Robust Design and Analysis for Machine Elements

Thereare certain errors caused by variable parameters caused by environmentalfactors that occur in production processes that prevent ergonomic anderror-free design. Keeping these errors to a minimum is critical importance inengineering science. Considering these situations, certain approaches based onnumerical analysis are made in the design phase of engineering. Theseapproaches are consists of two parts, deterministic and probabilistic. Probabilisticapproach is a highly effective method of excellence within the scope of takinginto account variable parameters. This method is one of the most effectivemethods in determining the dimensional parameters in the design, the structuralcondition of the part and the error variations that may occur due to productionsensitivities. In the design process based on engineering fundamentals,probabilistic approach and numerical analyzes should be applied synchronouslyto obtain a robust design. In this context, the Six Sigma Method, which is usedto provide operational excellence in design, is a very effective method inminimizing errors in the process from the design to production of a product.In this study, CADdesign of steel disc spring was modeled in SolidWorks program. Appropriate meshquality was created of the modeled disc spring in ANSYS Workbench program, andthen boundary conditions were determined. The disc spring was subjected tofinite element (SE-FEA) analysis, taking into account the operating conditionsand suitability for production. As a result of the assigned inputs, the sixsigma analysis module was used together with the parametric optimization, andsix sigma operational excellence was achieved in the design. Prototype andproduction costs are reduced, and engineering problems are solvedsignificantly, based on probability, by obtaining a higher quality product witha robust design and producing close to zero defects.