This paper describes a procedure for optimizing the allocation of tolerances considering manufacturing cost and product quality in a constrained optimization process. The procedure can utilize various existing models for relating manufacturing costs to part tolerances. It also includes a relationship between part tolerances and assembly tolerance to provide a quantitative measure of product quality using the Taguchi concept of quality loss. The two cost relationships are combined in a formulation which is convenient for solving the optimal tolerance allocation problem by nonlinear programming methods. Numerical optimization can then be directly applied to balance manufacturing cost and product quality allowing trade-offs to be explored.
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