Development of the parametric tolerance modeling and optimization schemes and cost-effective solutions

Abstract

Most of previous research on tolerance optimization seeks the optimal tolerance allocation with process parameters such as fixed process mean and variance. This research, however, differs from the previous studies in two ways. First, an integrated optimization scheme is proposed to determine both the optimal settings of those process parameters and the optimal tolerance simultaneously which is called a parametric tolerance optimization problem in this paper. Second, most tolerance optimization models require rigorous optimization processes using numerical methods, since closed-form solutions are rarely found. This paper shows how the Lambert W function, which is often used in physics, can be applied efficiently to this parametric tolerance optimization problem. By using the Lambert W function, one can express the optimal solutions to the parametric tolerance optimization problem in a closed-form without resorting to numerical methods. For verification purposes, numerical examples for three cases are conducted and sensitivity analyses are performed.