used so much when using CAD and analysis software. However, because of the distributive nature of the results of tolerance analysis, traditional methods of visualisation are not very affective.
This report addresses this by researching current methods for visualising analysis results and
seeing how they can be adapted for tolerance analysis. Then, a variety of visualisation methods will be suggested and evaluated. Finally a prototype of some of the visualisation methods will be created.

Contents
Summary……………………………………………………………………………………………..i
Acknowledgements ……………………………………………………………………………….ii
Contents …………………………………………………………………………………………….iii
1.0 Introduction ……………………………………………………………………………………1
Definition of the Problem…………………………………………………………………………………1
1.2 Objectives ……………………………………………………………………………………………….2
1.3 Minimum Requirements………………………………………………………………………………2
1.4 Possible extensions ……………………………………………………………………………………3
1.5 Deliverables…………………………………………………………………………………………….3
2.0 Background Research……………………………………………………………………….4
2.1 Tolerance analysis techniques………………………………………………………………………4
2.1.1 Worst Case and Root Sum Squares ………………………………………………………….4
2.1.2 Monte Carlo methods……………………………………………………………………………6
2.3 CAD and Tolerance Analysis Visualisation Methods ………………………………………….7
2.3.1 CAD Visualisation Methods…………………………………………………………………..7
2.3.2 Tolerance Analysis Visualisation Methods…………………………………………………8
2.4 Methods for visualising distributive results ……………………………………………………11
2.4.1 Multiple Windows……………………………………………………………………………..11
2.4.2 Multiple Overlaid Solid Models…………………………………………………………….11
2.4.3 Animation ……………………………………………………………………………………….12
2.4.4 Deformation and Contour Mapping………………………………………………………..13
2.4.5 Multiple Wire Frame Models………………………………………………………………..14
2.4.6 Evaluation of Visualisation Techniques …………………………………………………..15
3.0 Design ………………………………………………………………………………………….16
3.1 Overview ………………………………………………………………………………………………16
3.2 Consideration of Programming Languages ……………………………………………………16
3.3 Choice of case study ………………………………………………………………………………..16
3.3.1 Case Study Choice One……………………………………………………………………….16
3.3.2 Case Study Choice Two ………………………………………………………………………18
3.3.3 Evaluating the Case Studies………………………………………………………………….18
3.4 Modelling the Assembly…………………………………………………………………………….18
3.5 Implementing Visualisation Methods ……………………………………………………………20
Visualisation Methods for Tolerance Stack-up Analysis
iv
3.5.1 Animation ……………………………………………………………………………………….20
3.5.2 Multiple Windows……………………………………………………………………………..20
3.5.3 Overlaid Solid Models ………………………………………………………………………..21
3.5.4 Overlaid Wire Models…………………………………………………………………………21
3.6 User Instructions …………………………………………………………………………………….23
4.0 Evaluation…………………………………………………………………………………….25
4.1 Evaluation Criteria………………………………………………………………………………….25
4.1.1 Investigation and Research …………………………………………………………………..25
4.1.2 Implementation …………………………………………………………………………………25
4.1.3 Project Management …………………………………………………………………………..25
4.2 Evaluation …………………………………………………………………………………………….26
4.2.1 Investigation and Research …………………………………………………………………..26
4.2.2 Implementation …………………………………………………………………………………26
4.2.3 Project Management …………………………………………………………………………..29
4.3 Future enhancements ……………………………………………………………………………….29
References …………………………………………………………………………………………30
Bibliography………………………………………………………………………………………31
Appendix A – Personal Reflection ………………………………………………………….32
Appendix B – Basic Terms of Statistical Analysis

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