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Optimal tolerance allocation for non-rigid assembly considering the effect of deformation on functional requirement and quality loss cost

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Abstract

This paper proposes an optimal tolerance allocation method for the non-rigid assembly considering the effect of deformation variations on both the functional requirement and the quality loss cost during the assembly process. First, the functional requirement of the deformed non-rigid assembly is obtained using a deformed unified Jacobian–Torsor (J-T) model, which is developed by incorporating the deformation gradient models into the unified J-T model. Second, the statistical tolerance analysis and redesign of the deformed non-rigid assembly are performed with the deformed unified J-T model to obtain the functional requirement of the deformed non-rigid assembly and the redesigned tolerance of different deformed parts, which are used for the constraints for the optimization problem. Third, a multivariate quality loss cost function is used to integrate the quality loss cost due to the manufacturing variations with the quality loss cost due to the deformation variations, for the optimization objective function. The optimal tolerances allocated and the minimized total cost of producing the deformed non-rigid assembly are obtained by solving the optimization problem using the NSGA-II algorithm. Finally, the validity of the proposed optimal tolerance allocation method for the non-rigid assembly is verified through the case study; the results indicate that during the assembly process, the optimal tolerance allocated is different when compared to the rigid assembly, and the total cost of producing the non-rigid assembly considering the effects of deformation on the functional requirement and the quality loss cost also presents a different value compared with that obtained for producing the rigid assembly.

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Authors and Affiliations

  1. School of Mechanical and Electrical Engineering, University of Electronic Science and Technology of China, Chengdu, China

    Ibrahim Ajani & Cong Lu

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  1. Ibrahim Ajani
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  2. Cong Lu
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Correspondence to Cong Lu.

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Ajani, I., Lu, C. Optimal tolerance allocation for non-rigid assembly considering the effect of deformation on functional requirement and quality loss cost. Int J Adv Manuf Technol 125, 493–512 (2023). https://doi.org/10.1007/s00170-022-10687-1

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