Gap hull estimation for rigid mechanical joints considering form deviations and multiple pairs of mating surfaces

Abstract The embodiment of mechanical joints is a demanding activity during the design of mechanism. In this context, particularly the assessment of the effects of geometrical deviations on the behaviour of the mechanical joint is of strong importance. This paper presents an approach to the gap hull estimation for mechanical joints considering form deviations. The novelty of this approach lies in the ability to analyse the behaviour of mechanical joints considering multiple pairs of mating surfaces. The application of this method to a prismatic as well as to a cylindrical joint prove the versatility of the method regarding different kinds of joints with multiple pairs of contact surfaces. Moreover, the results of the application of this approach to the tolerance analysis of a two-pin-two-hole assembly confirm the importance of considering form deviations in the tolerance analysis and in the design of mechanical joints and mechanism.

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