A Novel Methodology for Simultaneous Minimization of Manufacturing Objectives in Tolerance Allocation of Complex Assembly

• Published in: Applied sciences 2021-10, Vol.11 (19), p.9164
• Main Authors: Nagarajan, Lenin, Mahalingam, Siva Kumar, Salunkhe, Sachin, Nasr, Emad Abouel, Davim, Jõao Paulo, Hussein, Hussein M. A.
• Format: Article
• Language: English
• Subjects: Assemblies; Design of experiments; Heuristic; heuristic approach; Lagrange multiplier; machine and process selection; Machine shops; Machining; Manufacturing; Methodology; Optimization; Optimization algorithms; Process selection; Production costs; Researchers; tolerance allocation; univariate search method; whale optimization algorithm
• ISSN: 2076-3417; 2076-3417
• DOI: 10.3390/app11199164

Tolerance cost and machining time play crucial roles while performing tolerance allocation in complex assemblies. The aim of the proposed work is to minimize the above-said manufacturing objectives for allocating optimum tolerance to the components of complex assemblies, by considering the proper process and machine selections from the given alternatives. A novel methodology that provides a two-step solution is developed for this work. First, a heuristic approach is applied to determine the best machine for each process, and then a combined whale optimization algorithm with a univariate search method is used to allocate optimum tolerances with the best process selection for each sub-stage/operation. The efficiency of the proposed novel methodology is validated by solving two typical tolerance allocation problems of complex assemblies: a wheel mounting assembly and a knuckle joint assembly. Compared with previous approaches, the proposed methodology showed a considerable reduction in tolerance cost and machining time in relatively less computation time.