公差-成本稳健性分析研究

 根据稳健设计的思想，提出了一种成本稳健性分析方法，以此来获得影响成本值及其稳健性的关键因素．首先研究了公差设计中成本模型的误差因素(不同的模型和模型参数的误差)，然后应用试验设计方法分析了这两类因素对成本最小值及其稳健性的影响，最后通过实例验证了本方法．     

基于双响应面法的公差设计研究

探讨了产品综合成本的构成,以此为基础提出了以产品综合成本最低为目标的公差稳健设计模型,并利用双响应面法(Response Surface Methodology ,RSM) 来实现公差的稳健优化设计。     

基于公理设计和相容决策支持问题法的稳健优化设计方法

 针对多目标稳健优化问题,建立了多目标稳健优化的损失函数,利用灵敏度分析方法确定各设计变量对各设计目标的影响程度,确定主要的设计参数,便于调整和控制设计参数的公差.根据信息公理与损失函数的一致性关系,建立以最小化各目标的总损失函数为目标函数.并在相容决策支持问题法框架基础上,提出一种基于公理设计和相容决策支持问题法的多目标稳健优化设计模型.实例分析表明,提出的方法是可行的.     

任意分布参数的机械零件的可靠性稳健设计（一）：理论部分

 将可靠性优化设计理论、可靠性灵敏度技术和稳健设计方法相结合，讨论了具有任意分布参数的机械零件的可靠性稳健设计问题，提出了可靠性稳健设计的计算方法．把可靠性灵敏度融入可靠性优化设计模型之中，将可靠性稳健设计归结为满足可靠性要求的多目标优化问题．在基本随机参数的前四阶矩已知的情况下，通过计算机程序可以实现具有任意分布参数的机械零件的可靠性稳健设计，迅速准确地得到具有任意分布参数的机械零件的可靠性稳健设计信息。     

汽车车身耐撞性设计参数的区间稳健性优化

基于区间分析,提出了一种考虑公差的汽车车身耐撞性稳健优化设计模型,可在有效降低耐撞性能对设计参数波动敏感性的同时实现公差范围的最大化。该模型首先利用对称公差来描述汽车碰撞模型中车身关键耐撞部件的主要尺寸、位置和形状等设计参数本身的不确定性,然后将参数设计和公差设计相结合,建立了以稳健性评价指标和公差评价指标为优化目标,设计变量名义值和公差同步优化的多目标优化模型。再次,利用区间可能度处理不确定约束,将该优化模型转换为确定性多目标优化模型。最后,将该模型应用于两个汽车耐撞性优化设计问题,并通过序列二次规划法和改进的非支配排序遗传算法进行求解,结果表明该方法及稳健优化设计模型可行且实用。     

多失效模式机械系统可靠性稳健设计方法研究

将机械系统可靠性设计理论和稳健设计方法相结合,讨论了多失效模式机械系统可靠性稳健设计问题,提出了多失效模式机械系统可靠性稳健设计的计算方法．把可靠性灵敏度融入可靠性优化设计模型之中,将机械系统可靠性稳健设计归结为满足可靠性要求的多目标优化问题．在基本随机参数的前二阶矩已知的情况下,可以迅速准确地得到机械系统可靠性稳健设计信息．     

基于UG的平面尺寸链的计算机辅助飞机公差设计

随着CAD 技术的普及,飞机三维外型计算机辅助设计基本实现数字化,但目前飞机公差设计尚未实现计算机辅助设计。公差设计仍然需要大量手工计算,导致飞机公差设计与产品总体设计不协调,制约飞机数字化设计、制造技术的发展。探讨如何以现有CAD 三维造型系统为技术平台,开发计算机辅助飞机公差设计模块,实现平面尺寸链的飞机公差分析和分配的计算机辅助设计。给出在UG 平台上实现计算机辅助飞机公差设计模块的开发方案,并有利用该模块进行飞机装配件公差设计的运行实例。     

机械零件可靠性设计理论与方法研究

机械可靠性设计的任务就是提供实际计算的数学模型和方法,在机械产品的研发阶段预测其在规定工作条件下的工作能力或寿命．结合可靠性理论研究的历史及现状对机械可靠性设计理论进行深入分析,阐明了可靠性优化设计、可靠性灵敏度设计、可靠性稳健设计、可靠性试验、传统设计方法与可靠性设计相结合等机械零件可靠性设计理论与方法的内涵,为机械零件可靠性设计提供系统的理论和方法．     

任意分布参数的机械零件的可靠性稳健设计（三）：弹簧

 应用具有任意分布参数机械零件可靠性稳健设计的理论方法，对具有任意分布参数机械典型弹簧系零件如扭杆弹簧和螺旋弹簧，进行了可靠性稳健设计，给出了计算仿真分析结果，对工程实际的机械零件的可靠性稳健设计提供了理论依据．     

具有应力集中的机械零件可靠性稳健设计

针对在工程中很难给出带有应力集中的机械零件的显式功能函数的问题,将有限元方法、神经网络技术和可靠性理论相结合,给出了带应力集中的机械零件的可靠性稳健设计方法,数值模拟得到随机设计变量与机械零部件结构响应之间的函数关系式,结合随机摄动法和可靠性灵敏度技术,进行结构可靠性稳健设计,从而解决了工程实际中很难给出极限状态函数显式的问题,为结构可靠性稳健优化设计提供了一种新方法。     

Simultaneous tolerance synthesis for manufacturing and quality

Tolerance allocation affects product design, manufacturing, and quality. No existing technique has been found by the authors that takes product design, manufacturing, and quality into account simultaneously. This paper introduces a new concurrent engineering method for tolerance allocation. A nonlinear optimization model was constructed to implement the method. The model minimizes the combination of quality loss and manufacturing cost simultaneously in a single objective function by setting both process tolerances and design tolerances simultaneously. The purpose of the model is to balance manufacturing cost and quality loss to achieve near-optimal design and process tolerances simultaneously for minimum combined manufacturing cost and quality loss over the life of the product. Compared to other models, this model shows significant improvements. Electronic Publication     

Concurrent optimal allocation of design and process tolerances for mechanical assemblies with interrelated dimension chains

Concurrent tolerance allocation has been the focus of extensive research, yet very few researchers have considered how to concurrently allocate design and process tolerances for mechanical assemblies with interrelated dimension chains. To address this question, this paper presents a new tolerance allocation method that applies the concept of concurrent engineering. The proposed method allocates the required functional assembly tolerances to the design and process tolerances by formulating the tolerance allocation problem into a comprehensive model and solving the model using a non-linear programming software package. A multivariate quality loss function of interrelated critical dimensions is first derived, each component design tolerance is formulated as the function of its related process tolerances according to the given process planning, both manufacturing cost and quality loss are further expressed as functions of process tolerances. And then, the objective function of the model, which is to minimize the sum of manufacturing cost and expected quality loss, is established and the constraints are formulated based on the assembly requirements and process constraints. The purpose of the model is to balance manufacturing cost and quality loss so that concurrent optimal allocation of design and process tolerances is realized and quality improvement and product cost reduction is achieved. The proposed method is tested on a practical example.     

QFD optimization using linear physical programming

A new approach to quality function deployment (QFD) optimization is presented. The approach uses the linear physical programming (LPP) technique to maximize overall customer satisfaction in product design. QFD is a customer-focused product design method which translates customer requirements into product engineering characteristics. Because market competition is multidimensional, companies must maximize overall customer satisfaction by optimizing the design of their products. At the same time, all constraints (e.g. product development time, development cost, manufacturing cost, human resource in design and production, etc.) must be taken into consideration. LPP avoids the need to specify an importance weight for each objective in advance. This is an effective way of obtaining optimal results. Following a brief introduction to LPP in QFD, the proposed approach is described. A numerical example is given to illustrate its application and a sensitivity analysis is carried out. Using LPP in QFD optimization provides a new direction for optimizing the product design process.     

Tolerance analysis and synthesis for cam mechanisms

Tolerance is one of the most important parameters in product and process design, so tolerancing plays a key role in design and manufacturing. Tolerance synthesis is in a period of extensive study due both to increased demands for quality products and to increasing automation of machining and assembly. Optimum tolerance design and synthesis ensures good quality product at low cost. This paper presents an analytical methodology for tolerance analysis and synthesis for a disk cam-translating follower system. Both dimensional ( size) and geometric tolerances ( position and profile ) on the components are considered. Tolerance analysis is performed on individual tolerances as well as on total tolerance accumulation. With the lowest manufacturing cost as its objective function a nonlinear optimization model is formulated for tolerance synthesis and solved by a sequential quadratic programming ( SQP) algorithm. An example is provided to illustrate the optimization model and solution procedure.     

Tolerance synthesis by a new method for system reliability-based optimization

The performance–cost ratio of a product may be significantly improved by a better tolerance assignment. Current practice guided by experience usually leads to a conservative and costly design. Because yield in mechanical engineering is analogous to system reliability in structural engineering, this article applies a system reliability-based optimization formulation to tolerance synthesis and presents a sequential approximate programming method. This method is an extension of the approach for the optimization with component reliability constraints. Two often-quoted examples are analyzed in detail to illustrate its effectiveness and a strategy for tolerance assignment is recommended.     

Concurrent optimization of assembly tolerances for quality with position control using scatter search approach

Tolerance allocation to individual parts in any assembly should be a vital design function with which both the design and manufacturing engineers are concerned. Generally design engineers prefer to have tighter tolerances to ensure the quality of their design, whereas manufacturing engineers prefer loose tolerances for ease of production and the need to be economical. This paper introduces a concurrent tolerance approach, which determines optimal product tolerances and minimizes combined manufacturing and quality related costs in the early stages of design. A non-linear multivariable optimization model is formulated here for assembly. A combinatorial optimization problem by treating cost minimization as the objective function and stack-up conditions as the constraints are solved using scatter search algorithm. In order to further explore the influence of geometric tolerances in quality as well as in the manufacturing cost, position control is included in the model. The results show how position control enhances quality and reduces cost.     

Optimal design of an oil pipeline with a large-slope section

One of the important issues in the operation of a long-distance oil pipeline in a large-slope area is pressure control, especially for the section after the turning point. In this study, a method to optimally design an oil pipeline with a large-slope section is proposed. The method is based on a stochastic mixed-integer linear programming model with minimal total cost as the objective function to determine the size of the pipeline, the location, the operational plan of pump stations and the location of pressure reduction stations. Hydraulic calculations and different types of oil product are considered. The uncertainty in flow rates of the pipeline is studied by the proposed stochastic programming approach. This method is applied to a real case of designing an oil product pipeline in a large-slope area.     

基于仿真的制冷产品质量预测与优化

产品质量的预测与优化是产品设计的关键。提出了基于仿真的制冷产品质量预测与优化方法,将现实中存在的不确定因素和设计参数的波动以概率分布的形式输入制冷系统仿真模型,并结合随机模型方法实现了在设计阶段对产品质量进行预测。同时提出了一种获取产品质量损失函数的新方法,即采用中心复合试验设计与蒙特卡洛模拟结合,获得设计能力指数随部件容差变化的响应面模型,将该模型作为约束条件,以成本最低为目标,对部件容差进行优化后显著提高了产品的质量与经济性。     

Sequential optimization of parameter and tolerance design for multiple dynamic quality characteristics

System design, parameter design and tolerance design are the three stages of design process as presented by G. Taguchi. Systems design identifies the basic elements of the design to provide new or improved products to customers. Parameter design determines the optimal parameter settings, which will minimize variation from the target performance of the product. Tolerance design finally identifies the components of the design, which are sensitive in terms of affecting the quality of the product, and establishes tolerance limits that will give the required level of variation in the design. Most studies have focused primarily on optimizing the parameter design or tolerance design for multiple static quality characteristics. In this paper, a mathematical formula corresponding to the model is derived from Taguchi's quadratic quality loss function to minimize the expected total cost for the parameter design of multiple dynamic quality characteristics. When the optimal parameter design is not sufficient to reduce the output variation, the first-order Taylor series expansion is then used to analyse the variations of noise factors for optimizing the tolerance design. It concludes with an example demonstrating this approach.     

Bivariate tolerance design for lock wheels by considering quality loss

In the design of tolerance allocation the cost–tolerance function is usually employed to represent the objective function which is to be minimized. The traditional cost–tolerance functions in the literature are concerned with only one characteristic. In this paper we obtain a bivariate cost–tolerance function to describe the relationship between the cost and tolerances of two characteristics (i.e. the thickness and inner diameter) of a lock wheel. Then the bivariate loss function is combined with the bivariate cost–tolerance function to determine the optimal tolerances for the thickness and inner diameter of a lock wheel such that the user's potential loss/cost may be evaluated. When the quality loss is considered, the tolerances of both characteristics become tighter. By including the effect of product degradation, the present work of expected bivariate quality loss is then introduced as a quality performance measure. By assuming linear drifts on both the thickness and inner diameter of the lock wheels, the model with the present worth of quality loss leads to tighter tolerances of both characteristics. In addition, a longer planning horizon (or a longer useful life of the product) leads to tighter tolerances and a larger user's discount rate results in looser tolerances for both characteristics. Copyright © 2000 John Wiley & Sons, Ltd.