Short answer

Incorporate deformation analysis into your CAD tolerancing process, especially for assemblies where parts are not perfectly rigid.

Field: Modelling
Source: Journal of Computing and Information Science in Engineering (2019)
Method: Algorithmic development and simulation-based analysis
Evidence: Strong effect

Accounting for component deformation during assembly in CAD models leads to more realistic digital mock-ups and reduces deviations between simulated and actual product behavior. This modelling research insight is drawn from a 2019 study published in Journal of Computing and Information Science in Engineering. Using Algorithmic development and simulation-based analysis, researchers explored how this design variable affects real-world outcomes. The key design takeaway: Incorporate deformation analysis into your CAD tolerancing process, especially for assemblies where parts are not perfectly rigid.

Study

ModellingHigh ImpactStrong effect

Non-rigid part deformation significantly impacts CAD assembly accuracy

Accounting for component deformation during assembly in CAD models leads to more realistic digital mock-ups and reduces deviations between simulated and actual product behavior.

Journal of Computing and Information Science in Engineering · 2019

Key Findings

01Neglecting component deformation in CAD assembly models causes significant deviations from realistic behavior.
02Integrating FE simulations of deformation with tolerancing analysis improves the accuracy of digital mock-ups.
03A novel algorithm can update mating constraints for assemblies with both rigid and non-rigid components.

Application

Design takeaway

Incorporate deformation analysis into your CAD tolerancing process, especially for assemblies where parts are not perfectly rigid.

How to apply

When designing assemblies with components made from plastics, composites, or thin metals, or where assembly forces are high, utilize FEA to simulate deformation and integrate these results into your tolerance stack-up analysis.

Project actions

01Consider the materials of your components and how they might deform under stress during assembly.
02Explore using simulation tools within your CAD software to predict these deformations.

Method & Evidence

AimHow can CAD models be enhanced to accurately represent the behavior of non-rigid part assemblies by integrating manufacturing defects and component deformations?

MethodAlgorithmic development and simulation-based analysis

ProcedureA new model was developed to integrate dimensional and geometrical tolerances into CAD assemblies, considering worst-case scenarios for defects and incorporating finite element (FE) simulations for realistic deformation analysis. An algorithm was created to update mating constraints between rigid and non-rigid parts.

ContextComputer-Aided Design (CAD) for mechanical assemblies

Variables

IV["Inclusion/Exclusion of component deformation in CAD assembly models"]

DV["Deviation between simulated and realistic assembly configurations","Accuracy of digital mock-ups"]

CV["Type of joints (planar, cylindrical)","Manufacturing defect modeling approach (worst-case tolerancing)"]

Strengths & Limitations

Strengths

+Addresses a critical gap in traditional CAD tolerancing by including physical deformation.
+Integrates FE simulation for a more realistic analysis.

Limitations

Performing accurate FEA can require specialized software and expertise, which may be a barrier for some design projects.

Reliability & validity

The validity of the model is supported by the use of FE simulations, which are a standard engineering tool for predicting physical behavior. Reliability would depend on the specific implementation of the FE solver and the accuracy of material property inputs.

Think critically

To what extent does the complexity of simulating non-rigid body dynamics limit its practical application in rapid prototyping or for designers with limited simulation resources?

Design Principles

"Digital models must account for the physical properties and behaviors of components, including deformation, to accurately predict real-world performance."

This research highlights a critical gap in traditional CAD tolerancing. By incorporating the physical realities of material deformation, designers can create more accurate digital representations, leading to improved product performance, reduced manufacturing errors, and more efficient design for assembly processes.

What This Means for Your Design

When you design things on a computer, sometimes you forget that parts can bend or squish a bit when you put them together. This study shows that if you add that 'bending' into your computer design, it will be a much more accurate picture of the real thing.

How to use in your project

1.Reference this study when discussing the limitations of purely geometric tolerancing and the need to consider physical properties like deformation in your design process.

Add to My Project

Quick Cite

Paragraph starter

The realistic modeling of product assemblies in Computer-Aided Design (CAD) requires consideration of physical factors beyond simple geometry. Research by Tlija et al. (2019) demonstrates that neglecting component deformations during assembly can lead to significant deviations between digital and physical outcomes. Their work proposes a novel model that integrates manufacturing defects and deformation analysis using Finite Element simulations, leading to more accurate digital mock-ups and improved design for assembly.

Source

Journal of Computing and Information Science in Engineering

A Novel Model for the Tolerancing of Nonrigid Part Assemblies in Computer Aided Design

journal · 2019

View source

Questions About This Research

What does the research say about non-rigid part deformation significantly impacts cad assembly accuracy?: Incorporate deformation analysis into your CAD tolerancing process, especially for assemblies where parts are not perfectly rigid. Evidence: Journal of Computing and Information Science in Engineering (2019).
Why does "Non-rigid part deformation significantly impacts CAD assembly accuracy" matter for design?: This research highlights a critical gap in traditional CAD tolerancing. By incorporating the physical realities of material deformation, designers can create more accurate digital representations, leading to improved product performance, reduced manufacturing errors, and more efficient design for assembly processes.
How can designers apply this research?: Incorporate deformation analysis into your CAD tolerancing process, especially for assemblies where parts are not perfectly rigid.
What were the main findings?: Neglecting component deformation in CAD assembly models causes significant deviations from realistic behavior.. Integrating FE simulations of deformation with tolerancing analysis improves the accuracy of digital mock-ups.. A novel algorithm can update mating constraints for assemblies with both rigid and non-rigid components.
What research method was used?: Algorithmic development and simulation-based analysis.
How strong is the evidence?: Evidence strength is rated Strong effect, based on a 2019 journal from Journal of Computing and Information Science in Engineering.
What should I do differently in my next project?: When designing assemblies with components made from plastics, composites, or thin metals, or where assembly forces are high, utilize FEA to simulate deformation and integrate these results into your tolerance stack-up analysis.
What are the limitations?: The study focused on specific joint types (planar and cylindrical) and may require further validation for a wider range of assembly configurations and material properties.