Using FE to simulate the effect of tolerance on part deformation

The research on tolerance synthesis has been confined to tolerance representation, design requirements, manufacturing processes, assembly sequences, quality methods and cost. The literature for establishing influence of dimensional tolerances over product function is very limited. It requires development of prototypes and evaluating the influence of tolerances in individual features. It might need unlimited resources of design, manufacturing and materials for production and is considered uneconomical at the initial design phase of a product. In present research, the possibility of using Finite Element simulations to establish relationships between product function and dimensional tolerances has been investigated. A dimensional tolerance application was selected and a test rig was designed and manufactured to conduct experiments. ABAQUS was used to simulate experimental conditions through Finite Element model. Experimental data and FE results were compared to confirm the dimensional tolerance relationship with product function.