Analysis of the deviations of a casting and machining process using a Model of Manufactured Parts

Abstract

In previous works, the authors have developed the Model of Manufactured Part (MMP), a method for modeling the different geometrical deviation impacts on the part produced (error stack-up) in a multi-stage machining process. The aim of this paper is to extend this model to other manufacturing processes like casting and forging and to propose a stochastic approach to analyze the dimensional quality of the produced parts. This paper firstly reminds the Model of Manufactured Part. The MMP is then extended to casting or forging processes. A method to analyze the dimensional quality of the produced parts is then developed. The simulation uses Monte Carlo approach to generate a population of virtually manufactured parts representative of the real produced parts. A case study is then proposed, for a part produced in a multi-stage casting and machining process. The result of the simulation for two quality criteria is given.