DFA-based algorithm for optimizing the accuracy and cost of shaft and hole assembly

: Based on the idea of DFA, this study proposes an optimization algorithm for the shaft and hole assembly accuracy and cost. By simplifying and analysing the formula proposed by Abdel-Malek for the calculation of shaft and hole assembly throughput, a mathematical model is established to explore the selection of optimal values for machining cost, part machining tolerance and equipment positioning accuracy. And, the relationship between shaft and hole assembly clearance and spring wire diameter is analysed. The study shows that, within the constraints of cost, the optimum value is selected in eight cases, with different strategies. The maximum resistance to insertion is achieved when the spring wire diameter reaches a value of 0.8 times the difference between the average diameter of the hole and the spring. In addition, this study refines the traditional DFA design system by providing the appropriate algorithms to lay the foundation for software implementation.