The inevitable presence of geometrical part deviations and their effects on the product function and quality forces companies to manage these deviations along the product life-cycle. Computer-aided tolerancing and variation simulation tools support these activities by enabling the early prediction and assessment of the effects of such part deviations. However, available approaches for the tolerance analysis and variation simulation imply shortcomings regarding the consideration of form deviations, particularly when analysing mechanism and moving systems. This paper presents an approach for the motion tolerancing, i. e. for the tolerance analysis of mechanism and moving systems, employing discrete geometry representations of parts with geometrical deviations (Skin Model Shapes). In this regard, a novel method for the parametrization of form deviations is proposed and the use of meta-modelling techniques for the reduction of the computational effort is illustrated. Moreover, the presented approach is applied on two case studies. Based on the obtained results, it can be found, that the consideration of form deviations in the tolerance analysis for mechanism and moving systems may lead to more purposeful tolerancing decisions.

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