2012 QUALITY TIPS

TOLERANCE STACK-UP ANALYSIS

Tolerance stack-up when the part dimension and tolerances specified using GD&T.
Tolerance stack-up analysis is very important for design engineers when they need analyse whether each part dimensions and tolerances are adequate to meet the assembly or functional requirement or performance requirements when they are assembled together. Manufacturing engineeron the other hand must be able to perform tolerance analysis to resolve any tolerance related problem encounter during production. Tolerance stack-up analysis is especially crucial during the design verification/review process. The Tolerance stack-up analysis approach is different when the part drawing is specified using Geometric Dimensional and tolerances as opposed to traditional +/- drawings because of : o Boundary Conditions (Worst case, Outer/inner and virtual) that present when the features is specified, controlled, or modified with modifier o Bonus Tolerances that becomes available under certain condition o Datum shift that becomes available under certain condition.

For example consider the following scenario. In this example, part A & B will be fastened with part C using fasterner D(2x). ( floating Fastener). When These four parts mate, the following questions need to be answered: 1. what is the maximum and minimum gap between part A and B? 2. Will there be any interference between these two parts? 3. If the the gap exceed the engineering specification, how are each Dimension/tolerance of each part adjusted to meet the requirement?

A C

QBASE ENGINEERING SDN BHD

|Advanced Quality Engineering Series

2012 QUALITY TIPS

TOLERANCE STACK-UP ANALYSIS

4.What will be the strategy to adjust the tolerace, which one is desirable?

This is another example where two parts mate (assembled) Note the following: 1- The tab and slots centerplane are controlled with TOP with Modifier. Therefore in this case the boundary condition exist and bonus tolerances applicable. In this example the following question need to be answered: 1- Maximum and minimum distances (2X) 2. Maximum and minimum width of the gaps ( 2X) 3. If there are specific requirements for the distance and gap, how do we adjust the dimension or tolerances for the part features? What strategy do we use? Which is desirable? To answer the above questions Tolerance stack-up Analysis need to be performed.

See: Tolerance Analysis Flow

QBASE ENGINEERING SDN BHD

|Advanced Quality Engineering Series