Reliability strength design se9st-a320196) Redon Foering a ote Sule $4 19) 7-92 1G Flsnor Scene Listed rine on Monti la. Align renee “4 nS ADVIS through inverse distributions—exponential and Weibull cases A. S. R. Murty & V.N. A. Naikan Reliabttie Engineering Cenire, Department uf Industiat Engng & Management, Indian instiwie of Technology, Kharagpur, Pin 721 302. Indie (Received 10 May 1994; sevepted 19 May 19%), This paper illusteates the inverse reliabibty design techniques tor exponential and Weibull stressstrength models. Expressions for factor of safety. mean Strength and its variability have been derived for a given range of target feliabiity and external Joad conditions. In the case of exponential models a slobal solution has been found out whereas in the case of the Weibull mode! Daly some specific cases have heen considered. The difficulty in obtaining = global solution in the Weibull model has been discussed with possible methods to attain it. ©) 1996 Elsevier Science Limited. NOTATION R Target reliability strength 8 Random variable representing stress (load) § Random variable representing strength 5 Mean toad «Mean strength (Standard Deviation (SD) of toad (fg Standard Deviation (SD) of strength Probability density function (pdf) of load distribution paf of strength distribution. 2 INTRODUCTION Reliability design of a component or product, in its nutshell, includes evaluation of minimum required strength and factor of safety of the component or product to mevt the target reliability. under a given set of environmental or external load conditions. In some cases. it also may include evaluation of the maximum allowable strength deviation from its mean value or, in short, the maximum allowable coefficient af variation to meet the target reliability demand, Mean ime to first failure (MTTF), Mean time between failures (MTBF) ete, are also acceptable reliability indices for design. In this work we focus on the sme independent stress-strength reliability design. Reliabi- tity evaluated using these techniques can be more effectively termed as Reliability Strength (or Strength Reliability) since the material strength is the only load or the term deciding factor for a given external environment, (Hereafter in this text reliability indicates reliability strength.) Moses & Kinser’ have done some fundamental studies in the area of inverse distributions applicable to structural reliability, Hart* has presented results of inversion of some distributions in his paper. These are also discussed in the book ‘Introduction to Reliability Enginecring” by Lewis.” Akelle & Verma.’ Gilboa! and Akela & Naikan' have proposed a method for evaluating the inverse values of Normal and Lognormal distributions. An inverse series proposed by them can be effectively used for designing structural components. In the inverse distribution techniques we decide the target reliability and evaluate the required strength parameters in a single straight forward step. Mean strength, maximum. allowable standard deviation (SD), minimum factor of safety, maximum allowable coefficient of variation (CV) etc., for the required target reliability can be evaluated from the strength distribution parameters. The basic principles of stress-strength interference (Araroff” and Kapur & Lamberson’) have been used for this purpose. In the following sections we consider two cases of stress (load)-strength. distributions, namely, Expone tial and Weibull. Finding the type of load distribution and evaluation of parameters are not discussed in this work because these are basically curve fitting and statistical estimation techniques which are available in standard statistical literature. However, in actual design cases. load distribution should be studied and its8 AS. R. Murty, V. parameters should be estimated with minimum possible error to achieve the best design. 3 EXPONENTIAL CASE In this case both load and strength follow exponential distributions. Typical examples can be cited from the failure statistics of electrical ad electronic com- ponents. The load and strength distributions can be represented as follows AAS) = Ay exp(~As 08s = a where A= 1/5 Kel) = Ag Exp Agk OER =~ Q) where Ay = 1/8. 3A Inversion ‘The time independent reliability can be evaluated from the well known load-strength models, ‘The probability of failure in such cases is evaluated from the area of interference between the load and strength distributions (ie., when s 2 the component fails). +. Reliability strength, R = imerierence area ~ probability(s = g) = [109[f seorac]as 6) Substituting f(s) and J,(g) in the above eqn (3) we we (4) But “sy Substituting eqa (4) in eqn (5) and re-arranging we et: OF or, Mean Strength, In other words, in the case of exponential istributions, the minimum required mean strength NA. Nathan can be defined ay the product of mean stress (or load) and the ratio of target reliability to unreliability, From eqn (6) we also get. a In conventional design procedures. however, the ratio of mean strength (0 the mean stress or load is termed as Factor of Safety or in short FS. rs ~ Tatget Reliabiity Unreliability ‘That means in probabilistic design procedure for exponential stress-strength models the required factor of safety is defined as the simple ratio of target reliability to the cortesponding unreliabi 3.2 IWastration The external foad on a resistor follows an exponential distribution. The load variation at different petiods of time are 9.64, 10.34, 9.84, 9.954, 101A. 108A, 1A, 10.64, 9.94. 10.44. The resistors are to be designed (0 achieve a reliability strength of 97.85%. Assume the strength follows an exponential distribution. 3.3 Solution Mean stress or load, Target reliability strength, R = 0.9785. Required Factor of Safety. 0.978 FSS FS 1 = 0.9785 45.51. Minimum required mean strength = 45.51*10.1454. 461.714 4 WEIBULL CASE, In this case both load and strength follow Weibull distributions. Mechanical engincering systems gene- rally follow these distributions. The probability density functions of load and strength can be expressed as follows Be wiayh ‘eof -(2)"] 08) (ay fs) = Kee= ie ‘evxf-(2)"1 “ where a, and @, are the scate parameters and 8, andReliability design through inverse distributions nm {are the shape parameters of the load and strength distributions, respectively. Substituting eqns (8) and (9) into eqn (3), (eqn (3) represents the general load-strength reliability model irrespective of the failure distributions) we get: ‘Target Reliability, [or tewf-42F-(2V J co integral equation the load. distribution parameters will be pre-evaluated from the load variation data collected in the actual or in the simulated environmental conditions in which the component will be finally put into use by following similar procedures mentioned in the previous sections. In the inverse reliability design procedure for a given larget reliability the strength parameters or a combination of the strength parameters a, and B, should be evaluated. Once these parameters are evaluated for given target reliability and load distribution, the other design variables can be evaluated, However, eqn (10) will not provide direct mathematical solution for a, and ,. Hence, in this work we follow the inverse numerical integration techniques to reach the required solution, The method can be summarised in the following steps. In this 4.1 Methodology illustrated Step 1 + Conduct a survey of external load in the actual or simulated environment. + Find the best fitting load distribution pattern and estimate the load parameters (a, and B,). Step 1 + Decide the target reliability (R) on the basis of type of application, cost constraints, safety requirements, ete. Step IH + Evaluate A, using eqn (10) by substituting a arget reliability (numerical value obtained in step IL above) and assuming a numerical value for a, + Repeat the procedure for alt possible values of Ge Step IV + Obtain mean and standard deviation of load tisribution by using the formulae: Mean, cs ~afa(t4 5] ay Standard deviation, analy +B) blo RHE a Step V + Obtain mean and standard deviation of strength distribution (44, and u,) by substituting of and for a, and B., tespectively, in eqns (11) and (12) aioe. + Evaluate factor of safety (FS) and coefficient of variation (CV) $0 as 10 achieve the target reliability demand by using the following relations mean strength _ jt, ay mean stress. cve wy Step VI + Plot ay against By. py against 7 and PS against CY for the pre-decided target reliability demand. + Obtain a best fit polynomial function for the above variables. Step Vil + Procure the machines for manufacturing with & minimum process capability of 6u,. (Under statistical control the process capability (PC) can be evaluated by using the equation PC = 6*8D.) Step VII + Now evaluate the actual standard deviation of strength from the machine performance and substitute in the polynomial functions to obtain the mean strength, Fix the machine alignment to achieve this strength. Soe the example for further clarification of the methodology. 5 GLOBALIZATION OF THE METHOD The methodology illustrated above can be repeated for different cases of target reliability requirements keeping the load conditions the same. A series of curves and polynomials will be obtained by following the methodology illustrated. (See also the example ‘and Figures 2-4) Such a solution space can be considered 4s a global one for a given stress or load conditions and can be interpolated to reach the exact solution. However, the solution space changes for different load environments and henee the full global solution can be derived only by repeating the illustrated methodology for all possible ranges of load