Modeling Surface Variations

For
Flexible Assemblies

by

Shrinivas Soman
Unigraphics Solutions

1
Analysis of Flexible Assemblies

Mean Assembly Force

{F} = [Keq]{ 0}

Assembly Force Variance

[ F] = [Keq][ 0][Keq]T

2
 Functional Surface Characterization

• Relates Surface Topography to Tolerance Analysis

3
 Functional Surface Characterization Procedure

• Data Acquisition
• Part Set-up, Fixture Design
• Establishment of Coordinate System
• Sampling Issues - Alias, Frequency, Filtration,
Leakage
• Data Analysis
• Separation of Random and Non-random Variations
• Statistical Characterization of Random Variations
• Computing Autocorrelation (Covariance)

4
 Sampling Issues
Alias in Frequency -
• Sampling rate must be higher than twice the highest frequency
Profile represented by sinusoid frequency of 10 Profile Sampling by sampling frequency of 100 and 12
1 1

0.8 0.8

0.6 0.6

0.4 0.4

0.2 0.2

profile height
profile height

0 0

-0.2 -0.2

-0.4 -0.4

-0.6
-0.6

-0.8
-0.8
-1
-1 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
spatial distance
spatial distance

5
 Effect of Alias in Frequency
-3
x 10
4

3.5

3
Fs = 32
2.5
amplitude, inch

2
Fs = 128
1.5
Fs = 512
1

0.5

0
0 5 10 15 20 25
spatial frequency, cycles/profile length

• Frequency Alias limits the number of data points in a part length.

6
 Leakage and Frequency Filtration

Figure 4.7A Waveform with f=105cycles/unit length

0.5
• Leakage -
waveformheight

0
Frequencies which are not multiples of
-0.5 fundamental frequency, leak into
-1
adjacent frequencies.
0 0.02 0.04 0.06 0.08 0.1
spatial distance

Figure 4.7B Frequency Spectrum

• Frequency Filtration -
0.6

Finite tip of stylus acts as a low pass

0.4
filter.
0.2

0
0 20 40 60 80 100 120 140
spatial frequency, cyles/unit length

7
Profiles Records in Spatial Distance Domain

0.665

0.66

0.655

Profile height
0.65

profile height, inch

0.64

0.635

0.63

0.625

0.62

0.615
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
spatial distance, inch

Spatial distance

8
 Profile Records After Removal of Non-characteristic
Variations
x 10 -3

Profile height
Z Stylus

prof ile height

Surface to be Characterized
Plane of Scanning -5

(0,0) Y
-10

-15
0 0.5 1 1. 5 2 2.5 3 3.5 4 4.5 5
s patial dis tanc e
Spatial distance

9
 Mean Surface Profile
-3
x 10 Mean Profile
6

2
Profile height

0
profile height

-2

-4

-6

-8

-10

-12
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
spatial distance
Spatial distance

10
 Random Variations, FFT’s and Autospectra
x 10-3 RandomVariations x 10-3 FFTs x 10-8 Autospectra
5
5

0 5

-5
0 0
0
x 10-3 2 4 0x 10-3 10 20 0x 10-8 10 20
5
5

0 5

-5
0 0
0
x 10-3 2 4 0x 10-3 10 20 0x 10-8 10 20
5
5

0 5

-5
0 0
0
x 10-3 2 4 0x 10-3 10 20 0x 10-8 10 20
5
5

0 5

-5
0 0
0
x 10-3 2 4 0x 10-3 10 20 0x 10-8 10 20
5
5

0 5

-5
0 0
0
x 10-3 2 4 0x 10-3 10 20 0x 10-8 10 20
5
5

0 5

-5
0 0
0 2 4 0 10 20 0 10 20

11
 Average Autospectrum and Spatial Frequency
Classification
LONG WAVELENGTH REGION
MEDIUM WAVELENGTH REGION
x 10
-8
SHORT WAVELENGTH
Average Autospectrum REGION
3.5

2.5
autospectrum

1.5

0.5

0
0 5 10 15 20 25
spatial frequency

12
 Stationary Process and Autocorrelation

(x )

(x)

(x )

n
• Autocorrelation Function R yy (x1, d) = (1 / n)  YK(x1) YK(x1 + d)
k=1
• For Stationary Process, R yy (x1, d) = R yy (x2, d) = R yy (x1, d) = -------= R yy (xi, d)

• Averaging the Autospectrum averages variations across

13
 Circular and Zero Padded Autocorrelation

Autocorrelation Profile Length

Circular

Zero Padded
Biased

Zero Padded Scale Zero Padded Biased

14
Autocorrelation for Population of Surface Profiles
x 10-6
6

4
circular AC
2
zero padded biased AC
0
Autocorrelation

-2

-4

-6
unbiased AC
-8

-10

-12
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
spatial distance

15
 Removing Effect of Long Wavelengths
x 10-3 Profiles x 10-3 Polynomial Curves x 10-3 Random Variations
2
5 5

0
0 0

-5 -5 -2
0 2 4 0 2 4 0 2 4
x 10-3 x 10-3 x 10-3
2
5 5

0
0 0

-5 -5 -2
0 2 4 0 2 4 0 2 4
x 10-3 x 10-3 x 10-3
2
5 5

0
0 0

-5 -5 -2
0 2 4 0 2 4 0 2 4
x 10-3 x 10-3 x 10-3
2
5 5

0
0 0

-5 -5 -2
0 2 4 0 2 4 0 2 4
x 10-3 x 10-3 x 10-3
2
5 5

0
0 0

-5 -5 -2
0 2 4 0 2 4 0 2 4
x 10-3 x 10-3 x 10-3
2
5 5

0
0 0

-5 -5 -2
0 2 4 0 2 4 0 2 4

16
 Improved Autocorrelation
x 10-8
6

circular AC
4

zero padded AC
2
Autocorrelation Function

-2

-4

unbiased AC
-6

-8
0 1 2 3 4 5 6
spatial distance

17
 Conclusion

• Spectrum Model is suitable for surfaces having dominant medium

• Long wavelengths distort Spectrum Model.

• Polynomial Curves for removing long wavelengths?

18