Professional Documents
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Tolerance Analysis
Tolerance Analysis
and
Stack-up Tolerances
Aditi Consultancy Services
#2, ANANDA, 19th Cross, 24th Main
J P Nagar 5th Phase, Bangalore-560078
Phone/Fax: 080-26580711; Mobile: 9449612671
Web Site: http://www.aditiconsultancy.com
TOLERANCES
BILATERAL TOLERANCE
EQUAL BILATERAL
UNEQUAL BILATERAL
UNILATERAL TOLERANCE
LIMIT TOLERANCE
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Bilateral Tolerance
A bilateral tolerance is a tolerance which is expressed as
plus and minus values, where neither is zero, to denote
permissible variations in both directions from the
specified size.
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Unilateral Tolerance
A unilateral tolerance is one which applies only in one
direction from the specified size, so that the permissible
variation in the other direction is zero.
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Limit Dimensioning
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Limits of Size
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Limits of Size
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Classification of Tolerances
Tolerances
Dimensional
Size
Geometric
Form
Orientation
Location
Run-out
Profile
Straightness
Parallelism
Position
Circular
Line
Flatness
Perpendicularity
Concentricity
Total
Surface
Circularity
Angularity
Symmetry
Cylindricity
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Fuel Pump
Fuel Pump
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Geometrical Variations
Geometry, GD&T...
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Assembly Problems
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Tolerance Accumulation
Chain Dimensioning
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Tolerance Accumulation
Base Line Dimensioning
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Tolerance Accumulation
Direct Dimensioning
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Change the design such that variation in distance between any two
surfaces is not more than 0.1mm
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Material Conditions
Maximum Material Condition (MMC)
That condition where a feature of size contains the maximum
amount of material within the stated limits of size.
Example: maximum shaft size and minimum hole size.
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Taylors Principle
FITS
Clearance Fit
Transition Fit
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Interference Fit
Deviations
Deviations
+ 0.3
Hole Tolerance
0.2
+ 0.1
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- 0.1
- 0.10
- 0.17
0.07
Shaft Tolerance
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+ 0.1
FITS
INTERFERENCE
FITS
p
m
H
g
e
k
j
f
TRANSITION FITS
d
c
b
CLEARANCE FITS
a
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Types of Fits
Extra Loose Running Fit
Loose Running Fit
Easy Running Fit
Running Fit
Close Running Fit
Slide Fit
Push Fit
Wringing Fit Easy Keying Fit
Light Keying Fit
Drive Fit
Light Press Fit
Press Fit
Heavy Press Fit
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Fundamental Deviation
Fundamental deviations are represented by the
following letter symbols:
Type of Fit
Hole
Shaft
Clearance
A, B, C, D, E,
EF,F,FG, G & H
a, b, c, d, e, ef,
f, fg, g & h
Transition
J, JS, K, M & N
j, js, k, m & n
Interference
P, R, S, T, U, V,
p, r, s, t, u, v, x,
X, Y, Z, ZA, ZB & ZC y, z, za, zb & zc
I T GRADES
INDIAN STANDARD IS 919-1963
18 FUNDAMENTAL TOLERANCES or
TOLERANCE GRADES .
For different grades values of standard
tolerance are determined from diff formulas.
Relative magnitude of each grade is
GRADES
IT5
IT6
IT7
IT8
IT9
IT10
IT11
IT12
IT13
IT14
IT15
IT16
VALUES
7i
10i
16i
25i
40i
64i
100i
160i
250i
400i
640i
1000i
Where i = 0.45
D + 0.001 D
Tolerance Grades
30m
H7
For a
50 hole/shaft
combination
Fundamental Deviations
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+ 0.2
0
- 0.05
- 0.15
mm.
37
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Tolerance Analysis
A
B
Nominal Condition
AB+C
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Tolerance Analysis
Aa
Bb
Cc
(A - a) (B + b) + (C + c)
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Tolerance Analysis
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Tolerance Analysis
Find the maximum and minimum gap values when the following 3 parts are
assembled.
+0.05
50 -0.02
30 0.1
19.5 0.2
3.019
+.012
-.000
3.031
+.000
-.012
3.028
+.003
-.009
3.022
+.009
-.003
3.025
.006
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Tolerance Synthesis /
Tolerance Allocation
Tolerance Analysis
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Tolerance Analysis
Functional Requirement:
The functional requirements for an assembly are normally expressed
as toleranced dimensions.
Functional Dimensions:
These are the dimensions on the components which directly affect
the functional requirements
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Z1 = E + D C B A
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Tolerance Analysis
+0.06
50 -0.04
30.03
29.95
20 0.02
Calculate the mean value of the gap with equal bilateral tolerance. Determine
the maximum and minimum values of the gap in the assembly.
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Tolerance Analysis
Find the maximum and minimum gap values when the following 3 parts are
assembled.
+0.05
50 -0.02
30 0.1
19.5 0.2
For the given nominal dimensions of the parts, fix the tolerances such that the
gap in the assembly is with in 0.4 to 0.6 mm
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C
52
A
10.5
B
GAP
0.4 0.6
C
A
49
41
C
+0.05
0
52
10.5
B
+0.1
0
G=ABC
C min = 40.95
C max = 41
The maximum and minimum values of the gap meet the two specified limits
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Determine the nominal dimension of C and fix the tolerances for B and C
+0.03
0
52
A
10
B
GAP
10.1
C
A
51
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Hydraulic
Cylinder
Plunger
Cap
Z1
Z2
Punch Stopper
Piston
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Z1 = E + D C B A
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E = 90.0
D = 125.0
B = 160.0
A = 16.0
C = 27 0.06
E = 90 0.06
A = 16 0.1
D = 125 0.06
57
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D is maximum
F is maximum
F maximum is 37.16
D is minimum
F is minimum
F minimum is 36.84
i.e., F = 37 0.16
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Column 2
Part #
Stack
Contributor
sign
Maximum
sign
Minimum
160.12
159.88
0.25
27.06
26.94
0.12
124.94
125.06
0.12
36.84
37.16
0.31
24.6
0.8
Totals
25.4
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MAXIM
UM
STEP ID
COMMENTS:
DESCRIPTION FROM/TO
SUB TOTALS
ANSWER
MINIM
UM
Component
Factored
Component
Tolerance
Total
Tolerance
Monte
Tolerance
Squared
Carlo
MRSS
RSS
MC
MAX
MIN
MIN
MAX
+
WORST CASE
OPTIMIZED?
DESIGN GOAL:
YES NO
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DESCRIPTION FROM/TO
MINIMUM
COMPONENT
FACTORED
COMPONENT
TOLERANCE
TOTAL
TOLERANCE
MONTE
TOLERANCE
SQUARED
CARLO
MAX
MIN
MIN
MAX
160.12
159.88
0.24
0.800
0.0576
27.06
26.94
0.12
0.800
0.0144
124.94
125.06
0.12
0.736
0.0144
36.84
37.16
0.32
0.640
0.1024
25.4
24.6
0.8
0.652
0.435
COMMENTS:
SUB TOTALS
ANSWER
WORST
CASE
MRSS
RSS
MC
OPTIMIZED?
DESIGN GOAL:
YES NO
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Clearance = -A + B - C + D - E + F - G
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Dimension
Nominal Value
.0505
8.000
.5093
.400
7.711
.400
.5093
.0015
.008
.0025
.002
.006
.002
.0025
Fixed
Design
Fixed
Design
Design
Design
Fixed
Tolerances(+/-)
The mean assembly clearance is the vector sum of the average part dimensions
in the loop: = -A + B - C + D - E + F - G
= -.0505 + 8.000 - .5093 + .400 - 7.711 + .400 - .5093
= .020
Let us say the functional tolerance for the assembly clearance is +/-.015.
The actual clearance tolerance is obtained by summing the given tolerances
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Each of the design tolerances has been scaled down to meet assembly
requirements. This procedure could also be followed assuming a statistical sum
for the assembly tolerance, in which case the tolerances would be scaled up.
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Dimension
Nominal Value
.0505
8.000
.5093
.400
7.711
.400
.5093
.0015
.008
.0025
.002
.006
.002
.0025
Fixed
Design
Fixed
Design
Design
Design
Fixed
Tolerances(+/-)
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Propagation of Variation
Rotational error due to surface variation
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Form Variation
Orientation Variation
Location Variation
Nominal
Position
Accumulation of Variation
Substrate Package
Substrate Package
Gap = A + B C + D + E
Where A = .040 .003
B = 0 .002
C = .125 .005
D = .185 .008
E = 0 .004
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Form Controls
Component Variation
Size variation
Form variation
Location variation
Orientation variation
Surface roughness variation
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Assembly Variation
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Floating Fasteners
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Floating Fasteners
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Fixed Fasteners
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Fixed Fasteners
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Centered
Shifted
Floating
Fasteners
Fixed
fasteners
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F
P
T
D
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or
T=H-F
HF
2
If part with tapped holes should have larger positional tolerance (T1)
than the part with clearance holes (T2), then 2T = T1 + T2,
i.e.
H = F + T1 + T2
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Example 1:
In case of a floating fastener assembly, fasteners are 3.5 diameter
maximum and the clearance holes are 3.94 diameter minimum. Find
the required positional tolerance
T
= HF
= 3.94 3.5
= 0.44 diameter for each part
Example 2:
In the above case, find the required positional tolerance if the assembly
had fixed fasteners
T
= (H F) / 2
= (3.94 3.5) / 2
= 0.22 diameter for each part
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Coaxial Features
The formula for the floating fastener
case also applies to mating parts
having two coaxial features where one
of these features is a datum for the
other.
Where it is desired to divide the
available tolerance unequally between
the parts, the formula used is:
H1 + H2 = F1 + F2 + T1 + T2
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Example 4:
In the previous example of coaxial features solve for T1 and T2.
H1 + H2 = F1 + F2 + T1 + T2
T1 + T2 = (H1 + H2) (F1+F2)
= (20 + 10) (19.95 + 9.95)
= 0.1 total available tolerance
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H7
g6
10g6
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Part must slide over 13.88 gauge pin Must lie flat on base of gage (Datum A)
Touch Datum B at least at two points along its length
Simultaneously touch Datum C at least at one point
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Position at RFS
Gap = A/2 + B
Where
A = .0625 .0001
B = .2250 .0011
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Gap = A - B /2
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Gap = A/2 + B
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and
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Gap = A/2 + B
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4X 16 0.4
0.16
0.04
G1
G2
50
20
50
25
A B C
A
Profile Tolerancing
Calculate the minimum value of Y and Z dimensions
Concentricity
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Motor Assembly
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Motor Components
Housing
Housing Cap
Stator
Rotor
Screw
Inner
bearing
Cap
Shaft
Bearing
Bearing
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Outer
bearing
Cap 117
Motor Components
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Motor Components
Housing
Housing Cap
Stator
Rotor
Screw
Inner
bearing
Cap
Shaft
Bearing
Bearing
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Outer
bearing
Cap 119
Establishing Performance/Assembly
Requirement
Requirement 1: The gap between the shaft and the inner bearing cap
must always be greater than zero to ensure that the rotor is clamped and
the bearings are preloaded
Requirement 2:The gap between the housing cap and the housing must
always be greater than zero to ensure that stator is clamped
Requirement 3:The The mounting surfaces of the rotor and stator must be
within .005 for the motor to operate
Requirement 4:The bearing outer race must always protrude beyond the
main housing. So that the bearing stays clamped
Requirement 5:The thread of the bearing cap screw must have a
minimum thread engagement of .200 inches
Requirement 6:The bottom of the bearing cap screw thread must never
touch the bottom of the female thread on the shaft
Requirement 7: The rotor and stator must never touch. The maximum
radial distance between the rotor and stator is .020
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Motor Assembly
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Motor Assembly
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Motor Assembly
Gap 6 0 : Requirement 6
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The new variable tolerances (t kv, wc, resized) are the old tolerances multiplied
by the factor Fwc.
t kv, wc, resized = Fwc * t kv
t kv, wc, resized = equal bilateral tolerance of the kth variable component in the
stackup after resizing using the worst case model
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Resizing
Factor:
.3929
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Normal Curve
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The new variable tolerances (t kv, rss, resized) are the old tolerances multiplied by
the factor Frss.
t kv, rss, resized = Frss * t kv
t kv, rss, resized = equal bilateral tolerance of the kth variable component in the
stackup after resizing using the RSS model
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Resizing
factor is:
1.7984
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In this model,
The mean shift factor is a number between 0 and 1.0
It represents the amount that the midpoint is estimated to shift as
a fraction of the tolerance range.
If a process were closely controlled, we would use a small mean
shift, such as .2. If we know less about the process, we would use
higher mean shift factors.
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A Raghunath
Aditi Consultancy Services
Email: training@aditiconsultancy.com
Tel / Fax: 91 80 26580711; Mobile: 9449612671
http://www.aditiconsultancy.com
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