Sensitivity Analysis of features in tolerancing based on constraint function level sets

Usually, the geometry of the manufactured product inherently varies from the nominal geometry. This may negatively affect the product functions and properties (such as quality and reliability), as well as the assemblability of the single components. In order to avoid this, the geometric variation of these component surfaces and associated geometry elements (like hole axes) are restricted by tolerances. Since tighter tolerances lead to significant higher manufacturing costs, tolerances should be specified carefully. Therefore, the impact of deviating component surfaces on functions, properties and assemblability of the product has to be analyzed. As physical experiments are expensive, methods of statistical tolerance analysis tools are widely used in engineering design. Current tolerance simulation tools lack of an appropriate indicator for the impact of deviating component surfaces. In the adoption of Sensitivity Analysis methods, there are several challenges, which arise from the specific framework in tolerancing. This paper presents an approach to adopt Sensitivity Analysis methods on current tolerance simulations with an interface module, which bases on level sets of constraint functions for parameters of the simulation model. The paper is an extension and generalization of Ziegler and Wartzack [1]. Mathematical properties of the constraint functions (convexity, homogeneity), which are important for the computational costs of the Sensitivity Analysis, are shown. The practical use of the method is illustrated in a case study of a plain bearing. •Alternative definition of Deviation Domains.•Proof of mathematical properties of the Deviation Domains.•Definition of the interface between Deviation Domains and Sensitivity Analysis.•Sensitivity analysis of a gearbox to show the methods practical use.