Toward cost-efficient tolerancing of 3D-printed parts: a novel methodology for the development of tolerance-cost models for fused layer modeling

Tolerance allocation methods significantly contribute to the qualification of Additive Manufacturing (AM) for (small-)series production ensuring high performance and efficiency. However, their usage prerequisites the availability of quantitative, reliable information on the impact of the assigned tolerances on the resulting manufacturing costs. The given article proposes a novel methodology for the systematic development of tolerance-cost curves for a cost-efficient tolerancing of 3D-printed parts. The proposed structured workflow aims at serving as a general guideline for both researchers and practitioners, while the exemplarily chosen perspective from Fused Layer Modeling (FLM) illustrates its adaption to a specific AM technology. The indirect, non-apparent interrelations between tolerances and resulting costs are modelled with the aid of an activity-based cost model, whereas the individual costs elements are mapped as function of the values for the machine-specific process parameters for AM, e.g., layer height or printing speed, which are required to achieve the assigned design tolerances. The total procedure covers all relevant steps, viz. the identification and quantification of the single cost items, the design of benchmark artifacts, adapted to given manufacturing and measuring techniques, the empirical determination of data on cost and geometrical accuracy by design of experiments and tolerance-cost curves. Its exemplary application to an academic use case shows its general applicability and benefits, but also its current limitations.

A Novel Methodology for Simultaneous Minimization of Manufacturing Objectives in Tolerance Allocation of Complex Assembly

Tolerance cost and machining time play crucial roles while performing tolerance allocation in complex assemblies. The aim of the proposed work is to minimize the above-said manufacturing objectives for allocating optimum tolerance to the components of complex assemblies, by considering the proper process and machine selections from the given alternatives. A novel methodology that provides a two-step solution is developed for this work. First, a heuristic approach is applied to determine the best machine for each process, and then a combined whale optimization algorithm with a univariate search method is used to allocate optimum tolerances with the best process selection for each sub-stage/operation. The efficiency of the proposed novel methodology is validated by solving two typical tolerance allocation problems of complex assemblies: a wheel mounting assembly and a knuckle joint assembly. Compared with previous approaches, the proposed methodology showed a considerable reduction in tolerance cost and machining time in relatively less computation time.

A Novel Methodology for Simultaneous Minimization of Manufacturing Objectives in Tolerance Allocation of Complex Assembly

A novel methodology is presented in this work to minimize the manufacturing objectives, namely tolerance cost and machining time for allocating optimum tolerance to the components of complex assemblies with considering the proper process and machine selections from the given alternatives. A methodology that provides a two-step solution is developed for this work. First, a heuristic approach is applied to determine the best machine for each process, and then a combined Whale optimization algorithm with a univariate search method is used to allocate optimum tolerances with the best process selection for each sub-stage/operation. The efficiency of the proposed novel methodology is validated by solving two typical tolerance allocation problems of complex assemblies: a wheel mounting assembly and a knuckle joint assembly. Compared with previous approaches, the proposed methodology showed a considerable reduction in tolerance cost and machining time in relatively less computation time.

Adaptation to simultaneous warming and acidification carries a thermal tolerance cost in a marine copepod

The ocean is undergoing warming and acidification. Thermal tolerance is affected both by evolutionary adaptation and developmental plasticity. Yet, thermal tolerance in animals adapted to simultaneous warming and acidification is unknown. We experimentally evolved the ubiquitous copepod Acartia tonsa to future combined ocean warming and acidification conditions (OWA approx. 22°C, 2000 µatm CO 2 ) and then compared its thermal tolerance relative to ambient conditions (AM approx. 18°C, 400 µatm CO 2 ). The OWA and AM treatments were reciprocally transplanted after 65 generations to assess effects of developmental conditions on thermal tolerance and potential costs of adaptation. Treatments transplanted from OWA to AM conditions were assessed at the F1 and F9 generations following transplant. Adaptation to warming and acidification, paradoxically, reduces both thermal tolerance and phenotypic plasticity. These costs of adaptation to combined warming and acidification may limit future population resilience.

Quantitative Assessment of Learning and Retention in Virtual Vocal Function Exercises

Purpose Successful voice therapy requires the patient to learn new vocal behaviors, but little is currently known regarding how vocal motor skills are improved and retained. To quantitatively characterize the motor learning process in a clinically meaningful context, a virtual task was developed based on the Vocal Function Exercises. In the virtual task, subjects control a computational model of a ball floating on a column of airflow via modifications to mean airflow (L/s) and intensity (dB-C) to keep the ball within a target range representing a normative ratio (dB × s/L). Method One vocally healthy female and one female with nonphonotraumatic vocal hyperfunction practiced the task for 11 days and completed retention testing 1 and 6 months later. The mapping between the two execution variables (airflow and intensity) and one error measure (proximity to the normative ratio) was evaluated by quantifying distributional variability (tolerance cost and noise cost) and temporal variability (scaling index of detrended fluctuation analysis). Results Both subjects reduced their error over practice and retained their performance 6 months later. Tolerance cost and noise cost were positively correlated with decreases in error during early practice and late practice, respectively. After extended practice, temporal variability was modulated to align with the task's solution manifold. Conclusions These case studies illustrated, in a healthy control and a patient with nonphonotraumatic vocal hyperfunction, that the virtual floating ball task produces quantitative measures characterizing the learning process. Future work will further investigate the task's potential to enhance clinical assessment and treatments involving voice control. Supplemental Material https://doi.org/10.23641/asha.13322891