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NEAR KINEMATIC CONSTRAINT. QKC characteristics: Arc contact Submicron repeatability Stiff, sealing contact Less expensive than KCs Easier to make than KCs. QKC Function: Ball & groove comply Burnish surface irregularities Elastic recovery restores gap. F or D. d final. d = 0.
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QKC characteristics: Arc contact Submicron repeatability Stiff, sealing contact Less expensive than KCs Easier to make than KCs QKC Function: Ball & groove comply Burnish surface irregularities Elastic recovery restores gap F or D dfinal d= 0 dinitial Quasi-Kinematic (QKC) alignment Spherical Protrusion Groove Seat Side Reliefs Feature Height, mils Distance along Cone Face, [inches]
+ BOLT BLOCK + = + CAST FORM TOOL FINISHED BEDPLATE PEG Details of QKC element geometry PAIRS OF QKC ELEMENTS OR TYPE 2 GROOVE MFG. ASSEMBLED JOINT
+ + Which variation of QKC to use • Design A Design B • In Design A, Peg deforms on edge -> reduced repeatability OR
y x QKC methods vs kinematic method Components and Definitions Relief Relief Cone Seat Ball Groove Surface Peg Surface Contact Point Force Diagrams
Material Contact Stiffness fn(dn) QKC Model Force/Torque Geometry Displacements Stiffness Modeling QKC stiffness Geometry Material Applied Loads [Fp & Mp] Resultant Forces [ni & Fi] Deflections d -> Dr Relative Error
^ l ^ n ^ s Rotating CS ^ k ^ ^ l n Rc ^ i QKC contact mechanics • MECHANICS: • • Use Rotating Coordinate System • • Assume Sinusoidal Normal Distance of Approach • • Obtain Contact Stress Profile as Function of Above • • Integrate Stress Profile in Rotating CS thru contact
10 mm Coupling + Others 5 mm Process 0 mm Example: DuratecTM assembly • Characteristics: • Ford 2.5 & 3.0 L V6 • > 300,000 Units / Year • Cycle Time: < 30 s Rough Error Budget
C C L L de JL JR r Block Bore Bedplate Bore a Assembly Bolts Bedplate C B Halves Block Block Bedplate Example: Assembly of DuratecTM block & bedplate COMPONENTS ERROR ASSEMBLY de MAX = 5 microns
Bearing assemblies in engines Block Block Main Bearing Half Crank Shaft Journal Piston Bedplate Main Bearing Half Crank Shaft Bedplate Main Bearing Halves
Results of DuratecTM QKC Research MANUFACTURING: DESIGN:
JL Cap Probe 1st Block Fixture CMM Head Bedplate Fixture Bedplate JR Cap Probe Axial Axial Cap Probe Sensitive 2nd Block Fixture Engine assembly performance (Range/2) = 1.35 mm (Range/2)|AVG = 0.65mm 9