Applied Reliability Engineering Volume I, 5th Ed.

  • Applied Reliability Engineering - Volume I

Applied Reliability Engineering Volume I, 5th Ed.

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Volume I of the book focuses upon metrics of reliability and methods of achieving reliable components.

Copyright © January 2006 by The Center for Reliability Engineering, University of Maryland, College Park, Maryland, USA.

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Product Description

Authors – Marvin Roush and Willie Webb

This book is organized to provide an introduction to reliability engineering, both for practicing engineers and for students. The emphasis throughout is on concepts and basic principles. It contains practical applications to guide the reader to appreciate the value of each topic presented. This book was not developed to be used as a handbook or reference book; such books commonly are made up of a number of self-contained modules that provide information about separate topics. Rather, this work is a carefully woven fabric of connected ideas that are progressively developed. Handbooks and other ‘how to’ books are meant to meet short term needs for carrying out a given process but do not lead to a full understanding of the subject as is the goal here. More advanced texts are cited for further reading on the mathematical and statistical aspect of reliability analysis and engineering.

The approach to engineering described here is one that has been evolving in many companies. They have moved away from an approach that only evaluated product designs through testing and data analysis to one that integrates all parts of the product design and development in a thoroughly integrated reliability program. The activities in such a program are not an end in themselves, but rather, are valuable when utilized to assist in making proper engineering and management decisions.

This book is used at the University of Maryland for a two-semester course for both upper-level undergraduate students and graduate students. By selecting the appropriate portions of the material, considerable flexibility is available for using this books as a reference for a one-semester course. The first part of the book focuses upon metrics of reliability and methods of achieving reliable components. The second half focuses upon system reliability, system analysis techniques and unique problems that arise from interactions between distinct parts of a system.

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Format

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Table of Contents

1 Introduction to Reliability Engineering 3
  1.1 Relationship of Quality and Reliability 3
  1.2 Reliability Engineering as a Technical Discipline 4
  1.3 The Engineering World in which Reliability Engineers Work 4
  1.4 Domain of Activity of Reliability Engineers 5
  1.5 Risk Analysis as A Technical Discipline 7
  1.6 Formal Definition of Reliability 8
  1.7 Some Models of Failure 10
    1.7.1 The Stress-Strength Model 11
    1.7.2 The Damage – Endurance Model 11
    1.7.3 The Challenge – Response Model 12
    1.7.4 The Tolerance-Requirements Model 12
Exercises 13
2 Why and How Things Fail 15
  2.1 Failure Causes and Mechanisms 15
    2.1.1 Basic Physics of Failure Concepts 15
    2.1.2 Failure of Material Objects 15
    2.1.3 Abrasive Wear 17
    2.1.4 Adhesive Wear 18
    2.1.5 Surface Fatigue 19
    2.1.6 Erosive Wear 21
    2.1.7 Cavitation Pitting 22
    2.1.8 Corrosion by Direct Chemical Attack 24
    2.1.9 Preventing Corrosion Failures 24
    2.1.10 Elastic Deformation of Materials 29
    2.1.11 Poisson’s Ratio 31
  2.1 12 Plastic Deformation 31
    2.1.14 Toughness of Materials 34
  2.2 Residual Stresses 39
    2.2.1 Thermal Residual Stresses 42
    2.2.2 Metallurgical Residual Stresses 47
    2.2.3 Mechanical Residual Stresses 48
    2.2.4 Chemical Effects on Residual Stresses 51
    2.2.6 Summary of Residual Stresses 53
  2.3 Preventing Mechanical Failures 53
    2.3.1 Stress Concentrations 54
    2.3.2 Fracture Resistance 55
    2.3.3 Critical Stress Intensity Factor 55
  2.4 Metal Fatigue 56
  2.5 Ceramics 58
    2.5.1 Mechanical Properties of Ceramics 62
    2.5.2 Stress-Strain Behavior of Ceramics 63
  2.6 Polymers 65
    2.6.1 Impact Strength 68
    2.6.2 Fatigue 68
  2.7 Software Failures 69
Exercises 73
3 Probabilistic Models of Failure Phenomena 77
  3.1 Distributions of Strengths of Materials 77
    3.1.1 Empirical Distribution 77
    3.1.2 Random Variables 80
    3.1.3 Measures of Central Tendency of Distributions 80
    3.1.4 Measures of Dispersion for a Distribution 82
    3.1.5 The Normal (or Gaussian) Probability Distribution 83
  3.2 Stress-Strength Interference 90
    3.2.1 Labeling Convention to be Used 90
  3.3 Probabilistic Engineering Design 94
    3.3.1 Probability Distribution for Strength – (Approach
in 2 ways)		 94
    3.3.2 Reliability Bounds in Probabilistic Design 95
    3.3.3 Safety Index 96
    3.3.4 Converting the Safety Index into Probability of Failure 99
    3.3.5 A Determination of Probability of Failure Example 100
    3.3.6 Modeling of Fatigue Phenomena 101
    3.3.7 Statistical Aspects of Fatigue 102
    3.3.8 Fatigue Measurements for a New Alloy 103
    3.3.9 Single-Stress Fatigue Data 103
    3.3.10 Cumulative Damage Considerations 106
    3.3.11 The Linear Damage Theory 106
    3.3.12 Cumulative Damage Theories 108
    3.3.13 Multiple Sampling of the Load Distribution 109
    3.3.14 Series System Under Load (Chain Model) 110
    3.3.15 Extreme Values 112
    3.3.16 Order Statistics 112
    3.3.17 Extreme-Value Distributions 113
  3.4 Graphical Analysis 118
    3.4.1 Graphing Process 119
  3.5 Extreme-Value Distribution Functions 124
    3.5.1 Summary for n-Link Chain 124
    3.5.2 Von Mises Form of the Extreme Value Distributions 125
  3.6 The Weibull Distribution 125
Exercises 129
4 Life Models for Non-Repairable Items 135
  4.1 Introduction 135
  4.2 Qualitative Differences in Hazard Function 141
  4.3 The Exponential Distribution 142
    4.3.1 Exponential Model Represents No Wearout 145
  4.4 Non-Parametric Methods 146
  4.5 A More Detailed Examination of the Weibull Distribution 149
    4.5.1 Mean and Variance of the Weibull Distribution 151
    4.5.2 The Gamma Function 151
  4.5 The Lognormal Distribution 160
  4.6 The Binomial Distribution 161
    4.6.1 Need for the Binomial Distribution 161
    4.6.2 The Binomial Expansion 161
    4.6.3 The Single-Term Formula 162
  4.7 Statistical Inference 163
  4.8 Different Types of Statistical Intervals 164
  4.9 Estimation and Hypothesis Testing 165
    4.9.1 Method of Moments 165
    4.9.2 Confidence Intervals — Characteristics of Interest 166
    4.9.3 One-Sided Confidence Bounds 167
    4.9.4 Component Tolerances 167
  4.10 Combining Random Variables 170
    4.10.1 Combining Random Variables for Simple Functions 170
  4.11 General Aspects of Reliability Data 173
  4.12 Acquisition of Data 174
    4.12.1 Types of Data 177
    4.12.2 Multicensored Data 178
    4.12.3 Multiple Failure Modes 180
    4.12.4 Reliability and Life Data 180
    4.14.5 Reliability Data Sources 182
  4.15 Estimation Theory 184
    4.15.1 Estimator Properties 184
Exercises 191
5 Reliability and Quality in Manufacturing 199
  5.1 Statistical Quality Control 199
    5.1.3 Statistical Basis of the Control Chart 202
    5.1.4 Process Capability 203
    5.1.5 Control Charts for Variables Measurements 204
  5.2 Quality Tools 217
    5.2.1 Cause and Effect Diagram 217
    5.2.2 Pareto Analysis 218
Exercises 221
Appendices 229
A Notation 231
B Definitions 235
C Rules of Boolean Algebra 243
D Statistical Tables 247
  Table D-1 Standard Normal Cumulative Distribution Function 249
  Table D-2 Critical Values of Student’s t Distribution 253
  Table D-3 Critical Values of Chi- Square χ2 α Distribution Function 255
  Table D-4 Critical Values of the Kolmogorov-Smirnov Statistic 257
  Table D-5 F-Cumulative Distribution Function, Upper 1Percentage Points 258
  Table D-6 F-Cumulative Distribution Function, Upper 5 Percentage Points 260
  Table D-7 F-Cumulative Distribution Function, Upper 10 Percentage Points 262
E References 265
F Answers to Selected Exercises 273
Subject Index 277

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