Tolerance analysis based on Monte Carlo simulation: a case of an automotive water pump design optimization
- PDF / 3,263,640 Bytes
- 15 Pages / 595.276 x 790.866 pts Page_size
- 60 Downloads / 158 Views
Tolerance analysis based on Monte Carlo simulation: a case of an automotive water pump design optimization Eduardo Umaras1 · Ahmad Barari2 · Marcos Sales Guerra Tsuzuki1,2 Received: 28 May 2020 / Accepted: 13 October 2020 © Springer Science+Business Media, LLC, part of Springer Nature 2020
Abstract Successful products are those presenting the highest quality at a fair cost. Although different approaches can be used to define the concept of quality, functional reliability is always a major requirement, due to implications such as safety and user losses regarding maintenance expenses, and product availability. Intelligent designs are robust and result in a fair cost. Robust designs are those insensitive to sources of variation occurring during the product life, keeping their performance under variable use conditions, like thermal and stress effects. The robustness approach is a function of two main design criteria: low complexity and tolerance design. Design for manufacture and assembly is closely related to decreasing complexity. Tolerance design is a tool in which the unavoidable manufacturing variations are considered during product development. This work presents a proposal for an intelligent design in an actual application by considering design simplification through the reduction of parts for an automotive water pump. The tolerance analysis is performed by means of a powerful statistical approach—a Monte Carlo simulation—in which process behavior is randomly simulated representing a high production volume. Additionally, service thermal effects are also contemplated, and assembly tests are proposed for automatic rejection of non-conforming parts, assuring high reliability and full compliance with functional requirements. This is an example of integrated design–manufacturing work aiming at both cost saving and improved reliability. Keywords Monte Carlo simulation · Design for manufacture and assembly · Automotive pump · Water pump · DFMA · DFM · DFA
Introduction The aim of this work is to propose an integrated design– manufacturing methodology by considering not only qualitative aspects, but also the quantitative ones in order to demonstrate its effectiveness. For this purpose, a design optimization of an existing product—an automotive water pump—is selected and a detailed calculation is developed to demonstrate the results of the proposed methodology. The focus is the design simplification, resulting in cost savings, while also keeping or even improving the product reliabil-
B
Marcos Sales Guerra Tsuzuki [email protected]
1
Computational Geometry Laboratory, Department of Mechatronics and Mechanical Systems Engineering, Escola Politécnica da Universidade de São Paulo, Av. Prof. Mello Moraes, 2231, São Paulo, SP, Brazil
2
Faculty of Engineering and Applied Science, University of Ontario Institute of Technology (Ontario Tech), Oshawa, ON, Canada
ity. Some design tools considered for these purposes are described in the following paragraphs. Until the 1980s, more precisely 1988 (Clausing 1994), design enginee
Data Loading...
