An integrated hybrid approach for assembly tolerance transfer and allocation

Purpose This study aims to develop an optimal tolerance allocation strategy involves integrating the unique transfer (UT) approach and the difficulty coefficient evaluation (DCE) routine in an interactive hybrid method. This method combines the strengths of both UT and DCE, ensuring simultaneous utilization for enhanced performance. The proposed tolerancing model manifests an integrated computer-aided design (CAD) tool. Design/methodology/approach By combining UT and DCE based on failure mode, effects and criticality analysis (FMECA) tool and the Ishikawa diagram, the proposed collaborative hybrid tool ensures an efficient and optimal tolerance allocation approach. The integration of these methodologies not only addresses specific transfer challenges through UT but also conducts a thorough evaluation of difficulty coefficients via DCE routine using reliability analysis tools as FMECA tool and the Ishikawa diagram. This comprehensive framework contributes to a robust and informed decision-making process in tolerance allocation, ultimately optimizing the design and manufacturing processes. Findings The presented methodology is implemented with the aim of generating allocated tolerances that align with specific difficulty requirements, facilitating the creation of a mechanical assembly characterized by high quality and low cost. To substantiate and validate the conceptual framework and methods, an integrated tool has been developed, featuring a graphical user interface (GUI) designed in MATLAB. This interface serves as a platform to showcase various interactive and integrated tolerance allocation approaches that adhere to both functional and manufacturing prerequisites. The proposed integrated tool, designed with a GUI in MATLAB, offers the capability to execute various examples that effectively demonstrate the benefits of the developed tolerance transfer and allocation methodology. Originality/value The originality of the proposed approach is the twining between the UT and DCE simultaneous in an integrated and concurrent tolerance transfer and allocation model. Therefore, the proposed approach is named an integrated CAD/tolerance model based on the manufacturing difficulty tool. The obtained results underscore the tangible advantages stemming from the integration of this innovative tolerance transfer and allocation approach. These benefits include a notable reduction in total cost and a concurrent enhancement in product quality.