A model- and simulation-based approach for tolerancing and verifying the functional capability of micro/nano-structured workpieces

Abstract The evaluation of functional features of manufactured workpieces is based on GO- and NO-GO-test results, which are obtained by comparing measured geometric characteristics with nominal dimensions and tolerances specified by the designer. These geometrical specifications are based on a tolerancing system, which was originally defined for the function mating capability . Against the background of upcoming lots of other new functions (like reduction of flow resistance, light absorption, reduction of friction, diffraction of light, self-cleaning or mass transmission) are to be realized with our products – particularly by micro- and nano scaled features. If the verification process will deliver the prediction of the achievable degree of functionality, the usability of a part can be assessed more accurately and in consequence quality and economics can be improved. So, a new principle for tolerancing and verifying turns out to be necessary. In this paper the fundamental deficit of the actual tolerancing and specification systems GPS and ASME Y14.5 is derived and the path for enlarging the system by preposing a functional model is shown. To verify the functional capability of the workpieces an approach based on simulations done with the parameterized mathematical–physical model of the function is suggested. Advantages of this approach will be discussed and demonstrated by examples with microstructured inking rolls, crankshafts and injection valves.

[1]  Angela Duparré,et al.  Design and characterization of nanostructured ultrahydrophobic coatings. , 2006, Applied optics.

[2]  H. E. Bennett,et al.  Relation between Surface Roughness and Specular Reflectance at Normal Incidence , 1961 .

[3]  J. Greenwood,et al.  Contact of nominally flat surfaces , 1966, Proceedings of the Royal Society of London. Series A. Mathematical and Physical Sciences.

[4]  Fritz Klocke,et al.  Development of an incremental rolling process for the production of defined riblet surface structures , 2007, Prod. Eng..

[5]  Stefano Filippi,et al.  The Design Guidelines (DGLs), a knowledge-based system for industrial design developed accordingly to ISO-GPS (Geometrical Product Specifications) concepts , 2007 .

[6]  T. Kwon,et al.  Mass-producible replication of highly hydrophobic surfaces from plant leaves , 2006 .

[7]  Enrico Savio,et al.  Investigating the technological limits of micro-injection molding in replicating high aspect ratio micro-structured surfaces , 2014 .

[8]  David J. Whitehouse,et al.  Function maps and the role of surfaces , 2001 .

[9]  Vijay Srinivasan.  Reflections on the role of science in the evolution of dimensioning and tolerancing standards , 2013 .

[10]  D. Lucca,et al.  Surfaces in Precision Engineering, Microengineering and Nanotechnology , 2003 .

[11]  Andreas Loderer,et al.  Automated extraction and assessment of functional features of areal measured microstructures using a segmentation-based evaluation method , 2014 .

[12]  David J. Whitehouse,et al.  Technological shifts in surface metrology , 2012 .

[13]  Manfred Geiger,et al.  New Developments for the Qualification of Technical Surfaces in Forming Processes , 1997 .

[14]  H. Weber,et al.  Functionality-oriented evaluation and sampling strategy in coordinate metrology , 1995 .

[15]  J. Pfitzner,et al.  Poiseuille and his law , 1976, Anaesthesia.

[16]  George Barbastathis,et al.  Nanotextured silica surfaces with robust superhydrophobicity and omnidirectional broadband supertransmissivity. , 2012, ACS nano.

[17]  Liam Blunt.  Structured geometry surfaces features for optimised function , 2011 .

[18]  R. Hocken,et al.  Replication of micro and nano surface geometries , 2011 .

[19]  T. Thomas,et al.  Roughness and function , 2013 .

[20]  Joseph E. Ford,et al.  Planar micro-optic solar concentrator. , 2010, Optics express.

[21]  Wenlong Lu,et al.  Modelling the Integration between the Design and Inspection Process of Geometrical Specifications for Digital Manufacturing , 2011 .

[22]  Gavin D. MacAulay,et al.  Comparison of segmentation techniques to determine the geometric parameters of structured surfaces , 2014 .

[23]  Zbigniew Humienny,et al.  Animated visualization of the maximum material requirement , 2012 .

[24]  Jörg Krujatz.  Herstellung von Spiegelschichtsystemen auf der Basis von Aluminium und Silber für den Einsatz in der Mikrosystemtechnik , 2002 .

[25]  Sebastian Stiller,et al.  Introduction of a Quality Oriented Production Theory for Product Realization Processes , 2014 .

[26]  Satish G. Kandlikar,et al.  Comparison of Roughness Parameters for Various Microchannel Surfaces in Single-Phase Flow Applications , 2009 .

[27]  Philip S. Yu,et al.  Challenges and Trends , 2010 .

[28]  Agostino G. Bruzzone,et al.  Advances in engineered surfaces for functional performance , 2008 .

[29]  Albert Weckenmann,et al.  Function-oriented method for the definition and verification of microstructured surfaces , 2013 .

[30]  Wei Gao,et al.  Surface form metrology of micro-optics , 2013, Other Conferences.

[31]  Satish G. Kandlikar,et al.  ESTIMATING ROUGHNESS PARAMETERS RESULTING FROM VARIOUS MACHINING TECHNIQUES FOR FLUID FLOW APPLICATIONS , 2007 .