Computer-Aided Tolerancing (CAT) software has become the standard for statistically analyzing the effects of geometrical part variations on product quality. Irrespective of CAT’s scope and technical depth, Finite Element Analysis (FEA) software, used to simulate the physical product behavior for ideal part geometry in the first place, is also often used for studies with geometrical shapes deviating from their nominal. However, this requires a manual translation of the tolerances specified in the design phase into geometrical variations represented by Finite Element (FE) meshes and their transfer to the FEA software. The method presented in this article exploits the potential of Model-Based Definition by establishing a link between Computer-Aided Design and FEA software to empower the latter for variation simulation based on semantic Geometric Dimensioning and Tolerancing (GD&T) information. To transfer this information exchanged via the Quality Information Framework (QIF) standard, a new mapping algorithm is presented that automatically decomposes FE meshes into geometrical face elements and creates a semantic link with the GD&T information carried in QIF. As a result, geometrical features are simultaneously described through meshes with nodes in the 3D Euclidean space and mathematical geometrical faces in the 2D parameter space. Exploiting this duality, mesh deviations are modeled indirectly by adjusting the mapped feature descriptions. An exemplary implementation in ANSYS® and its usage for non-intrusive structural simulations illustrates that sharing tolerancing information via QIF enables an automated, GD&T standards-compliant variation simulation within FEA software environments and is one step closer to a seamless digital thread for geometry assurance.

An essential premise for a reliable variation simulation is that information on the geometrical part variations and their accumulation and propagation within an assembly is available, accessible, interchangeable, and usable in all geometry-related downstream activities. For this reason, this article studies the potential of the QIF (Quality Information Framework) standard. It illustrates how it can be used in the sense of Model-Based Definition to close gaps in the digital geometry assurance process. Besides benefits in the automation of variation simulation, it demonstrates that the semantic, feature-based linkage between product specification and inspection information in QIF 3.0 facilitates the augmentation of variation simulation with more detailed feature information for pre-production applications and feeding the digital twin to assure and optimize product quality in the production phase. • Enhancing variation simulation with the Quality Information Framework (QIF) standard. • Mapping “as-design” and “as-inspected” QIF 3.0 information to surface meshes for variation simulation. • Mesh segmentation with Boundary Representation information from QIF 3.0. • Using QIF 3.0 for statistical predictions and digital twin applications in geometry assurance.