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 AcknowledgementsAbout the EditorsContributorsPART One METHODOLOGY1 IntroductionBo Bergman and Martin Arvidsson1.1 Background1.2 Failure Mode Avoidance1.3 Robust Design1.4 Comments and Suggestions for Further ReadingReferences2 Evolution of Reliability Thinking – Countermeasures for Some Technical IssuesÅke Lönnqvist2.1 Introduction2.2 Method2.3 An Overview of the Initial Development of Reliability Engineering2.4 Examples of Technical Issues and Reliability Countermeasures2.5 Discussion and Future Research2.6 Summary and ConclusionsReferences3 Principles of Robust Design MethodologyMartin Arvidsson and Ida Gremyr3.1 Introduction3.2 Method3.3 Results and Analysis3.4 Discussion3.5 ConclusionsReferencesPART Two METHODS4 Including Noise Factors in Design Failure Mode and Effect Analysis (D-FMEA) – ACase Study at Volvo Car CorporationÅke Lönnqvist4.1 Introduction4.2 Background4.3 Method4.4 Result4.5 Discussion and Further Research4.6 SummaryReferences5 Robust Product Development Using Variation Mode and Effect AnalysisAlexander Chakhunashvili, Stefano Barone, Per Johansson and Bo Bergman5.1 Introduction5.2 Overview of the VMEA Method5.3 The Basic VMEA5.4 The Enhanced VMEA5.5 The Probabilistic VMEA5.6 An Illustrative Example5.7 Discussion and Concluding RemarksAppendix: Formal Justification of the VMEA MethodReferences6 Variation Mode and Effect Analysis: An Application to Fatigue Life PredictionPär Johannesson, Thomas Svensson, Leif Samuelsson, Bo Bergman and Jacques de Maré6.1 Introduction6.2 Scatter and Uncertainty6.3 A Simple Approach to Probabilistic VMEA6.4 Estimation of Prediction Uncertainty6.5 Reliability Assessment6.6 Updating the Reliability Calculation6.7 Conclusions and DiscussionReferences7 Predictive Safety Index for Variable Amplitude Fatigue LifeThomas Svensson, Jacques de Maré and Pär Johannesson7.1 Introduction7.2 The Load–Strength Reliability Method7.3 The Equivalent Load and Strength Variables7.4 Reliability Indices7.5 The Gauss Approximation Formula7.6 The Uncertainty Due to the Estimated Exponent β7.7 The Uncertainty Measure of Strength7.8 The Uncertainty Measure of Load7.9 The Predictive Safety Index7.10 DiscussionAppendixReferences8 Monte Carlo Simulation versus Sensitivity AnalysisSara Lorén, Pär Johannesson and Jacques de Mar´e8.1 Introduction8.2 Transfer Function8.3 Example from an Industrial Context8.4 Highly Nonlinear Transfer Function8.5 Total Variation for Logarithmic Life8.6 ConclusionsReferencesPART Three MODELLING9 Model Complexity Versus Scatter in FatigueThomas Svensson9.1 Introduction9.2 A Statistical Model9.3 Design Concepts9.4 A Crack Growth Model9.5 Partly Measurable Variables9.6 ConclusionsReferences10 Choice of Complexity in Constitutive Modelling of Fatigue MechanismsErland Johnson and Thomas Svensson10.1 Background10.2 Questions10.3 Method10.4 Empirical Modelling10.5 A Polynomial Example10.6 A General Linear Formulation10.7 A Fatigue ExampleReferences11 Interpretation of Dispersion Effects in a Robust Design ContextMartin Arvidsson, Ida Gremyr and Bo Bergman11.1 Introduction11.2 Dispersion Effects11.3 DiscussionReferences12 Fatigue Damage UncertaintyAnders Bengtsson, Klas Bogsjöand Igor Rychlik12.1 Introduction12.2 Fatigue Review12.3 Probability for Fatigue Failure – Safety Index12.4 Computation of E [D(T )|k] and V [D(T )|k]12.5 Non Gaussian Loads – ExamplesReferences13 Widening the PerspectivesBo Bergman and Jacques de Maré13.1 Background13.2 Additional Engineering Perspectives on Reliability13.3 Organizational Perspectives on Reliability13.4 Industrialization of Robust Design Methodology13.5 Adoptions of Fatigue Reliability Methodology13.6 Learning for the FutureReferencesList of AbbreviationsIndex

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