Sampling-based Tolerance-Cost Optimization of Systems with Interrelated Key Characteristics

Hallmann, Martin; Schleich, Benjamin; Wartzack, Sandro

doi:10.1016/j.procir.2020.02.153

Cited by 14 publications

(5 citation statements)

References 23 publications

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“…The FKCs are therefore bounded with an upper specification limit (USL). For more complex FKCs lower and upper specification limits can be applied like in [46]. The scrap rate is then calculated by taking the fraction of all conform parts of the N samples, i.e.…”

Section: Tolerance Optimizationmentioning

confidence: 99%

Tolerance Optimization of Patch Parameters for Locally Reinforced Composite Structures

Franz

Wartzack

2022

Appl Compos Mater

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A rising number of applications and increasing volume of composite structures production lead to a high relevance of variation management during their design. Structural optimization for lightweight purposes often results in designs consisting of a base laminate with local reinforcement patches. Nominally, these optimized designs offer a thorough exploitation of lightweight potential. Yet, they suffer from variations of the reinforcements resulting in a worsened manufacturing behavior and reduced structural performance. To ensure the quality, tolerances should be allocated for the parameters of the local reinforcement patches. Therefore, in the current contribution a tolerance optimization method is presented identifying optimal tolerance values for the design parameters of the reinforcements with respect to the structural behavior. This includes the discussion of challenges regarding the suitable parametrization and modeling of local reinforcement patches for variation simulation based on Finite Element Analysis (FEA), the usage of surrogate modeling to reduce the computational effort of structural analyses, as well as an approach to penalize tight tolerances of different parameter types. The proposed tolerance optimization is applied to a use case. Tolerances for the patch parameters are optimized, meeting the structural quality constraints of the composite structure.

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Section: Tolerance Optimizationmentioning

confidence: 99%

Tolerance Optimization of Patch Parameters for Locally Reinforced Composite Structures

Franz

Wartzack

2022

Appl Compos Mater

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“…All conform samples are counted as q j,lc,k = 1. To avoid multiple counting of a non-conform sample, logical disjunction according to [61] is used. The formulation of the quality constraint considers a sample as non-conform if at least one boundary value B lc,k of the K FKCs is violated by the FKC value Y j,lc,k .…”

Section: Tolerance Optimisationmentioning

confidence: 99%

Tolerance management during the design of composite structures considering variations in design parameters

Franz¹,

Schleich²,

Wartzack³

2021

Int J Adv Manuf Technol

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Composite structures play an important role in realising resource-efficient products. Their high lightweight potential and improved manufacturing technologies lead to an increased use in high-volume products. However, especially during the design and development of high-volume products, the consideration of uncertainties is essential to guarantee the final product quality. In this context, the use of modern lightweight materials, such as fibre reinforced plastics (FRP), leads to new challenges. This is due to their high number of design parameters, which are subject to deviations from their nominal values. Deviating parameters, e.g. ply angles and thicknesses, influence the manufacturing process as well as the structural behaviour of a composite part. To consider the deviating design parameters during the design process, a new tolerance optimisation approach is presented, defining tolerance values for laminate design parameters, while ensuring the functionality of the composite structure. To reduce the computational effort, metamodels are used during this optimisation to replace finite element simulations. The proposed approach is applied to a use case with different key functions to show its applicability and benefits.

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“…Tolerance analysis is incorporated into the constraints to assure product quality with respect to the predefined K KCs. In doing so, a single scrap rate or non-conformance rate for each KC as well as a total product scrap rate ẑtot are commonly used to ensure product functionality [70,71]. The optimization problems can generally be defined as follows [46,71]: optimal parameter design: least-cost tolerance design:…”

Section: Effects Of Robust Concept Design On Parameter and Tolerance Optimizationmentioning

confidence: 99%

“…To find the optimal robust parameter and tolerance design, the optimization problems from Equations ( 1)-(3) are solved in MATLAB R2019b using advanced optimization and sampling techniques. The utilized optimization process is thoroughly described in [70,71]. Additional information needed for the optimization of the concepts, such as design parameters and tolerances, is summarized in Table A1 in Appendix A.…”

Section: Parameter and Tolerance-cost Optimizationmentioning

confidence: 99%

“…In tolerance-cost optimization, the quality assurance is measured by the non-conformance rate representing the relative fraction of assemblies that do not meet the requirements. A non-parametric, empirical estimation technique is used to realistically consider the dependencies between the KCs in tolerance-cost optimization according to [71] forming the inequality conditions of Equations ( 2) and (3). With respect to computational efficiency, instead of ordinary Monte Carlo Sampling, the Latin Hypercube Sampling is used for tolerance analysis to evaluate the influence of uncertainty on the system behavior in terms of the quality loss and non-conformance rate.…”

Section: Parameter and Tolerance-cost Optimizationmentioning

confidence: 99%

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Early Robust Design—Its Effect on Parameter and Tolerance Optimization

2021

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The development of complex products with high quality in dynamic markets requires appropriate robust design and tolerancing workflows supporting the entire product development process. Despite the large number of methods and tools available for designers and tolerance engineers, there are hardly any consistent approaches that are applicable throughout all development stages. This is mainly due to the break between the primarily qualitative approaches for the concept stage and the quantitative parameter and tolerance design activities in subsequent stages. Motivated by this, this paper bridges the gap between these two different views by contrasting the used terminology and methods. Moreover, it studies the effects of early robust design decisions with a focus on Suh’s Axiomatic Design axioms on later parameter and tolerance optimization. Since most robust design activities in concept design can be ascribed to these axioms, this allows reliable statements about the specific benefits of early robust design decisions on the entire process considering variation in product development for the first time. The presented effects on the optimization of nominal design parameters and their tolerance values are shown by means of a case study based on ski bindings.

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Sampling-based Tolerance-Cost Optimization of Systems with Interrelated Key Characteristics

Cited by 14 publications

References 23 publications

Tolerance Optimization of Patch Parameters for Locally Reinforced Composite Structures

Tolerance Optimization of Patch Parameters for Locally Reinforced Composite Structures

Tolerance management during the design of composite structures considering variations in design parameters

Early Robust Design—Its Effect on Parameter and Tolerance Optimization

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