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    Design For Manufacturability Me317 DFM

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    Yohannes Gebre
    ME317 dfM at Stanford (c)2006 K. Ishii Robust design Fundamentals Kos Ishii, Professor Department of Mechanical Engineering Stanford University "robust means product and process insensitive to noises" today's agenda next four lectures: Robust Design Introduction--simple examples 2. Design of Experiments (DoE) / Taguchi Method 3. Variation Patterns / Confounding, Case Study 4. Robust Conceptual Design (Dr. Russell Ford)

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    Design For Manufacturability Me317 DFM

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    Yohannes Gebre
    47 views24 pages
    ME317 dfM at Stanford (c)2006 K. Ishii Robust design Fundamentals Kos Ishii, Professor Department of Mechanical Engineering Stanford University "robust means product and process insensitive to noises" today's agenda next four lectures: Robust Design Introduction--simple examples 2. Design of Experiments (DoE) / Taguchi Method 3. Variation Patterns / Confounding, Case Study 4. Robust Conceptual Design (Dr. Russell Ford)

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    ME317 dfM at Stanford (c)2006 K. Ishii Robust design Fundamentals Kos Ishii, Professor Department of Mechanical Engineering Stanford University "robust means product and process insensitive to noises" today's agenda next four lectures: Robust Design Introduction--simple examples 2. Design of Experiments (DoE) / Taguchi Method 3. Variation Patterns / Confounding, Case Study 4. Robust Conceptual Design (Dr. Russell Ford)

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    Download as ppt, pdf, or txt
    47 views24 pages

    Design For Manufacturability Me317 DFM

    Uploaded by

    Yohannes Gebre
    ME317 dfM at Stanford (c)2006 K. Ishii Robust design Fundamentals Kos Ishii, Professor Department of Mechanical Engineering Stanford University "robust means product and process insensitive to noises" today's agenda next four lectures: Robust Design Introduction--simple examples 2. Design of Experiments (DoE) / Taguchi Method 3. Variation Patterns / Confounding, Case Study 4. Robust Conceptual Design (Dr. Russell Ford)

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    ME317 dfM at Stanford

    2006 K. Ishii
    Design for Manufacturability
    ME317 dfM
    Robust Design Fundamentals

    Kos Ishii, Professor
    Department of Mechanical Engineering
    Stanford University
    ishii@stanford.edu
    http://me317.stanford.edu
    Robust means product & process
    insensitive to noises
    Genichi Taguchi, 1985
    ME317 dfM at Stanford
    2006 K. Ishii
    Todays Agenda
    Next Four Lectures: ROBUST DESIGN
    1. Robust Design Introduction--simple examples
    2. Design of Experiments (DoE) / Taguchi Method
    3. Variation Patterns / Confounding, Case Study
    4. Robust Conceptual Design (Dr. Russell Ford)

    Today: Robust Design Fundamentals
    Concept of Robustness
    DoE Basics
    Cantilever Example: Using Analytical Models
    ME317 dfM at Stanford
    2006 K. Ishii
    Whats Robustness?
    Seek candidate design whose performance is
    insensitive to variation
    Focus on variation that affect performance
    Manufacturing variation
    Deterioration of parts/materials
    Environmental variables
    Illustrative Examples
    Kos Rectangular Cookie
    Force Sensor (Cantilever Beam Structure)
    Profile Modified Helical Gears
    CD Pickup Mechanism (Dynamic Performance)
    Robust Dimensional Fit
    EXAMPLE
    Design a hood hinge with excellent alignment
    Low manufacturing and assembly cost
    SOURCES OF VARIANCE
    Manufacturing variation
    Assembly errors
    ME317 dfM at Stanford
    2006 K. Ishii
    Robustness Optimization
    Peak vs.
    Robust
    Optimum
    Parameter X
    P
    R
    R h
    P l
    3o
    3o
    R l
    P h
    3o
    O
    b
    j
    e
    c
    t
    i
    v
    e

    F
    u
    n
    c
    t
    i
    o
    n

    L

    TIP
    ROOT
    START
    ROLL
    ANGLE
    AMT. OF
    RELIEF
    ME317 dfM at Stanford
    2006 K. Ishii
    Robust Design Philosophy
    System--Parameter--Tolerance
    SYSTEM DESIGN
    Function Requirements System Configuration
    Russell Fords Lecture
    PARAMETER DESIGN
    System Configuration Detailed Design
    Hit Target Response while Minimize Variation
    TOLERANCE DESIGN
    Detailed Design Tolerance Specification
    Tighten tolerances sensitive to performance
    variation but insensitive to cost
    ME317 dfM at Stanford
    2006 K. Ishii
    Robust Design Approach
    The Principles of Parameter Design
    Use a limited set of experiments to determine the
    design sensitivities
    Design the product and process to minimize the
    sensitivity of the quality measures to noise
    R X
    X
    f
    X f X f
    X
    + A
    c
    c
    =
    0
    ) ( ) (
    0
    Tolerance Design
    Tightening tolerance induces higher control cost
    Applied after parameter design
    Tighten the tolerance of most sensitive variables
    ME317 dfM at Stanford
    2006 K. Ishii
    Noise and Loss
    Control Factors:
    Designers have control, e.g., parameter set points

    Noise Factor:
    Designers do not have control
    Need to minimize effects on performance

    Types of Noise Factors:
    External (outer): environmental noise
    Unit to Unit (product): mfg. variations
    Deterioration (inner): changes in the product
    ME317 dfM at Stanford
    2006 K. Ishii
    Example: Noise Factors
    Noise Factors for braking distance of a car
    External
    wet or dry road
    Unit-to-Unit Variation
    friction characteristics of brake pads
    Deterioration
    wear of brake pads
    ME317 dfM at Stanford
    2006 K. Ishii
    Loss Function
    Various Form of Loss Functions





    m m+
    0
    m-
    0
    Step
    m m+
    0
    m-
    0
    Quadratic
    Quadratic Loss functions:
    Nominal-is-Best: k(y-m)
    2

    Smaller-is-Best: ky
    2

    Larger-is-Best: k(1/y
    2
    )

    ME317 dfM at Stanford
    2006 K. Ishii
    Many forms of criteria (Nominal-is-Best Case)
    Average Loss =
    S
    2
    = variance, m = target performance = mean







    Robustness Objective Criteria
    m m+
    0
    m-
    0
    y
    Distribution of y
    L(y)
    y
    Quality Loss
    y
    k[S
    2
    +(y m)
    2
    ]
    ME317 dfM at Stanford
    2006 K. Ishii
    Robust Design Basics
    1. Establish the concept configuration
    Dr. Russell Fords Lecture
    2. Define performance goals
    3. Identify factors which influence performance
    Classify into categories
    Draw Cause-and-effect diagram
    Select factors that form the basis of experiments

    Important to consider all possible factors
    May need to identify significant factors and iterate
    Utilize analytical / numerical models if available
    ME317 dfM at Stanford
    2006 K. Ishii
    Force Sensor Example
    Step 1: Design Concept
    Cantilever Bar + Strain Gauge
    Step 2: Robust objective
    Hit the target stiffness!
    ME317 dfM at Stanford
    2006 K. Ishii
    Identify pertinent variables
    Step 3: Cause & Effects Diagram
    (Ishikawa Dia.)
    List all the variables that
    influence performance
    Classify significant control and
    noise parameters
    Causes
    Effects
    Material
    Type
    Amount
    Clamp
    Material
    Shape
    Dimensions
    h
    b
    Tolerance
    L
    h
    o
    b
    L
    o
    o
    Uniform
    Stiffnesss
    ME317 dfM at Stanford
    2006 K. Ishii
    Factors in the Force Sensor Example
    Control Factors: b, h, L ( L < 2 inch)
    Noise Factors:
    Thickness h: +0.0001 inch
    Width b: +0.001 inch
    Length L: +0.005 inch

    Goal
    Minimize variation on stiffness
    Target Objective: K
    0
    =0.05 lb/in
    LAL
    bAb
    hAh
    M a t e r i a l : A l u m i n u m
    E = 1.25x10
    7
    psi
    Strain
    Gauge
    ME317 dfM at Stanford
    2006 K. Ishii
    Closed Form Approach
    The Rectangular Cookie Problem
    If there is a closed form expression
    Could lead to analytical solutions
    E.g. for the force sensor:
    K =
    Ebh
    3
    4L
    3
    X
    Y
    A
    Very simple example:
    A = X Y
    Target A0
    Noise on X and Y
    Find target X and Y that Minimize Variation
    ME317 dfM at Stanford
    2006 K. Ishii
    Derive the Robustness Criteria
    Relate performance variation to noise
    A
    0
    = XY
    A
    0
    +AA=(X +AX)(Y +AY)
    A
    0
    +AA= XY +AXY +AYX +AXAY
    1 +
    AA
    A
    0
    =
    XY
    XY
    +
    AX
    X
    +
    AY
    Y
    +
    AXAY
    XY
    AA
    A
    0
    =
    AX
    X
    +
    AY
    Y
    0
    1
    ME317 dfM at Stanford
    2006 K. Ishii
    Find the robust optimum
    Find the value of X that minimizes variation on A
    A
    0
    = XY Y =
    A
    0
    X
    AA
    A
    0
    =
    AX
    X
    +
    XAY
    A
    0
    c
    AA
    A
    0
    |
    \

    |
    .
    |
    cX
    =
    AX
    X
    2
    +
    AY
    A
    0
    = 0
    X
    2
    AX
    =
    A
    0
    AY
    X
    Opt
    = A
    0
    AX
    AY
    ME317 dfM at Stanford
    2006 K. Ishii
    X Y Delta A
    1.00 8.00 1.72
    2.00 4.00 1.02
    3.00 2.67 0.85
    4.00 2.00 0.82
    5.00 1.60 0.84
    6.00 1.33 0.89
    7.00 1.14 0.95
    8.00 1.00 1.02
    9.00 0.89 1.10
    10.00 0.80 1.18
    11.00 0.73 1.27
    12.00 0.67 1.35
    13.00 0.62 1.44
    14.00 0.57 1.53
    15.00 0.53 1.63
    16.00 0.50 1.72
    An Example Cookie
    A0 = 8; Ax = 0.2; Ay = 0.1
    2
    4
    X
    Opt
    = A
    0
    AX
    AY
    = 8
    0.2
    0.1
    = 4.0
    ME317 dfM at Stanford
    2006 K. Ishii
    0.00
    0.20
    0.40
    0.60
    0.80
    1.00
    1.20
    1.40
    1.60
    1.80
    1
    .
    0
    0
    2
    .
    0
    0
    3
    .
    0
    0
    4
    .
    0
    0
    5
    .
    0
    0
    6
    .
    0
    0
    7
    .
    0
    0
    8
    .
    0
    0
    9
    .
    0
    0
    1
    0
    .
    0
    0
    1
    1
    .
    0
    0
    1
    2
    .
    0
    0
    1
    3
    .
    0
    0
    1
    4
    .
    0
    0
    1
    5
    .
    0
    0
    1
    6
    .
    0
    0
    How about Numerical Optimization
    Use simulation and optimization methods
    2
    4
    ME317 dfM at Stanford
    2006 K. Ishii
    Force Sensor Example
    Closed Form Approach
    Define a cost function = variation in K
    VERY IMPORTANT STEP
    (
    (

    |
    .
    |

    \
    |
    c
    c
    +
    |
    .
    |

    \
    |
    c
    c
    +
    |
    .
    |

    \
    |
    c
    c
    =
    2
    2
    2
    2
    2
    2
    2
    L
    K
    b
    K
    h
    K
    S S S
    V
    L b h
    Monotonicity Analysis of V
    Determines L
    Use expression for target K and relate b and h
    Expression of V on one variable, b of h
    Set dV/dh = 0 or dV/dh = 0 and find the optimum
    ME317 dfM at Stanford
    2006 K. Ishii
    Robust Design of Helical Gears
    Using Computational Models
    Objectives
    Minimize transmission error
    Indication of noise and vibration
    Use gear profile modification
    Design variables in profile modification
    TIP
    ROOT
    START
    ROLL
    ANGLE
    AMT. OF
    RELIEF
    Performance Contour Plots
    of Transmission Error
    Peak to Peak Transmission Error
    Weighted Objective Function
    F(X, |) =
    y
    +| o
    y
    ME317 dfM at Stanford
    2006 K. Ishii
    Variations (Simulated with DoE matrix*)
    0.00015 in tip relief
    1.5 degrees in roll angle
    Shaft misalignment of 0.0005
    Torque variations of 25%
    *L8 is one type of DoE matrix, to be explained in next lecture
    P
    P
    T
    E

    i
    n

    m
    i
    c
    r
    o

    i
    n
    c
    h
    e
    s
    0
    15
    30
    45
    Peak Statistical
    Worst of L8
    Target
    Helical Gear Example

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