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    GD & T Tolerance Stack Up

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    Hemant
    The document discusses tolerance interpretation and stacking. It introduces three cases of tolerance stacking and calculates the expected dimensions and tolerances. It then discusses tolerance stacking from a manufacturing perspective, noting that size, location and orientation are random variables. The document suggests using a normal distribution to model the cutting process and calculates the probability of features being out of tolerance. It notes that as the number of features increases, the probability of a part being out of tolerance also increases.

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    GD & T Tolerance Stack Up

    Uploaded by

    Hemant
    111 views19 pages
    The document discusses tolerance interpretation and stacking. It introduces three cases of tolerance stacking and calculates the expected dimensions and tolerances. It then discusses tolerance stacking from a manufacturing perspective, noting that size, location and orientation are random variables. The document suggests using a normal distribution to model the cutting process and calculates the probability of features being out of tolerance. It notes that as the number of features increases, the probability of a part being out of tolerance also increases.

    Original Description:

    analysing tolerance stack up for assembly design

    Original Title

    Gd & t Tolerance Stack Up

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    The document discusses tolerance interpretation and stacking. It introduces three cases of tolerance stacking and calculates the expected dimensions and tolerances. It then discusses tolerance stacking from a manufacturing perspective, noting that size, location and orientation are random variables. The document suggests using a normal distribution to model the cutting process and calculates the probability of features being out of tolerance. It notes that as the number of features increases, the probability of a part being out of tolerance also increases.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    111 views19 pages

    GD & T Tolerance Stack Up

    Uploaded by

    Hemant
    The document discusses tolerance interpretation and stacking. It introduces three cases of tolerance stacking and calculates the expected dimensions and tolerances. It then discusses tolerance stacking from a manufacturing perspective, noting that size, location and orientation are random variables. The document suggests using a normal distribution to model the cutting process and calculates the probability of features being out of tolerance. It notes that as the number of features increases, the probability of a part being out of tolerance also increases.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 19

    Agenda

    Introduction to tolerance interpretation


    Tolerance stacks
    Interpretation

    Tolerance interpretation
    Frequently a drawing has more than one
    datum
    How do you interpret features in secondary or
    tertiary drawing planes?
    How do you produce these?
    Can a single set-up be used?

    TOLERANCE STACKING
    Case #1
    1

    1.0.05

    1.5.05

    1.0.05

    What is the expected dimension and tolerances?


    D1-4= D1-2 + D2-3 + D3-4
    =1.0 + 1.5 + 1.0
    t1-4 = (.05+.05+.05) = 0.15

    TOLERANCE STACKING
    Case #2
    1

    1.0.05

    1.5.05
    3.5.05

    What is the expected dimension and tolerances?


    D3-4= D1-4 - (D1-2 + D2-3 ) = 1.0
    t3-4 = (t1-4 + t1-2 + t2-3 )
    t3-4 = (.05+.05+.05) = 0.15

    TOLERANCE STACKING
    Case #3
    1

    1.0.05

    1.000.05

    3.500.05

    What is the expected dimension and tolerances?


    D2-3= D1-4 - (D1-2 + D3-4 ) = 1.5
    t2-3 = t1-4 + t1-2 + t3-4
    t2-3 = (.05+.05+.05) = 0.15

    From a Manufacturing Point-of-View


    Case #1
    1

    1.0.05

    1.0.05
    ?

    1.0.05

    Lets suppose we have a


    wooden part and we
    need to saw.
    Lets further assume
    that we can achieve .
    05 accuracy per cut.

    How will the part be produced?

    Mfg. Process
    3
    2

    Lets try the following


    (in the same setup)
    -cut plane 2
    -cut plane 3

    Will they be of appropriate quality?

    So far weve used Min/Max


    Planning
    We have taken the worse or best case
    Planning for the worse case can produce
    some bad results cost

    Expectation
    What do we expect when we manufacture
    something?
    PROCESS

    DIMENSIONAL
    ACCURACY

    DRILLING

    + 0.008
    - 0.001

    REAMING

    + 0.003

    SEMI-FINISH
    BORING

    FINISH BORING

    + 0.005
    + 0.001

    POSITIONAL
    ACCURACY

    0.010
    (AS PREVIOUS)
    0.005
    0.0005

    COUNTER-BORING
    (SPOT-FACING)

    + 0.005

    0.005

    END MILLING

    + 0.005

    0.007

    Size, location and orientation are


    random variables
    For symmetric distributions, the most likely
    size, location, etc. is the mean

    2.45 2.5

    2.55

    What does the Process tolerance


    chart represent?
    Normally capabilities represent + 3 s
    Is this a good planning metric?

    An Example
    Lets suggest that the cutting process produces (,
    2) dimension where (this simplifies things)
    =mean value, set by a location
    2=process variance
    Lets further assume that we set = D1-2 and that
    =.05/3 or 3=.05
    For plane 2, we would surmise the 3of our parts
    would be good 99.73% of our dimensions are good.

    We know that
    (as specified)
    D2-3 = 1.5 .05
    If one uses a single set up, then
    (as produced)
    and
    .95 1.0

    D1-2

    1.05
    D1-2

    2.45 2.5

    2.55

    D1-3

    D2-3 = D1-3 -

    D1-2

    What is the probability that D2-3 is bad?


    P{X1-3- X1-2>1.55} + P{X1-3- X1-2<1.45}
    Sums of i.i.d. N(,) are normal
    N(2.5, (.05/3)2) +[(-)N(1.0, (.05/3)2)]= N (1.5, (.10/3)2)
    So D2-3

    1.4

    1.5

    1.6

    The likelihood of a bad part is

    P {X2-3 > 1.55}-1 P {X2-3 < 1.45}


    (1-.933) + (1-.933) = .137

    As a homework, calculate the likelihood that

    D1-4 will be out of tolerance given the same


    logic.

    What about multiple features?


    Mechanical components seldom have 1
    feature -- ~ 10 100
    Electronic components may have
    10,000,000 devices

    Suppose we have a part with 5 holes


    Lets assume that we plan for + 3 s for each
    hole
    If we assume that each hole is i.i.d., the
    P{bad part} = [1.0 P{bad feature}]5
    = .99735
    = .9865

    Success versus number of features


    1 feature = 0.9973
    5 features = 0.986
    50 features = 0.8735
    100 features = 0.7631
    1000 features = 0.0669

    Should this strategy change?

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