This paper introduces and formalizes a method for specifying independent functional tolerances in an optimal least-cost manner. Previous methods have been thwarted by formulation and computational difficulties presented by nontrivial designs. This method is versatile, submits to a diversity of mechanical problems, and relates the production process and cost to process tolerance in the optimization. This tolerance-specification scheme follows Balas’ zero-one algorithm. Generality and efficiency of the method are discussed. Effects of tolerance relaxation on costs are given. Small and large design problems, constructed to satisfy the requirements of the algorithm, show the practical ramifications. The problem is treated with limit, sensitivity, and probability analysis. Widespread adoption of the method throughout industry is encouraged.
A process called dynamic chip-breaking introduces a controlled low frequency vibration in the direction of the feed travel of a lathe tool. This superimposed vibration is given an amplitude such that continuous ductile chips are broken prematurely by the action of the tool. The dynamic chip-breaking process can be adjusted to give optimum values for the quality of the surface topography and free chip length. This exploratory study investigates the prospects of breaking chips from ductile materials by methods other than the conventional chip-curling type of breaker. Rational and empirical results are given which provide encouragement for additional development.
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