Linking Model-Based Definition and Non-Intrusive Finite Element Analysis for Automated Variation Simulation

Journal article, 2026

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.