Part tolerancing through multicale defect analysis

When manufactured parts undergo large deformations during the manufacturing process, the global specifications of a part based on the concept of tolerance zone defined in the ISO 1101 standard [1] enable one to control the part's global defects. However, the extent of this tolerance zone is too large when the objective is to minimize local defects, such as hollows and bumps. Therefore, it is necessary to address local defects and global defects separately. This paper refers to the ISO 10579 standard [2] for flexible parts, which enables us to define a stressed state in order to measure the part by straightening it to simulate its position in the mechanism. The originality of this approach is that the straightening operation is performed numerically by calculating the displacement of a cloud of points. The results lead to a quantification of the global defects through various simple models and enable us to extract local defects. The outcome is an acceptable tolerance solution. The procedure is first developed for the simple example of a steel bar with a rectangular cross section, then applied to an industrial case involving a complex 3D surface of a turbine blade. The specification is described through ISO standards both in the free state and in the straightened state.