Concurrent multi-objective tolerance allocation of mechanical assemblies considering alternative manufacturing process selection

Sivakumar, K.; Balamurugan, C.; Ramabalan, S.

doi:10.1007/s00170-010-2871-4

Cited by 37 publications

(35 citation statements)

References 22 publications

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“…48 However, lesser tolerances usually results in poorer performance, premature wear, and frequent part rejection. Yang et al 50 summarized several functions that can be used to define the cost verses tolerance relationship including the reciprocal, reciprocal-squared, Sutherland-Roth, exponential, and Michael-Siddall functions, etc.…”

Section: Manufacturing Cost Modelingmentioning

confidence: 99%

Robust geometric accuracy allocation of machine tools to minimize manufacturing costs and quality loss

Cheng

Zhao

Liu

et al. 2016

Proceedings of the Institution of Mechanical Engineers, Part C:

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With increasing demands of machining accuracy, designing of machine tools for satisfactory performance using costeffective geometric accuracy configurations is becoming a complex problem to the machine tool manufacturers. In this paper, a novel robust accuracy allocation method is proposed for multi-axis machine tools based on multi-objective quality and cost trade-offs. To model the volumetric accuracy of machine tool based on geometric errors, the multi-body system theory was introduced. A manufacturing cost model for the machine tool components with a significant effect on geometric errors was established based on the machining features. The quality loss of the machine tool was also integrated into a single optimization objective. After identifying the relationship between the accuracy grade parameters of the feeding components and the geometric errors, the maximum in the Euclidean norm of all the accuracy parameters was defined as another optimization objective. The robust accuracy allocation was performed using Isight software and the Non-Dominated Sorting Genetic Algorithm-II built in the MATLAB. The optimization results for a four-axis horizontal machining center showed that the proposed method can realize the optimization of geometric accuracy and can determine the optimal accuracy grade of the feeding components satisfying the machining accuracy requirements.

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Section: Manufacturing Cost Modelingmentioning

confidence: 99%

Robust geometric accuracy allocation of machine tools to minimize manufacturing costs and quality loss

Cheng

Zhao

Liu

et al. 2016

Proceedings of the Institution of Mechanical Engineers, Part C:

View full text Add to dashboard Cite

show abstract

“…There is a strong relationship between the manufacturing cost of a component and the tolerance specified [4]. The manufacturing cost usually increases with closer tolerances on the quality characteristics as more refined and precise operations are needed and the acceptable range of the output is reduced [38]. However, lesser tolerances usually result into poorer performance, premature wear, and more frequent part rejection.…”

Section: Geometric Error-cost Modelingmentioning

confidence: 99%

An approach of comprehensive error modeling and accuracy allocation for the improvement of reliability and optimization of cost of a multi-axis NC machine tool

Zhang

Liu

Cheng

et al. 2016

Int J Adv Manuf Technol

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Machining accuracy is critical for the quality and performance of a mechanical product, and the reliability of a multi-axis NC machine tool reflects the ability to reach and maintain the required machining accuracy. The objective of this study is to propose a general methodology that will simultaneously consider geometric errors and thermal-induced errors to allocate the geometric accuracy of components, for improving machining accuracy reliability under certain design requirements. The multi-body system (MBS) theory was applied to develop a comprehensive volumetric error model, showing the coupling relationship between the individual errors of the components of this machine tool and their volumetric accuracy. Additionally, a thermal error model was established based on the neural fuzzy control theory and was compared to the common thermal error modeling method called BP neural network. Based on the traditional cost model and the reliability analysis model, a geometric error-cost model and a geometric error-reliability model were established, taking the weighted function principle into consideration. Then, an allocation approach of the geometric errors, for optimizing total cost (manufacture and QLF) and reliability, subject to the geometrical and operational constraints of the machine tool, was proposed and formulated into a mathematical model, in order to perform the optimization process of accuracy allocation by using the advanced NSGA-II algorithm. A case study was also performed in a five-axis machine tool, and the traditional NSGA algorithm was used for comparison. The optimization results for the five-axis machining center showed that the proposed approach is effective and able to perform the optimization of geometric accuracy and improve the machining accuracy and the reliability of the machine tool.

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“…Muthu et al [28] used metaheuristic method to balance the 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. In 2010 K. Sivakumar, et al proposed a novel multi-objective optimization method to enhance the operations of the non-traditional algorithms and Multi-Objective Particle Swarm Optimization and systematically distribute the tolerances among various the components of mechanical assemblies [32]. From the above literature, the previous researches on tolerance allocation mainly focus on structural design taking manufacturing cost or manufacturing process into consideration, besides, there are many of accuracy allocation in the field of hull construction, robotics, military application, and instruments [35,24,37,42,34].…”

Section: Accuracy Allocationmentioning

confidence: 99%

A geometric accuracy design method of multi-axis NC machine tool for improving machining accuracy reliability

Cai¹,

Zhang²,

Cheng³

et al. 2015

Eksploatacja i Niezawodnosc - Maintenance and Reliability

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Concurrent multi-objective tolerance allocation of mechanical assemblies considering alternative manufacturing process selection

Cited by 37 publications

References 22 publications

Robust geometric accuracy allocation of machine tools to minimize manufacturing costs and quality loss

Robust geometric accuracy allocation of machine tools to minimize manufacturing costs and quality loss

An approach of comprehensive error modeling and accuracy allocation for the improvement of reliability and optimization of cost of a multi-axis NC machine tool

A geometric accuracy design method of multi-axis NC machine tool for improving machining accuracy reliability

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