Abstract
Tolerance design plays an important role in the modern design process by introducing quality improvements and limiting manufacturing costs. Tolerance synthesis is a procedure that distributes assembly tolerances between components or distributes final part design tolerances between related tolerances. Traditional tolerance design assumes that all objects have rigid geometry, overlooking the role of inertia effects on flexible components of assembly. The variance is increasingly stacked up as components are assembled without considering deformation due to inertia effects. This study deals with the optimal tolerance design for an assembly simultaneously considering manufacturing cost, quality loss and deformation due to inertia effect. An application problem (motor assembly) is used to investigate the effectiveness and efficiency of the proposed methodology.
Highlights
IntroductionDesign procedure mainly includes two phases: functional design (product design) and manufacturing design (process design)
Design procedure mainly includes two phases: functional design and manufacturing design
This study deals with the optimal tolerance design for an assembly simultaneously considering manufacturing cost, quality loss and deformation due to inertia effect
Summary
Design procedure mainly includes two phases: functional design (product design) and manufacturing design (process design). Where m is the total number of components from q assembly dimensions in a finished product, Kj the cost coefficient of the jth resultant dimension for quadratic loss function, Uij the jth resultant dimension from the ith experimental results, ij the jth resultant variance of statistical data from the ith experimental results, Tj the design nominal value for the jth assembly dimension, tik the tolerance established in the ith experiment for the kth component, and CM(tik) the manufacturing cost for the tolerance tik. Tolerance allocation in assembly design is performed using FE simulation as a virtual tool [24].This article proposes a method by which the deformation of the parts due to inertia effects are determined using FEA and by integrating the same in tolerance design process
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