Machining and tolerances in a flexible and integrated manufacturing context

Part tolerance design is the process to define the optimal values of part functional characteristics. It is a complex and iterative process because technological and economical parameters should be considered together with functional requirements. It involves the plan of the most convenient manufacturing process allowing to obtain the specified functional requirements. This means to consider different process macro cycles able to produce the part with the specified functional tolerances and, then, to make a cost based choice. However, the manufacturing processes introduce a dimensional and geometrical variability that should be correlated with the part functional tolerances. This work tackles the problem of manufacturing feasibility of assigned part tolerances. It considers separately the manufacturing variability and the functional specifications and it tries to find relationships between them. It takes into consideration the possible correlation among functional requirements. An assembly that is widely used to test the performances of different design methods represent the case study. This work is the first step towards the development of a module to support the designer during the definition of a functional project. This module belongs to a flexible and integrated environment that orients and controls manufacturing.