Precise Geometrical Alignment of Assembly Design from Tolerance Simulation Perspective

Precision geometry alignment with rigorous deviation is one of the key assembly issues to be designed in product development. Propagation of tolerances causes large misalignment in assemblies leading to a cast-off and undesirable product functionality. There is always an imperativeness to calculate the assembly characteristic with tighter tolerances for functionally critical dimensions so that geometry imperfections can be compensated. Tolerance analysis and simulation techniques have been utilized by designer supporting such problem solving process. In this paper, a precise geometrical alignment of assembly design has been performed with the help of tolerance simulation. Both worst case and statistical tolerance analysis approaches are applied to provide design alternatives. In this research, a two-component thin walled alignment assembly structure has been chosen to present the design by tolerance simulation procedures. Tolerance ranges have been calculated and recommendations have been provided comparing the worst case and statistical analysis results.