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Tolerance analysis based on Monte Carlo simulation: a case of an automotive water pump design optimization

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Abstract

Successful products are those presenting the highest quality at a fair cost. Although different approaches can be used to define the concept of quality, functional reliability is always a major requirement, due to implications such as safety and user losses regarding maintenance expenses, and product availability. Intelligent designs are robust and result in a fair cost. Robust designs are those insensitive to sources of variation occurring during the product life, keeping their performance under variable use conditions, like thermal and stress effects. The robustness approach is a function of two main design criteria: low complexity and tolerance design. Design for manufacture and assembly is closely related to decreasing complexity. Tolerance design is a tool in which the unavoidable manufacturing variations are considered during product development. This work presents a proposal for an intelligent design in an actual application by considering design simplification through the reduction of parts for an automotive water pump. The tolerance analysis is performed by means of a powerful statistical approach—a Monte Carlo simulation—in which process behavior is randomly simulated representing a high production volume. Additionally, service thermal effects are also contemplated, and assembly tests are proposed for automatic rejection of non-conforming parts, assuring high reliability and full compliance with functional requirements. This is an example of integrated design–manufacturing work aiming at both cost saving and improved reliability.

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Authors and Affiliations

  1. Computational Geometry Laboratory, Department of Mechatronics and Mechanical Systems Engineering, Escola Politécnica da Universidade de São Paulo, Av. Prof. Mello Moraes, 2231, São Paulo, SP, Brazil

    Eduardo Umaras & Marcos Sales Guerra Tsuzuki

  2. Faculty of Engineering and Applied Science, University of Ontario Institute of Technology (Ontario Tech), Oshawa, ON, Canada

    Ahmad Barari & Marcos Sales Guerra Tsuzuki

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  1. Eduardo Umaras
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  2. Ahmad Barari
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  3. Marcos Sales Guerra Tsuzuki
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Correspondence to Marcos Sales Guerra Tsuzuki.

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Umaras, E., Barari, A. & Tsuzuki, M.S.G. Tolerance analysis based on Monte Carlo simulation: a case of an automotive water pump design optimization. J Intell Manuf 32, 1883–1897 (2021). https://doi.org/10.1007/s10845-020-01695-7

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  • DOI: https://doi.org/10.1007/s10845-020-01695-7

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