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Mechanical Tolerance Stackup and Analysis Mechanical Tolerance Stackup and Analysis a eo MECHANICAL ENGINEERING A Series of Textbook nd Reference Books Posing Eat LL. Faulkner Columbus Divison, Bane Memorta Instiute ‘an Deparoent of MochvielBngicering ‘he Ohio State Univers (Cantus, Oo ‘Soler Engheonng fer Dares Buldngs, Willan A. Hin ‘opted Engnceing Mecho: Sates and Dynarcs, G-Booboyd snd Sor ‘Genta Pomp Cin gor Kara ‘Gomputer dod Knees fr Masie Desi, Dane Ryan ‘Praies Posse Deg Handbak, Part A Matias and Components Part £8 Procnsee and Design fr Processes, ede by Ednars ‘Tubomoehinry: Base ery and Appleaton Eat Logan. J ‘ats of Sats and Plates, Wer Socda Flt and Corugatad Captrapr Desi Handbook, Mario Givens ‘races! Sess Anas Engoorng Desi, Aart Ble ‘a inroaicton tothe Desig and Bohavor of Bote Jos, JohnH. ‘esters Optial Engrg Deon Prieines and Agplcatons James N.S Shing Marufactuin Handbook Haris Caton ‘dutta se Cart: Pandan and Apaatns, to by Lows ‘Gears ond Tha Vivato: Base Approach fo Understanding Gear Nase, Dare Sm “Gini Yor Power Tranonisson and Mate! Hang: Design ard Apo ‘Salons Handbook, Amarcan Chai Assodabon {Carian "and Coneson Pretecion ‘Handbook, edted by Phiip A ‘Gear Ove Systm Desion and potato, Peer Lyewande inPlont Arbane ‘Consminants:Systams Design and Cal. catators, Joh D. Constance (GABCAi Syetns Planing end implementation, Chars S,Krox Protas Engineering Das: Poco and Appicatios, dames N Sisal Tracten Devs: Slecton and Application, Fredrick W, Helich Wand Eugene Shue Fine Element Metods: An Introduction, Ronald L. 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Baron Mechantal Prepares of Engoored teal Wole Saboyelo FRlaoley Veriton, Tesing, end Arajls Engneonng Desir Cay 8. ‘Waseomen Fodomnta Mechanics of Fis: Ti Elon, |G, Caio Intermost Heo Transfer Kaui vine Wong HVAC Water Chere ond Cosig Towers: Fundamentat, Appesten, and (peat Het W Star (Goer Noe and Viton’ Second Eton, Revised and Expanded, J Bere Sh 156, 189, 60 402. 1 10 1, 167, 18 470. am. we 173 174 175 1 178 178, $81 2 1. ancbock of Tubomachiery: Second Eten, Revised and Expanded, ‘oa by Ea Logan. and Ramona Roy Fog and Prine Engiroarng: Design, Constr, Maintenance, Ig- fy, and par, Gog A Arik Tubomactiney: Design end Theo, Rams S. R. Gata ané jae Arend Kan Target Costing: Market Oren Product Dasgn, M. Brat’ Cito, Hemy MB. Bi, Robert E Atiano, ana Wesley. Townsend ‘pated Conran, San la soning: AN Intodscten fo Paremeterahg Geamatic Mods Vig Sevasan Handrook ct Mechanical All Design, edited by Geog E. Tote, Ln Xe, {yoshi Fura ‘Stutal Analyse Polymone Compose Matris Mark Tale IMadetng and Simulation for Matorl Seccton and Mechants! Design, ‘ted by Gorge E- Toto, Lin Xe, ard Kyat Paclan ‘anabock ef Preumate Conveying Enghestng, David Mis, Nak G. ones end Vay Agar eas ond tas eson ant Sot, Secon Eat, lam C Randementls of Fld Flim Lubrcaton: Second Eon, Berard Hamer, StovenR Stn, and Bo 0. Jacobson ‘Handbook of Lead Free Solr Techie or Mcoeecoic Assembles, (doy Ka. Pats ond Katieen A Ser Vente Sty, Dean Kamo Mochoncal Wear Fundamotat and Testing: Second Eaton, Revised and Expanded, Rejtond 6. Bayer Lad Paine Phare, © Sash Meron Sold Fue Conbusion and Gasca ar de Soa-Sanoe MochantalTeleranes Sackup and Anais BR chee Engineering Doser Wear Rayong G Bayer \nvatons a Sets and Plates: Third Eso, Revised and Expanded, Wee et Soe Fetactones Handbook toby Chats A. Schacht Practica Enginerng Faure Anta Har MTavancy, Anwar Ube, Noredan Me xbbae ‘Mectantl Along and Meg, C. Suyanceayan. Mechanta! Vivato Analy, Uncotantes, and Cart, Second Eton, ‘Revised and Expande, tam Bosraya Der ofa tina, So Oty Practica Facue Mectants i» Desi Socond Eaton, Rewsed and Bx. Banded, Aun Sul ‘racial Gute to Desked Experiments, PaO. Frkontusch Adon! Volumes a Preparation ne Sore ‘Spring Desig wih an BHP, A Ditch esta Ded Fre ays: Wn alr Ara yt Sore Mechanical Tolerance Stackup and Analysis Bryan R. Fischer 4 7 aheE oy SR 1 Background ‘oleancing, Tolerance Analysis and Tolerance Stackups hve hee around In one form or another fora Longtime. Sometine inthe past it became ‘ees to determine whether a collin of pats woud together before ‘hey weremanofatired. A design eum may have nos t know bow tina part store coud become duriag manufacture, make sue the pat would Fenuissrong enough to work, They may have neded to know ho age ae ould be now frit ole fom it nominal potion to ake sie tee Was enough surface contact to properly dre the fa! fom 8 Jasener. Peeps the manufactring tum nooded t0 enderand Wi ah ‘stembly of prt that mat the drawing speiations dl not topthr at ‘stenbly. By performing Tolerance Amal and Tolerance Stackups, thse ‘nd many other important questions about the design canbe aster. ec thats why Tolerance Anls and Tolerance Stackups ae doae—t0 ‘onde answers to questions. The cchniqus inthis text wil belp you, he Teale, understand your tolerancng probes, answer your tolvanciag ‘ueton and vole sour tolrancig problems "ow can the designer envare tha prt wl together at asemby? ‘etry hw canbe deser nme that mere pat il ogsther at ‘sembly, as al parte are imperfect? How much imperfection or vations lomabe? Does tnt prt is mpulutured sit are ha noi ‘nd the mating part is manufactsad sealer than nominal? What both ‘ts are manafacrred on the smal side and mating Hoes i each part are lighted or out of poston? What fects the performance fhe seb 'Bore—vaiatonin iz or vrai in poston? What happens toaTeaure ot 2 nape ‘one parti surface onthe mating ar tite? These quetions al ead tos Tolerance Stactup “Tolerance Analysis and Tolerance Stackup techniques have evoied overtime increasing in comple tome! he ineresingl compa seed of hs prods they say. Inerestngy, a change in manuractrig pioeo- hiss ely the primary reson that Tolerance Stackps ae so portant foday. Design took and techniques bve changed the design comunity ad ‘he manufactuing community have econ separate cies and the ned 0 ‘erly and unamtaguoulycommanisate devin equiseneats between he two has driven the ned for Tolerance Sackups ‘The need for and the abiity Yo design ever more complex parts and sembly the need o guarantee taney and the wend to fuarantee interchangeably of pars have contbutt grey to the widespread neod for Tolerance Ansys. Comply san stresing iste it iat to determine if complex design il sats) is obptves even wheal parse thei nominal state Tow in varation and te problem can be ove hlming. Through the application of standardized Tolerance Analyst Tecigues, suchas te oes presented inset the problem an be reduced toa more manageable or and solved, The need fr interchangeable pars and the aed fr pats that wil without rowork adjustment tase an only be ented by Tolerance Anas Theefastrs ae hallmarks of oder manufactrig posi, andthe only way to ensure thee goals sate achive is through the proper we of Tolerance Anal ecigues Tolerance Anafss can be found today in nea all sanulactaing Indore, rom the very small geome found in ntepatd cee to the ‘erylarge geometry Found o rockets, the Space SbullesndtheInroatiol Spice tation. Anywhere that parts mus ttogetbar, anywhere the polis of accumulated triton may cave # problem, or merely needs to be lndersood and quanied, Tolerance Analysis and Tolerance Stak ‘echaiguor are being wed, “Although its ot the ely environment where Tolerance Anais is needed, Tolerance Analpis has founds greatest application it mass ‘production, where interchangeably of Sindy slsted prt sexsi ‘tine manufacturing ineases the demand for pat hat abot ‘mus a assmbly, as its mich eekly td Yo ve a stock of Spare arts wating inthe warehouse. Tolerance Analysis the oly way to eaute that the toleraoss pied on drawings wil lead to pars tha “Tolerance Anal equally benef in escuch and development (R&D) and for on-oFakind components and seen, as tere i 80 ‘thes way to ensre tat the acamlted variation of said pct fe. ‘acess nctionaly acceptable, Whether tithe to obi end eon ‘ona robotic am a cover that fs over a enlosie, a slerance hole thal sackourd 3 sus allow a fastener to pas, oF the location ofa bracket in an assembly, ‘Tolerance Analysis the only way to guaratce that pats wil it ogethe at sembly or milemi, mankind has heen doing and manufacturing parts, sssembboy and sractres Early onthe person that dened an sem treo reponse for manafcaring the pars hat made up the asienbl Td, tbe design wat’ complete unl fal asemy, where many pals ‘er ground, scraped, dled, Dnt and modified to mutch th ating pars. Such assenblis work well enough, but they were one of king. Tt vas eounon fal the parts ia such an assembly tobe easton Bt, This or of ‘aston, raftsman-orented mapufitring philosophy wasocessry back in tbe diy before automate, high-precision manufaetring machinery. twas {ben wy that the craftsman col be sre the parts oul be asiernble Sich anemblins, however, presented huge problem in tm of cot tine (both production tie and sembly ine) and matenance ‘Asallparswerecueatall) one of Kind, abd equed a great amount of abr by the eafsman, the cost Was high’ It ao took a fng tine 10 ‘manufacture such an assembly, as only afew could be made a any sven Sine Lastly, and ths is perhaps the gestest problem, was the problem of ‘ephcemeat parts, There was no easy way to replace a prt hat male ‘ona or broke in serie. Because the most oral of the pats had been custom at asembly, ther was bo guarantee hat replacement pat pled ‘ifthe shelf would work without more dling. grinding, nd modiction. Machinery dsened so manufactured sing thse methods Is subject to ‘xtende dowatime when 4 faire occurs The eration a te extra abor Feyuredin geting he replacement par to match the mating Parts us 0 ad the dowatime i the use of the machinery cas ead to potently large prot Tose ‘Overtime, designs mature, This yeu’ new desig borrowed bits and ces rm previous designs, improving upon eabetapproaches. As Sess ‘came more comple, designers develope ito spessizn! prop, ith Sls and aes unique to ther era Likewise, asthe process ad methods ‘wed to manufactze the pars and asembieshecame more comple, the frallsme that made the prs alo became more speed, evling ito 4 Sinn, highly skied and talented group. Eventually, the person that Signed the part and the person that made the prt were diferent people NNolongerwasit satisfactory for jst the designer fo know what was equed ‘ofthepartsmaking up theassembl)—eideas and requrerenisor the pars sod assembles had to be communicatd to someone els, communiaed fo ‘the caftsmen who were manufacturing the parts abd asembls, ‘Diag thi transtion it Bese evident that drawings were nde to ‘lce what wast he made, to communicate the designer eas to tose 4 haptr 1 manufctsing he componet. Drains i oe dincaions, alt Some infomation ad tbe speedo the Sawing, ina ltd decent conveyed vera Ont ame oon tht te best ‘ay tesa the part or seh being mafactre sts the eds of Uh deseo mas to completely dimension he ravi “Today, ritually al manfred tons ae dined by engineering deanings: Among or thigs, engecring Savings Jee ot dfn he eon: oranda ofall comer eatreron ar sual impo, ‘lowrg dings ads or dct losip beeen arn {Semb) fentues,coding th late srcnation and acon "Thee tn smpogets 0 the eon of par geome: esp on ofthe nominal state an destipion ofthe alowable aration Te ‘ode te ote wodiensonal GD) daving gentry nce btwn proves dexripion oe nomial sate Dinesonngis an “tension f the deseptin ofthe nomial sats, a dinenonng tal ‘sprees the nomial codon of pr geomet. Tleanng va dea ‘Soft alowabl anon ota erate at aur Tope these provide comple Sspon or enon of a one biesionsitvatsion pee "very fentre on» prt bold bs fly imensioned and tle, hich inclu ech etre’ form, se as apis) retton ad Iain relate othe ret of the part. The denoning system map we taditona psi dneesons and tla, my he Comets Di ‘Benning snd Tolsanng (ODEN) oritay wes cmbnton bath ‘rene, Alhoughallo the method recommoaa atta, isthe Atthorsopnon tht he sb bx metodo use GDR =i y fer ihe Gare, mos acct snd a problematic method fo dete the inenoning and folancng egurenents or prs and sci, the signers salt comply snd unambiguous dene te oie {omer retina betwee lat estore to onan hatte prt ome wil any non egestas soon, ten CDE s {tony way too. The protiens an aps he oyna se ‘AcrrteTolase Anas can oat el be done on parts and suc dmensonedand olrnsod wing D&T there ssfartoo any inconsistencies and sumptions reqare fo reba parts dened aa ineancd ng the plsfnnoe tom son. That sd th et covers ‘olernce Anaypug he plsminos tem and GDA, as many peodued prs of semble eed he es Metta re + ie it ig ete nti or benbie wal be rect duc to eoeig te cas ‘statistical result Heesislass Four 81. Grssn stdin, Stata Tolrance Scans or -As presented in Chapter 3, desgn nominal and marfecaring nominal ae cry if eve the sme Ths presets a problem when consierng the “Shove ssumpsons. The rauiements or RSS statisti Tolerance Analysis Sethe manufacturing peosster shall be centered and ottput normal “Euetbtions Ths wort to the Cy and Cy vals encoun in ta fiscal proces contol (SPC), which addres proces spread and process ‘Seri. Ts beyond the sope of hist to ads the sas plztions regarding thse apporentdscontnuiss in great deta Satie to thei ference betwee the design noms a manufactaring Moa ‘Bulan the fc that some prosetes aren as "cootolle as they shouldbe Teed tomlin the sara elt by acocficiet greater than one. Tis (Sct ls adesses the fat that most ofthe conditions ted in the ‘iviouparesaph are no alnays 100% appbiabl to every dimension and TShrnce, Malupying the RSS revel bys coticient restr than Tavs the (ated tata es. “Three scveraltatsal methods avaiable for Tolerance Anas Rootsuguire (RSS) and Monte Calo simulations arte two most co ‘Row, Roocaumsquatescommooly eed om manually modeled and spread- ‘essed ttn Tolerance tackops ‘Monte Caro simaton i tpl used with computer-based Toler ance Anus simulation software, Simply pu, Monte Cao simltions ake {ifthe wanabis in eToleaace Stskup, ve dem a random value within thir range, derive arse erate ths proces thousands of mes, and ‘Rerage seul, The fe por stats! approach, These are very Powertools, an ae great for slag tree-mesioal Tolerance Stack- {pms these teas allow te Tolerance Analyt o look st many combinations TFeshationa nd totaal vartin, Thee toolare alo fay expensive hdcomplertoeara and we, tina god idea to dedicat Tt eam ow to se the too, as modeling can be compbated “This teu uss the rootsumerguare method. The rootsumaguare method takes cach tolerance vale squares it adds the squared tolerance ‘Guc,and takes the square root of the esl, Hence the mie rootsm- “ure, The formula cam be seen sn Fig. 82. This resol is the statistical ‘Grane Tete areseeal variations on thismethod sing combinations of torts snd sat foleraning.o adjasng the rest by lpi it yn vale SI, Ar mentioned clr, the static tolerance 1 often tind by an adjstment factor such a 1S. This ota text on tain rune 82 Root sum forma for iil Toletncng. Wher Ty Tolan Site Tora Stuy, 08 . ‘ddoes ot attempt cover this important arin great deta The reader Avs to mor define sources fr background, jstifeation and dei Yon of formulas and methods, such ae the Dinenining ond Toeancy Handbook, which contains several chapters devoted tote study ovatus ‘ttisialclerancing tchniqcs, ‘have Been asked many times wha the RSS Tolerance Stackup result presents in terms of sigma (o) or standard visions. Students want 10 {now if an RSS Tolerance Stackup represents & = lay so, 260, ee, sistebation. Te generally assumed tha al the inividnl tolerances ‘ered into the Tolerane Stack ae produced by prosee contol fo 1 then the RSS Tolerance Stackup rest soo represents To pute nother way, its geerlly assumed that the lvl of process conto he input tepresents the level of process controls af the ouput (See Fp 83}. Likenseiallte component tshrances ar astute, 25, of n fen the RSS Tolerance Stackup result represen io, i2o, or abo, respects. The batter sou know your process, the mare secure the Matisizal Tolerance Stckup rest ICs very import fo arn tbo he ‘mansficturing processes where posse and to obain telat data feo ‘tistical controled prone. Tn the real worl, however, likly that he processes wed to manic fcture al the par features in'aToleratce Stackup and thelr anoited toleaness are nt conto othe sme lee. That iy the tolerances fn “Tolerance Stachup are probably manufactred wing a few 22 proces few so process afew 14 process, te, and perhaps chen some process here thee ofconrlisunknowa So snmany evitamensitia ie tat the tolraness in Tolerance Stackup represet sited bag of peocet caput. Thisisespeily true wher other factorsenternt he caaion, ‘veh a datum feature sit or assembly aif. Assombly shi spray roblematie sit iafunction of heassembly pros and unless tess ‘roc is monitored and measured like evry eter proces ily nl controll Indesdasembly shi etn mae in ts wort aa oe, See Chapters and9formorecoterage nm asembly shit Agi this he ‘more reson to use an austen actor men iatrpeting sat rl A step-by-step explanation of how to petfrm statsial Tolerance Saokups follows. Tiss exactly the same proces a presented in Chaper xcept for ew alton steps in which the tolerance values are squared hd ‘esque oot of theirsumis taken adil yan jon acer described above, These methods can be easly performed smultansoty ‘ng pdt ‘aime 8 Pat sgmas ~ seb sigs, erally endo tht the RSS ‘Sin! Toleace Suc Rol eoxathe ame oe proce cao {Be Tolerances tat mane tp the Toles Sakap. So, for Sap le ‘ohsanr inthe Tolan Schup sere pode iy proses cone 0 wg oun 84 Sui csinof Dinenon and Tolerances 10 Chapter ‘STATISTICAL TOLERANCE STACKUP WITH DIMENSIONS. (DIFFERENCES FROM WORST-CASE HIGHLIGHTED nirauics) 1. Sdlet the dance (gap or interffene) whose vatiation ist be termine, Label one end ofthe distance aod the eter cod B eee 84). 2. Detemineifaone. tw or three imensionl nsysiss regi. If two-dimensional analysis i equired, dete if both ‘retons can bereaved into oae-diension wing tego rome. aot liner Tolerance Sticup sno appropiate, Sida computer program shouldbe aed for te Tolerance Taree dimensional analysis i require, list Tolerance Sackups probably notappeopriae anda computer progr Stould be wid for the Tolerance Anas. 3. Determines postive diction and 3 nepnive dition, 4 Ihre is a dimension tat spans distance 4-8 abel it ea postive dimension by pacing 4 "+" sgn adjacat tothe Alimension value (Gee Fi 8) It boul ao be signed ¢ ‘retion by plicing a dimension orga symbol a the ed here the densi stars an am srowhea athe ater ed | »3— aces Foun 85 Sasa! cin of Denso and Tees #2 7 ‘ie “Staten! Tolerance Sac ” ‘he the neon tint. Al dimes inh cain {Dimes and Tarn tat flowed oie ection tn be abs ss youtne dimenson. All ‘noon at flied he ope ston sal fetabiot sacar dimensions 1 po incon spans dase 48, sar at pin 4. fe clon af then fom point 4 ro toa ‘hough orem apt the ab poste ne SVE fn dmenon on ymin and arowhead certain dsm yom gi Babe Sque( He £9) enya of Dest nd ‘Secs fom pit to post ssh a Sines inibese neon poste cee, ated ye “amotio Renee, tena comenson ating though damn 4-8 tau be beds 4 Poe dinero Fatt icin of Dinesons on Tolan om point A {Dun Bou sold bea ffl toto poh aunt 86 Satta cisn of Dineson and Toler #3, we cmp _StatstealTorance Statins ¥9 {oo he tar tothe end of ach densin inthe cia rom ae point dt point se Fig 8, ae in Gisexample te ist dienson starsat pint 4 and nds ath le elg ofthe pat. The second dimension starts ‘there the first dimenon ens and end athe ight edge ofthe ‘st The ted dimension stats whee the eond dimension Ends Te fourth dnension stare bere the hind dimension dead ends pot the dimensions ae ot propery labled, the nominal sistance wl be negative afer the negate totals subtracted from theo oa this happens check the* or ~ labels assigned fo the dimensions, aking sare ht the sum of the Postively label dimecsions sIarer tba the sam of the egativey abled dimensions. Remember that the tl value Heme 87_ Sutil chs Dine an Tora Faw tin ‘of the postive dimensions most include distance 4-B. 1 eso conte i dechae | ° Punt AP make se tee ae a0 wssng veo Ff 1st 7 conta Sepp [ose Foune 88 Statitlchin of Dinetslon and Tokens 5, Cone all Dimensions nd Toa ool iat rma. Punt 89. Sata cun of Dineson and Talons #6 onan 8 4. Comer a dimensions and tolerances oe tisteral format (the same vale) Istrotons or howto do arene Chapter 42s Fig 88), . Nowallthedimensionsand tolerances must be ptintoa chart and Totaled for reporting purposes. Pace each posive dimension ‘ae in the poste column ona sparte line Plas cach mes tive dimension vals inthe neptve cota oa a seperate ac meets Ee + |= [roman | etre ‘Poune 8.40 Stasi in of Diserins dd Toes 7 ‘Stats! Taree Stchups 6 1 Pace the tolerance value foreach dimension i the tolerance Column adscet to each dmenson. Ti ale eal he Lota “aration allowed bythe oeranee. Toke eoch tleronce valu and square It. Place ths vale On the Stata! Tolerance column nex to cack tolerance (0 Fi 8.10) ‘Add the entries in each column entering the ress at the Bottom, of he char Fig. 8.10. Take the square root of he sam of tata olerances (RSS). amet rons gee se] Fane 811. Siti of Dison and Totes #8. — | ja . vias pu — Fan + | Toners reuse as] "ai i [NEGATIVE TOTAL / une 812 Sutil hain 0 Dimensions nt Tolan 9. Enter hs rout he etom of th chart. Tithe RSS Tolerance Yate (este 84 Subtract the negative ota rom the pote total. This gives the ‘nominal dimeasion or dtane (ee Fig 8.13) Apply the ror! sare telernce. Adiga subtracting te ‘tattiel tolerance fom the namin dinenion geste itl oF ‘probate maximum and mininae tance ales (ce Fig. 813) {is desired othe a stighy more conservative approach malig ‘he RSS tclerance By on adutmon factor such 14 ths. a Soe Faune 8.18 Stati chan of Dimes and Toleanss 0 ample) perform http here, subtig she lrger sed RSS ‘tle forthe RSS vane oe Fig 814), Far and vay the eset method to soe inne Tolerance Stckup probiemsisto wes cst report oral despa oraspredset program ich at Microsoft Excel or Lotus 12-3. The addons mathemateal Steps fn be built nto the spreadstect: ace the data is entered, the worsteate, Satiticl, and adjusted statistical slutions ae cleulted and dspayed simulans, making easy to compre the eit ofboth methods. The a i ve =i aes Meowice a yottaener nee oudRanGE VALUE Fine 8.14 Stas cin of Denes Tans ‘math ad he format aenseparable, making fran easy-to-use and easy o- Understand problem-solving and reporting fo, Teeannot be overstated how important sto we aay aad easo- ‘ea eportng format as commuriction ofthe Tolerance Stackup es slnos always required. Using such a tool as described above cousitenty tals it easier for everyone involved in a proj to understand the iar, ‘ton quickly serine and money Fane 8.15 Semple Tolan Suckyp tpt form. 12 noir Preformatted Tolerance Stacey spreads oo for solving worst ase and stata nar Tolerance Stickips ar svalable fom Daneman, ing and Tolerancing fms sch a Advanced Danensional Manageneat™| ‘An examples shown in Fig 8 15 “The Tolerance Stakup report form shown in Fg, 5 contain the fet Toning information + Product ame + Moe number (apples) + ite Revision of say + Direion of study Problem statement Objective of sad Componeat or ay name Tem aumber for reference) tem descption Tolerance value (+ and —) Tolerance souree and cleans Worse resale + Sttsial sets + Adjusted statistical eats + Note at bottom if needed Use of a consistent, standard Format is very important, I¢ makes leasing to perform complex Tolerance Stckupe ease at faite 6 onistnt approach to saving Tolerance Analy problems Data i sate ere clelations are mae, 2 data entered in the Format the amy fey time also makes tease For your customers, howe poole who ml Imterpet he data you provide andunderstad the work you ave done ‘Note that all ssmptions have ben noted, ad sources of data ae lined where applicable is common thane to search for information shee Peforming Tolerance Sackups Sometimes ssumptins and super date ‘hon sure forthe equirediformation Mate suetoitlade the soures for your informatio, ‘STATISTICAL TOLERANCE STACKUP EXAMPLES. ‘The Tolerance Stackup examples that follow a he sme st Examples 7.1- 2.6 that wee soled worst-case in Chapter 7. The reader ean compas ibe statiszal resus with the worstcaso reas, wich or lo presented here This gives the render the opperuaity to see the eft that state _Sttetca!Tobrance Stckups a ‘shige nd manipulation have onthe ress ofthe Tolan tasks ‘Asin thepreiouhuper lof theeampleare ned on pat eased {nd ere sing the pias 2) sem. ‘As prenld earn thn chap, sing Tolerance Stacks or the srg 8) an ad Sts ey ny ae few more ape than solving forth worst cae rer Rese he may tase hn theca cused ine worse cate ony tie Sonate equi bai te stata ula be sci ere ample 81 In ths example pin eh soja of tay. Ss Fi 8.16) The gol of ths Tolerance Sckupis to deeose he mum sod maximum kof the eoorein the pn The Tolerance Stack rr aeshowe op 847 “Tae Tolan Stash seth ig 8.17 shows theca of Bien sion an Toles for hi probly ih sth sme when sang he problem worse The Tole Supra. indoe ane chmnche sauna obras tie ote columns ge te se she worse {Sone ia Chap 7. Svetlana! neste ded teow cha ‘Spor te RSS trans valet the aud RSS tly ale “he dinendon van cach sun se tole tthe eae tal ‘ssuhracl rom pie fol uch ie thesia datas blog ‘adie Ech tans va gute nd he gue alee oad s -+ eae 0 or Seen nin Manan cap Faun 818 Po with soe Me Bias 364 Srves | 2: Tek Si en Seana a ee ee SLL Adie 9 Toc ae Poste Ta a6 stencil Se Lorene eae Sumeane=a7 ‘fund Tere Von ‘Nae bcuz roy evenness i ac, rnd Thee seni shown he cmt Stackyp Drecton ‘Soho for Statstea Minimum and Maximum Gap AB Foun 8.17 Pia with oo soled sail States Trance Stackope i ‘The square oot akon ofthe sum ofthe squared tolerances, which she [SS tolerance, Foe thee example, the aured RSS tolerance wil bo uss, ‘nich inthis cae meas the RSS tolerances multiple by 1S Te adjusted RSS toleranoe is eubrsted from and added tothe nominal! dance to etc th statistic minimum and maximum dstanoes, respective. The ‘nim and massa dance are report, “The worsteasefleanceis 12. The adjusted RSS tolerances 21, ‘The worsens minim groove with wat reported a8 aod the asi nm was 3.0m Caper 7 The adjsed RSS miu eroove wih 8 07 td the maximum 29, Because there ate only thee dimensions aad toleranee is this Tolerance Sack, iis probaly a beter idea to use the worse snus, Example 82 In this example, a partlbe he one presented atthe begining of hs chapter ‘hesubjet ofthe std. (See Fig. 818) The goal of tb Tolerance Stackup is to determine the misimat and maximum distance between two paral surfaces on th part. The distance being sti i dierent tha in the materia presented earlier in the chapter. “The Tolerance Stack sketch in Fig 819 shows the chain of Dimen- sions and Tolerances fr this problem, whichis the same a when solving the Problem worst sae = Seco ton Feune 818 Spl part 24 : ol LI Be Tora Secip Sah + — =| ramares| rate | oeitin TE sess oan vie sehen tas LP recrsranee = 4 Pun prance “872 ‘ted 95 Tear va Stackup Dreaion So or Stata Minera and Maufnrm Distance AS Foun 8.49 Simpl pat sobed atta, ‘Stata! Tolerance Stacks 105 “The Tolerance Stackupreportin Fig. § 19 includes new column forthe savaredtolerances—the other columns ae the same as im the worst-case ‘ale in Chapter 7. Several odionn lines ae added blow dhe chat to ‘Spor the RSS olrane vale andthe ated RSS olerance ale, "The dhmension ales nach clu are olled, and th egative total is subtracted fom the positive toa, wich ges the nominal distance Beng stale, Esch tolerance vale ested aod the guard ales are totes “The square root taken of the sun ofthe suated fleraces, which the [RSS tolerance. For thee exams, the ajted RSS tolerance wll be usd, ‘veh inthis case meta the RS tolerances mukiped by 15. The adjusted RSS tolerance subtracted from aad adSod tothe inal distance to etre the satis and maxima Stance, pete. The ‘inimum and maximum distances are report. "The worstsase folrance 4425. The adjusted RSS tolerance i {EATLL The worstease minimum distance was reported a5 6, and the inauimun was 1485 n Chapter. The adjstod RSS minimum distance is (67g and the maximum M14. nasa +$—4 . yop | BAT Fass] 1b zane Stack Dieton esi ed Mini Cap AB ours 8.20. Sinn sen Sateea Toerance Sacons wa ve Chapter 8 pap 83 Se ‘In this example, simple assembly is studied. (see Fig. 8.20.) The goal ofthis Ons 4 orrae ‘Tolerance Stackup is to determine the minimum and maximum distance reese rues on epee inte 4] “eons Sp ng sw en of ine soared Toe tt pion eas tesa sane pois cme etn chet. vu fr he sure ost oe maa etn ae toes Spe ltClpar 7 esa Inset he eco ‘Salis inc aca tated RS eum ao “Wedaramsncncanesund ot tel oe ener Na samputzed fects onl nica bret sonon ee ay ae eset Stan! atest ee mana eras le Or Meet] tL eee Foe caoes noes aber oe fo ofioe ocelot 3 3S Bis ota Fees cup ated Satna peace Tout dca ne decker caedy Tec = Tectia canoe eel dean oe 2 |= [rn omer ‘Si esminislnounsodaatnun dso ops Tea = aso ‘Biu'aninus sound ee te Nona bat 6 S758 The tated RSS lean is se ‘467 evo nn repre re nes Sa oe a seLRistchper todd HSS ta ple DS nd aera me manana s_["reas_|~arars) Jeo Foor “ ee BT Ane ae ite, ean 8965 Ee pe orc ‘Solve fr Statstea nem. ‘Stackup Ditton Maximum Gap AS Pune 821. Sine ssl sohed stats, eta ua eas Coa oune 822. Hanger sembly (th avi and ase shi). = neon 8 Exampie 84 1 thin example, am assembly with parts ase nthe etal tons studi (See Fig. 8.2, The goal oft Tolerance Sachupisto determine he ‘maximum distance between the upper sre ofthe fame andthe owes Surface of the racket, ‘The assembly will be greatly fect bythe fore of rity, which will ‘most iy pul the Bracks (part umber 3) down ein thc fatores Te fasteners wil in trn be polled down aginst the bees inthe hanger pure Immber 2) 1 i assumed thatthe fame (part umber 1 andthe hangs afte in space Individual part drawings for items 2 and} ae shows a Fr $23 ‘The Tolerance Stactyp result are shown Figs 826 and 828. The ‘Tolerance Stackop sketch in Fig. 824 show the chain of Dicom td ‘Tolerances for this prob, which she same ss when sling the probee orstaie. The Tolerance Stackup report in Fig. £2 incase cats forth sguaedtolerances—the other ealsmns se the same as nthe mors, ‘ase example in Chapter 7. Several additonal ines re added below the cha 10 report the RSS tolerance valu and the adjusted RSS tolerance ates, ‘The dimeasion ves inthe postive eolemn ae totaled, whch the nominal stance ing sted Fach oleracea squared, a the sgened ‘alosare totaled The square oo ten ofthe sum othe square lence, hic isthe RSS tolerance Fortes exampisy, the adjsed RSS lta eal ‘be wo, which in thi ets means the RSS toltaces mud By 1 Tae used RSS tokrance i add 10 the nomial datane fo deters the ‘ata maximum dstaace, The maxinum distance eepored ‘The worstesetoleranneis 7.1. The adised RSS tolerance 489 The worstcase maximum dtnce Was reported at 73.1 in Chapee 7 The ujsted RSS maximo distance 7089. i tT - ca Freire 823. Pa or anger ese Faun 824 Sutstclworstase hanger ase ad Tolerance Saks seth 31a | es [own sae uers cyto a8 3 | sa |e srs sar a-2057. 428 ee) si en eure 825 ToeaceSacap repo sel sts ad Ones Example 85 Inthis example, an inseparable assembly or weldment is suid (Fig £820) Notice the dimensions and tokvaces have aleay been comer fo sgoa-iterl format. The gal ofthis TelranceStacp isto dete ‘he minimum and maximum distance between prs Sand in thence, The Tolerance Stacup rests are shown in Figs 827 and 828, The ‘Tolerance Stackup sketch in Fig. 8.27 shows the chain of Dimensions and ‘oleranss for this probe, which tthe sae as when sohing the robe 4km worstase The Tolerance Stackup report in Fig 824 incades 4 see ‘soln for he gud tlerances—the ote columns are hemes the ortease example in Caper 7. Several addnal nes ae ad teow {he chart to report th RSS tolerance vale and he ated RSS toes vate, A of i _Socip Orton Pune 825 Comrie wld sent 19 Fount 827 Conpes weed asemy (Fle Stans. Ain x_n omen Se Ta Te arg geo {it aaern a ae 55°15) See so suse tn Non Feune 828 ToeaceStalap repo soled satitaly 192 . The dimension values nea columa are total andthe egaive total Ss subtracted fom the pose rota which pve the aominal distance bang ‘ied. ach tolerance alu square, athe squared vals se ee ‘The square rot is taken ofthe sum ofthe stared tolranes, wich ste [RSS tleance, For the amples, the adjusted RSS tolerance wl Be sed, hich in thicse means the RSS clrsne emul by 15 The ajo ASS tolerance is subi from and ad to the nominal danas to determin the sail minimum and mains distances espetvey. Ths Imininem and maximum distenes ate report. ssi ‘Sah cam Lt L soma 8) map Din Fount 8.29 Complex toed assembly Stats! Tobrance Sckpe ° The worst-case tolerance i +24, The adjusted RSS tleranc: i #18. dat), an the maxim a5 ‘The worm minum gap was repr he mimi ws {3in Chapter The adjusted RSS muinum gap is 3, and the #79, xampo 88 ie sty as ample compl ey ead. ee i 829) The [Sy iote welts nb previous ump coe aces rit | alla a eed eu 8.90, Pats for somple bd ase. 196 . este todas penn ning eld. The gat Toke Stacey sto dtrineie inna sn anes aeeaees s46ithe nem Thban psa thetic ae dade oP, ‘The Toe Sukap rea ov in Figs 831 ane 48 Te Teac Sc sketch in Fp 31 showy le cn of ies Teles or ht pole, wc the sense slag een, wontatte The Tones Suleprepon afi Ss noes ean ie sar tut othe ane ain Bee es uct, tn rao nse RS ea ren wa ae Fume 829 Competed aes stay en) Al lens we ied ova tir Inge re, The rasa te ions oe iin aan tae ot eet, a fossil aang e ft inte Age Bie Pat cit tr Sat fs ee al athe hn cee a am 9 Geometric Dimensioning and Tolerancing (GD&T) “Themostimportant ference betwoon drawings crete using GD&T and = Note The dimension vale and ths erase abe wil be pd on separate lines in the Tolerance Stackup report. " UNILATERAL PROFILE TOLERANCES. sini oe Toleanes sty vr onlin oe det fo omic nn rot om he pt The mol ee eps ot Soto te Trance rane Thee se soe Tokens th the Tener eckson ay bene loos + Ultra outward or oie Sn op +) sometiag sin) ating + Ulteatinward or neato Ser to pls) nothing / ins ()something mer ‘Tho Unter Prof Tolerance Shown in Fig. 25, tay Be Converted a Fatow + Givens unisterly displaced profile Tolerance of 0.1, Profile 01 profile Toerans = total Tolerance seo) Sra eet — | ale SS Pete Tolan Une Oxted S Uni MEANS [o/c | LA “BEY. a3 UME 85 Uninerlpole loc. nT L omar Binensonng and Toran us + Coosert th wiser pofe Tolerance ino the unilateral + To crane valve. The total Tolerance zone 0.1 mia wid. The zone ‘rend rom 0 sun ouside the surface tthe minal surface, 00 ‘im insite srTce. These luecaa be ely convertediio + tnd Toleranes, 0.1 mam outa ~ 40. Tolerance value 0 Tolerance vale (sm wae ot “0 + Takethe ve ofthe basic dimension aig the srfce as nominal os [Nominal dimension value = 038 Esublih upper and lower iil. Add the plus Tolerance to the ‘ominal vas thi the upper imi Subtat the minus Tolerance ftom the nominal vale; hte lowe iit Unilateral Tolerance value Upper mit = 035 +01 = 045 Lower limit 035 -0= 038 Divide the total Tolerance by 2 to oblast equal bist Tol trance vale, qu bilateral Tolerance value= 0.1 = 4005 ‘Ada the equal ister Tolerance veto he ower ii Tass tbe ‘djsted nominal value Fstablsh the adjsted nominal vale os 03500 (Note: The adjusted nominal vals can also he obtained by su tetng the eqoal itera Tolerance vale fom the upper Limit) Conversion complet: gual bilateral equiatent = 0.4 005 [Note The dineasion vale snd the tolerance valve wil te placed on separate lines inthe Tolerance Stackap report. The sme proce my ‘brpeformod to conver ute inward profile Tolerance nothing, * fathing oan equal steal Tolerance 8 chapters ‘COMPOSITE PROFILE TOLERANCES Compose roe tolerances are speed in composite (multiple segment) feature contra frames The tolerance aes defined in he upper and lower semnentsofs composite pote feature contol fame aredeurbedin Fig 9 & ‘The profletolerance specitin te uppermost segment of theatre conta frame represents the otal allowable varstion in lean ofthe estar) toa datum reference frame, Typically the tolerance defined in the upperst Sexment sued in Tolerance Stacups, The prof tolranc defined the uppermost semen of x compte feature contr fxne is nal the same 48 single sepnent profi tlerancefentoreconl frame withthe sane ‘The tolerance zon) defini the uppermost seis of a composite ‘roi eatur control fame are basically lcated to Gat ference fae, sorte entre) areal located to the datum reference rane The tolerance zones defined in the lower segments of«cmapoite ee ‘ure contol fame are aot basically lected toa data ference rane they ‘may only be busily oriented to adatom referee fume and ae scl Toctad to cach ther in the ease of «pater, some cas the profi olraor peed in lower spent maybe ‘of mre importance, buts ks common. The profi tolerance secede Jowersegneat may bused Teevanee Stachup fhe TolraceStackups between tures ina patter, For example, conser the two side scare of "he roo. in Fig 9.7. Both sures re toleranced wig the same compare ‘broil ature contol frame. Using this techie makes the surfaces mo 8 tern—they are grouped together by virtue ofthe tolesncng sme The pole olerancespeid in lower segment may also be used with ‘more advanced tolerancing echniqus, sich whee “vinltaneous rue, ‘meat s esplicily stated beneath two or more soup featur cote fumes ested tothe same data reference frame, This kage sla cose bins the fetes olerance by the composite festre coil faes into singe pattern, "Even though here isa dferene between the upper segment tolezance nd th lower segment oetaes, both ae ialaded td formatted he Tolerance Stskup eprt the sane way ae dog ssment rfl tolertace ‘wolinesarcenered ato the Tolerance Stackp report the profi olerance Isentere onthe fist tine and datum ate shit eters on he second ine ‘The technique for ineating prfe tolerance information in a Tolerance Stacup sketch and Tolerance Stackupzeport spree in Chapters 13 fad i ‘Asa general ru ifthe location ofthe fate or pattern of features) ales he distance eg studied, the upper segment profi eerance sul soma Benning and Tterancing ur “anasto _# {natant inca at 6 chapter SERRE) [ SieorB ~ | comme! Lal a {ou a ‘Aco einstein ce reas ‘mesma totmocrcetartiesce es ne Emm nce awe Sogan ets to oune 8.7 Conpose pole olesacing ample pst. be used in the Tolerance taku, The upper segment profile eens is abo ‘wed inthe Tolerance Stackap when the feature) tolerant withthe compost feature control fame aod fete folerawad wth a dict feature contol fame onthe sume pat ae included inthe chan o Dies ‘Sons and Tolerance, ‘Ara genera ruth peo tolerance defied inthe lover segment of ‘compost fatre contol fame s wed inthe Tolerance Stackup when the hain of Dimensions and Tolerances ply includes the toleranced fetus within pater apd des not include any othe fetuses om the same pat I the dxiance bing sted is only fated by the fentreo-fetae elation, ‘hip within the pater of fenore the ler same pelle eres ul bousd inthe Toleruace Stackup, i Geometic Dinning an Tolerance ue Several examples that show the uppermost sepment ad the lover sepments of composte profile awe contol frames wed in Tolerance Suckups flow. ample 91 Rafer back othe pr shown a Fig 97. this tame the goa of te ‘Tokrance Sacha fo ean ow low tts le of he pat the foot may bs The rove wales nerneed compete pole ad {felt cgc oft prdatun xe The prtleloancetn be pet Seonen ofthe compose ature conti ame wel la Ge Toran Sbckap bcs the Upper sept ence cats the oe walls the \ 7? Leben af teow orecineuy [28 Oro om wants |S 7 recone St “Tolerance Stackup Between Lo roo Wal and en edge af Part (Os Feature BY User Segre Tolerance Used ene tem 4 como Prof Toland Foume 98 Cinpoite pole Token ck th chapter 9 Geometric Omensianng and Twang 151 atu rfeense frame, The Tolerance Stackup sketch for this example i Showa in Fig 98. The ToleraneStackup zepert or tis examples shown in ig 99, The uppr segment profil tlrance would alo bused the goal of the Tolerance Stackop was to determine the dane Rebeen one of the root walls andthe 26 201 hole, because both entures are elated to the me dati ference rae Ia tht cumple, techn of Dimensions and ‘olerances wv ara the groove wall pss through the datum reference -| ii eee ah capa 92 EB i ‘Ain refer ack th prt shown in Fig 97. Tn this te gos ofthe if i {Tolerance Stackup sto determine the tinimurn aod maximum alloable i ; a ee eee een jetninemrengone : qe |) va a a i F or) | eRe i & (Loft Groove Wal) La ‘Right Groove Walt) Hi i 3 ae 3 oT 3) aie |] |e | iil i 3 ° Ha |? : : Ht Hy ay ore “res tn en one l acter enone pein 10 ont ple ty th Foume 8.11 Compote proc TlenceSaskp goo wd Gooner Bnensoning and Ttareng 1 prflefeature contol frame the wall are considered a patie, and the Ff tolerance seed it the lower segment is wood inthe Tolerance ‘isckup, Notice tha the cin of Dimensions and Tolerance doesnot pss through the datum reference frame and ony inetdes the Sm basic

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