CHAPTER 6

TOLERANCE ANALYSIS
Contents
1.0 What is tolerance analysis ?
2.0 What is Tolerance Stackup ?
3.0 Generally, the Tolerance Stackup Process
4.0 Method and Types of Tolerance Analysis
5.0 Worst-case Tolerance Stackup
6.0 Assembly shift
7.0 Worst-Case Tolerance Stackup Example
1.0 What is tolerance analysis
Is a global term that includes two
subcategories.
1.0 It describes the methods used to determine
the meaning of individual tolerancing
specification
2.0 It is the process of determining the cumulative
variation possible between two or more
feature ( Tolerance Stackup )
First Step :
Before a Tolerance Stackup can be performed,
the dimensioning and tolerancing specification
applied to a drawing must be clearly
understood.
Tolerancings specifications are complex, it
takes training and practice to be able to fully
understand tolerancing specification.
Second Step:
By using tolerance stackup techniques, it allows
the Tolerance Analyst to study the cumulative
effects of multiple tolerances.
A distance or displacement is chosen as the
subject of the study (usually represents a
nominal gap or interference)
Typically the distance or gap between the
features to be studied is not directly
dimensioned or tolerance ( the distance
between two parts that must not enough)
Is a study of individual tolerances an their
meaning, and it is the study of the cumulative
variation between part feature.
Are the means of analyzing and predicting that
variation, regardless of whether the features
only exist on paper or if parts have already
been manufactured
Tolerance
Analysis
Tolerance
Stackup
The most common application;
# to verify needed clearance or it may be to verify
a needed interference condition.
# to verify fit
# determined the size location, and orientation of
every clearance hole and tapped hole that
receives a fastener
Some of this tolerance analysis are so
simple that the engineer doesnt even realize
that he or she is analyzing tolerances!!
2.0 What is Tolerance Stackup ?
Quite simple : Is a decision making tool
By performing tolerance stackup, information is
obtained that helps to answer one or more
questions about a particular design.
The result of tolerance stackup is almost always
a minimum and maximum distance.
The information obtained can be used to
determined if a change must be made to the
dimensions and /or tolerances of the parts
being studied.
3.0 Generally, the tolerance stackup
process
The distance to be studied is identified and
labeled
The positive and negative directions of the
Tolerance Stackup are identified
A Tolerance Stackup sketch is create
The dimensions in the positive direction are
added together
The dimensions in the negative direction are
added together.
The negative direction total is subtracted from
the positive direction total to find the nominal
distance.
All applicable tolerances are added together.
This is the total possible variation.
Half of the total possible variation is added to
the nominal distance to find the Upper Limit for
the distance
Half of the total possible variation is subtracted
from the nominal distance to find the lower limit
for the distance.
4.0 Method and Types of Tolerance
Analysis
Two method
1.0 Manually modeled
Analyses done by hand, using pen and paper or
spreadsheet programs.
2.0 Computer Modeled
Analyses performed by computer statistical
simulation programs. Three-dimensional analyses
are best suited to computer-modeling tools.
Tolerance stackups may be done on any
toleranced part, or any assembly of toleranced
parts.
A tolerance stackup cannot be done on a part
or assembly that is not toleranced.
Single part with missing dimensions
Assemblies with missing dimensions
5.0 Worst-case Tolerance Stackup
Worst-case Tolerance Stackup determine the
absolute maximum variation possible for a
selected distance or gap. This distance is
usually not dimensioned (it may have a
reference dimension) and is not directly
toleranced
This method assumes that all dimensions in the
Tolerance Stackup may be at their worst-case
maximum or minimum
Tolerance Stackups as defined in this chapter
follow a chain of Dimensions and Tolerances.
The dimensions and tolerances in a Tolerance
Stackup are called a chain of Dimensions and
Tolerances.
It is because the Dimensions and Tolerances
that make up the Tolerance Stackup are
arranged like the links in a chain, and followed
head-to-tail from one end of the distance being
studied (call it point A ) to the other ( call it point
B)
The flow
process in
implement
worst-case
method
Step 1:
Indicate the
distance (gap
or
interference)
want to
analyze (as
indicate A and
B in figure
1.1).
Step 2: Change the
dimension on the drawing to
mean dimensions and mean
tolerances (refer figure 1.2)
Mean Dimension
= [(Upper Limit + Lower
Limit) / 2]
Mean Tolerance
= [(Upper Limit - Lower
Limit)/2]
Step 3: Set the positive
(+ve) and negative ( ve)
direction. For this analysis,
the right
direction is +ve and left
direction is ve. (no rule to
choose +ve and ve
direction but both of its
must be opposite
direction). (See figure 1.3).
Step 4: Draw the first
vector. The first vector
started at the one of the
point to be analyzed.
The second vector must
start from the end of the
first vector. The third
vector will starts from the
end of the second
vector. The next vector
will continue draw until
the last vector which will
finished at the Point B.
(see figure 1.3). Figure
1.4 shows the chain
of the vector starts from
Point A and finished at
Point B. The distance
(gap or interference)
between the starting
point and finishing point
will be analyzed.
Step 5: From the chain of the vector shows in figure 1.4, the
dimensions and tolerances are filled into the Table 1.1. The totals
of dimensions in positive and negative direction are calculated.
The cumulative of the tolerance also calculated.
Step 6: Based on data on Table 1.1, the maximum and minimum
distance gap
are calculated by equation (1) and (2). From tolerance analysis
done for this part, the
maximum distance is 15 and the minimum distance is 8. This
calculation can easy applied by using Microsoft Excel.
So, if the maximum and minimum distance (15 and 8) is not fulfilled
the Product Designer, the changes can be make easily by
changing any tolerances and dimension.
The minimum distance = [(Total +ve direction) (Total ve
direction)]-(Total Tolerance)
= [(56.5) (45)] - (3.5)
= 8 ------------------------------------------------------------------------------ (1)
The maximum distance = [(Total +ve direction) (Total ve
direction)]+ (Total Tolerance)
= [(56.5) (45)] + (3.5)
= 15 ---------------------------------------------------------------------------- (2)
6.0 Assembly shift
The amount that part can move during
assembly due to the clearance between a hole
and a fastener, a hole and a shaft, a width and
a slot or between any external feature within an
internal feature.
Assembly shift accounts for the freedom parts
have to move from their nominal locations due
to the clearance between mating internal and
external features at assembly.
Shift about a fastener
Shift about a fastener
Consider an 8-mm fastener passing through a
10 mm hole, there is 2mm clearance and the
part can shift 2 mm total, or 1 mm in any
direction normal to its axis.
Given the hole and fastener combination, it is
apparent that the maximum assembly shift is
possible when the hole is manufactured at its
largest (LMC) size of 10.6 mm. The worst-
case assembly shift is determined by
subtracting the smallest possible fastener
diameter from the largest possible hole
diameter.
Worst-case assembly shift
The worst-case assembly shift
applies to each part. Each part
may shift +/-1.3mm relative to
the fastener, leading to Total
Assembly Shift of 2 *1.3 =
2.6
7.0 Worst-Case Tolerance Stackup
Example
The tolerance Stackup example that follow
increase in complexity from finding a minimum
and maximum distance on a very basic part
and to finding a minimum and maximum
distance on a complex welded assembly.
All of the examples are based on parts
dimensioned and toleranced using the
plus/minus () system.
Example 1
A pin is the subject of study
To determine the minimum and maximum
width of the groove in the pin.
The groove was not directly dimensioned and
toleranced on the drawing.
Unfortunately, drawings are not always
dimensioned and toleranced functionally, and
this example shows how tolerances may
accumulate when the dimensioning and
tolerancing scheme is not optimized.
Given
Pin with groove
Pin with groove solve
Example 2
A part like the one presented at the beginning
of this slide
To determine the minimum and maximum
distance between two parallel surfaces on the
part.
The distance was not directly dimensioned and
toleranced on the drawing.
If this distance had been directly dimensioned
and toleranced a Tolerance Stackup would not
be required.
Simple part
Simple part solve
Example 3
A simple assembly is studied.
To determine the minimum and maximum
distance between opposing surfaces on two
parts in the assembly.
The distance was not directly dimensioned and
toleranced on the drawing.
Simple assembly
81
Simple assembly solved
Simple assembly solved
Example 4
An assembly with parts assembled in the vertical
direction is studied.
The assembly will be greatly affected by the force of
gravity, which will most likely pull the bracket ( part
number 3) down against the fasteners.
The fasteners will in turn be pulled down against the
holes in the hanger ( part number 2). This will add
assembly shift to the chain of Dimensions and
tolerances twice, one for the hole in the hanger and
once for the hole in the bracket.
It is assumed that the frame ( part number 1) and the
hanger are fixed in space.
To determine the maximum distance between the
upper surface of the frame and the lower surface of
the bracket
Hanger assembly { with gravity and
assembly shift)
Part for hanger assembly
Worst-case hanger assembly and
Tolerance Stackup sketch
Tolerance Stackup report solved
Example 7.5
An inseparable assembly ( or weldment) is
studied.
To determine the maximum distance between
part 5 and 6 in the assembly.
The distance was not directly dimensioned and
toleranced on the drawing.
If this distance had been directly dimensioned
and toleranced a Tolerance Stackup would not
be required, as the minimum and maximum
value could be easily calculated right from the
drawing.
Complex welded assembly
Complex
welded
assembly
{ Tolerance
Stackup
sketch)
Tolerance Stackup report solved
The end