scholarly journals Investigation of the fake reject cases with unqualified operational dimension based on the error compensation and tolerance compression

Author(s):  
Xiaosan Ma ◽  
Feng Jiao ◽  
Wenhui Feng ◽  
Wenbo Bie ◽  
Fan Chen

A fake reject (FR) with unqualified operational dimension often occurs during part machining when the operational data do not coincide with the design ones. This may lead to unnecessary waste. A novel judgment and remedial measures for FR are investigated in this paper to enhance products' qualification rate. Firstly, the reasons for the FR occurrence are discussed based on the fact that the operational dimension tolerance calculated using the worst-case method of the process dimension chain calculation is too tight. Secondly, a novel judgment method of FR is proposed by calculating a new dimension chain. The operational dimension is treated as the concluding link. The actual deviations of the dimensions generated before the operational dimension generation are used to replace their upper and lower deviations. Finally, based on the error compensation relationship among the component links in the process dimension chain, a novel remedial measure of FR by compressing dimension tolerance in subsequent processing is proposed. The calculation flow of the dimension tolerance after tolerance compression is worked out. This study's results of this study are considered for instrumental in judging and processing FR in part machining.

Author(s):  
Hua Wang ◽  
Jialei Zhang ◽  
Junyang Yu

Abstract Pneumatic percussive riveting is an important way to join the sheet metals. In order to ensure the load transfer and the fatigue performance of riveted joint, the interference of the rivet/hole is strictly specified. The interference of the rivet/hole is highly correlated with the process capability of the pneumatic hammer and the diameter of the pre-hole. It is a critical step to choose the appropriate pneumatic hammer to ensure the interference requirements. Energy per blow of the pneumatic hammer is a proclaimed parameter from the riveting hammer manufacturer. It is difficult for the designer to choose the riveting hammer in practical riveting scheme based on energy per blow. Tolerance analysis is an efficient way to model the manufacturing variation and implement process control. This paper presents the tolerance allocation of the pneumatic percussive riveting based on the process capability of the pneumatic hammer. In order to obtain the designed interferences of the rivet/hole, a tolerance chain is built with the process capability of the pneumatic hammer, the diameter of the pre-hole and the diameter of the rivet shank. The process capability of the pneumatic hammer is represented with the interferences of the rivet/hole after riveting. It is an intuitive parameter for the designer to choose the riveting hammer in practical riveting scheme. The process capability of the pneumatic hammer is obtained from the designed riveting experiments with the pneumatic percussive riveting platform. The diameter of the pre-hole affects the interference of the rivet/hole also. The tolerance for manual hole-drilling should be determined to assure the interference requirements and high drilling operation efficiency simultaneously. The variation of the pre-hole is obtained from the manual drilling experiments and diameter measurements. Different hole-drilling results in different mating conditions between the pre-hole and the rivet. The fit conditions of different pre-holes are modeled and the final interferences after riveting are analyzed. Worst case method and statistical analysis method are two common methods for tolerance analysis. For the manual hole-drilling and the pneumatic percussive riveting, worst case method is employed to analyze the constructed tolerance chain in order to accomplish the interferences of the rivet/hole. The different analyzed dimensions, rivet-hole clearances and pre-hole drilling variation, are investigated respectively. The reported work enhances the understanding of the tolerance allocation for the pneumatic percussive riveting. The interference based process capability of the pneumatic hammer provides good reference for pneumatic hammer choosing in riveting scheme. The reported tolerance chain of the interference could be used for the tolerance determination of manual hole-drilling with good quality and high efficiency.


2020 ◽  
Vol 14 (3) ◽  
pp. 265-272
Author(s):  
Živko Kondić ◽  
Đuro Tunjić ◽  
Leon Maglić ◽  
Amalija Horvatić Novak

The determination of tolerances has a huge impact on the price and quality of products. The objective of tolerance analysis is to provide the widest possible tolerance range of parts, without disturbing the functionality of the assembly. Tolerance analysis should be performed during the design process because then there is still the possibility for change. For the purpose of carrying out the analysis, three methods will be used: Worst Case method, Root Sum Square method and Monte Carlo Simulation. Methods are explained through simple examples and applied on the one-way clutch.


1984 ◽  
Vol 61 (9) ◽  
pp. 780 ◽  
Author(s):  
Roy Gordon ◽  
Miles Pickering ◽  
Denise Bisson

2021 ◽  
Author(s):  
Shahad M. Al-Ward

One of the main challenges to treatment of lung cancer with radiation therapy is the tumor motion due to respiration. Previously, a novel approach was developed to generate treatment plans which compensate for respiratory motion and its variations. The worst case method is based on combining two intensity maps from two 4D plans optimized on the two worst cases of motion variations. The worst case planning method was previously tested on simulated motion variations. The goal of this project was to further test the worst case approach on realistic patient motion variations and treatment planning data. Two approaches to combining worst case plans were investigated: the first method takes the average of the two intensity maps, and the second method takes the maximum intensity of the two intensity maps. The robustness of worst case plans was compared with ITV plans and nominal 4D plans on three different motion variation scenarios. Study 1 and 2 investigated the robustness of the worst case methods on amplitude variations and patient motion variations on simulated image data. Study 3 investigated the robustness of the worst case methods on patient motion variations using real patient image data. The average intensity worst case method was only robust to Study 3 motion variations. The maximum intensity worst case method, the margin based, and the nominal approaches were not robust to any of the motion variations. Further evaluation over a wide range of tumour sizes, motion amplitudes and variability is required to determine the clinical applicability of the worst case planning method.


2021 ◽  
Author(s):  
Shahad M. Al-Ward

One of the main challenges to treatment of lung cancer with radiation therapy is the tumor motion due to respiration. Previously, a novel approach was developed to generate treatment plans which compensate for respiratory motion and its variations. The worst case method is based on combining two intensity maps from two 4D plans optimized on the two worst cases of motion variations. The worst case planning method was previously tested on simulated motion variations. The goal of this project was to further test the worst case approach on realistic patient motion variations and treatment planning data. Two approaches to combining worst case plans were investigated: the first method takes the average of the two intensity maps, and the second method takes the maximum intensity of the two intensity maps. The robustness of worst case plans was compared with ITV plans and nominal 4D plans on three different motion variation scenarios. Study 1 and 2 investigated the robustness of the worst case methods on amplitude variations and patient motion variations on simulated image data. Study 3 investigated the robustness of the worst case methods on patient motion variations using real patient image data. The average intensity worst case method was only robust to Study 3 motion variations. The maximum intensity worst case method, the margin based, and the nominal approaches were not robust to any of the motion variations. Further evaluation over a wide range of tumour sizes, motion amplitudes and variability is required to determine the clinical applicability of the worst case planning method.


2013 ◽  
Vol 13 (16) ◽  
pp. 3330-3334
Author(s):  
Gao Yin-Han ◽  
Wang Tian-Hao ◽  
Yang Kai-Yu ◽  
Zhang Jun-Dong ◽  
Song Yu-He ◽  
...  

Author(s):  
Henry Cathcart ◽  
Christopher Meyer ◽  
Mark Joyce ◽  
Richard Green

Abstract Modern industrial gas turbines (IGTs) must be capable of operational flexibility to fulfil the requirements of an evolving power industry. Base load applications require turbines to operate for long periods at full load conditions whilst load-following applications require turbines to undergo repeated start-stop cycles. Traditional design and lifing approaches, which are based around an assumed worst case operational scenario and critical damage mechanism, cannot fully represent the durability of components when exposed to flexible operation. Condition based assessments, conversely, consider multiple operating scenarios and damage mechanisms to more accurately predict the durability of components. Condition based assessments are particularly powerful when applied to digital assets, where component lives can be calculated for each individual turbine based on detailed operational data. Despite the additional data available to conduct assessments of a digital asset, the information about the asset’s manufacture, maintenance or environment is unlikely to be complete or perfect. This leads to uncertainty in the current and future condition of the asset, which must be accounted for when deciding upon maintenance, retirement or life extension. The uncertainty can be accounted for using bounding assumptions or safety factors, but these approaches often lead to overly conservative results and do not provide any insight into the underlying causes of the uncertainty. Probabilistic methodologies provide a means to accurately evaluate and interrogate this uncertainty, by explicitly considering the potential variation in calculation inputs and assumptions. The degradation of hot gas path components by creep-fatigue mechanisms often limits turbine life. Probabilistic creep-fatigue assessment methods have been developed and are used to predict and understand the uncertainty in creep-fatigue damage. However, deploying these methods across a large fleet of digital assets, each with multiple components presents several challenges: the assessments rely on Monte Carlo sampling or other discretised calculations and hence are too computationally intensive to be used in real time on a large fleet; assets have often not been digitized for their entire operating lives, hence periods of missing data must be accounted for; finally, predicting the uncertainty of future operation requires information about the likely distribution of future operating regimes. This paper presents a methodology to effectively calculate the uncertainty on hot gas path component creep-fatigue assessments across a large fleet of IGTs. The methodology divides operational periods into two categories. In the first category a full suite of operational data is available. Damage is modelled using an emulator of a full Monte Carlo assessment. The emulator accounts for the fact that different operational profiles may result in different degradation uncertainty, and that the mode of operation of an asset may change throughout its life. In the second category no information is available. This category covers both future operation and historical operation prior to the instrumentation of the asset. These periods are modelled by considering fleet-wide statistics of degradation and the pathdependency of creep-fatigue damage progression. The predictions for both categories of operation are integrated into a system that can predict distributions of the damage accumulated within a turbine component and the future progression of this damage.


Energies ◽  
2020 ◽  
Vol 13 (18) ◽  
pp. 4920
Author(s):  
Florian Schäfer ◽  
Martin Braun

Integrating active power curtailment (APC) of renewable energy sources (RES) in power system planning reduces necessary investments in the power system infrastructure. In current target grid planning methods, APC is considered by fixed curtailment factors without considering the provided flexibility to its full extent. Time-series-based planning methods allow the integration of the time dependency of RES and loads in power system planning, leading to substantial cost savings compared to the worst-case method. In this paper, we present a multi-year planning strategy for high-voltage power system planning, considering APC as an alternative investment option to conventional planning measures. A decomposed approach is chosen to consider APC and conventional measures in a long-term planning horizon of several years. The optimal investment path is obtained with the discounted cash flow method. A case study is conducted for the SimBench high-voltage urban benchmark system. Results show that the time-series-based method allows for reducing investments by up to 84% in comparison to the worst-case method. Furthermore, a sensitivity analysis shows the variation in total expenditures with changing cost assumptions.


2021 ◽  
Author(s):  
◽  
James Irvine

<p>The poor performance of residential foundations in past earthquakes, prompted a practical investigation to quantify the adequacy of Wellington timber dwellings’ foundations, including the sub-floor bracing, sub-floor fixings and general condition of the foundation. The adequacy of a sample of 80 dwellings’ foundations was assessed against the current “Light Timber Framed Construction Standard” NZS3604:1999. The NZS3604 standard was introduced in 1978 and has been subsequently tested by many New Zealand earthquakes, most significantly being the Edgecumbe earthquake in 1987. The observed damage to dwellings built to the then current NZS3604:1984, showed only negligible damage due to foundation inadequacies and as a result, the standard required only minor amendments. The most current 1999 edition of NZS3604 is therefore considered to have seismically appropriate detailing and provisions to withstand design earthquakes; so for the purposes of this study, NZS3604:1999 is assumed to be the residential benchmark for seismic adequacy. The results from the study suggest that 39% of the sample had inadequate sub-floor bracing. Overall, 16% of the sample relied solely on the strength of ordinary piles, while 11% relied entirely on large concrete anchors. 76% of dwellings had some form of fixing deficiency, ranging from degradation to incorrect or non-existent fixings. The overall condition of the sample dwellings was compared with the House Condition Survey 2005. The results of this study showed that inadequacies identified in the House Condition Survey 2005, were also prevalent in the majority of sampled dwellings in the study, including non compliance with minimum height and sub-floor ventilation requirements. However, the House Condition Survey produced by BRANZ does not assess any rented accommodations and so the condition results may be underestimated. The study sample, however includes a proportion of rented dwellings, but may still be unrepresentative of the actual average dwelling, in terms of condition and range. After identifying the common deficiencies both in the sample and also from similar studies, remedial measures were costed and applied to different foundation types based on the required strength and suitability to the existing foundation system. The remedies, to upgrade bracing, fixings and the general condition, including labour, ranged between $15 per m² and $60 per m². These costs were then projected to all Wellington City foundations, which totalled over $250 Million. It was assumed that each dwelling should be remedied to comply with the standards in NZS3604:1999 and the remedies were applied based on the average condition of the sample. To understand the anticipated losses and therefore benefits of upgrading, the estimated damage cost to residential dwellings was calculated using an Earthquake Loss Modeller, which was supplied by the Institute of Geological and Nuclear Sciences. The cost was calculated by assuming an earthquake of Magnitude 7.5, at a depth of 7.5km centred on the Wellington fault line, around Kaiwharawhara. In order to formulate a cost saving, or economic benefit from upgrading foundations, the cost of specific damage and collapse to residential dwellings was calculated to be $2.1 Billion, assuming no remedial measures had been applied. The Mean Damage Ratio for each foundation type was then modified, based on similar earthquake damage projections based on the same Wellington earthquake scenario. Dwellings that had either significant configuration issues or were located in an area likely to experience higher earthquake shaking, were still anticipated to collapse despite applying sub-floor remedies. The cost of damage to dwellings following remedial measures was calculated at just over $1.1 Billion. Therefore, the total savings were anticipated to be around $950 Million. These results were considered as a ratio of cost over benefit which is used to understand whether the associated economic benefit is greater than the anticipated cost of remedy. The cost / benefit ratio for dwellings likely to collapse is less than 10% , while extensively damaged dwellings have a higher cost / benefit ratio of around 25%. The highest benefit was seen in Piled dwellings, where savings upwards of $500 Million were projected. The economic saving due to the application of remedial measures has the potential to reduce pressure on the public sector including emergency management systems, hospitals and organisations involved with evacuations and erection of temporary shelters. In addition, there will also be a saving for both the public and private insurers, which will facilitate the quicker reconstruction of the postearthquake society to pre-earthquake levels. For the results of this study to be beneficial to New Zealanders, the information must be disseminated and implemented using proactive initiatives. These must be targeted at the homeowner in an easily understandable format, which is focussed on better performance and savings, rather than on the worst case scenario which has been shown to increase ambivalence and fatalistic mindsets within society.</p>


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