What you'll learn
Worst-Case approach
Statistical approach (RSS)
Six-Sigma approach
Create the loop for tolerance analysis in 2D
Estimate the quality level of the assembly
Estimate the expected Defects Per Million of Opportunities (DPMO)
Inflation factors for non-normal distributions (Ci)
Process capablity index (Cp) from manufacturing
Dynamic shift (k) for loss of performance over time
Understand trade-offs for tolerance analysis
Customer requirements (LSL, USL)
Requirements
We start from the basics, but some fundamentals of statistics are recommended
Description
Stack up and Tolerance Design is all about quality, or in other words, the allowable parts to be rejected during the process. In escence, this results in an iterative process between the design department, manufacturing and the customer. In this course you will learn all this concepts to master tolerance stack ups in 2D. At then end, you will become a valuable member for your company because you will be capable to assess assemblies and propose changes to meet critical requirements. Although currently there are several software which run complex tolerance analysis in 3D, in my experience, most of the times you can simplify the problem with a 2D analysis, so as mechanical designer YOU MUST be capable of performing 2D analysis in order to save valuable resources to the company.First, you will learn the basics: The definition of nominal value, tolerance, standard deviation, normal distribution and the importance of tolerance analysis in mechanical design. Then. you will learn how to create the sketch (loop) to follow in the calculation of tolerance analysis. Several exercises will be provided so you can practice this process.Next you will Learn how to perform a linear stack ups with three approaches: Worst Case: When no rejections are allowed. This apporach results in the most expensive, but it is used in critical applications.Statistical: Some rejections are allowed. The costs are reduced because some defects will always be presented.Six-Sigma: Complex considerations such as process distributions, process caapability and loss of performance are taken into account to improve the design at different quality levels. Finally, for each approach I will provide you five assemblies with different requirements. You will need to apply the concepts to find the suitable design which meet the quality levels and solve the critical clearances. A template in excel will allow you to perform these calculations.This course is based in my own experience as designer in the aerospace industry for 10 years. I used this methods everyday to discuss initial changes with customer, find a suitable provider and reduce costs with manufacturing.
Overview
Section 1: Introducción
Lecture 1 Intro
Lecture 2 What is tolerance analysis (Stack up)?
Lecture 3 Fundamentals & definitions
Lecture 4 Standard deviation
Lecture 5 Dimensioning methods
Lecture 6 Steps to perform a tolerance analysis
Lecture 7 Example of sketch creation
Section 2: Sketch creation
Lecture 8 Instructions for the following homeworks
Section 3: Worse-Case approach (WC)
Lecture 9 What is the Worst-Case approach?
Lecture 10 Mathematical definition of WC
Lecture 11 Example WC
Lecture 12 Template in excel for WC
Lecture 13 Practice problems WC (watch before the following videos)
Lecture 14 Solution: Assembly I
Lecture 15 Solution: Assembly II
Lecture 16 Solution: Assembly III
Lecture 17 Solution: Assembly IV
Lecture 18 Solution: Assembly V
Section 4: Root Sum Square approach (RSS)
Lecture 19 What is RSS approach?
Lecture 20 Mathematical definition of RSS
Lecture 21 Example RSS
Lecture 22 Template in Excel for RSS
Lecture 23 Practice problems RSS (watch before the following videos)
Lecture 24 Solution: Assembly I
Lecture 25 Solution: Assembly III
Lecture 26 Solution: Assembly IV
Lecture 27 Solution: Assembly V
Section 5: Six-Sigma approach
Lecture 28 What is Six-Sigma approach?
Lecture 29 Mathematical definition for mixed distributions
Lecture 30 Example using mixed distributions
Lecture 31 Mathematical definition for process capability
Lecture 32 Example using process capability
Lecture 33 Mathematical definition for dynamic shift
Lecture 34 Example using dynamic shif
Lecture 35 General equation for tolerance analysis
Lecture 36 Template in Excel for Six-Sigma approach
Lecture 37 Practice problems Six-Sigma (watch before the following videos)
Lecture 38 Solution: Assembly I
Lecture 39 Solution: Assembly III
Lecture 40 Solution: Assembly IV
Lecture 41 Solution: Assembly V
Mechanical designers (entry level),Mechanical engineers,Students of mechanical engineering


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