In a multi-operational machining process (MMP), the final product variation is an accumulation or stack-up of variation from all machining operations. Modeling and control of the variation propagation is essential to improve product dimensional quality. This paper presents a state space model and its modeling strategies to describe the variation stack-up in MMPs. The physical relationship is explored between part variation and operational errors. By using the homogeneous transformation approach, kinematic modeling of setup and machining operations are developed. A case study with real machined parts is presented in the model validation.

Issue Section:
Technical Papers
Topics:
Errors, Machining, Modeling, Machine tools
1.
Fortini, E. T., 1967, Dimensioning for Interchangeable Manufacture, Industrial Press, NY.
2.
Gilson, J., 1951, A New Approach to Engineering Tolerances, The Machinery Publishing Co., London, UK.
3.
Greenwood
,
W. H.
, and
Chase
,
K. W.
,
1987
, “
A New Tolerance Analysis Method for Designers and Manufactures
,”
ASME J. Ind.
,
109
, pp.
112
–
116
.
4.
Ding, Y., Jin, J., Ceglarek, D., and Shi, J., 2002, “Process-Oriented Tolerancing for Multi-Station Assembly System,” IIE Transactions on Design and Manufacturing (to appear).
5.
Jin
,
J.
, and
Shi
,
J.
,
1999
, “
State Space Modeling of Sheet Metal Assembly for Dimensional Control
,”
ASME J. Manuf. Sci. Eng.
,
121
, pp.
756
–
762
.
6.
Ding, Y., Shi, J., and Ceglarek, D., 2002, “Diagnosability Analysis of Multi-Station Manufacturing Processes,” ASME Transactions, Journal of Dynamics Systems, Measurement, and Control, Vol. 124, pp. 1–13.
7.
Mantripragada
,
R.
, and
Whitney
,
D. E.
,
1999
, “
Modeling and Controlling Variation Propagation in Mechanical Assemblies Using State Transition Models
,”
IEEE Robotics and Automation
,
15
, pp.
124
–
140
.
8.
Lawless
,
J. F.
,
Mackay
,
R. J.
, and
Robinson
,
J. A.
,
1999
, “
Analysis of Variation Transmission in Manufacturing Processes—Part I
,”
J. Quality Technol.
,
31
, pp.
131
–
142
.
9.
Agrawal
,
R.
,
Lawless
,
J. F.
, and
Mackay
,
R. J.
,
1999
, “
Analysis of Variation Transmission in Manufacturing Processes—Part II
,”
J. Quality Technol.
,
31
, pp.
143
–
154
.
10.
Cai
,
W.
,
Hu
,
S. J.
, and
Yuan
,
J. X.
,
1997
, “
Variational Method of Robust Fixture Configuration Design for 3-D Workpiece
,”
ASME J. Manuf. Sci. Eng.
,
119
, pp.
593
–
602
.
11.
Choudhuri
,
S. A.
, and
De Meter
,
E. C.
,
1999
, “
Tolerance Analysis of Machining Fixture Locators
,”
ASME J. Manuf. Sci. Eng.
,
121
, pp.
273
–
281
.
12.
Chen
,
J. S.
,
Yuan
,
J. X.
,
Ni
,
J.
, and
Wu
,
S. M.
,
1993
, “
Real-time Compensation for Time-variant Volumetric Errors on a Machining Center
,”
ASME J. Ind.
,
115
, pp.
472
–
479
.
13.
Martinsen, K., 1993, “Vectorial Tolerancing for All Types of Surfaces,” ASME Advances in Design Automation, Vol. 2, pp. 187–198.
14.
ASME, Y14.5 M Dimensioning and Tolerancing, 1994.
15.
Frey
,
D. D.
,
Otto
,
K. N.
, and
Pflager
,
W.
,
1997
, “
Swept Envelopes of Cutting Tools in Integrated Machine and Workpiece Error Budgeting
,”
CIRP Ann.
,
46
, pp.
475
–
480
.
Copyright © 2003
 by ASME
You do not currently have access to this content.