Tolerance Stack-ups

Problems due to tolerance stack-ups

include:

Failure to assemble
Interference between parts
Failure of parts to engage
Failure to function as intended

Overview:
Tolerance stack-ups are
accumulations of variations on
drawings or in part assemblies.

Example: Accumulation of tolerances on a drawing.

3.000.01
7.000.01

What is the effective dimension and tolerance between the two holes?

In this case the tolerances add directly

The furthest apart the two centers can be is
7.01-2.99=4.02
The closest is
6.99-3.01=3.98
Thus, the effective dimension and tolerance is
4.000.02
This addition of tolerances may make it hard to join
with a mating part that has two pins that fit in those
holes.

What can we do as designers to

improve this?

The logical thing is to put the dimension and tolerance directly

on the hole spacing if that is the location most important to
function.

7.000.01

Example: Assembly of individual parts

Suppose we have two blocks, A and B that are to fit into a slot in
C, all with tolerances shown.
Aa
Bb

Cc

Gap

Lets look at the largest and smallest gap that we could have.
Largest Gap = (C+c) (A-a) (B-b)
= C (A+B) + (a+b+c)
Smallest Gap = (C-c) (A+a) (B+b)
= C (A+B) (a+b+c)
Consequently the dimension and tolerance of the gap is
effectively:
{C-(A+B)} (a+b+c)

If we have 10 parts (say a clutch pack) that all have to fit into
a housing, the addition of all those tolerances can be
significant.
If controlling the spacing of the clutches is important to
function we have a problem.

What can we do as designers?

Solutions
Tighten up the tolerances on each component
so the sum of the tolerances is lower.
Include a spacer that comes in different sizes
to take up any slack resulting from the
tolerance addition (similar to shimming).
Design so that the tolerance stacks are not
relevant to function.
Consider that the variation in each part is
likely to be statistically distributed.

Example: 2-D
Consider a swing weight governor similar to the one shown
below

Simplifying further, assume:

Holes are perfectly located

Pins and holes have zero clearance and move
freely
Only length of links has tolerance
L1l1
H
L2l2

The height can be found using geometry (specifically, the Law

of Cosines).
H2 = L12 + L22 - 2l1l2cos
(where is the angle between the legs)
And
Hmax2 = (L1+l1)2 + (L2+l2)2 2(L1+l1)(L2+l2)cos
Hmin2 = (L1-l1)2 + (L2-l2)2 2(L1-l1)(L2-l2)cos

Tolerance stack of swing weight governor

L1

4 L1max

4.02

l1

0.02 L1min

3.98

L2

3 L2max

3.02

l2

0.02 L2min

2.98
Angle
alpha

Hmax

Hmin

Hnom

+/-

180

7.04

6.96

0.04

170

7.014

6.934

6.974

0.040

160

6.935

6.856

6.896

0.039

150

6.805

6.728

6.766

0.039

140

6.624

6.549

6.587

0.038

130

6.394

6.322

6.358

0.036

120

6.117

6.048

6.083

0.035

110

5.795

5.730

5.763

0.033

100

5.431

5.370

5.401

0.030

90

5.028

4.972

5.000

0.028

80

4.590

4.539

4.564

0.025

70

4.120

4.075

4.098

0.022

60

3.625

3.586

3.606

0.019