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Dimensional Variation Analysis (DVA) is a decision-making methodology for tolerance analysis, and is employed to evaluate assembly variations and identify problems in manufacturing assembly processes at early stages of design. In this study, the impact of component tolerances on manufacturing and assembly process variations is presented on a case study. The case study includes the alignment analysis between crankshaft and input shaft for clutch systems. The impact of component tolerances on axial alignment measurements in regard to these applications is discussed. The study shows that when combined with effective tolerance combinations, Variation Simulation Analysis (VSA) facilitates operational visibility; thus improve quality, reduce manufacturing cost, and enable reduction of production release time. The case study presents the impact of component tolerances at two levels: 1. Pre-Design, 2. Optimized Design.

This study investigates the significance levels of the clutch pedal effort parameters in heavy duty vehicles with manual transmission. A non-linear multibody dynamic model of the clutch system is developed to show the effect of clutch system parameters on clutch pedal performance in an experimental design. The most critical factors are selected the release load on release bearing, mechanical ratio, clutch servo assist air pressure, hydraulic ratio, expansion loss ratio, spring forces. The two level factorial designs for each critical factor represent the experimental design. The results of the study show that clutch servo assist air pressure has the most significant effect on the pedal effort, and the level selected in the experimental design is an important parameter for the reliable results.