International Journal of Engineering and Techniques - Volume 3 Issue 6, Nov - Dec 2017 ISSN: 2395-1303 http://www.ijetjournal.org Page 675 DESIGN AND OPTIMIZATION OF MECHANICAL COMPONENTS AND ITS MECHANISM USING MONTE CARLO SIMULATION K. NIRMALA 1 , Dr. K.SATISH BABU 2 , Dr.K. HEMACHANDRA REDDY 3 1(Research Scholar, JNTUA Ananthapuramu) 2 (Principal Ravindra College of Engineering for Women) 3 (Professor Dept of Mech JNTUA Ananthapuramu ) Introduction: Assembly tolerance analysis is a key element in industry for improving product quality and reducing overall cost. It provides a quantitative design tool for predicting the effects of manufacturing variation on performance and cost, and promotes concurrent engineering by bringing engineering requirements and manufacturing requirements together in a common model. Assembly tolerance analysis involves determining how the components in an assembly interact with each other and how their variations affect assembly constraints. The simple two- component assembly consists of a cylinder in a groove. Kinematic adjustment due to component size variations Assembly Tolerance Analysis Methods Statistical tolerance analysis methods can be applied to geometric models of assemblies to predict the magnitude of variation in critical assembly features. The resulting statistical distributions may be used to estimate the percent rejects and to see if the assembly quality specifications will be met. Method developed for RESEARCH ARTICLE OPEN ACCESS Abstract: This paper studies in detail about the background and implementation of a MONTE CARLO SIMULATION based optimization with differential operator for optimization task of a few mechanical components, which are essential for most of the mechanical engineering applications. Like most of the other heuristic techniques, CARLO SIMULATION is also a population-based method and uses a population of solutions to proceed to the global solution. A differential operator is incorporated into the CARLO SIMULATION for effective search of better solutions. To validate the effectiveness of the proposed method, three typical optimization problems are considered in this research: firstly, to optimize the tolerance in cylinder, secondly, to optimize the volume in cylinder, and finally to optimize the weight of the cylinder. Simulation result on the optimization (mechanical components) problems reveals the ability of the proposed methodology to find better optimal solutions compared to other optimization algorithms. Keywords — Monte Carlo Simulation ,FEM.