Dimensional Variation Analysis (DVA) Mission A Group Dedicated

Dimensional Variation Analysis (DVA) Mission A Group Dedicated

Dimensional Variation Analysis (DVA) Mission A Group Dedicated to Deploying Advanced Processes and Tools in Statistical Tolerance Analysis for Improved Reliability, Cycle Time, Comparative Advantage, and ROE. 4 Tier Approach Tier 1; Nom. Clearances & Worst Case (WC) Analysis & Tier 3; Monte Carlo Simulation using @Risk Tier 4; VSA/PRO-E 3-D Variation Simulation /C W Assembly Tolerance Increasing Firepower Tier 2; Modified WC and RSS Statistical Analysis lity Rea RSS # Tolerances & DVA Team Concept Engineering Leader

Engineering Leader Engineering Leader AHD Signature DVA Team Engineering Leader Greg Steinrock & Mike Baker Class II PDE Engineering Leader Class I Engineering Leader Engineering Leader Engineering Leader CEP CTC JEP Standard Graphical User Interface CPK= 1.0

Angular Misalignment (Degrees) CPK= 1.67 Angular Misalignment (Degrees) Tornado Diagram For Tolerance Allocation Geometry, GD&T... Fuel Pump Assembly, FEA, Wear ... DVA Results Radial Clearance DVA Simulation Design No Fly Zone 0.42% SHAFT STRAIGHTNESS TOL (Non Zone D or entire shaft) 0.00% SHAFT STRAIGHTNESS TOL (Zone D; gear area only) 10.40% OD/ID GEAR RUN-OUT TOL Add Structural Effects

ROBUST FINAL DESIGN 1.61% PERP TOL (CTR DOWEL BORES) Add Thermal Effects Dimensional Variation 4.13% PERP TOL (FR/RR COVER DOW ELS) 5.22% TRUE POS TOL (FR /RR BUSHING BORES) 2.60% Add Wear Effects --> Net Cumulative Distribution TOTAL GEAR ID TOLERANCE 0.94% SHAFT DIA TOLERANCE (A) (total) 14.98% BUSH WALL THICK TOL (total) 1.66% BUSHING BORE DIA TOL (total) End Clearance 58.04% POCKET RAD FORM TOL ("total") 2.60% GEAR OD TOLERANCE (total)

0 Tolerance Reallocation Gear Design Change Nominal Shift 0.1 0.2 0.3 0.4 0.5 0.6 0.7 Hydraulic Control Valve Frequency of Solenoid Spacer by Part Number Needle Valve Stop Spacer Frequency of Use By Part Number 14.00% 13.00% 35.00% Frequency of Needle Valve Spacer by Part Number 12.00% 30.00% 11.00%

55.00% 10.00% 25.00% 5.00% 20.00% 2.00% 15.00% 1.00% 10.00% 0.00% 5.00% 3329841 3329840 3329839 3329838 3329837 3329836 3329835

3329834 3329833 3329832 3329831 3329830 3329829 3329828 3329827 3329826 3329825 3329824 0.00% 3329823 Part Number None None None None New P/N

New P/N New P/N New P/N? 3348587 3348586 Part Number Solenoid Spacer 3348588 Part Number 0.00% 4010247 3.00% 10.00% 4010248 4.00% Capability Data 30.00% 3329822 5.00%

Capability Data 15.00% 35.00% None 6.00% Capability Data 20.00% 40.00% 3330062 7.00% 45.00% None 8.00% 50.00% 25.00% Frequency Frequency 9.00% Questions?

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