POKOK BAHASAN:

.....
Material Properties & Type
Material Selection
Design for Manufacturability
Tolerance
Design for Assembly
Design for Environment
Economic & Manufacturing Cost

TOLERANCE
DESIGN

DESIGN SPECIFICATIONS AND

TOLERANCE
Develop

from quest for production quality

and efficiency

Early

tolerances support designs basic

function

Mass

production brought
interchangeability

Integrate

design and mfg tolerances

DEFINITION

The total amount by which a given

dimension may vary, or the
difference between the limits
- ANSI Y14.5M-1982(R1988) Standard [R1.4]

Source:ToleranceDesign,p10

AFFECTED AREAS

Engineering
Tolerance
ProductDesign

QualityControl

Manufacturing

QUESTIONS

Can customer tolerances be accommodated by

product?
Can product tolerances be accommodated by the
process?

TOLERANCE VS. MANUFACTURING

PROCESS

Nominal tolerances for

steel

Tighter tolerances =>

increase cost $

GEOMETRIC DIMENSIONS
Accurately

communicates the function of part

Provides

uniform clarity in drawing

delineation and interpretation

Provides

maximum production tolerance

TOLERANCE TYPES
Size
Form
Location
Orientation

SIZE TOLERANCES

FORM TOLERANCES

LOCATION TOLERANCES

ORIENTATION TOLERANCES

TOLERANCE BUILDUP

STATISTICAL PRINCIPLES

Measurement of central tendency

Mean

Median
mode

Measurement of variations
Range

Variance

Standard

deviation

LSL

USL

X
3

tolerance

PROBABILITY
Probability
Likelihood

Capability
Relate

of occurrence

the mean and variability of the

process or machine to the permissible range
of dimensions allowed by the specification
or tolerance.

TOLERANCE SPC CHARTING

FigureSource:ToleranceDesign,p125

TOLERANCE ANALYSIS METHODS

Worst-Case analysis
Root Sum of Squares
Taguchi tolerance design

INITIAL TOLERANCE DESIGN

Initial
Tolerance
Design

FigureSource:ToleranceDesign,p93

REFERENCES

Handbook of Product Design for Manufacturing: A Practical Guide

to Low-Cost Production, James C. Bralla, Ed. in Chief; McGrawHill, 1986
Manufacturing Processes Reference Guide, R.H. Todd, D.K. Allen &
L. Alting; Industrial Press Inc., 1994

Standard tolerances for mfg processes

Machinerys Handbook; Industrial Press

Standard Handbook of Machine Design; McGraw-Hill
Standard Handbook of Mechanical Engineers; McGraw-Hill
Design of Machine Elements; Spotts, Prentic Hall

FigureSource:ToleranceDesign,p9293

WORST-CASE METHODOLOGY
Extreme

or most liberal condition of

tolerance buildup

tolerances

must be assigned to the

component parts of the mechanism in such
a manner that the probability that a
mechanism will not function is zero
- Evans (1974)

WORST-CASE ANALYSIS
m

WCmax N p i Tp i
i1
m

WCmin N p i Tp i
i1

Ne + Te => Maximum assembly envelope

Ne - Te => Minimum assembly envelope

Source:Sixsigmamechanicaldesigntolerancing,p1314.

ASSEMBLY GAPS
m

Gmax N e Te N p i Tp i
i1
m

Gmin N e Te N p i Tp i
i1
m

Gnom N e N p i
i1

WORST CASE SCENARIO EXAMPLE

Source:ToleranceDesign,pp109111

WORST CASE SCENARIO EXAMPLE

Source:ToleranceDesign,pp109111

WORST CASE SCENARIO EXAMPLE

Largest=>0.05+0.093=0.143
Smallest=>0.050.093=0.043

Source:ToleranceDesign,pp109111

NON-LINEAR TOLERANCES

y f (x1, x 2 , x 3 ,...x n )
f
f
f
f
Toly
tol1
tol2
tol3 ...
toln
x1
x 2
x 3
x n

f
f
f
f
Nomy
x1
x2
x 3 ...
xn
x1
x 2
x 3
x n

Wource:Sixsigmamechanicaldesigntolerancing,p104

ROOT SUM-OF-SQUARE
RSS
Assumes normal distribution behavior

1
(1/ 2)[x )/ ] 2
f (x)
e
2

Wource:Sixsigmamechanicaldesigntolerancing,p16

RSS METHOD

Assembly tolerance stack equation

f (x) T T T ...T
2
1

2
2

2
3

2
n

Wource:Sixsigmamechanicaldesigntolerancing,p128

POOL VARIANCE IN RSS

adjusted

gap

Tol

3Cp

Tpi
Te

3Cp
i1 3Cpi
2

Wource:Sixsigmamechanicaldesigntolerancing,p128

PROBABILITY

Q Gnom
ZQ
gap

ZQ

Q N e N pi

i1
2

Te
Tpi

3Cp
i1 3Cpi
2

Wource:Sixsigmamechanicaldesigntolerancing,p128

PROBABILITY FOR LIMITS

ZG min

ZG max

Gmin Gnom
2
Te 2 m Tpi

3Cpi
3Cp
i1

Gmax Gnom
2
Te 2 m Tpi

3Cp
i1 3Cpi

Wource:Sixsigmamechanicaldesigntolerancing,p128

DYNAMIC RSS
ZG min

ZG max

Gmin Gnom
2
Te 2 m Tpi

3Cpk i
3Cpk
i1

Gmax Gnom
2
Te 2 m Tpi

3Cpk
i1 3Cpk i

Wource:Sixsigmamechanicaldesigntolerancing,p128

NONLINEAR RSS
f 2 2 f 2 2 f 2 2
f 2
Toly
tol 1
tol 2
tol3 ...
toln
x1
x 2
x 3
x n

adjusted

Toli

3Cpki

Wource:Sixsigmamechanicaldesigntolerancing,p128

RSS EXAMPLE

Largest=>0.05+0.051=0.101
Smallest=>0.050.051=0.001
Wource:Sixsigmamechanicaldesigntolerancing,p128

TAGUCHI METHOD
InputfromthevoiceofthecustomerandQFDprocesses
Selectproperqualitylossfunctionforthedesign
Determinecustomertolerancevaluesforterms
inQualityLossFunction
Determinecosttobusinesstoadjust
CalculateManufacturingTolerance
Proceedtotolerancedesign
Wource:Sixsigmamechanicaldesigntolerancing,p21

TAGUCHI
Voice of customer
Quality function deployment
Inputs from parameter design

Optimum

control-factor set points

Tolerance estimates
Initial material grades

Wource:Sixsigmamechanicaldesigntolerancing,p22

SUMMARY
Importance of effective tolerances
Tolerance Design Approaches

Worst-Case

analysis
Root Sum of Squares
Taguchi tolerance method

Continual process
Involvement of multi-disciplines

REFERENCE:

Six Sigma Mechanical Design Tolerancing,

Harry, Mikel J. and Reigle Stewart, Motorola
Inc. , 1988.

Creveling, C.M., Tolerance Design, AddisonWesley, Reading, 1997.

Wade, Oliver R., Tolerance Control in Design
and Manufacturing, Industrial Press Inc., New
York, 1967.