FOR 2271:  Prozessorientiertes Toleranzmanagement mit virtuellen Absicherungsmethoden

• Subject Area: Mechanical and Industrial Engineering
• Term: from 2016 to 2023
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 260682773

The comprehension of geometric part deviations and their sources as well as the investigation of their effects on the function and quality of technical products builds the framework for the planned research unit “process-oriented tolerance management based on virtual computer-aided engineering tools”. The aim of this research unit is the provision of holistic methods and efficient tools for the comprehensive management of geometric deviations along the product origination process, which are to be validated in a model factory. In doing so, a particular focus is set on the development of a procedure for the fruitful cooperation of all departments involved in geometric variations management, from product development, to manufacturing and to metrology, which will enable companies to quickly specify functional tolerances, which are manufacturable and measurable, and consequently to save costs and to reduce the time to market. In this regard, the vision of the research unit is to enable the close collaboration of product development, manufacturing and metrology in computer-aided tolerancing, i. e. the joint formulation of functional tolerances, which are manufacturable and measurable. By enabling this close collaboration, all manufacturing related sources of later problems regarding the product function and quality can be considered already during early phases of virtual product and process development. As a consequence, tolerances can be specified efficiently and optimized inspection plans as well as robust manufacturing and operating windows can be identified, which allows the development of robust products to be manufactured and measured at low costs. Since geometric part deviations are inevitable and affect the function and quality of technical products, their management along the product origination process is essential for the development of functioning products, which conform to the quality and usage requirements of customers and are successful on international markets.The focus of the second funding period of the research unit is therefore particularly on the consideration of operation-related wear during the process-oriented tolerance allocation. The scientific challenge is the acquisition of wear information, its transformation into mathematical models and the subsequent integration into tolerance analysis and optimization. Finally, this allows the assignment of production- and test-compliant tolerances which ensure the functionality of technical products over the entire intended product lifetime. The scientific findings and the transferable generally applicable methods of the research unit thus make a valuable contribution to the success of the German economy.

• DFG Programme: Research Units

Projects

• Analysis of performance-related, process related structure and shape deviations of plastic gears for application related design (Applicant Drummer, Dietmar )
• Consideration of functionally relevant geometric deviations in the design of metal forming processes for the production of gears by extrusion (Applicant Merklein, Marion )
• Coordination Funds (Applicant Wartzack, Sandro )
• Coordination Funds (Applicant Wartzack, Sandro )
• Fuzzy-arithmetical modeling of processes with uncertain prarameters (Applicant Willner, Kai )
• Metrology and measurement data evaluation for the geometrical product verification within a holistic tolerance management (Applicant Hausotte, Tino )
• Virtual and experimental tolerance analysis of deviated assembly groups (Applicants Schleich, Benjamin ;  Wartzack, Sandro )

• Spokesperson: Professor Dr.-Ing. Sandro Wartzack