Statistical tolerance analysis of over-constrained mechanisms with gaps using system reliability methods

One of the aims of statistical tolerance analysis is to evaluate a predicted quality level at the design stage. One method consists of computing the defect probability PD expressed in parts per million (ppm). It represents the probability that a functional requirement will not be satisfied in mass production. This paper focuses on the statistical tolerance analysis of over-constrained mechanisms containing gaps. In this case, the values of the functional characteristics depend on the gap situations and are not explicitly formulated with respect to part deviations. To compute PD, an innovative methodology using system reliability methods is presented. This new approach is compared with an existing one based on an optimization algorithm and Monte Carlo simulations. The whole approach is illustrated using two industrial mechanisms: one inspired by a producer of coaxial connectors and one prismatic pair. Its major advantage is to considerably reduce computation time. •Gaps cannot be considered as random variables.•The tolerance analysis issue is formulated thanks to the quantifier notion.•Two defect probabilities are defined: functionality defect probability and assembly defect probability.•Defect probabilities are computed using a system reliability method: FORM system.