Dimensional Quality Oriented Reliability Modeling for Complex Manufacturing Processes

Abstract

The stability of process is certainly one of the most important aspects to fulfill the task. Now, it is still a challenge to put forward a model to deal with the stability of manufacturing process mathematically. Aiming at solving the problem, this paper discusses the issues by the notion of manufacturing process reliability and its sensitivity. Based on state space model, the process performance function which is used to describe the relations between the key product characters (KPC) of the machined part and the key control characters (KCC) of multistage process in machining system has been built. Furthermore, the measure index to the process reliability of multistage machining system is proposed, which facilitates the forming of the ways to model the process reliability mathematically. To determine the weakest stage during machining process, the sensitivity of process reliability to KCC of the process has been put forward and the corresponding ways how to calculate it. Because of the multistage process is highly non-linear process, chaos optimization algorithm and mutative scale chaos optimization algorithm are used to calculate this kind of robust reliability index．Finally, A simple 2-D case study has been used to validate the proposed model. It shows that the process reliability can be calculated effectively.

Process reliability modeling method considering discrete state and continuous performance

“…Ignoring the composition of the processing system will lead to the fact that the modeling results cannot accurately characterize the state of the system, and then cannot be used for production decision-making [8] . Based on the above understanding, some scholars have interpreted the connotation of process reliability from the perspective of system functional characteristics, such as product quality [9] , demand satisfaction probability [7] , and so on. However, there is still a lack of research that can comprehensively consider the system composition and the functional characteristics of each part and put forward the process reliability modeling method from the perspective of engineering application.…”

Dynamic Modeling Method of Mission Reliability of a Multi-State Manufacturing System With Multiple Production Lines

“…Zhang et al [18] proceeded from the purpose of manufacturing system functions; regarding the formation of product quality in the manufacturing process as the research object, they establish a reliability model of manufacturing systems from the perspective of the process. However, the above studies only focus on product quality and machine performance, fail to cover the whole factors of dynamic operation of a manufacturing system, and do not consider key issues such as buffer effect and multi-state characteristics, which cannot predict the operation state of the whole system.…”

Modeling and Analysis of the Reliability of Machining Process of Diesel Engine Blocks Based on PFMECA

“…Lin et al [14] proposed a Bayesian procedure to judge whether the process satisfies the preset quality reliability requirement. Based on state space model, Zhang et al [15] built the process performance function which is used to describe the relations between the key product characters (KPC) of the machined part and the key control characters (KCC) of multistage process in machining system. Lu et al [16] studied the reliability of the technology of grinding process by discerning the potential causes, and regarded the product surface residual stress as the bridge between the grinding process parameters and product reliability to establish the grinding process reliability model.…”