Abstract
Identification of the optimal production sequence and allocation of machining tolerance are important activities in process planning for reducing production cost. This paper presents an approach that is capable of determining the optimal production sequence and its optimal process tolerance to achieve the minimum production costs. A new mathematical model, representing the cost–tolerance relationships and showing significant accuracy improvement over existing models, is introduced to allocate process tolerance. Stock allowance constraints on the selected switching tolerance are also considered to yield practical solutions. A prototype system for hole-making components is used to verify and evaluate the effectiveness of the new approach.
Similar content being viewed by others
References
Chang, T. C. (1990) Expert Process Planning for Manufacturing, Addison-Wesley Publishing Company.
Chase, K. W., Greenwood, W. H., Loosli, B. G. and Hauglund, L. F. (1990) Least cost tolerance allocation for mechanical assembles with automated process selection. Manufacturing Review, 3(1), 49–59.
Dieter, G. E. (1983) Engineering Design: a Materials and Processing Approach, McGraw-Hill, New York.
Dong, Z. and Hu, W. (1991) Optimal process sequence identification and optimal process tolerance assignment in computer-aided process planning. Computers in Industry, 17, 19–32.
Dong, Z. and Soom, A. (1990) Automatic optimal tolerance design for related dimension chains. Manufacturing Review, 3(4), 262-271.
Dong, Z., Hu, W. and Xue, D. (1994) New production cost-tolerance models for tolerance synthesis. Journal of Engineering, Industry, 116, 199–206.
Gerald, C. F. and Wheatley, P. O. (1994) Applied Numerical Analysis, Addison-Wesley Publishing Company.
James, M. L., Smith, G. M. and Wolford, J. C. (1993) Applied Numerical Methods for Digital Computations, Harper Collins College.
Lee, W. J. and Woo, T. C. (1989) Optimum selection of discrete tolerances. Transactions of the ASME, Journal of Mechanical Design, 111, 243–251.
Mathews, J. H. (1992) Numerical Methods for Mathematics, Science, and Engineering, Prentice Hall.
Michael, W. and Siddall, J. N. (1981) Optimization problem with tolerance assignment and full acceptance. Journal of Mechanical Design, 103, 842–848.
Nunhez, J. R., Mori, M. and D'avila, S. G. (1993) Fitting thermodynamic data using the modified spline technique. Computers in Chemical Engineering, 17(11), 1091–1099.
Sfantsikopoulos, M. M. (1990) A cost-tolerance analytical approach for design and manufacturing. The International Journal of Advanced Manufacturing Technology, 5, 126134.
Speckhart, F. H. (1972) Calculation of tolerance based on a minimum cost approach. Journal of Engineering for Industry, 94(2), 447–453.
Spotts, M. F. (1973) Allocation of tolerances to minimize cost of assembly. Journal of Engineering for Industry, 95(3), 762–764.
Sutherland, G. H. and Roth, B. (1975) Mechanism design: accounting for manufacturing tolerances and costs in function generating problems. Journal of Engineering for Industry, 98, 283–286.
Thompson, W. J. (1992) Computing for Scientists and Engineers, Wiley.
Trucks, H. E. (1976) Design for Economical Production, SME, Dearborn, MI.
Wu, Z., Elmaraghy, W. H. and Elmaraghy, H. A. (1988) Evaluation of cost-tolerance algorithms for design tolerance analysis and synthesis. Manufacturing Review, 1(3), 168–179.
Xue, D. and Dong, Z. (1993) Automated concurrent design based on combined feature, tolerance, production process and cost model. Advances in Design Automation, 2, 199–210.
Zhang, C. and Wang, H. B. (1993) Optimal process sequence selection and manufacturing tolerance allocations. Journal of Design and Manufacturing, 6, 135–146.
Author information
Authors and Affiliations
Rights and permissions
About this article
Cite this article
Yeo, S.H., Ngoi, B.K.A. & Chen, H. Process sequence optimization based on a new cost–tolerance model. Journal of Intelligent Manufacturing 9, 29–37 (1998). https://doi.org/10.1023/A:1008895224256
Issue Date:
DOI: https://doi.org/10.1023/A:1008895224256