Session #1 : The Basics

Objectives:
How to calculate mean dimensions with equal Bilateral Tolerances Calculating Inner and Outer Boundaries Virtual and Resultant Conditions

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What is Tolerance Stack-up Analysis?

Tolerance Stack-up Analysis (also called as Gap Analysis, Loop Diagrams or Circuit Analysis) is the process of calculating minimum and maximum airspaces or wall thickness or material interferences in a single part or assemblies Its a logical process broken in few steps

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Steps in Tolerance Stack-up Analysis

Step #1:

Identify objectives: for example, you want to test if no interference is possible at a certain place in an assembly, then you set your requirement as Gap must be equal to or greater than zero

Step #2:

Identify all dimensions that contribute to your objectives as defined in step #1 (gap) and convert them to equal bilateral toleranced dimensions; if they are not already

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Steps in Tolerance Stack-up Analysis

Step #3:

Assign each dimension a +ve or ve value. For Radial stacks (going up and down); start at the bottom of gap and end up at the top of gap
Down direction is ve (top of gap to bottom) Up direction is +ve (bottom of gap to top OR towards end)

Stacks that go left and right in the assembly, start at the left side of gap and end up at the right side of the gap.
Left direction is ve (right of gap to left) Right direction is +ve (left of gap to right OR towards end)

Remember that you are working one part at a time; so deal with o ne parts significant features before jumping to next part. This is the best way to work with assemblies having many parts

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Steps in Tolerance Stack-up Analysis

Step #4 (Basic Rules):

Remember that one set of mating features between parts creates the variable you are looking for. Variable in this case is either minimum gap or maximum gap or maximum overall assembly dimension. One set mating featur es creates it. So, though multiple routes may have to be investigated to fi nd this most significant set of features, only one set creates worst case, fr om one part to next. Its often mistake to follow one route from one set of mating fea tures (holes/shaft, hole/pin) then continue the same route through ano ther set. One of these sets creates the smallest or biggest gap or maximum ove rall dimension, Once you find, which it is, others become non -factors in analysis. Using more than one set of features within same two parts, will most likely produce wrong results. Still tolerances from other features may contribute to the critical set you are using. For example: when datum features are referenced at MMC or when more than one set of datum features co me into effect.

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Steps in Tolerance Stack-up Analysis

Step #5 (Basic Rules):

When a single feature or a pattern of features are controlled by more than one Geometric Tolerance (such as orientation combined with position), the designer must determine which, if either is contributing factor to variable. It is also possible that none of geometric tolerance is a factor and instead size dimensions are factors. The Designer must deduce what factors are pertinent through sketches and reasoning. The judgment of designer is critical in these determinations.

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Beginning Tolerance Stack-up Analysis

Add all +ve and ve dimensions which will calculate your mean gap. If mean gap is ve number, your requirement of no material interference (or clearance in other words) is already violated! Then we must add sum of equal bilateral tolerances (1/2 of total tolerance) to the mean dimension (or gap) to determine maximum gap. Then we must subtract the sum of equal bilateral tolerances (1/2 of total tolerance) from the mean dimension (or gap) to determine minimum gap. Again any ve value for minimum or maximum gaps indicate interference situation Maximum gaps are maximum clearance (or in case of interference fits, minimum interference) Minimum gaps are minimum clearance (or in case of interference fits, maximum interference)

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Beginning Tolerance Stack-up Analysis

Its important to mentally shove all the features and parts in the directions that will create the max or min gap (variable). This is to allow your routes always pass through material and you dont want to jump over an air space unnecessarily in analysis You should position the features of the parts against each other so that you will get extremes and make clear to you the correct path and +ve v/s ve designations for each number.

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Finding Mean Dimensions

Few Important Concepts of Tolerance Stack-up Analysis:

There is NO difference between equal, unequal or unilaterally toleranced dimension. There is NO difference between a limit dimension and a plus or minus toleranced dimension They all have extremes and they all have means. So, first thing is to change any dimension to an equal bilateral toleranced dimension

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Finding Mean Dimensions

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Finding Mean Dimensions

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Finding Mean Dimensions : Exercise

Convert following Dimensions to an equal bilateral toleranced dimensions

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Boundaries

Boundaries are generated by collective effects of size and Geometric tolerances applied to feature(s) and often referred to as simply inner and outer boundaries There are two types of boundaries
Virtual Condition boundary (VCB) Resultant Condition Boundary (RCB)

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Virtual Condition Boundaries

2.11)

(Refer ASME Y14.5M section

FCFs that use m (MMC symbol), generate constant boundaries (VCB) for features under consideration and are calculated as:

VCB for internal FOS such as hole = MMC Size Boundary Geometric Tolerance value VCB for external FOS such as pin = MMC Size boundary + Geometric Tolerance

VC Boundaries are Constant and do not vary based upon actual mating size of the feature

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Virtual Condition Boundaries

section 2.11)

(Refer ASME Y14.5M

FCFs that use l (LMC symbol), generate constant boundaries (VCB) for features under consideration and are calculated as:

VCB for internal FOS such as hole = LMC Size Boundary + Geometric Tolerance value VCB for external FOS such as pin = LMC Size boundary Geometric Tolerance.

VC Boundaries are Constant and do not vary based upon actual mating size of the feature
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Resultant Condition Boundaries

Y14.5M section 2.11)

(Refer ASME

RC Boundaries are non constant in nature and are generated on opposite side of the virtual conditions. When RFS (Regardless of Feature Size) concept applies to FOS, they generate only non-constant or RC boundaries.

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Case#1: Internal FOS controlled at MMC

Hole MMC Concept

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Case#1: Calculating VC & RC boundaries

VCB for internal FOS (such as hole) controlled at MMC = MMC Size Boundary Geometric Tolerance value VCB for external FOS (such as pin) controlled at MMC = MMC Size boundary + Geometric Tolerance value

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Case#1: Creating equal Bilateral Toleranced Dimension from VCB and RCB

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Case#2: Internal FOS controlled at LMC

Hole LMC Concept

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Case#2: Calculating VC & RC boundaries

VCB for internal FOS (such as hole) controlled at LMC = LMC Size Boundary +Geometric Tolerance value VCB for external FOS (such as pin) controlled at LMC = LMC Size boundary - Geometric Tolerance value

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Case#2: Creating equal Bilateral Toleranced Dimension from VCB and RCB

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Case#3: Internal FOS controlled at RFS

Hole RFS Concept

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Case#3: Calculating RC boundaries

Since its a RFS Callout, no virtual condition boundaries exist and all boundaries are non -constant

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Case#3: Assumption about feature form in case of RFS callout

Only if the hole has a significant depth, might this median line curvature (out of straightness) be a consideration. For thin parts, such as sheet metal, it is probably not of concern in these analyses. In fact many designers would agree that a banana shaped hole is not likely to occur on most products.

Therefore we are ignoring axially out of straightness consideration from the analyses.

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Case#3: Creating equal Bilateral Toleranced Dimension from Inner and Outer Boundaries

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Case#4: External FOS Controlled at MMC

Shaft MMC Concept

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Case#4: Calculating VC & RC boundaries

VCB for internal FOS (such as hole) controlled at MMC = MMC Size Boundary Geometric Tolerance value VCB for external FOS (such as pin) controlled at MMC = MMC Size boundary + Geometric Tolerance value

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Case#4: Creating equal Bilateral Toleranced Dimension from VCB and RCB

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Case#5: External FOS controlled at LMC

Shaft LMC Concept

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Case#5: Calculating VC & RC boundaries

VCB for internal FOS (such as hole) controlled at LMC = LMC Size Boundary +Geometric Tolerance value VCB for external FOS (such as pin) controlled at LMC = LMC Size boundary - Geometric Tolerance value

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Case#5: Creating equal Bilateral Toleranced Dimension from VCB and RCB

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Case#6: External FOS controlled at RFS

Shaft RFS Concept

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Case#6: Calculating RC boundaries

Inner Boundary

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Case#6: Assumption about feature form in case of RFS callout

In case of RFS Callout, one may want to consider additional deviation arising out of form to determine absolute worst case inner boundary.

This applies only if shaft length is significant. For very shirt shafts / pins, it is probably not of concern in the analysis. Therefore we are ignoring out-of-straightness consideration from our analysis. If your product runs a risk of banana shaped shafts, you may wish to consider illustration on the left in your calculations.

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Case#6: Creating equal Bilateral Toleranced Dimension from Inner and Outer Boundaries

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Formulae to Remember

For Internal FOS controlled at MMC / LMC:

VCB at MMC (IB) = MMC Size Boundary Geometric Tolerance value at MMC VCB at LMC (OB) = LMC Size Boundary + Geometric Tolerance value at LMC

For External FOS controlled at MMC / LMC:

VCB at MMC (OB) = MMC Size boundary + Geometric Tolerance value at MMC VCB at LMC (IB) = LMC Size boundary - Geometric Tolerance value at LMC

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Finding Inner & Outer Boundaries : Exercise

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Session #2: Analyzing a Box Assembly

Objectives: To determine min and max gap for a simple eleven parts assembly
Perform the calculations Create a Loop Analysis Diagram Create a Number Chart

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Box Assembly

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Box Assembly: Part #1

Cavity in part#1 has limit dimensions (392.43 384.81); so we need to convert these to mean with equal bilateral toleranced dimensions

Add limit dimensions : 392.43 + 384.81=777.24 Find Mean dimension: 777.24/2=388.62 Find total tolerance by subtracting limit dimensions: 392.43 384.81=7.62 Find equal bilateral tolerance=7.62/2=3.81 Finally express limit dimensions as equal bilaterally toleranced dimension as: 388.62`3.81

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Box Assembly: Part #2- #11

parts MMC (1)

parts LMC (2)

Add (1) and (2) (3)

Subtract (1) and (2)(4) Half of (3) (5) Half of (4) (6) (5) (6)

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Box Assembly: Part #1 & Part #2- #11 put together

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Box Assembly : Loop Analysis Diagram

Loop Diagram begins by showing Gap to be calculated at the top So, loop diagram begins at Part#11 (plate) and progresses downward constantly through material until it reaches at the last plate at the bottom of an assembly (ie. Part#2 or plate#2) The sum of all these ve mean dimensions, which run from top to bottom is 381and has total tolerance of `3.81 The loop then reverses and progresses up through cavity (ie. Part #1). This portion of the loop is +ve since it progresses from bottom to top The logic of +ve and ve is simple material removes airspace (therefore ve) and cavity which lacks material adds to airspace (therefore +ve)

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Box Assembly : Loop Analysis Diagram

The mean dimension of cavity is 388.62 and has a total tolerance of `3.81 So, in numbers chart, we add means: (+)388.62 + ( )381.00 = 7.62 (1) If this number is ve, it would have proven that even mean sizes of parts, when produced result in interference. Now that sum is +ve, we can proceed

Next step is to add, charted plus or minus tolerances : 3.81+3.8 1 = 7.62 (2) Next step is to calculate min and max gaps (airspace or interfer ence): Mean dimensions difference + sum of tolerances = (1) + (2)= (+)7 .62+(+)7.62=+15.24 (max gap) Mean dimensions difference - sum of tolerances = (1) - (2)= (+)7.62-(+)7.62=0 (min gap)

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Box Assembly : Alternate Method to calculate min / max gap

From situations such as this, it is easier to simply calculate t he MMC of the cavity and the collective MMCs of the plates and subtract them to get minimum gap.

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Box Assembly : Loop Analysis Diagram

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Session #2: Exercises

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Session #3: Loop Analysis for Features of Size (FOS)

Objectives:

Using Loop Analysis Technique; determine Max and Min gap in Horizontal and Vertical Directions Determine proper start and End points for stack-ups Graph the numbers calculated into Loop Diagram

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Analyzing FOS: Problem Description

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Analyzing FOS: Charts to be used

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Analyzing FOS: Steps Involved (Horizontal Direction)

Convert horizontal limit dimensions of part #1 to equal bilatera l toleranced dimension. (26.615`0.405) Convert horizontal limit dimensions of part #2 to equal bilatera l toleranced dimension. (25.705`0.105) Graph the loop from left-to-right through material, using appropriate signs (+ve / -ve) (- 25.705 and + 26.615) Add these mean dimensions (dont forget signs) to get difference between mean dimensions ((-) 25.705 + (+) 26.615)=+0.910 Add plus and minus tolerances for part#1 and part#2 to get total plus and minus tolerance (0.105+0.405)=0.510 Max gap in horizontal direction is = sum of difference between mean dimensions and total of plus and minus tolerances (0.910+0.510=1.42) Min gap in horizontal direction is = difference (subtraction) of difference between mean dimensions and total of plus and minus tolerances (0.9100.510=0.4)

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Analyzing FOS: Steps Involved (Vertical Direction)

Convert vertical limit dimensions of part #1 to equal bilateral toleranced dimension. (26.615`0.405) Convert vertical limit dimensions of part #2 to equal bilateral toleranced dimension. (24.390`0.610) Graph the loop from top-to-bottom through material, using appropriate signs (+ve / -ve) (- 24.390 and + 26.615) Add these mean dimensions (dont forget signs) to get difference between mean dimensions ((-) 24.390 + (+) 26.615)=+2.225 Add plus and minus tolerances for part#1 and part#2 to get total plus and minus tolerance (0.610+0.405)=1.015 Max gap in vertical direction is = sum of difference between mean dimensions and total of plus and minus tolerances (2.225+ 1.015)=3.24 Min gap in vertical direction is = difference (subtraction) of difference between mean dimensions and total of plus and minus tolerances (2.2251.015)=1.21

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Analyzing FOS: Easier Method using MMC and LMC

Calculating min and max gaps may be easier as discussed before ( slide #48); by subtracting the MMCs for minimum gaps and LMCs for maximum gaps as shown below:

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Analyzing FOS: Charts and Loops with dimensions

Part #1, vertical direction Part #1, horizontal direction Part #2, vertical direction

Part #2, horizontal direction

Material side (-ve) Part #2 thickness

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Session #3: Exercise

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Session #4: Analysis of an assembly with Plus and Minus tolerancing

Objectives:
Calculate the airspaces and interferences for a plus and minus toleranced assembly Performing multiple loop analyses on an assembly

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Assembly with plus and minus tolerances : Problem Description

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Assembly with plus and minus tolerances : Charts to be used

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