Several new production cost-tolerance models and a hybrid-model tolerance optimization formulation for tolerance synthesis are presented. These new models are introduced based upon the empirical cost-tolerance data of typical production processes, including hole producing, turning, milling, grinding and casting. The introduced models fit empirical cost-tolerance data with considerably less errors, and provide more reliable results for tolerance synthesis. In addition, the hybrid-model tolerance optimization formulation provides further modeling error reduction. The systematic evaluation of various cost-tolerance models provides model selection guidelines for tolerance synthesis. A typical tolerance design example is used to illustrate the method.

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