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Discrete shape modeling for geometrical product specification : contributions and applications to skin model simulation

Abstract : The management and the control of product geometrical variations during the whole development process is an important issue for cost reduction, quality improvement and company competitiveness in the global manufacturing era. During the design phase, geometric functional requirements and tolerances are derived from the design intent. Geometric modeling tools, now largely support the modeling of product shapes and dimensions. However, permissible geometrical variations cannot be intuitively assessed using existing modeling tools. In addition, the manufacturing and measurement stages are two main geometrical variations generators according to the two well know axioms of manufacturing imprecision and measurement uncertainty. A comprehensive view of Geometrical Product Specifications should consider not only the complete tolerancing process, tolerance modeling and tolerance representation but also shape geometric representations, and suitable processing techniques and algorithms. GeoSpelling as the basis of the GPS standard enables a comprehensive modeling framework and an unambiguous language to describe geometrical variations covering the overall product life cycle thanks to a set of concepts and operations based on the fundamental concept of the “Skin Model”. However, the “operationalization” of GeoSpelling has not been successfully completed and few research studies have focused on the skin model simulation. The skin model as a discrete shape model is the main focus of this dissertation. We investigate here discrete geometry fundamentals of GeoSpelling, Monte Carlo Simulation Techniques and Statistical Shape Analysis methods to simulate and analyze “realistic shapes” when considering geometrical constraints requirements (derived from functional specifications and manufacturing considerations). In addition to mapping fundamental concepts and operations to discrete geometry one’s, the work presented here investigates a discrete shape model for both random and systematic errors when taking into account second order approximation of shapes. The concept of a mean skin model and its robust statistics are also developed. The results of the skin model simulations and visualizations are reported. By means of a case study based on a cross-shaped sheet metal part where the manufacturing process is simulated using Finite Element Analysis considering stochastic variations, the results of the skin model simulations are shown, and the performances of the method are described.
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Min Zhang. Discrete shape modeling for geometrical product specification : contributions and applications to skin model simulation. General Mathematics [math.GM]. École normale supérieure de Cachan - ENS Cachan, 2011. English. ⟨NNT : 2011DENS0040⟩. ⟨tel-00670109⟩

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