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ME222/424
MSC 424
TME 424
Summing tolerances
Worst-case
Statistical
More complex systems
Tolerance = D
LSL = m - D
USL = m + D
Range of values m ± D
Statistical
Absolute limit
For simplicity here, we will assume that all distributions are normal.
Examples:
D = 1 s 68.3 % in tolerance average ± one standard deviation
D = 3 s 99.73 % in tolerance
D = 6 s 99.9999998% in tolerance
D = 4.5s 99.99966% in tolerance
Note: D = 4.5s (evaluated over an extended time period) is sometimes used as the
cut-off point for “Six Sigma Quality” less than 3.4 DPMO (defects per million
opportunities) “rule of thumb” to adjust for drift in product mean
?±?
PD Funkenbusch (ME 222/424)
Example
9
m1 ± D1 m2 ± D2 m3 ± D3 Fit three components
end to end into a slot
machined into a fourth
m4± D4 component.
m2 ± D2
mg ± Dg
mg = m4 - m1 - m2 - m3
Tolerance
always sum
Uncertainty increases with each
component included
mg Dg 0.5 to 1.5 mm
Tolerance type
Summation
method Absolute Statistical
Some product out of
Worst-case All product within
tolerance (generally
(add D’s) tolerance
small %)
Fraction in tolerance
Statistical Difficult to estimate
related to components’
(add D2 ’s) (“depends”)
fraction in tolerance
As examples,
variability in the output voltage of an electrical circuit because of differences in
component properties (resistances, capacitances, etc.) and geometry/assembly
variability in engine performance due to component wear, ambient temperature,
fuel quality, etc.
Modeling
Need a good mathematical model
May be able to solve analytically, depending on complexity
Alternatively use the model to “test” different combinations of
component /environment values
Monte Carlo random sampling based on frequency of occurrence.
Generally requires large numbers of samples (1,000s or 10,000s)
must be practical with the model
Various systematic approaches, e.g. Tolerance design
Experimental
Need to be able to identify and monitor or adjust sources of
variability
Analyze data collected “in the field” is suitable data available?
Systematic testing, e.g. Tolerance design
P
trabecular
t
cortical
1.20E+03 1.40E+05
1.20E+05
1.15E+03
1.00E+05
1.10E+03
MSE (N*N)
8.00E+04
Load (N)
6.00E+04
1.05E+03
4.00E+04
1.00E+03
2.00E+04
9.50E+02 0.00E+00
1 10 100 1000 10000 1 10 100 1000 10000
N N
1.20E+03 1.40E+05
1.20E+05
1.15E+03
1.00E+05
1.10E+03
MSE (N*N)
8.00E+04
Load (N)
6.00E+04
1.05E+03
4.00E+04
1.00E+03
2.00E+04
9.50E+02 0.00E+00
1 10 100 1000 10000 1 10 100 1000 10000
N N
TOLERANCE AS VARIABILITY
Experiment
estimate variance for the product
determine contribution of each component variance to the total
decide how to best improve tolerance (i.e. reduce variance) as needed
h values show sensitivity of final product variance to tolerance
(variance) of each component think about the units…
Knobs (dimensions A, B, C)
m - s and m + s for each dimension
Eight possible combinations
Manufactured all eight combinations
Handles (dimensions D, E, F)
m - s and m + s for each dimension
Eight possible combinations
Manufactured four of the combinations
Tube (dimension G)
Manufactured two tubes, one with m - s and one with m + s
Definitions of tolerance
Based on % in/out of tolerance
Absolute all in tolerance
Statistical known % out of tolerance
Summation of tolerances
“worst-case” summation of tolerances
“statistical” summation of the squares
Tolerance design
Based on reducing the product variance
Assumes product variance is proportional to component variances
DOE to estimate total product variance, component contributions,
and the effects of changing component tolerances