#1 THE BASICS

Designating positive and negative routes

What dimensions are factors
How to push the parts to create the worst case
Which geometric tolerances are and are not factors
Calculating boundaries for GD&T, MMC, LMC and RFS Material Condition modifiers
Mean boundaries with equal bilateral tolerances

#2 STACK-UP ANALYSIS OF AN ELEVEN PART ASSEMBLY USING PLUS AND MINUS TOLERANCING

The calculations
The loop analysis chart
The numbers analysis chart
Finding MIN and MAX gaps

#3 VERTICAL vs. HORIZONTAL LOOP ANALYSES FOR FEATURES OF SIZE

Where to start and end

Graphing the loop
Minimum and maximum gap analysis

#4 ASSEMBLIES WITH PLUS AND MINUS TOLERANCES

Multiple dimension loops

Positive and negative values
Airspace vs. interferences

#5 FLOATING FASTENER FIVE PART ASSEMBLY ANALYSIS

Resultant conditions
Virtual conditions
Inner and outer boundaries
Mean boundaries
Complex loop analyses with geometric dimensioning and tolerancing

#6 FIXED FASTENER ASSEMBLIES

Calculating overall minimum and maximum assembly dimensions

Mixing slots, tabs, holes and shafts
Calculating minimum and maximum gaps within the assembly
Projected tolerance zones for total runout as a factor
Determining if geometric tolerances are a factor
Ruling out features and patterns as factors

#7 A RAIL ASSEMBLY

Threaded features
Multiple geometric controls
Projected tolerance zones
Gaps with and without perpendicularity as a factor
Calculating interference
Theoretically vs. physically worst case possibilities
When logic becomes an integral step
Factoring in assembly conditions
Maximum wall thickness vs. minimum airspace for assemblies

#8 SINGLE-PART ANALYSIS

Two-single segment positional controls

Switching datum reference frames and accumulating geometric tolerances
Datum features at MMC (pattern shift)
Envelopes of perfect form at MMC
Creating envelopes of perfect orientation at MMC
MIN and MAX axial separation
Datum planes vs. datum features
Separate requirements and accumulating tolerance
Tolerances in degrees; Trigonometric function introduction
Composite positional tolerancing

#9 FIVE PART ROTATING ASSEMBLY ANALYSIS

Threaded holes with projected tolerance zones

Mounted screws
Part to part analysis (from two parts to an infinite number of parts
Runout
Positional coaxiality
Simplifying a complex assembly
Determining assembly housing requirements
Radial clearance MIN and MAX calculations
Interference calculations
 #10 TRIGONOMETRY AND PROPORTIONS IN TOLERANCE STACK-UP ANALYSIS

Rocking datum features

Constructing a valid datum
Consideration of differing orientations from measurement to assembly
An in-depth assembly analysis using trigonometric functions
Computer programs vs. a personal analysis
Vertical stacking as it effects horizontal housing requirements
When stacked parts are not flat or parallel
Formulae to calculate worst case fit conditions when trigonometry is a factor
Using proportions and trigonometry to calculate fit conditions beyond the GD&T formulae

#11 THE THEORY OF STATISTICAL PROBABILITY

Gaussian Frequency Curve

Standard Deviations
Plus or Minus 3 Sigma
Root Sum Square Formula
Steps to Calculate and Apply Statistical Tolerances
Statistical Tolerancing Applied to Plus and Minus Toleranced Assemblies
Statistical Tolerancing Applied to Geometric Toleranced Assemblies
When Best to Allow Statistical Tolerances and When it Should Not Be Allowed
The Logic of Statistical Tolerancing
Modifying the Root Sum Square Formula with a Safety/Correction Factor
Reintegrating the Statistical Tolerance into the Assembly

Prerequisites
Basic GD&T knowledge. This course is directed to anyone with the professional responsibility of analyzing or applying tolerances
to assemblies, or anyone seeking a more thorough understanding of tolerance analysis. Attendees should have a basic working
knowledge of ASME Y14.5M-1994. A knowledge of GD&T principles is required to allow all participants to be successful in
learning the techniques of tolerance stack-up analysis. [Each course participant needs to bring a hand-held calculator.]

Training Goals
Calculate minimum and maximum wall thickness, airspaces and interferences for assemblies.
Create loop analysis/circuit diagrams for tolerance stack-up analysis for both plus and minus toleranced dimensions and
geometric tolerances.
Create both simple and complex number charts for stack-up analysis using a variety of geometric tolerances, basic dimensions,
resultant conditions, virtual conditions and plus and minus toleranced dimensions.
Do tolerance stack-up analysis for floating fastener situations for clearance holes, screws and shafts.
Do tolerance stack-up analysis for fixed fastener situations using screws, clearance holes, slots, tabs, overall dimensions and
projected tolerance zones for threaded holes.
Calculate minimum and maximum gaps for assemblies that use a variety of datum structures.
Learn a system of logic and mathematics to analyze tolerances.
Calculate the effects of angular stack-up using trigonometry and proportions.
Calculate statistical tolerances using a variety of methods and learn how to re-integrate these tolerances back into the assembly’s
details.
Understand the requirements of GD&T, reduce the leadtime of design, reduce the engineering change, improve the design quality.
Learn how to apply GD&T to understand the design purpose of the customer, improve the reliability of product design and process
design.
Emphasize the understanding principles of verifying GD&T
Learn the concept of MMC, LMC and RFS
Use GD&T to improve the dimension verification and inspection, understand the ASME Y14.5M-1994 requirements, such as
geometric tolerance, symbols, terms, rules and application
Understand the differences between GD&T requirements of North America (ASME Y14.5M) and Chinese Standard of
Dimensioning and Tolerances