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Coolant pipes are a prime connection units present in any engines that facilitates the flow of coolant and thereby keeping the engine under its optimum operating condition. Among the several influencing factors that deteriorate engines performance, the coolant leak is also one of the contributors. This could be caused primly due to leakage issues that arises from the pipe press fit zones. Henceforth it is very important to understand the root cause of this press-fit connection failure. The present study deals with press-fit between the pipe and housing in an engine which is subjected to extreme thermal loads (min of -40°C to a max temperature of +150°C) thereby causing the press-fit loosening effect.

Process Tolerance Analysis is used to compute the accumulation of operation variations and to predict if manufactured components will meet required tolerances. The analysis can also be used for process design. A GM Powertrain software tool, Process Planning System-I (PPS1), has been developed for tolerance analysis of turned parts. PPS1 uses ICAD® software to read Unigraphics (CAD) and manufacturing data, and generates a minimum stock size needed to support machining, in-process dimensions, and stock-removal tolerances. PPS1 has reduced analysis time, eliminated calculation errors, and improved manufacturing plans. The analysis procedure and PPS1 are described.