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    Understanding Statistical Tolerance Analysis

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    veenamk
    Statistical tolerance analysis calculates the expected variation of an output based on the variations of multiple inputs. It is used to understand how feature tolerances in a mechanical design contribute to performance characteristics. A 1D tolerance stackup analyzes the contribution of tolerance values to overall variation in a single cross-sectional dimension. Root-sum squared (RSS) statistical analysis considers the distributions of input variations but assumes normal distributions and linear relationships, while second-order tolerance analysis incorporates additional distribution moments like skewness and kurtosis to better model real-world manufacturing scenarios with non-linear assemblies or non-normal inputs. Second-order analysis is generally required except for simple linear fits with normal inputs.

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    Understanding Statistical Tolerance Analysis

    Uploaded by

    veenamk
    219 views2 pages
    Statistical tolerance analysis calculates the expected variation of an output based on the variations of multiple inputs. It is used to understand how feature tolerances in a mechanical design contribute to performance characteristics. A 1D tolerance stackup analyzes the contribution of tolerance values to overall variation in a single cross-sectional dimension. Root-sum squared (RSS) statistical analysis considers the distributions of input variations but assumes normal distributions and linear relationships, while second-order tolerance analysis incorporates additional distribution moments like skewness and kurtosis to better model real-world manufacturing scenarios with non-linear assemblies or non-normal inputs. Second-order analysis is generally required except for simple linear fits with normal inputs.

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    Important for manufacturing

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    Statistical tolerance analysis calculates the expected variation of an output based on the variations of multiple inputs. It is used to understand how feature tolerances in a mechanical design contribute to performance characteristics. A 1D tolerance stackup analyzes the contribution of tolerance values to overall variation in a single cross-sectional dimension. Root-sum squared (RSS) statistical analysis considers the distributions of input variations but assumes normal distributions and linear relationships, while second-order tolerance analysis incorporates additional distribution moments like skewness and kurtosis to better model real-world manufacturing scenarios with non-linear assemblies or non-normal inputs. Second-order analysis is generally required except for simple linear fits with normal inputs.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    219 views2 pages

    Understanding Statistical Tolerance Analysis

    Uploaded by

    veenamk
    Statistical tolerance analysis calculates the expected variation of an output based on the variations of multiple inputs. It is used to understand how feature tolerances in a mechanical design contribute to performance characteristics. A 1D tolerance stackup analyzes the contribution of tolerance values to overall variation in a single cross-sectional dimension. Root-sum squared (RSS) statistical analysis considers the distributions of input variations but assumes normal distributions and linear relationships, while second-order tolerance analysis incorporates additional distribution moments like skewness and kurtosis to better model real-world manufacturing scenarios with non-linear assemblies or non-normal inputs. Second-order analysis is generally required except for simple linear fits with normal inputs.

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    © All Rights Reserved
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    Download as docx, pdf, or txt
    of 2

    Understanding

    Analysis

    Statistical

    Tolerance

    Definition of Statistical Tolerance Analysis

    A statistical tolerance analysis is when you take the variation of a set of inputs to calculate
    the expected variation of an output of interest. In mechanical engineering, a product design is
    composed of multiple features, each with tolerance values that control the variable aspects of
    those features. Statistical tolerance analysis is used to understand how these tolerances
    contribute
    the
    various
    performance
    characteristics
    of
    the
    design.
    1D
    Tolerance
    Stackup
    The simplest form of tolerance analysis is the single direction, 1D Tolerance Stackup. A
    1D Tolerance Stackup is created by creating a cross section of a model and adding the
    tolerance values for each feature in a straight line. The variation in each contributes to the
    overall
    output/outcome.

    Worst-Case Analysis vs RSS (Root-Sum Squared) Statistical Analysis


    In a Worst-Case Analysis, each dimension will have a minimum and maximum value that
    represents the range of acceptability for that dimension. Worst-Case answers the question, if I
    take the maximum range on each input, what is the maximum range for the measurement of
    interest or stackup? We are therefore dealing with the limits of acceptability and not
    probability.
    RSS (Root-Sum Squared) Statistical Analysis does not focus on the extreme values, but
    focuses on the distribution of the variation for each dimension. Each dimension will have a
    unique distribution of values based on the manufacturing process. Tool wear, operator
    differences, changes in material and environment all contribute to variation in the dimension
    value. Each dimension has its own distribution curve.
    When you combine the probabilities for each dimension (each separate curve) you get the
    probability for the total and therefore the distribution curve of the total. Statistical analysis
    answers the question, given the distribution of variation on each dimension what is the
    probability that my performance characteristic will fall within defined acceptable limits. The
    limitation of RSS is that it assumes all inputs are normally distributed and all performance
    characteristics have a linear relationship with the dimension. These assumptions do not
    account for the breadth of conditions that exist in typical scenarios found in manufacturing.
    Second Order Tolerance Analysis

    Because manufacturing methods vary for different types of parts, the distribution moments or
    parameters change as well. RSS only uses standard deviation and does not include the higher
    moments of skewness and kurtosis that better characterize the effects tool wear, form aging
    and other typical manufacturing scenarios. Second Order Tolerance Analysis incorporates all
    distribution moments:

    Second Order Tolerance Analysis is also needed to determine what your output is going to be
    when the assembly function is not linear. In typical mechanical engineering scenarios
    kinematic adjustments and other assembly behaviors result in non-linear assembly functions.
    Second order calculations are much more complex so hand calculations are not advisable but
    the computation accuracy is greatly improved and becomes viable within a tolerance analysis
    software package.

    Summary
    of Statistical
    Tolerance
    Analysis
    for
    practical
    useage
    The choice in tolerance analysis method is based on many factors, but the can be
    summarized as Which method best matches the manufacturing and inspection process of
    the assembly. For simple fit problems, a 1D stack-up may be sufficient. RSS is sufficient for
    the small number of scenarios where the inputs are normal and the assembly relationships
    are linear. For all other scenarios, Second Order Tolerance Analysis is required to address the
    real world of manufacturing.

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