Zero Tolerance for Error
Basic Training Manual Version 8.1 for Pro/ENGINEER (2009.0216)
CETOL 6 Version 8.1 for Pro/ENGINEER Basic Training Manual
Revision History Rev. No.
Date
20080602 2008062 20080625 5 20080703 20080723 2008090 20080903 3 20090216
2 Jun. 2008 25 June 2008 3 July 2008 23 July 2008 3 Sept. 2008 16 Feb. 2009
Description
Beta version Initial release Corrections Correcti ons and Revisions Corrections Correcti ons 8.1 Production release Corrections Correcti ons and Revisions
Copyright © 2009, Sigmetrix, LLC, All Rights Reserved. Printed in the United States of America. Except as permitted under the United States Copyright Act of 1976, no part of this publication may be reproduced or distributed in any form or by any means, or stored in a data base or retrieval system, without the prior written permission of the publisher. The information and/or drawings set forth in this document and all a ll rights in and to inventions disclosed herein and patents that might be granted thereon disclosing or employing the materials, methods, techniques, or apparatus described herein are the exclusive property of Sigmetrix, LLC. No disclosure disclosure of information information or drawing shall shall be made to any other other person or organization organization without without the prior consent consent of Sigmetrix, LLC. Sigmetrix, LLC 105 West Virginia Street McKinney, TX 75069 Produced by Sigmetrix, LLC.
Trademarks CETOL 6 σ σ and and CETOL Six Sigma are trademarks of Sigmetrix, LLC. Pro/ENGINEER is a registered trademark of PTC.
CETOL 6 Version 8.1 for Pro/ENGINEER Basic Training Manual
Revision History Rev. No.
Date
20080602 2008062 20080625 5 20080703 20080723 2008090 20080903 3 20090216
2 Jun. 2008 25 June 2008 3 July 2008 23 July 2008 3 Sept. 2008 16 Feb. 2009
Description
Beta version Initial release Corrections Correcti ons and Revisions Corrections Correcti ons 8.1 Production release Corrections Correcti ons and Revisions
Copyright © 2009, Sigmetrix, LLC, All Rights Reserved. Printed in the United States of America. Except as permitted under the United States Copyright Act of 1976, no part of this publication may be reproduced or distributed in any form or by any means, or stored in a data base or retrieval system, without the prior written permission of the publisher. The information and/or drawings set forth in this document and all a ll rights in and to inventions disclosed herein and patents that might be granted thereon disclosing or employing the materials, methods, techniques, or apparatus described herein are the exclusive property of Sigmetrix, LLC. No disclosure disclosure of information information or drawing shall shall be made to any other other person or organization organization without without the prior consent consent of Sigmetrix, LLC. Sigmetrix, LLC 105 West Virginia Street McKinney, TX 75069 Produced by Sigmetrix, LLC.
Trademarks CETOL 6 σ σ and and CETOL Six Sigma are trademarks of Sigmetrix, LLC. Pro/ENGINEER is a registered trademark of PTC.
Table Table of Cont ents Training Introduction Introduction .... ................... ................................ ................................... ................................... .................................. ................................ ............... 1-1 Chapter 1. CETOL CETOL Overview Overview .... ..................... ................................... .................................... .................................... ................................. ............... 1-1 Lesson 1-1. The CETOL User Interface............................................................................... Interface.... ........................................................................... 1-2 Starting CETOL CETOL & Pro/E ................................................................................................................ .... ............................................................................................................ 1-2 1-2 The CETOL 6 σ ................................................................................................ 1-2 1-2 σ Modeling Interface ................................................................................................ Interacting Interacting with Pro/ENGINE Pro/ENGINEER ER .................................................................................................... .... ................................................................................................ 1-5 1-5 Options ............................................................................................................................................ ............................................................................................................................................ 1-5 1-5 Getting Help .................................................................................................................................... .... ................................................................................................................................ 1-5 1-5
Exercise 1-1: CETOL Interface Basics..................................................................................... Basics.....................................................................................1-6 1-6
Lesson 1-2. The CETOL Model......................................................................................... Model......................................................................................... 1-11 Exercise 1-2: Exploring a CETOL Model Model ..... .............................................................................. ......................................................................... 1-12
Lesson 1-3. The CETOL 6 σ Analyz Analyzer er ... ..... ............................................................................ .......................................................................... 1-14 Analysis View..... View................................................................................................................................. ............................................................................................................................ 1-14 1-14
Exercise 1-3: Running an Analysis......................................................................................... Analysis..... ....................................................................................1-16 1-16
Chapter 2. Fundamentals.... Fundamentals.................... .................................. .................................... .................................... ................................... ........................ ....... 2-1 Lesson 2-1. Tolerance Fundamentals .... ................................................................................... ............................................................................... 2-2 Tolerance Design Design Process.... Process ............................................................................................................... ........................................................................................................... 2-2 2-2 Dimensions, Dimensions, Variations Variations and Tolerances.... Tolerances.......................................................................................... ...................................................................................... 2-2 2-2 Causes of of Variation Variation ......................................................................................................................... .... ..................................................................................................................... 2-3 2-3 Worst-Case Design and Analysis .................................................................................................... .... ................................................................................................ 2-5 2-5
Exercise 2-1: Worst-Case Analysis Analysis of a Shaft.... Shaft .......................................................................... ...................................................................... 2-6 Statistical Design Design and Analysis Analysis ....................................................................................................... .... ................................................................................................... 2-7 2-7
Exercise 2-2: Calculating Part Quality Metrics ..... ...................................................................... ................................................................. 2-12 Exercise 2-3: Analysis of a Shaft............................................................................................ Shaft..... .......................................................................................2-13 2-13
Chapter 3. Measurements.................... Measurements...................................... ................................... ................................... .................................... ........................ ...... 3-1 Lesson 3-1. Measureme Measurements nts .... ................................................................................................... ............................................................................................... 3-2 Adding Measurement Measurementss ..................................................................................................................... .... ................................................................................................................. 3-2 3-2 Measurement Measurement Properties Properties ................................................................................................................. ................................................................................................................. 3-3 3-3
Exercise 3-1: Defining Measurements...................................................................................... Measurements.... ..................................................................................3-8 3-8
Chapter 4. Introduction Introduction to Assembly Assembly Modeling .... .................... ................................... ..................................... ....................... ..... 4-1 Lesson 4-1. The CETOL Assembly Model.......................................................................... Model.... ...................................................................... 4-2 Adding Joints Joints ................................................................................................................................... ................................................................................................................................... 4-2 4-2 Assembly Model Structure Structure.... ............................................................................................................... ........................................................................................................... 4-3 4-3 Joint Properties Properties ............................................................................................................................... .... ........................................................................................................................... 4-4 4-4
Lesson 4-2. Setting Degrees-of-Freedom............................................................................. Degrees-of-Freedom.... ......................................................................... 4-6 Setting the Degrees Degrees of Freedom Freedom ...................................................................................................... .... .................................................................................................. 4-6 4-6 Degrees-of-Varian Degrees-of-Variance ce ....................................................................................................................... ....................................................................................................................... 4-7 4-7 Under-Constraints Under-Constraints and Over-Constraints.... Over-Constraints.... ................................................................................... 4-9 4-9 Modifying Joint Joint DOFs................................................................................................................... DOFs..... .............................................................................................................. 4-11 4-11 Checking the Assembly Constraints ..... ......................................................................................... 4-12 4-12
Exercise 4-1: Piston/Cylinder Sub-Assembly .........................................................................4-14
Chapter 5. Introduction to Part Modeling ........................................................................ 5-1 Lesson 5-1. The CETOL Part Model....................................................................................5-2 Part Model Structure........................................................................................................................5-3
Lesson 5-2. Features..............................................................................................................5-3 Adding Features ...............................................................................................................................5-3 Feature Properties ...........................................................................................................................5-3
Lesson 5-3. Constraints.........................................................................................................5-4 Constraint types................................................................................................................................5-4 Constrain Feature Wizard ............................................................................................................5-5 Adding Constraints...........................................................................................................................5-6 Constraint Properties.......................................................................................................................5-6 Feature Order ..................................................................................................................................5-8
Lesson 5-4. Variables............................................................................................................5-8 Invariant variables ...........................................................................................................................5-8 Variable Properties..........................................................................................................................5-8 Highlighing Dimensions and Variables ...........................................................................................5-9
Exercise 5-1: Defining a Dimensioning Scheme.....................................................................5-10
Chapter 6. Creating Accurate Assembly Models............................................................. 6-1 Lesson 6-1. More on setting Degrees-of-Freedom ...............................................................6-2 Modeling Physical Constraints ........................................................................................................6-2 Fixing DOF Problems in the Tolerance Model ...............................................................................6-4 Solving for Closure...........................................................................................................................6-5
Exercise 6-1: Modeling small planar contact ............................................................................6-7 Exercise 6-2: Modeling thin cylindrical contact......................................................................6-10
Lesson 6-2. Assembly Variation.........................................................................................6-12 Assembly Process Variables...........................................................................................................6-12
Lesson 6-3. Dealing with Assembly Clearance ..................................................................6-13 Fastened Interfaces ........................................................................................................................6-13
Exercise 6-3: Modeling Fastened Interfaces ...........................................................................6-15 Exercise 6-4: Changing Fastener Joint Bias Condition...........................................................6-20 Exercise 6-5: Modeling Fastener Float....................................................................................6-23
Lesson 6-4. Basic Fit Analysis............................................................................................6-24 Exercise 6-6: Modeling for Assembly Fit .................................................................................6-1
Lesson 6-5. Multi-level Assemblies......................................................................................6-3 Exercise 6-7: Medical Sprayer Assembly .................................................................................6-4
Lesson 6-6. Configurations ...................................................................................................6-9 Exercise 6-8: Configurations for Sprayer Assembly...............................................................6-10
Chapter 7. Creating Accurate Dimensioning Schemes.................................................... 7-1 Lesson 7-1. Defining an Accurate Part Overlay Model........................................................7-2 Dimension Types ..............................................................................................................................7-2 Defining the Topology of the Part....................................................................................................7-2
Relating Datums to Geometry Features.......................................................................................... 7-7
Lesson 7-2. Checking the Dimensioning Scheme................................................................ 7-8 DOF states....................................................................................................................................... 7-8 Constraint Order ............................................................................................................................. 7-8
Exercise 7-1: Defining Dimensions and Topology................................................................. 7-10
Lesson 7-3. Applying Geometric Tolerances..................................................................... 7-16 Adding Geometric Tolerances..... .................................................................................................. 7-16 Datum Reference Frames .............................................................................................................. 7-16 Geometric Tolerance Properties ................................................................................................... 7-17 Constraint Order ........................................................................................................................... 7-17
Exercise 7-2: Adding Geometric Tolerances to a Part ........................................................... 7-19 Exercise 7-3: Overlay Model for a Plate ................................................................................ 7-22
Chapter 8. Defining Dimensional Variation.................................................................... 8-1 Lesson 8-1. Tolerances & Distributions............................................................................... 8-2 Component Variation Rules ............................................................................................................ 8-2 Invariant Variables.......................................................................................................................... 8-3
Exercise 8-1: Defining Tolerances and Variation..................................................................... 8-4
Chapter 9. Reviewing and Interpreting Results............................................................... 9-1 Lesson 9-1. Reviewing Results of Derivative-based Analysis.... ......................................... 9-2 Variation Plots................................................................................................................................. 9-2 Quality Metrics................................................................................................................................ 9-3 Sensitivities ...................................................................................................................................... 9-3 Contributions................................................................................................................................. 9-10 Modifying Analyzer Layouts.......................................................................................................... 9-13 Reports........................................................................................................................................... 9-16
Exercise 9-1: Reviewing and Interpreting Results in the Modeler ......................................... 9-17 Exercise 9-2: Reviewing and Interpreting Results in the Analyzer........................................ 9-19
Chapter 10. File Management and Data Reuse.............................................................. 10-1 Lesson 10-1. Data Management ........................................................................................... 10-2 Exercise 10-1: Importing CETOL models from .cxm files .................................................... 10-3
Chapter 11. Applying CETOL 6σ.................................................................................. 11-1 Lesson 11-1. Gaining Confidence in your Results............................................................... 11-2 Exercise 11-1: Complex Part Overlay .................................................................................... 11-4 Exercise 11-2: Cam-Rocker Mechanism ................................................................................ 11-6 Completing Basic Training.......................................................................................................... 11-11 Applying CETOL 6 σ to Your Models .......................................................................................... 11-11
Training Introduction This training manual is intended to be used as a Basic Training Guide for a user who is new to CETOL 6σ Version 8.1. It has been written with enough completeness and detail to be used as a self-paced training manual. This manual has been written in modular format. Each chapter has been written to teach a specific aspect of the software. The chapters are broken down into one or more lessons. Most lessons have exercises to complete. In order to get the most out of this training manual, please read each lesson carefully before going on to the exercise. Take your time as you are going through the exercises. Make sure that you understand each step before going on to the next. This training guide does not serve as complete documentation of the CETOL software. Although the most important functionality of the software is covered here, certain aspects of the software are not. You should familiarize yourself with the content of the CETOL 6 σ User Reference Manual and refer to it when seeking more detailed information.
Downloading Training Files In order to complete the exercises in this manual, you must first obtain the related files. You can download these files from the Sigmetrix Support Center web site (http://support.sigmetrix.com). A simple registration is required in order to access this web site. The act of downloading the training files registers you as CETOL self-paced training customer and qualifies you for Sigmetrix training support. These files are protected by copyright and are not to be shared with anyone. Do not distribute these files anyone else, even others who are also going through this same training. Each trainee must personally download the training files in order to register as a training customer and be eligible for Sigmetrix training support. The file that you download from Sigmetrix is a WinZip archive. You must extract all of the files from the archive using WinZip (or similar program). When you extract the files, you should select the “Usefoldernames” option so that the directory structure is properly preserved.
Sigmetrix Training Support If you are using this manual for self-paced training, you may need to get help getting through the exercises or you may need additional explanation about a particular topic. You can submit a question to Sigmetrix Training Support by submitting a training support ticket on the Sigmetrix Support Center website. In most cases, you will receive a response within two business hours. Sigmetrix training support hours are Monday through Friday, 8:00 am until 5:00 pm Eastern Standard Time.
Reporting Problems If you encounter any problems related to CETOL 6 σ Basic Training, please report the problem by submitting a training support ticket on the support center website. If you find a mistake in this manual (i.e., typo, grammatical error, etc.), please make a copy of the page, mark it up, and FAX it to the attention of Sigmetrix Training at (317)818-9195.
Chapter 1. CETOL Overview In this chapter, you will learn about the CETOL 6 σ user interface and how it interacts with Pro/ENGINEER.
The CETOL User Interface Startin g CETOL & Pro /E When you want to use CETOL with Pro/Engineer you should launch Pro/E as you normally would (via a startup icon, startup script, etc). On Windows systems, you can start CETOL from a desktop icon or from the Sigmetrix program group in the Start menu.
The CETOL 6 Modeling Interface The main CETOL window includes a Menu bar, Command Bar, Tree View, Properties View, Graph View, Advisor view and Status Bar. Menu Bar
Command Bar
Properties View
Tree View
Advisor View Graph View Status Bar
The figure above shows the CETOL 6 σ Modeler interface on Windows XP. You may notice some minor differences on other OS versions. In this manual, the figures and icons represent what you would see on Windows XP.
