Cost optimization of process tolerance allocation-a tree based approach

Tolerance transfer techniques are used extensively for allocation of tolerances for each machining operation in the process sequence, and hence are used to coordinate the process planning and the design activities in the evolution of a new product. This paper deals with an extended approach to allocate process tolerances based on a tree topology called technologically and topologically related surfaces (TTRS) and its subsequent extension to cost optimization. The benefit of this approach is that equations are generated explicitly with regard to tolerance transfer. These have been exploited by implementing the cost function in the generated explicit equations and subsequent optimization. The TTRS approach has been extended which scores over the limitations of some of the already existing techniques in that, it is optimal with respect to two factors namely, cost of producing the required tolerances, as also the process capability of the machines involved in producing the part. This technique has been proved practically feasible as it has been implemented in an industry. To enable a better view of the advantages of the approach, a comparative study with the existing techniques has been carried out in addition to a simulation using the Monte Carlo method.