Integrated product design and manufacturing using geometric dimensioning and tolerancing

This book addresses the preparation and application of design layout analyses with concurrent engineering teams in six steps that capture design intent and add value to design process. It offers tools for eliminating costly trial-and-error approaches and deliver economically viable products. The authors discuss product design techniques that alleviate the constraints between product definition, manufacturing, and inspection, the prediction of variation effects on product function and manufacturing efficiency, functional inspection techniques that include CMM measurement, optical comparators, and surface plate and functional gaging, and more.

Author Notes

Campbell, Bob

Ed Boyer

Foreword	p. v
Preface	p. ix
Acknowledgments	p. xiii
1 Introduction	p. 1
2 What Are the Techniques?	p. 7
2.1 Introduction	p. 7
2.2 Product Definition	p. 8
2.3 The Language of Concurrent Engineering--Y14.5M	p. 11
2.4 Concurrent Engineering	p. 13
2.5 Summary	p. 22
References	p. 23
3 The Basis of the System	p. 25
3.1 Introduction	p. 25
3.2 Y14.5M Concepts	p. 26
3.2.1 Datum Reference Frames	p. 26
3.2.2 Tooling and Gage Datum Elements	p. 33
3.2.3 Interrelated and Interchangeable Features	p. 36
3.2.4 Boundary and Axial Concepts	p. 37
3.2.5 Taylor's Principle	p. 40
3.2.6 Refinement of Controls	p. 43
3.3 Application Considerations	p. 44
3.3.1 Production Variation	p. 45
3.3.2 Datum Accuracy	p. 45
3.3.3 Interchangeability and Assembleability	p. 46
3.3.4 Verifiable Controls	p. 46
3.3.5 Material Modifiers	p. 47
3.3.6 Basic Interchangeability Gages	p. 51
3.4 Summary	p. 53
References	p. 54
4 Design Layout	p. 55
4.1 Introduction	p. 55
4.2 Product Architecture	p. 55
4.3 The Six-Step Methodology	p. 58
4.3.1 Design Layout	p. 59
4.3.2 Identification and Removal of Critical Characteristics	p. 61
4.3.3 Mechanical Simulation	p. 65
4.3.4 Consideration of DFA	p. 66
4.3.5 Design of Experiments	p. 67
4.3.6 Physical Prototyping	p. 69
4.3.7 Metrology and Product Development	p. 70
4.4 Summary	p. 72
References	p. 72
5 A Producible Component	p. 73
5.1 Introduction	p. 73
5.2 Step One: The Datum Reference Frame	p. 75
5.3 Step Two: The Fixture Layout	p. 78
5.4 Step Three: Gaging and Measurement	p. 83
5.5 Step Four: Fixture Controls	p. 85
5.6 Step Five: Tooling Package	p. 88
5.7 Step Six: Engineering Changes	p. 90
5.8 Summary	p. 91
References	p. 91
6 First Steps Toward Production	p. 93
6.1 Introduction	p. 93
6.2 Design	p. 95
6.2.1 Datum Specification	p. 95
6.2.2 Setups	p. 96
6.2.3 Datum Selection	p. 96
6.2.4 Datum Qualification	p. 96
6.2.5 Datum Identification	p. 97
6.3 Single Datum Reference Frame Dimensioning	p. 99
6.4 Tolerancing	p. 100
6.4.1 Positional Tolerance Specification	p. 101
6.4.2 The Zero Positional Control	p. 101
6.5 Phantom-Gage Dimensioning	p. 102
6.5.1 Design Layout	p. 103
6.5.2 Part/Gage Design Parameters	p. 104
6.5.3 Defining Functional Gages from the Design Layout	p. 105
6.6 Applications of Phantom Gaging	p. 107
6.7 Conclusions	p. 108
7 Dimensional Measurements	p. 109
7.1 Introduction	p. 109
7.2 Measurement Theory	p. 110
7.2.1 The Measurement Model	p. 110
7.2.2 True Value	p. 110
7.2.3 Error and Uncertainty	p. 114
7.2.4 Precision and Accuracy	p. 114
7.2.5 Precision, Bias, Accuracy--An Illustration	p. 115
7.3 Statistical Techniques	p. 117
7.3.1 Statistical Concepts	p. 117
7.3.2 Random Uncertainties	p. 120
7.3.3 Systematic Uncertainty	p. 122
7.3.4 Uncertainty in Definition	p. 123
7.3.5 Averages and Individuals--An Example	p. 123
7.4 Measurement Planning	p. 127
7.4.1 Functional Representation/Design Intent	p. 128
7.4.2 Derived Geometry	p. 129
7.4.3 Conformance	p. 129
7.4.4 Methods and Procedures	p. 131
7.4.5 Link to System of Units	p. 131
7.5 Summary	p. 132
References	p. 133
8 Inspection and Verification	p. 135
8.1 Introduction	p. 135
8.2 Process Planning	p. 136
8.2.1 Process Variation	p. 136
8.2.2 Measurement Quality	p. 140
8.2.3 Plan Content	p. 141
8.3 Inspection Process Uncertainty	p. 142
8.4 Tolerance Characteristics and Modeling	p. 144
8.5 Setup	p. 147
8.5.1 Datum Planes	p. 147
8.5.2 Point Contact	p. 148
8.5.3 Axis Angularity	p. 148
8.6 Temperature Changes	p. 150
8.7 Equipment Inaccuracies	p. 151
8.8 Operator-Induced Uncertainty	p. 153
8.8.1 Bias	p. 153
8.8.2 Observation	p. 154
8.8.3 Computation	p. 154
8.8.4 Setup	p. 154
8.9 Free-State Variation	p. 154
8.10 Recording Inspection Results	p. 155
8.10.1 Recording Setup	p. 155
8.10.2 Recording Hole Axis Angularity	p. 157
8.10.3 Recording Tolerances	p. 157
8.11 Conclusion	p. 157
References	p. 158
9 Functional Gaging	p. 159
9.1 Introduction	p. 159
9.2 Functional Gaging Principles	p. 161
9.3 Feature Relation Gages	p. 162
9.3.1 Internal Feature Patterns	p. 162
9.3.2 External Feature Patterns	p. 169
9.4 Design Principles for Feature Location and Relation Gaging	p. 172
9.4.1 Critical (RFS) Part Datum Features	p. 172
9.4.2 Critical (MMC) Part Datum Features	p. 176
9.4.3 Independent Hole Patterns	p. 179
9.4.4 Two Critical Datum Features	p. 180
9.4.5 Multiple Datum Features, with Independent Hole Pattern	p. 182
9.4.6 Datum Features Related to Primary Datum Plane	p. 184
9.4.7 Three-Hole Pattern and External Datum Feature	p. 186
9.4.8 Three-Hole Pattern and Internal Datum Feature	p. 187
9.4.9 Cylindrical Part with Two-Pin Patterns	p. 188
9.4.10 Two Radial Patterns of Pins and Slots	p. 190
9.5 Review of Principles and Applications	p. 191
10 Functional Gage Tolerancing	p. 193
10.1 Introduction	p. 193
10.2 Gaging Element Size and Material Modifiers	p. 194
10.3 Workpiece Example	p. 195
10.4 Zero Positional Tolerance at LMC	p. 197
10.4.1 LMC Gage Pin at True Position	p. 198
10.4.2 MMC Gage Pin at True Position	p. 198
10.4.3 MMC Gage Pin with Maximum Positional Error	p. 199
10.5 Results	p. 200
10.6 Alternate Form of Analysis	p. 202
10.7 Fits and Allowances	p. 204
10.8 Building the Gage	p. 204
10.8.1 Machine Tool Capabilities	p. 204
10.8.2 Single-Setup Gage Feature Manufacture	p. 206
10.8.3 Gage Assembly Operations	p. 208
10.9 Summary	p. 209
References	p. 210
Appendix 10.A	p. 211
11 Functional Inspection Techniques	p. 219
11.1 Introduction	p. 219
11.2 Functional Gaging with Surface Plates	p. 220
11.2.1 Gaging Positional Tolerances	p. 220
11.2.2 Gaging Form and Orientation Tolerances	p. 224
11.3 Functional Gaging with Coordinate Measuring Machines	p. 226
11.3.1 Functional CMM Programming	p. 227
11.3.2 Hypothetical Conversion	p. 228
11.3.3 Examples	p. 229
11.4 Functional Gaging with Optical Comparators	p. 232
11.4.1 Applications	p. 233
11.4.2 Profile Tolerancing	p. 233
11.5 Paper Layout Gaging	p. 236
11.5.1 Application	p. 237
11.5.2 Parts That Can Be Paper Gaged	p. 239
11.5.3 Paper Gaging Procedure	p. 240
11.5.4 Inspection Results Layout	p. 241
11.5.5 Tolerance Layout	p. 243
11.5.6 Combining Layouts	p. 244
11.5.7 Allowance Factors	p. 245
11.5.8 Analyzing Results	p. 247
11.5.9 Paper Gages Compared to Other Functional Gages	p. 248
11.6 Summary	p. 249
References	p. 249
12 Functional Workholding and Fixturing	p. 251
12.1 Introduction	p. 251
12.2 Functional Fixtures	p. 253
12.3 Functional Fixturing Principles	p. 253
12.4 Fixture Design Concepts	p. 254
12.5 Design Details	p. 260
12.5.1 Functional Versus Process Frame	p. 260
12.5.2 Number of DRFs	p. 261
12.5.3 Location of the Fixture	p. 263
12.5.4 Design of Datum Feature Simulators	p. 264
12.6 Application Issues	p. 267
12.7 A Practical Example	p. 268
12.7.1 Traditional Processing of Part	p. 270
12.7.2 Single-Setup Processing of Part	p. 276
12.8 Summary	p. 279
References	p. 280
13 Does It All Work?	p. 281
13.1 Introduction	p. 281
13.2 The Initial Situation	p. 282
13.3 Component Definition	p. 285
13.4 The Six-Step Process	p. 286
13.5 The Results	p. 294
14 Implementation and Process Improvement	p. 297
14.1 Introduction	p. 297
14.2 Why Focus on the Definition?	p. 298
14.2.1 Management Tool	p. 298
14.2.2 Communication	p. 298
14.2.3 Education	p. 299
14.2.4 Problem Solving	p. 299
14.2.5 A Benchmark	p. 300
14.3 Stages of Implementation	p. 301
14.3.1 Audit Existing Design Process	p. 301
14.3.2 Education in Documentation Principles	p. 303
14.3.3 Senior Management's Support	p. 304
14.3.4 Require a Structured Design	p. 305
14.3.5 Core Implementation Group	p. 305
14.3.6 Training Issues	p. 305
14.3.7 Identification of an Advocate	p. 306
14.3.8 Management Support	p. 307
14.3.9 Controlled Implementation	p. 308
14.3.10 Upgrade Metrology/Inspection Capabilities	p. 309
14.3.11 Review and Critique	p. 310
14.3.12 Expand Training	p. 312
14.3.13 Require Use	p. 313
14.4 Conclusion	p. 313
References	p. 315
Index	p. 317

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