Optimal Tolerance Allocation in a Complex Assembly Using Evolutionary Algorithms

Tolerance design is a vital factor which influences product and process development. Further, it determines the manufacturing cost, the functionality and quality of a product. It is evident that optimal tolerance normally leads to produce ample parts, better operation of mechanical systems and excellent assembling. In contrast, tight tolerance leads to increase in manufacturing cost for an assembly. An ideal relationship exists among production cost and operation, while determining the optimum tolerance. Based on this relation a new approach by implementing the Non-traditional techniques: Genetic Algorithm (GA), Elitist Non-dominated Sorting Genetic Algorithm (NSGA-II) and Differential Evolution (DE) for determining the optimum tolerance, zero percentage rejection and manufacturing cost considering the varying quality loss constants for an assembly namely overrunning clutch assembly, is discussed in this paper. From the result obtained, it is evident that, the proposed approach is best suitable for solving problems involving complex assemblies. (Received in May 2015, accepted in September 2015. This paper was with the authors 1 month for 1 revision.)