Implementation and Interpretation of a Scrap and Failure Oriented Multi-Objective Optimization Considering Operational Wear

Abstract

The tolerancing of products for manufacturing is usually performed at the end of the design process and the responsibility of the designer. Although components are commonly tolerated to ensure functionality, time-based influences, like wear, that occur during operation, are often neglected. This could result in small amounts of scrap after production, but high quantities of failure during operation. To overcome this issue, this paper presents an approach to perform a multi-objective optimization considering tolerances based on a wear simulation. Thereby, mean shifts serve as optimization variables, while the aim of the optimization is to generate an optimal ratio of scrap to failure. In addition, the optimization results are interpreted and further options for the designer are presented. Moreover, the approach is exemplary applied to a use case.

Ilmenau’s contributions to Design Science

“…In research, questions concerning all steps of the development process are discussed, in order to develop robust solutions in the context of the different requirements and external as well as internal influences (Eifler & Schleich 2021;Husung et al 2023;Li et al 2023). Increasingly, approaches from Virtual Product Development are being used: from tolerance simulations (Heling et al 2018) to Pareto optimisations (Bode et al 2023) and knowledge-based solutions (Faheem et al 2023;Walsh et al 2023). Thus, the variance of parameters can be taken into 54/73 account early on, helping master the complexity of mechatronic or cybertronic solutions.…”