10 Tolerance Stackup Upd

Engineering Drawing
Tolerance stack-up
Politecnico di Torino DIGEP
September 20th, 2019
DTI September 20th, 2019 1 / 68

1 Tolerance stack-up analysis
Functional dimensions
Tolerance stack-up
Stack-up methods comparison
Direct tolerance stack-up on a part
Direct tolerance stack-up on an assembly
Tolerance allocation
A practical example of tolerance allocation
Comparison of dimensioning intents
Advantages and disadvantages
Comparison of functional and technological stack-up
Functional to Technological tolerance transfer

Technological tolerance transfer

Tolerance stack-up analysis
Tolerance stack-up analysis

Tolerance stack-up analysis Functional dimensions
Introduction
Some common functional requirements for a design are:

mechanical strenght,
overall dimensions,
weight,
assemblability,
operational conditions,
aesthetic aspect.
The last three points can dene geometrical functional requirements.
Functional dimensions are intended to guarantee the assemblability of the
parts.

Functional dimensions
Denition
Functional dimensioning distinguish between:
functional dimensions,
non-functional dimensions,
auxiliary dimensions.
In order to identify them it is required to:
analyze the assembly geometry,
dene the functional requirements of the design (at assembly level),
identify the functional dimensions on the parts.

Study case
Identify the functional dimensions of the assembly.

Retaining ring assembly
Functional requirements:
1 retaining ring assemblability (groove always visible),
2 non-zero, but limited, axial clearance

Possible problems

Functional dimensions to protect assemblability
0.7 1.2
Functional dimensions and goals: a = 0+
+0.2 , b =+
0.2

Functional requirement: axial play

Possible problems

1
Functional dimensions and goals: c = 0+
+2.5
Functional requirements: assemblability and rotation

Functional dimensions and goals: d > e, f <g

Functional requirements: assemblability and rotation
0.6
Functional dimensions and goals: h = 0+
+0.1
Stack path with functional dimensions at part level

Stack path with functional dimensions at part level

Tolerance stack-up result: tolerances on the part's drawing

Functional dimension
Denition
A functional dimension is a dimension which variation beyond the tolerance
limits, dened at design stage, hinders the functionality of the machine in
which the parts are assembled.
Assembly functional dimension: as a dimension, it is a dependent variable

dened at assembly level. It is aected by the results of:
part functional dimensions: as dimensions, they are independent variables
dened at part level and they are subjected to tolerances.

Tolerance stack-up analysis Tolerance stack-up
The requirements of Design and Production engineering I

Production: Design:
Production costs Functionality
Tools, machines and processes Appearance
Worker skills Performaces
Assembly Reliability
Monitoring, checking, Durability
inspection Maintainability
Narrow tolerances are usually Large tolerances are usually
required. required.

The requirements of Design and Production engineering II

The requirements usually conicts:
Design engineering requires limited tolerances to guarantee the
functionality and performaces,
Production engineering requires large tolerances, to reduce
manufacuring costs.
Solution: to allocate the maximum possible tolerances compatibly with the
functionality of the assembly.

Mathematical background of calculation I
Worst case: functional dimensions at part's level are considered in their

(upper or lower) limit dimensions and they sum up in the
assembly to maximize the eects on the functional measure
of the assembly. The interchangeability of the parts is always
guaranteed, but at the price of high production costs.
Mathematical model: algebraic sums.
Statistical: to every actual dimension in the tolerance eld is applied a
probability distribution. Weighting the probability of extreme
values to occur near the limit dimensions1 allows to dene
larger tolerances. To the result of the calculation is applied a
reliability percentage: some assembled products will not be
functional and would require repair. The wider tolerances
permit cost savings over large production volumes and
compensate for the reworking costs, making the process
Mathematical background of calculation II

convenient. Mathematical models: statistical propagation of
uncertainty.
The analysis can be applied to:
features inside a parts,
dierent parts assembled in a product,
technological tolerance transfer.
1
It rarely occours that all the dimensions are at their limit and sum up to give the
worst eect on the assembly at the same time.
Direct Tolerance stack-up
Input Output
Tolerances of the
Component
assembly functional
tolerances
dimensions

Tolerance allocation
Input Output
Tolerances of the
Component
assembly functional
tolerances
dimensions
Technologial tolerance transfer
To calculate the
Given a functional
technological tolerances of
goal on the
the processes
assembly drawing
a1 =?
a = 70−0.2
a2 =?

A simple example of stack-up
Rmax = Amax + Bmax = 8.4 + 12.2 = 20.6 mm

Rmin = Amin + Bmin = 8.1 + 12 = 20.1 mm
0.6
R = 20+
+0.1
A wrong dimensioning example

Counter-example I
Amin = Rmin − Bmax = 20.1 − 12.2 = 7.9 mm

Amax = Rmax − Bmin = 20.6 − 12 = 8.6 mm
0.6
A = 8+
−0.1
Counter-example II
0.6
A = 8+
−0.1 Incongruence!
Dimensions must be identied only once. No redundancies.

Correct dimensioning scheme
Correct dimensioning with reference dimension.

Study case
On this assembly are to be dened:

parts,
fastening, mating constraints,
functional dimensions,
basic dimensions,
tolerances.
Basic dimensions
G = R − (A + B + C ) = 70 − (20 + 12 + 36) = 2 mm

First attempt tolerances from ISO2768-m

Limit dimensions
Gmax = Rmax − (A + B + C )min = 70.2 − (19.8 + 11.8 + 35.7) = 2.9 mm

Gmin = Rmin − (A + B + C )max = 69.8 − (20.2 + 12.2 + 36.3) = 1.1 mm
0,9
G = 2+
−0,9 = 2 ± 0, 9 Result on the assembly functional dimension

Tolerance stack-up
Denition
In a tolerance stack-up, the sum of the part's tolerances must be equal to
the tolerance of the functional dimension of the assembly.
Let's consider again the formulas of slide 35 and subtract each member:
Gmax = Rmax − (A + B + C )min

Gmin = Rmin − (A + B + C )max
tG = tR + (tA + tB + tC )
In the previous example:

tG = tR + (tA + tB + tC ) = 0.4 + (0.4 + 0.4 + 0.6) = 1.8 mm
Tolerance stack-up analysis Tolerance allocation
Tolerance allocation steps
The following information must be dened for making a tolerance

allocation:
functional dimension (at assembly level),
stack path dimensions (at part level),
origin and positive direction,
1st attempt tolerances.
Then:
1 a direct stack-up calculation is done,
2 the dierences with the tolerance goal are evaluated,
3 the recovery quantities are applyed to the dimensions.

Information gathering
Parts geometry, dimensions, assembly, mating conditions, fasteners,

assembly sequence.
Nominal clearance: 2 mm
Design goal: 2 ± 0.2

1st attempt tolerances
From ISO2768-m

Tolerance stack-up table
+ U.D.L. + L.D.L
Dimension - L.D.L. - U.D.L Tolerance
Total:
Goal:
Dierence:
1 2 3 4

Table columns and rows
1 Unique reference to the dimension on the stack-path (opt. part name),

2 If the vector dimension is aligned along the positive direction then:
write + on the left column and the Upper Dimensional Limit (U.D.L.)
in the right column,
otherwise write - on the left column and the Lower Dimensional Limit
(L.D.L.) in the right column.
3 If the vector dimension is aligned along the positive direction then:
write + on the left column and the Lower Dimensional Limit (L.D.L.)
in the right column,
otherwise write - on the left column and the Upper Dimensional Limit
(U.D.L.) in the right column.
4 Algebraic dierence between column two and three (Col2 − Col3
values).

Example Direct calculation with 1st attempt tolerances
+ U.D.L. + L.D.L
A - Base + 70.3 + 69.7 0.6
B - Red Block - 19.8 - 20.2 0.4
C - Gray Block - 11.8 - 12.2 0.4
D - Yellow Block - 35.7 - 36.3 0.6
Total: + 3 + 1 22
Goal: + 2.2 + 1.8 0.43
Dierence: - 0.8 + 0.8 -
2
The dierence of Col2 − Col3 results must be equal to the sum of column 5 items,
as shown on page 36. This represent how the assembly behaves with the current 1st
attempt tolerances.
3
This represent the available tolerance, permitted by the goal.
Column role
Remark
Column two compares the least material condition of the parts
constituting the assembly: the largest box
a and the smallest blocks . It
b
returns the maximum clearance.
Column three compares the maximum material condition of the parts
constituting the assembly: the smallesy box
c and the largest blocks .
d
a
For the internal feature the LMC condition is the largest feature.
b
For the external feature the LMC condition is the smallest feature.
c
For the internal feature the MMC condition is the smallest feature.
d
For the external feature the MMC condition is the largest feature.

Example Recovery denition
+ U.D.L. + L.D.L
A - Base + 70.3 (− . ) 0 3
+ 69.7 (+ . )0 2
0.6
B - Red Block - 19.8 (− . ) 0 1
- 20.2 (+ . )0 2
0.4
C - Gray Block - 11.8 (− . ) 0 1
- 12.2 (+ . )0 2
0.4
D - Yellow Block - 35.7 (− . ) 0 3
- 36.3 (+ . )0 2
0.6
Total: + 3 + 1 2
Goal: + 2.2 + 1.8 0.4
Dierence: - 0.8 + 0.8 -

Example Tolerance synthesis
+ U.D.L. + L.D.L
A - Base + 70 + 69.9 0.1
B - Red Block - 19.9 - 20 0.1
C - Gray Block - 11.9 - 12 0.1
D - Yellow Block - 36 - 36.1 0.1
Total: + 2.2 + 1.8 0.4
Goal: + 2.2 + 1.8 0.4
Dierence: 0 0 -

Result interpretation
The table contains the limit dimensions, that can be rewritten using
deviations and then put into the drawing:
A ∈ [69.9, 70] A = 700−0.1
B ∈ [19.9, 20] B = 200−0.1
C ∈ [11.9, 12] C = 120−0.1
0.1
D ∈ [36, 36.1] D = 36+
0

Destination of the dimension
On the assembly drawing:
On the part drawings:

The documents constituting the stack-up
+
+ U.D.L. + L.D.L
A - Base + 70 + 69.9 0.1
B - Red Block - 19.9 - 20 0.1
C - Gray Block - 11.9 - 12 0.1
D - Yellow Block - 36 - 36.1 0.1
Total: + 2.2 + 1.8 0.4
Goal: + 2.2 + 1.8 0.4
Dierence: 0 0 -
The table alone is useless.

Tolerance stack-up analysis A practical example of tolerance allocation
Transmission shaft
1
Goal: G = 0++0.5
0.9
1st attempt tolerances: A = 84+
+0.7 , C = 4±0.1 , d = 76±0.3

Direct calculation
+ U.D.L. + L.D.L
C - Bushing - 3.9 - 4.1 0.2
D - Support - 75.7 - 76.3 0.6
C - Bushing - 3.9 - 4.1 0.2
A - Shaft + 84.9 + 84.7 0.2
Total: + 1.4 + 0.2 1.2
Goal: + 1 + 0.5 0.5
Dierence: - 0.4 + 0.3

Recoveries
+ U.D.L. + L.D.L
C - Bushing - 3.9 - 4.1 (+ . )
0 1
0.2
D - Support - 75.7 (− . )
0 4
- 76.3 (+ . )0 1
0.6
C - Bushing - 3.9 - 4.1 (+ . )
0 1
0.2
A - Shaft + 84.9 + 84.7 0.2
Total: + 1.4 + 0.2 1.2
Goal: + 1 + 0.5 0.5
Dierence: - 0.4 + 0.3

Tolerance synthesis
+ U.D.L. + L.D.L
C - Bushing - 3.9 - 4 0.1
D - Support - 76.1 - 76.2 0.1
C - Bushing - 3.9 - 4 0.1
A - Shaft + 84.9 + 84.7 0.2
Total: + 1 + 0.5 0.5
Goal: + 1 + 0.5 0.5
Dierence: 0 0

Tolerance stack-up analysis Comparison of dimensioning intents
Dimensioning intents
Priority based on:

Functionality → Functional dimensioning
Manufacturing → Technological dimensioning
Functional dimensioning Technological dimensionig

Dimensions clearly conveys Dimensions denes tool motions
functions or dimensions
The largest tolerances, compatible Reduced tolerances for all the
with functionality, are specied manufacturing process
No constraints over Limitation on manufacturing
manufacturing setup setup exibility

Advantages of functional dimensioning
1 problems are identied and solved during the design phase,

2 the design intent is conveyed more clearly,
3 larger tolerances,
4 cost reduction,
5 quality improvement,
6 reduction of disputes.

Study case: a belt tightener

Functional stack-path
a = 7±0.2 , b = 36±0.3 , a = 22±0.2 .

The resulting dimensioning of the bushing

The technological dimensioning of the bushing
Denition prior to the stack-up.

The technological stack-path
a1 = 19±0.2 , a2 = 12±0.2 , b = 36±0.3 , a = 22±0.2 .

Results with functional dimensions
First attempt
+ U.D.L. + L.D.L
?a - 1st bushing head thickness - 6.8 - 7.2 0.4
b - Base width + 36.3 + 35.7 0.6
?a - 2nd bushing head thickness - 6.8 - 7.2 0.4
c - Shaft lenght - 21.8 - 22.2 0.4
Total: + 0.9 - 0.9 1.8
Goal: + 1.5 + 0.5 1
Dierence: + 0.6 + 1.4
Tolerance synthesis
+ U.D.L. + L.D.L
?a - 1st bushing head thickness - 6.8 - 7(+ . ) 0.2
= 70−0.2
0 2
b - Base width + 36.6(+ . )

0 3
+ 36.2(+ . )
0 5
0.4 a
?a - 2nd bushing head thickness - 6.8 - 7(+ . )
0 2
0.2
+0.6
c - Shaft lenght
Total:
-
+
21.5(+ . )
1.5
0 3
-
-
21.7(+ . )
0.5
0 5
0.2
1 b = 36+ 0.2
Goal: + 1.5 + 0.5 1
0.3
Dierence: 0 0
c = 22−
−0.5
? same recoveries applied.

Results with technological dimensions

First attempt
+ U.D.L. + L.D.L
?a1 - 1st bushing total lenght - 18.8 - 19.2 0.4
•a2 - 1st bushing turned lenght + 12.2 + 11.8 0.4
b - Base width + 36.3 + 35.7 0.6
•a2 - 2nd bushing turned
+ 12.2 + 11.8 0.4
lenght
?a1 - 2nd bushing total lenght - 18.8 - 19.2 0.4
c - Shaft lenght - 21.8 - 22.2 0.4
Total: + 1.3 - 1.3 2.6
Goal: + 1.5 + 0.5 1
Dierence: + 0.2 + 1.8
Tolerance synthesis
+ U.D.L. + L.D.L
Dimension - L.D.L. - U.D.L Tolerance a1 = 190−0.1
?a1 - 1st bushing total lenght - 18.9 - 19 0.1
= 120+0.1
(−0.1) (+0.2)
•a2 - 1st bushing turned lenght + 12.1(− . ) + 12(+ . ) 0.1

b1
0 1 0 2
b - Base width + 36.6(+ . )

0 3
+ 36.2(+ . )
0 5
0.4
•a2 - 2nd bushing turned
0.6
+ 12.1(− . ) + 12(+ . ) 0.1
= 36+
0 1 0 2
lenght b
?a1 - 2nd bushing total lenght - 18.9(− . )
0 1
- 19(+ . )
0 2
0.1 +0.2
c - Shaft lenght - 21.5(+ . ) - 21.7(+ . ) 0.2
0.3
= 22−
0 3 0 5
Total: + 1.5 - 0.5 1 c −0.5

Goal: + 1.5 + 0.5 1
Dierence: 0 0
? same recoveries applied. • same recoveries applied.
First, the same recoveries of measures b and c from page 60 where applied, then the recoveries for a1 and a2 were
adjusted.

Results comparison
a = 70−0.2 a1 = 190−0.1
0.1
a2 = 12+
0

Drawbacks
a is a small basic dimension with a large tolerance. a1 and a2 are large

basic dimensions with half the tolerance available. Higher production
costs.
Functional parts could be rejected: given the technological dimensions
0
a1 = 19−0.1
+0.1
a2 = 120
With:
a1 = 19.1 mm (Rejected)
b1 = 12.1 mm
it results:
a = 7 mm
A functional part is discarded because it is outside the technological

limits.
Tolerance stack-up analysis Functional to Technological tolerance transfer
When it is required to transform Functional tolerances into

Technological tolerances
Design goal dened Technological tolerances to be

on drawing determined
a = 70−0.2 a1 =?
a2 =?
Tolerance stack-up analysis Technological tolerance transfer
Goal of the technological tolerance transfer
Technological tolerance transfer is a manufacturing engineering problem.

The input data is a drawing of a single part, dimensioned with functional
dimensions, that must be manufactured.
The output data are the technological dimensions required to guide the
production process (tool positioning, working length, tool dimensions) and
the pertaining tolerances required to control the production quality.
A tolerance stack-up is dened using the functional measures and their
known tolerances as a goal. The stack-path is built using technological
measures.

Technological transfer stack-path description I

Technological transfer stack-path description II

Description:
a is the functional dimension, provided with functional
tolerance, by the design engineering. It is used as the result
of the stack-path made up with technological dimensions
with unknown tolerances.
Manufacturing engineering decides to produce the part using the following
dimensions:
a1 is the cutting lenght of the bushing.
a2 is the turning lenght of the bushing body.
Given the tolerance on a the goal is to calculate the tolerances on a1 and

a2 that will guide the manufacturing process and the quality inspection in
order to satisfy the a requirement.

Results with technological dimensions

Goal: a = 70−0.2 from functional drawing
First attempt tolerances: a1 = 19 ± 0.2, a2 = 12 ± 0.2.
First attempt
+ U.D.L. + L.D.L
a1 - bushing cutting length + 19.2 + 18.8 0.4
a2 - bushing turning lenght - 11.8 - 12.2 0.4
Total: + 7.4 + 6.6 0.8
Goal: + 7 + 6.8 0.2
Dierence: - 0.4 - 0.2
Tolerance synthesis
+ U.D.L. + L.D.L
a1 - bushing cutting length + 19(− . )
0 2
+ 18.9( . )
0 1
0.1
a2 - bushing turning lenght - 12(− . )
0 2
- 12.1( . )
0 1
0.1
Total: + 7 + 6.8 0.2
Goal: + 7 + 6.8 0.2
Dierence: 0 - 0
0.1
Results: a1 = 190−0.1 , a2 = 12+
0 . The same limitations of page 63 apply.

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Engineering Drawing

Politecnico di Torino  DIGEP

September 20th, 2019

DTI September 20th, 2019 1 / 68

Functional to Technological tolerance transfer

DTI September 20th, 2019 2 / 68

Tolerance stack-up analysis

DTI September 20th, 2019 3 / 68

Some common functional requirements for a design are:

DTI September 20th, 2019 4 / 68

DTI September 20th, 2019 5 / 68

Identify the functional dimensions of the assembly.

Retaining ring assembly

DTI September 20th, 2019 7 / 68

DTI September 20th, 2019 8 / 68

Functional dimensions to protect assemblability

DTI September 20th, 2019 9 / 68

Functional requirement: axial play

DTI September 20th, 2019 10 / 68

DTI September 20th, 2019 11 / 68

Functional dimensions to protect assemblability

Functional requirements: assemblability and rotation

DTI September 20th, 2019 13 / 68

Functional dimensions to protect assemblability

Functional dimensions and goals: d > e, f <g

Functional requirements: assemblability and rotation

Stack path with functional dimensions at part level

DTI September 20th, 2019 16 / 68

Stack path with functional dimensions at part level

DTI September 20th, 2019 17 / 68

Tolerance stack-up result: tolerances on the part's drawing

DTI September 20th, 2019 18 / 68

Assembly functional dimension: as a dimension, it is a dependent variable

DTI September 20th, 2019 19 / 68

The requirements of Design and Production engineering I

DTI September 20th, 2019 20 / 68

The requirements of Design and Production engineering II

DTI September 20th, 2019 21 / 68

Mathematical background of calculation I

Worst case: functional dimensions at part's level are considered in their

Mathematical background of calculation II

Direct Tolerance stack-up

DTI September 20th, 2019 24 / 68

Technologial tolerance transfer

DTI September 20th, 2019 26 / 68

A simple example of stack-up

Rmax = Amax + Bmax = 8.4 + 12.2 = 20.6 mm

A wrong dimensioning example

DTI September 20th, 2019 28 / 68

Amin = Rmin − Bmax = 20.1 − 12.2 = 7.9 mm

DTI September 20th, 2019 30 / 68

Correct dimensioning scheme

Correct dimensioning with reference dimension.

On this assembly are to be dened:

DTI September 20th, 2019 33 / 68

First attempt tolerances from ISO2768-m

DTI September 20th, 2019 34 / 68

Gmax = Rmax − (A + B + C )min = 70.2 − (19.8 + 11.8 + 35.7) = 2.9 mm

DTI September 20th, 2019 35 / 68

Gmax = Rmax − (A + B + C )min

Politecnico di Torino DIGEP

On this assembly are to be dened:

The following information must be dened for making a tolerance

Example Direct calculation with 1st attempt tolerances

Example Recovery denition

Example Tolerance synthesis

1 problems are identied and solved during the design phase,

Denition prior to the stack-up.

Design goal dened Technological tolerances to be