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NV Tolerance
NV Tolerance
ToleranceDesign
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#1
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DesignSpecificationsandTolerance
Developfromquestforproductionqualityand
efficiency
Earlytolerancessupportdesignsbasicfunction
Massproductionbroughtinterchangeability
Integratedesignandmfgtolerances
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#2
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Definition
Thetotalamountbywhichagiven
dimensionmayvary,orthedifference
betweenthelimits
ANSIY14.5M1982(R1988)Standard[R1.4]
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#3
Source:ToleranceDesign,p10
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AffectedAreas
Engineering
Tolerance
ProductDesign
QualityControl
Manufacturing
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#4
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Questions
Cancustomertolerancesbe
accommodatedbyproduct?
Canproducttolerancesbe
accommodatedbytheprocess?
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#5
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Tolerancevs.ManufacturingProcess
Nominaltolerancesfor
steel
Tightertolerances=>
increasecost$
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#6
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GeometricDimensions
Accuratelycommunicatesthefunctionofpart
Providesuniformclarityindrawingdelineation
andinterpretation
Providesmaximumproductiontolerance
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#7
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ToleranceTypes
Size
Form
Location
Orientation
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#8
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SizeTolerances
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#9
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FormTolerances
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#10
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LocationTolerances
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#11
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OrientationTolerances
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#12
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ToleranceBuildup
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#13
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StatisticalPrinciples
Measurementofcentraltendency
Mean
Median
mode
Measurementofvariations
Range
Variance
Standarddeviation
LSL
USL
X
3
tolerance
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#14
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Probability
Probability
Likelihoodofoccurrence
Capability
Relatethemeanandvariabilityofthe
processormachinetothepermissible
rangeofdimensionsallowedbythe
specificationortolerance.
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#15
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ToleranceSPCCharting
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#16
FigureSource:ToleranceDesign,p125
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ToleranceAnalysisMethods
WorstCaseanalysis
RootSumofSquares
Taguchitolerancedesign
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#17
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InitialToleranceDesign
Initial
Tolerance
Design
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#18
FigureSource:ToleranceDesign,p93
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References
HandbookofProductDesignforManufacturing:APracticalGuideto
LowCostProduction,JamesC.Bralla,Ed.inChief;McGrawHill,1986
ManufacturingProcessesReferenceGuide,R.H.Todd,D.K.Allen&L.
Alting;IndustrialPressInc.,1994
Standardtolerancesformfgprocesses
MachinerysHandbook;IndustrialPress
StandardHandbookofMachineDesign;McGrawHill
StandardHandbookofMechanicalEngineers;McGrawHill
DesignofMachineElements;Spotts,PrenticHall
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#19
FigureSource:ToleranceDesign,p9293
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WorstCaseMethodology
Extremeormostliberalconditionoftolerance
buildup
tolerancesmustbeassignedtothe
componentpartsofthemechanisminsucha
mannerthattheprobabilitythatamechanism
willnotfunctioniszero
Evans(1974)
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#20
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WorstCaseAnalysis
m
WCmax = ( N p i + Tp i )
i=1
m
WCmin = ( N p i Tp i )
i=1
Ne+Te=>Maximumassemblyenvelope
NeTe=>Minimumassemblyenvelope
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#21
Source:Sixsigmamechanicaldesigntolerancing,p1314.
GATEWAY
Assemblygaps
m
Gmax = N e + Te ( N p i Tp i )
i=1
m
Gmin = N e Te ( N p i + Tp i )
i=1
m
Gnom = N e ( N p i )
i=1
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#22
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WorstCaseScenarioExample
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#23
Source:ToleranceDesign,pp109111
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WorstCaseScenarioExample
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#24
Source:ToleranceDesign,pp109111
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WorstCaseScenarioExample
Largest=>0.05+0.093=0.143
Smallest=>0.050.093=0.043
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#25
Source:ToleranceDesign,pp109111
GATEWAY
NonLinearTolerances
y = f (x1, x 2 , x 3 ,...x n )
f
f
f
f
Toly =
tol1 +
tol2 +
tol3 + ...+
toln
x1
x 2
x 3
x n
f
f
f
f
Nomy
x1 +
x2 +
x 3 + ...+
xn
x1
x 2
x 3
x n
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#26
Wource:Sixsigmamechanicaldesigntolerancing,p104
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RootSumofSquare
RSS
Assumesnormaldistributionbehavior
1
(1/ 2)[x )/ ]2
f (x) =
e
2
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#27
Wource:Sixsigmamechanicaldesigntolerancing,p16
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RSSmethod
Assemblytolerancestackequation
2
1
2
2
2
3
2
n
f (x) = T + T + T + ...T
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#28
Wource:Sixsigmamechanicaldesigntolerancing,p128
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PoolVarianceinRSS
adjusted
gap
Tol
=
3Cp
2
Tpi
Te
= +
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#29
Wource:Sixsigmamechanicaldesigntolerancing,p128
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Probability
Q Gnom
ZQ =
gap
ZQ =
Q N
e N pi
i=1
2
Te
Tpi
+
3Cp i=1 3Cpi
2
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#30
Wource:Sixsigmamechanicaldesigntolerancing,p128
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ProbabilityforLimits
ZG min =
ZG max =
Gmin Gnom
2
Te 2 m Tpi
+
3Cp i=1 3Cpi
Gmax Gnom
2
Te 2 m Tpi
+
3Cp i=1 3Cpi
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#31
Wource:Sixsigmamechanicaldesigntolerancing,p128
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DynamicRSS
ZG min =
ZG max =
Gmin Gnom
2
Te 2 m Tpi
+
3Cpk i=1 3Cpk i
Gmax Gnom
2
Te 2 m Tpi
+
3Cpk i=1 3Cpk i
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#32
Wource:Sixsigmamechanicaldesigntolerancing,p128
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NonlinearRSS
f 2 2 f 2 2 f 2 2
f 2
Toly = tol 1 + tol 2 + tol3 + ...+ toln
x
1
x
2
x
3
x
n
adjusted
Toli
=
3Cpki
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#33
Wource:Sixsigmamechanicaldesigntolerancing,p128
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RSSExample
Largest=>0.05+0.051=0.101
Smallest=>0.050.051=0.001
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#34
Wource:Sixsigmamechanicaldesigntolerancing,p128
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TaguchiMethod
InputfromthevoiceofthecustomerandQFDprocesses
Selectproperqualitylossfunctionforthedesign
Determinecustomertolerancevaluesforterms
inQualityLossFunction
Determinecosttobusinesstoadjust
CalculateManufacturingTolerance
Proceedtotolerancedesign
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#35
Wource:Sixsigmamechanicaldesigntolerancing,p21
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Taguchi
Voiceofcustomer
Qualityfunctiondeployment
Inputsfromparameterdesign
Optimumcontrolfactorsetpoints
Toleranceestimates
Initialmaterialgrades
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#36
Wource:Sixsigmamechanicaldesigntolerancing,p22
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QualityLossFunction
Identifycustomercostsforintolerableperformance
Quadraticqualitylossfunction
Ao
L(y) = k(y m) =
(y m) 2
o
2
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#37
Wource:Sixsigmamechanicaldesigntolerancing,p208
GATEWAY
CostofOffTargetandSensitivity
Costtobusinesstoadjustofftarget
performance
Sensitivity,
Ao
A
Ao
A = [(x m)]2
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#38
Wource:Sixsigmamechanicaldesigntolerancing,p226227
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ManufacturingTolerance
Sl.#39
Ao o
A
DepartmentofMechanicalEngineering,TheOhioStateUniversity
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Summary
Importanceofeffectivetolerances
ToleranceDesignApproaches
WorstCaseanalysis
RootSumofSquares
Taguchitolerancemethod
Continualprocess
Involvementofmultidisciplines
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#40
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Credits
Thismoduleisintendedasasupplementtodesignclassesin
mechanicalengineering.ItwasdevelopedatTheOhioState
UniversityundertheNSFsponsoredGatewayCoalition(grant
EEC9109794).Contributingmembersinclude:
GaryKinzel.Projectsupervisor
PhuongPham.....Primaryauthor
Reference:
SixSigmaMechanicalDesignTolerancing,Harry,MikelJ.andReigle
Stewart,MotorolaInc.,1988.
Creveling,C.M.,ToleranceDesign,AddisonWesley,Reading,1997.
Wade,OliverR.,ToleranceControlinDesignandManufacturing,
IndustrialPressInc.,NewYork,1967.
DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#41
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Disclaimer
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DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#42