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Kevin N. Otto. Painter, Christopher D. (Christopher Donald), 1972- Massachusetts Institute of Technology. Department of Mechanical Engineering 2005-08-19T18:48:28Z 2005-08-19T18:48:28Z 1998 1998 http://hdl.handle.net/1721.1/9596 42192354 Thesis (S.M.)--Massachusetts Institute of Technology, Dept. of Mechanical Engineering, 1998. Includes bibliographical references (leaves 73-75). Variation reduction techniques are developed which explore an entire system for improved quality, rather than a single manufacturing operation. This system-level modeling approach is explored with an example of a complex assembly of aluminum extrusions and castings welded into a structural frame. By making use of modeling techniques such as Finite Element Analysis (FEA) and Design of Experiments (DOE), it can be shown how this method can also be applied to systems that include complex processes such as welding. Modeling the entire system of manufacturing operations allows key sources of variation and difficult output quality characteristics to be identified. In addition, intermediate tolerances can be determined in relation to the final required output tolerances. Determining intermediate tolerances is a two step process. First, a system of block diagrams are created to clearly outline ho-v1· variation propagates forward through the system. These block diagram representations are linearized models that map the transformations between the input variations and the output variations of a particular manufacturing operation. Secondly, using the combined transformation matrix of the system, intermediate tolerances, at a particular manufacturing operation can be determined by back-propagating final output tolerances. This provides a means by which design tolerances on the final product can be used in determining the allowable tolerances on Work-In-Progress (WIP) at intermediate manufacturing processes. by Christopher D. Painter. S.M. 83 leaves 5429581 bytes 5429339 bytes application/pdf application/pdf eng Massachusetts Institute of Technology M.I.T. theses are protected by copyright. They may be viewed from this source for any purpose, but reproduction or distribution in any format is prohibited without written permission. See provided URL for inquiries about permission. http://dspace.mit.edu/handle/1721.1/7582 Mechanical Engineering System variation analysis of MIG welded aluminum structural frames Thesis application/pdf Publication unknown unknown <Publication xmlns="https://www.openaire.eu/cerif-profile/1.1/" id="6af61fb5-276b-44f6-aeb8-4c505e64072c"> <Type xmlns="https://www.openaire.eu/cerif-profile/vocab/COAR_Publication_Types">http://purl.org/coar/resource_type/c_1843</Type> <Language>eng</Language> <Title>System variation analysis of MIG welded aluminum structural frames</Title> <PublishedIn> <Publication> </Publication> </PublishedIn> <PublicationDate>1998</PublicationDate> <Authors> <Author> <DisplayName>Painter, Christopher D. (Christopher Donald), 1972-</DisplayName> <Affiliation> <OrgUnit> </OrgUnit> </Affiliation> </Author> </Authors> <Editors> </Editors> <Publishers> <Publisher> <DisplayName>Massachusetts Institute of Technology</DisplayName> <OrgUnit /> </Publisher> </Publishers> <License>http://dspace.mit.edu/handle/1721.1/7582</License> <Keyword>Mechanical Engineering</Keyword> <Abstract>Variation reduction techniques are developed which explore an entire system for improved quality, rather than a single manufacturing operation. This system-level modeling approach is explored with an example of a complex assembly of aluminum extrusions and castings welded into a structural frame. By making use of modeling techniques such as Finite Element Analysis (FEA) and Design of Experiments (DOE), it can be shown how this method can also be applied to systems that include complex processes such as welding. Modeling the entire system of manufacturing operations allows key sources of variation and difficult output quality characteristics to be identified. In addition, intermediate tolerances can be determined in relation to the final required output tolerances. Determining intermediate tolerances is a two step process. First, a system of block diagrams are created to clearly outline ho-v1· variation propagates forward through the system. These block diagram representations are linearized models that map the transformations between the input variations and the output variations of a particular manufacturing operation. Secondly, using the combined transformation matrix of the system, intermediate tolerances, at a particular manufacturing operation can be determined by back-propagating final output tolerances. This provides a means by which design tolerances on the final product can be used in determining the allowable tolerances on Work-In-Progress (WIP) at intermediate manufacturing processes.</Abstract> <Access xmlns="http://purl.org/coar/access_right" > </Access> </Publication>