Preface	5
	Contents	8
	1 Introduction to Reliability Design of Mechanical/Civil System	12
	Abstract	12
	1.1 Introduction	12
	2 Reliability Disasters and Its Assessment Significance	18
	Abstract	18
	2.1 Introduction	18
	2.2 Reliability Disasters	21
	2.2.1 Versailles Rail Accident in 1842	23
	2.2.2 Tacoma Narrows Bridge in 1940	24
	2.2.3 De Havilland DH 106 Comet in 1953	25
	2.2.4 G Company and M Company Rotary Compressor Recall in 1981	26
	2.2.5 Firestone and Ford Tire in 2000	28
	2.2.6 Toshiba Satellite Notebook and Battery Overheating Problem in 2007	29
	2.2.7 Toyota Motor Recalls in 2009	30
	2.3 Development of Reliability Methodologies in History	31
	2.3.1 In the Early of 20s Century—Starting Reliability Studies	31
	2.3.2 In the World War II—New Electronics Failure in Military	35
	2.3.3 In the End of World War II and 1950s—Starting the Reliability Engineering	37
	2.3.4 In the 1960s and Present: Mature of Reliability Methodology—Physics of Failure (PoF)	41
	References	45
	3 Modern Definitions in Reliability Engineering	46
	Abstract	46
	3.1 Introduction	46
	3.1.1 Bathtub Curve	47
	3.2 Fundamentals in Probability Theory	48
	3.2.1 Probability	49
	3.2.1.1 Mean	50
	3.2.1.2 Median	50
	3.2.1.3 Mode	50
	3.2.1.4 Standard Deviation	50
	3.2.1.5 Expected Value	51
	3.2.2 Probability Distributions	51
	3.2.2.1 Reliability Function	51
	3.2.2.2 Cumulative Distribution Function	52
	3.2.2.3 Probability Density Function (PDF)	52
	3.2.2.4 Failure Rate	53
	3.2.2.5 Cumulative Hazard Rate Function	53
	3.3 Reliability Lifetime Metrics	55
	3.3.1 Mean Time to Failure (MTTF)	55
	3.3.2 Mean Time Between Failure (MTBF)	56
	3.3.3 Mean Time to Repair (MTTR)	57
	3.3.4 BX% Life	57
	3.3.5 The Inadequacy of the MTTF (or MTBF) and the Alternative Metric BX Life	58
	3.4 Statistical Distributions	60
	3.4.1 Poisson Distributions	60
	3.4.2 Exponential Distributions	62
	3.5 Weibull Distributions and Its Applications	63
	3.5.1 Introduction	63
	3.5.2 Shape Parameters ?	65
	3.5.3 Confidence Interval	65
	3.5.4 A Plotting Method on Weibull Probability Paper	66
	3.5.5 Probability Plotting for the Weibull Distribution	67
	Reference	70
	4 Failure Mechanics, Design, and Reliability Testing	71
	Abstract	71
	4.1 Introduction	71
	4.2 Failure Mechanics and Designs	73
	4.2.1 Product Design––Intended Functions	74
	4.2.2 Specified Design Lifetime	76
	4.2.3 Dimensional Differences Between Quality Defects and Failures	77
	4.2.4 Classification of Failures	78
	4.3 Failure Mode and Effect Analysis (FMEA)	80
	4.3.1 Introduction	80
	4.3.2 Types of FMEA	82
	4.3.3 System-Level FMEA	82
	4.3.4 Design-Level FMEA	83
	4.3.5 Process-Level FMEA	83
	4.3.6 Steps for Performing FMEA	84
	4.3.6.1 Defines System and Its Associated Requirements (Step1)	85
	4.3.6.2 Describe the System and Its Associated Functional Blocks (Step 2)	85
	4.3.6.3 Identify Failure Modes and Their Associated Effects (Failure Analysis, Step 3)	86
	4.3.6.4 Risk Assessment (Step 4)	86
	4.3.6.5 RPN (Risk Priority Number)	86
	4.3.6.6 Optimization (Step 5)	88
	4.4 Fault Tree Analysis (FTA)	89
	4.4.1 Concept of FTA	89
	4.4.2 Reliability Evaluation of Standard Configuration	93
	4.5 Robust Design (or Taguchi Methods)	95
	4.5.1 A Specific Loss Function	96
	4.5.1.1 On-Target, Minimum-Variation (for Example, a Mating Part in an Assembly)	96
	4.5.1.2 Smaller the Better––Variance (for Example, Carbon Dioxide Emissions)	97
	4.5.1.3 Larger the Better––Performance (for Example, Agricultural Yield)	98
	4.5.2 Robust Design Process	99
	4.5.2.1 System Design	99
	4.5.3 Parameter (Measure) Design	100
	4.5.4 Tolerance Design	100
	4.5.5 A Parameter Diagram (P-Diagram)	101
	4.5.6 Taguchi’s Design of Experiment (DOE)	101
	4.5.6.1 Orthogonal Arrays	102
	4.5.7 Inefficiencies of Taguchi’s Designs	103
	4.6 Reliability Testing	104
	4.6.1 Introduction	104
	4.6.2 Maximum Likelihood Estimation	105
	4.6.3 Time-to-Failure Models	107
	4.6.3.1 Arrhenius Equation	107
	4.6.3.2 Inverse Power Law	109
	4.6.3.3 Eyring Equation	109
	4.6.4 Reliability Testing	110
	5 Load Analysis	116
	Abstract	116
	5.1 Introduction	116
	5.2 Modeling of Mechanical System	117
	5.2.1 Introduction	117
	5.2.2 D’Alembert’s Modeling for Automobile	118
	5.3 Bond Graph Modeling	121
	5.3.1 Introduction	121
	5.3.2 Basic Elements, Energy Relations, and Causality of Bond Graph	122
	5.3.3 Case Study: Hydrostatic Transmission (HST) in Seaborne Winch	127
	5.3.4 Case Study: Failure Analysis and Redesign of a Helix Upper Dispenser	133
	5.4 Load Spectrum and Rain-Flow Counting	136
	5.4.1 Introduction	136
	5.4.2 Rain-Flow Counting	138
	5.4.3 Goodman Relation	140
	5.4.4 Palmgren-Miner’s Law for Cumulative Damage	141
	References	146
	6 Mechanical System Failures	147
	Abstract	147
	6.1 Introduction	147
	6.2 Mechanism of Slip	150
	6.3 Facture Failure	152
	6.4 Fatigue Failure	154
	6.4.1 Introduction	154
	6.4.2 Type of Fatigue Loading	155
	6.4.3 Stress Concentration at Crack Tip	158
	6.4.4 Crack Propagation and Fracture Toughness	160
	6.4.5 Crack Growth Rates	161
	6.4.6 Ductile–Brittle Transition Temperature (DBTT)	163
	6.4.7 Fatigue Analysis	165
	6.5 Stress–Strength Analysis	167
	6.6 Failure Analysis	168
	6.6.1 Introduction	168
	6.6.2 Procedure of Failure Analysis	170
	6.6.3 Case Study: PAS (Photo Angle Sensor) in Automobile	172
	6.6.4 Fracture Faces of Product Subjected to a Variety of Loads in Fields	175
	References	177
	7 Parametric Accelerated Life Testing in Mechanical/Civil System	179
	Abstract	179
	7.1 Introduction	179
	7.2 Reliability Design in Mechanical System	180
	7.3 Reliability Block Diagram and Its Connection in Product	183
	7.4 Reliability Allocation of Product	184
	7.4.1 Introduction	184
	7.4.2 Reliability Allocation of the Product	185
	7.4.3 Product Breakdown	186
	7.4.3.1 Automobile	187
	7.4.3.2 Airplane	188
	7.4.3.3 Domestic Appliance	188
	7.4.3.4 Machine Tools	189
	7.4.3.5 Agricultural Machinery and Heavy Construction Equipment	190
	7.5 Failure Mechanics, Design, and Reliability Testing	192
	7.6 Parametric Accelerated Life Testing	195
	7.6.1 Acceleration Factor (AF)	196
	7.6.2 Derivation of General Sample Size Equation	201
	7.6.3 Derivation of Approximate Sample Size Equation	204
	7.7 The Reliability Design of Mechanical System and Its Verification	206
	7.7.1 Introduction	206
	7.7.2 Reliability Quantitative (RQ) Specifications	208
	7.7.3 Conceptual Framework of Specifications for Quality Assurance	212
	7.8 Testing Equipment for Quality and Reliability	214
	7.8.1 Introduction	214
	7.8.2 Procedure of Testing Equipment Development (Example: Solenoid Valve Tester)	217
	References	226
	8 Parametric ALT and Its Case Studies	228
	Abstract	228
	8.1 Failure Analysis and Redesign of Ice Maker	228
	8.2 Residential Sized Refrigerators During Transportation	236
	8.3 Water Dispenser Lever in a Refrigerator	240
	8.4 Refrigerator Compressor Subjected to Repetitive Loads	249
	8.5 Hinge Kit System (HKS) in a Kimchi Refrigerator	260
	8.6 Refrigerator Drawer System	270
	8.7 Compressor Suction Reed Valve	275
	8.8 Failure Analysis and Redesign of the Evaporator Tubing	286
	8.9 Compressor with Redesigned Rotor and Stator	295
	8.10 French Refrigerator Drawer System	303
	9 Parametric ALT: A Powerful Tool for Future Engineering Development	314
	Abstract	314
	Reference	317