Robust Design Methodology for Reliability

Bo Bergman has held the post of SKF professor at the Department of Quality Sciences at Chalmers University of Technology, Sweden since 1999. From 1983 to 1999 he was Professor of Quality Technology and Management at Linköping University, where he was responsible for the creation of education and research in the quality field, and previous to this he held varying engineering and managerial positions in the fields of reliability, quality and statistics at Saab Aerospace. His research interests cover wide areas of quality of both a quantitative and a qualitative nature. He has authored more than 50 papers in international scientific journals and has authored and co-authored a number of books — including new, completely revised English versions of Quality from Customer Needs to Customer Satisfaction and Six Sigma; the Pragmatic Approach. Jacques Demaré has held the post of Professor of Mathematical Statistics at Chalmers University of Technology since 1999. The focus of his work has been on both chemical and mechanical applications and he is currently working with statistical methods for material fatigue in co-operation with the Swedish National Testing and Research Institute. At Chalmers he has also worked in different ways to bring the mathematical and engineering disciplines closer together. Thomas Svensson is a research engineer at the Technical Research Institute of Sweden (SP). He obtained his PhD in Fatigue Life Prediction in Service — A Statistical Approach in 1996, and is a member of the editorial board of Fatigue and Fracture of Engineering Materials and Structures.

Preface Acknowledgements

About the Editors

Contributors

PART One METHODOLOGY

1 Introduction

Bo Bergman and Martin Arvidsson

1.1 Background

1.2 Failure Mode Avoidance

1.3 Robust Design

1.4 Comments and Suggestions for Further Reading

References

2 Evolution of Reliability Thinking – Countermeasures for Some Technical Issues

Åke Lönnqvist

2.1 Introduction

2.2 Method

2.3 An Overview of the Initial Development of Reliability Engineering

2.4 Examples of Technical Issues and Reliability Countermeasures

2.5 Discussion and Future Research

2.6 Summary and Conclusions

References

3 Principles of Robust Design Methodology

Martin Arvidsson and Ida Gremyr

3.1 Introduction

3.2 Method

3.3 Results and Analysis

3.4 Discussion

3.5 Conclusions

References

PART Two METHODS

4 Including Noise Factors in Design Failure Mode and Effect Analysis (D-FMEA) – A

Case Study at Volvo Car Corporation

Åke Lönnqvist

4.1 Introduction

4.2 Background

4.3 Method

4.4 Result

4.5 Discussion and Further Research

4.6 Summary

References

5 Robust Product Development Using Variation Mode and Effect Analysis

Alexander Chakhunashvili, Stefano Barone, Per Johansson and Bo Bergman

5.1 Introduction

5.2 Overview of the VMEA Method

5.3 The Basic VMEA

5.4 The Enhanced VMEA

5.5 The Probabilistic VMEA

5.6 An Illustrative Example

5.7 Discussion and Concluding Remarks

Appendix: Formal Justification of the VMEA Method

References

6 Variation Mode and Effect Analysis: An Application to Fatigue Life Prediction

Pär Johannesson, Thomas Svensson, Leif Samuelsson, Bo Bergman and Jacques de Maré

6.1 Introduction

6.2 Scatter and Uncertainty

6.3 A Simple Approach to Probabilistic VMEA

6.4 Estimation of Prediction Uncertainty

6.5 Reliability Assessment

6.6 Updating the Reliability Calculation

6.7 Conclusions and Discussion

References

7 Predictive Safety Index for Variable Amplitude Fatigue Life

Thomas Svensson, Jacques de Maré and Pär Johannesson

7.1 Introduction

7.2 The Load–Strength Reliability Method

7.3 The Equivalent Load and Strength Variables

7.4 Reliability Indices

7.5 The Gauss Approximation Formula

7.6 The Uncertainty Due to the Estimated Exponent β

7.7 The Uncertainty Measure of Strength

7.8 The Uncertainty Measure of Load

7.9 The Predictive Safety Index

7.10 Discussion

Appendix

References

8 Monte Carlo Simulation versus Sensitivity Analysis

Sara Lorén, Pär Johannesson and Jacques de Mar´e

8.1 Introduction

8.2 Transfer Function

8.3 Example from an Industrial Context

8.4 Highly Nonlinear Transfer Function

8.5 Total Variation for Logarithmic Life

8.6 Conclusions

References

PART Three MODELLING

9 Model Complexity Versus Scatter in Fatigue

Thomas Svensson

9.1 Introduction

9.2 A Statistical Model

9.3 Design Concepts

9.4 A Crack Growth Model

9.5 Partly Measurable Variables

9.6 Conclusions

References

10 Choice of Complexity in Constitutive Modelling of Fatigue Mechanisms

Erland Johnson and Thomas Svensson

10.1 Background

10.2 Questions

10.3 Method

10.4 Empirical Modelling

10.5 A Polynomial Example

10.6 A General Linear Formulation

10.7 A Fatigue Example

References

11 Interpretation of Dispersion Effects in a Robust Design Context

Martin Arvidsson, Ida Gremyr and Bo Bergman

11.1 Introduction

11.2 Dispersion Effects

11.3 Discussion

References

12 Fatigue Damage Uncertainty

Anders Bengtsson, Klas Bogsjöand Igor Rychlik

12.1 Introduction

12.2 Fatigue Review

12.3 Probability for Fatigue Failure – Safety Index

12.4 Computation of E [D(T )|k] and V [D(T )|k]

12.5 Non Gaussian Loads – Examples

References

13 Widening the Perspectives

Bo Bergman and Jacques de Maré

13.1 Background

13.2 Additional Engineering Perspectives on Reliability

13.3 Organizational Perspectives on Reliability

13.4 Industrialization of Robust Design Methodology

13.5 Adoptions of Fatigue Reliability Methodology

13.6 Learning for the Future

References

List of Abbreviations

Index