Unit 4 Part Stacks Using Coordinate Dimensions Unit - 4 PART STACKS USING COORDINATE DIMENSIONS Upon completion of this unit the student will be able to : + Perform the 4 basic steps in a stack + Fill in the stack form * Calculate part stacks using coordinate dimensionsUnit 4 Part Stacks Using Coordinate Dimensions Explanation ‘THE 4 BASIC STACK STEPS ‘There are 4 basic steps in doing a stack. They are: 1, Identify the problem 2. Choose the desired answer (VWov~X Cor Aciew) 3, Identify the stack path 4. Perform the math Step 1 Identify the Problem ‘The first of the Four Basic Stack Steps three actions. ‘A. Document the stack objective , B. _List the conditions under which the stack is being calculated C. “Label the start point, end point and direction of the stack s to identify the problem—this step involves Let’s look at these actions one by one. A. Document the stack objective To document the stack objective, write a one sentence description of the stack. Then label the stack on a picture of the part or assembly an example is shown in figure 4-1. -O@ Stack Objective @ Find the max. and min. distance between the shoulder and the left side of the groove. FIGURE 4-1, DOCUMENTING THE STACK OBJECTIVE Now let’s look at the second action we take to identify the problem.” Be Li iis whi ing cale To do this, specify: ‘The temperature of the parts Whether the parts micet print specifications Whether the stack includes Or excludes wear ‘The amount of deflection om the parts ‘Any unusual conditions present in stack way Write the conditions on the stack form (we'll introduce you to the form a bit later on).Part Stacks Using Coordinate Dimensions ‘Throughout this course we will have five default conditions for all the stacks. They are shown in figure 4-2. These default conditions will automatically apply unless they are superceded in the text. Any variances from these default conditions must be listed sepa- rately in the comments Gox on the stack form. pe omens oo 4, PARTS ARE ATROOM TEMPERATURE 2, PARTS ARE TO PRINT a 3. NOWEAR wX | & ZERODEFLECTION y 8. NOUNUSUAL CONDITIONS FIGURE 4-2. COURSE STACK DEFAULT CONDITIONS, Now let’s look at the final action we take in identifying the problem. C. Label the start point and directions of the stack ‘The start point of the stack is always one of the part features we named, The end point is the other. A stack indicator is added at the start point of the stack. A Slack indicator is a pair of opposing arrows with positive "+" and negative "-" assigned to each arrow. Directions are assigned to the stack indicator as follows. ‘The arrow pointing toward the end point of the stack is "+". ‘The arrow pointing away from the end point is “K ‘“Theietore, when the end pomntis toward the Hght ofthe start pots, the stack indicator would look like this: <= =++. [enpponty ‘The stack indicator serves two important purposes : 1. It shows when to add or subtract in the stack calculation. “fa part dimension is going in the "+" direction it is added in the stack. If a part dimension is going in the "-" direction itis subtracted in the stack, 2, Ithelps to interpret the stack answer. If the answer is positive "+" then the end point is in the positive "+" direction relative to the start point. ( Cdaormco) Ifthe answer is negative "then the end pointis im the negative direction relative to THESE point. 7 vatorjoramaa)Part Stacks Using Coordinate Dimensions In reality, it does not matter which feature is the start point and which is the end point; the answer will be the same either way. But for simplicity, in this course we will use the rule-shown in figure 4-3, AXIAL STACKS START ON THE LEFT “RADIAL STACKS START ON THE BOTTOM FIGURE 4-3, RULE FOR STACK STARTING POINT. Anexample of a stack indicator is shown in figure 4-4. The start point is the shoulder and the end point is the groove surface. The stack objective is shown and the stack is labeled on the picture. A stack indicator is shown on the starting point of the stack. The stack indicator shows the positive "+" and negative "-" directions for the stack. The stack indicator may seem simple to you, but using it will spare you numerous mistakes and headaches later on. ‘Stack Objective +--— Find the.max, and min. distance between the ake shoulder and the left side of the groove. FIGURE 4-4._ STACK INDICATOR EXAMPLE ‘And that’s all there is to Identifying the Problem. Now lets look at the second of the three basic stack steps. . & ae EMEMBER.. | Axial stacks start on the le i start on the bottor Radial st ics pa} Previous anspicalion 4 Step 2 Choose the Desired Answer a 1 do the problem. This step involves writing down the answer(s) you desire befor powerful tool for ‘The answer is called the design goal. It sounds strange at first, but it Towering product costs.Here is how it works. You answer the following question about the stack: What is the extreme max (or min) answer that would be acceptable and allow the produet fo func __28 intended? Then, write this answer into the design goal “You complete the stack, compare the actual is within the extreme max (or min) as stat tolerance may be assigned to the paris. ‘This step is explained in detail in Unit 20. For now, we will skip this step until we enya OEE cra) Manel: earn the basics of stacks. Step 3. Identify the Stack Path. A Stack path is a series or chain of distances (part dimensions) the stack to the end point of the stack. This chain of distances mus * Consist only of known distances — which are dimensions _d.value calculated from dimensions on the drawing. ‘Be the shortest possible chain of di “Be continuous — each distance must begin wh To identify the stack path: 1. Locate the shortest continuous chain of distances, as defined by dimensions or values calculated from dimensions, from the start point to the end point. 2. Mark each of these distinces on the sketch with a liné, Place a dot whe: distance begins, and 3. “Label each distance with a code letter: A, B, C and so.on, ‘Take'a look at figure 4-5. T's the same part We used before, only now we've included 7 ‘some dimensions. d an arrow where it ends, stack form. Then, as answer to the stated design goal. If the answer inces from. isn tien oi, te veal 268 38.0 340 sss 108_ |e 18 00 ‘1 +5 12 age — 32 as FIGURE 4-5. PART WITH DIMENSIONS 45Stack Objective © Find thé max. and min, distance between the shoulder and the left side of the groove. FIGURE4-6, STACK PATH EXAMPLE Figure 4-6 shows an example of a stack path. A stack indicator is shown on the start point. There are three distances shown A, B, and C. Distance A begins from the start point of the stack and is in the *." direction, Distance B is in the "+" direction and dis- tance C is in the "=" direction. Notice that: * Only known dimensions are use + The shortest possible chain of dimensions from the start point to the end point are used. + Each dis begins where the previous.one ends. In figure 4-6, distance C is a very short part distance. Notice how itis shown on the drawing. A dot is placed where the distance begins and an arrow is pointing towards where the distance ends. Note °c dimensions needed to complete the stack calculation were used in the stack path, You may have already observed that the way the partis dimensioned has a ‘major impact on the stack path, By the end of the course you will be able to dimension parts in a manner that will improve stacks. Let's look at the fourth basic stack step. Step 4 Perform the Math This step involves four actions. A. Transfer the distances on to the stack form B, Add each column of numbers C. Check the subtotals D. Evaluate the answerUnit 4 Part Stacks Using Coordinate Dimensions A. Transfer the distances from the stack path onto the stack form. This action involves entering cach distance from the stack path into the appropriate columns ton the stack form. The stack indicator shows whetheF the number will be added or suburacted in the siack. The column headings show you which column to put the For pc alues the max goes in the left column and the min in right column, For negative Values the min goes in the left column and the max in “the right column, B. Add each column of numbers. Write the answers in the subtotals boxes. C. Check the subtotals. The difference between the max and min subtotals should, equal the tolerance subtotal. Sans D. Evaluate the answer, Bring down the subtotal into the answer box. A positive answer is almost always good \s clearance (or the min thickness or machine stock) or whatever your stack objective was. ‘That completes.the four basic stack steps. fe 4 ba sic stack stops ae aS 1. Tdentify the problem ‘THE STACK FORM Using the stack form provides three main benefits. v1) Consisiency. ‘The stack form systematizes the stack process. It ensures stacks * afe done the right way, and the same way, each time. 2) Math check. The stack form facilitates the essential math-check function which helps us to de-bug the stack. v3) Documentation. The stack form is an essential part of the "paper trail" of the design process. It is an especially useful tool for dealing with engineering change requests. Now let's look at stack #1 (from Figure 4-6) on a stack form.Unit 4 Part Stacks Using Coordinate Dimensions In figure 4-7 on the facing page is a completed stack example. Let's go over each area of the stack form so you can see how stack information is shown on the form. Location Information A The stack number, B A brief description of the stack objective. c Picture showing the stack path. D Enter a distance from the stack path in each labeled row. E The part number. F The part revisidn level. G Comment number. / Leetacr ow pr Hq Description of each distance. The start point a point are described and are separated by a slash, For a list of “abbreviations see page 4-9, I In these four columns enter the max and min values for each distance in the stack path, J If the direction of a distance is negative (in the negative direction of the stack indicator), enter a "=" sign in K golumns I and K. L For negative distances the min value goes in column J and the max value goes in column L. If the direction of a distance is positive (in the positive direction of the stack indicator), enter a "+" sign in_ golumns I and K. For positive distances the max.value goes in column J and the min value goes in column L. Tum to page 4-10 for the rest of the stack explanation,Unit Part Stacks Using Coordinate Dimensions ‘oavective:_FIND THE MAX AMIN DISTANCE BETWEENTHE ‘SHOULDER AND THE LEFT SIDE OF THE GROOVE, See geet Hi or 10.6_| 10.0 DESCRIPTION FROM/T0 [RS SHOULDER US Par LS PART/ RS OF GROO| IRS OF GROOVE / 1S OF GROOVE SUB TOTALS [+ zs [| 24 5 as [as cee) FIGURE 4-7, PART STACK EXAMPLE. 8 BO = Bowndary CP = Contorphine cSt = Cost DAs Datum Ae Bee c aes DP = Datum Pina PT = Point ‘Smal ED = Edge Ro = Radius Surface La = Lage RS = Aigh'Sio* “Tue Pesiton 1S = Lottsice SH = Shouldor TPA = True Profle LOC = Location SI = Sido = Conterine A= Machina Si_= Set = Diametering Coordinate Dimensions M "The difference between the max and min foreach distance goes in this column, The tolerance is always positive. N A description of the comments, Comments are stack _assumptions or special stack conditions. ° In this row, columns J, L, & M are added. The subtotals are shown and whether they are positive or negative is also shown, ‘The tolerance is always positive. Checking the sub-totals Note: The difference between the max and min subtotal should equal the tolerance subtotal. If these columns don't balance it means you have made an error in your stack. To find an error can be frustrating. See figure 4-8 for some tips on de-bugging a stack. P In this row, the appropriate subtotals are brought down as answers. In the case of a single part stack both the max and min are “true answers". A positive or negative value indicates which direction the end point is from the start point. Q ‘The signature of ihe person doing the stack. R The date the stack was done. s The desired design goal. T The sheet number of the stack. ‘What to do when sub-totals don't balance Check the math in each column (adding from bottom up) Check the math in each row (hint - use your calculator) Check each row to be sure the max and min are in the proper columns according to their signs Check the signs in each row to make sure they are correct Aska friend to do the above FIGURE 4-8, TIPS ON DEBUGGING A STACK ——————— 410Unit 4 Part Stacks Using Coordinate Dimensions FIND THE MAX & MIN DISTANCE BETWEEN THE = 7 SHOULDER ANO THE LEFT SIDE OF THE GAOOVE ee teeta - 388 _ Hi 360 |B gt 40 | 236 sth Z “iro tos [ot 18 10,0 its EO RS SHOUOER/ISPART LS PART / RS OF GROOVE RS OF GROOVE/LS OF GROOVE SUBTOTALS |" ms |] te o zs [| ata aa) NaMe._O2ZIE.B__oaTE_1Balat_ ‘a FIGURE 4-7. (REPEATED) PART STACK EXAMPLE.Part Stacks Using Coordinate Dimensions Unit4 Exercises ‘Complete the 5 stacks on the following pages. (Do not choose a design goal until Unit 20.) Exercise 4-1 STACK NO, coovcenve; CALCULATE THE MAX AND MIN DISTANCE BETWEEN THE “RIGHT SIDE OF THE GROOVE ANDTHE END OF THE SHAFT. gee. 2 PLACES X10 age 04 ‘X 45° 2 PLACES: DESCAIPTION FROM/TO eS ity ‘SUB TOTALS: rd 4-12Part Stacks Using Coordinate Dimensions Unit Exercise 4-2 STACK NO, (OF THE SHAFT ANO THE LEFT SIDE OF THE GROOVE. i 20.4") | a4 = 20 80 int 18 2 PLACES Oe 7 04 +X 45° 2 PLACES y re PARTNO, | REV DESCRIPTION FROM/TO a Hi “4 i [$0 252 c es el a | a rle2.d |. ( ‘COMMENTS susroras |-| 9,4 fe NAME DATE.Part Stacks Using Coordinate Dimensions Exercise 4-3 STACK NO. ‘opsecrive: CALCULATE THE THICKNESS BETWEEN THE RIGHT SIDE OF ATE THE THICKNESS BETWEEN THE RIGHT SIDE OF _ "THE GROOVE AND THE END OF THE PART. SHEET__1_OF_1 x-102~ See drawing package for part dimensions. PART NO, | REV DESCRIPTION FROM/TO eft Hl t Tbe Tio oe a2 46 dy Boh ond Lt s.é Kl 2.2 to : esses ‘COMMENTS: ‘SUB TOTALS [A Leer 11.5 2.38 LS DESIGN GOAL aM DATEPart Stacks Using Coordinate Dimensions eT Exercise 4-4 STACK NO. ‘OBJECTIVE: _ FIND THE MAX AND MIN DISTANCE BETWEEN THE RIGHT Si ‘OF THE GEAR AND THE THRUST WASHER SURFACE, SHEET_1_OF i See drawing package for part dimensions. PART No. | REV ff DESCRIPTION FROM/TO ‘SUB TOTALS |-|Exercise 4-5 STACK NO. ‘OBJECTIVE: _FIND THE MAX AND MIN CLEAN-UP STOCK. SHEET_1_oF_1 13.0 12.0 Sce drawing package for part dimensions. PART NO. | REV DESCRIPTION FROM/TO bi tnaersatiia| ea a be] 1929 PT 20.0 1 | fa _ Lfos 2 We ‘COMMENTS ‘SUB TOTALS [1] ei o.2 [2 2.3 HE Oo .2 DESIGN GOAL NAME. 4-16Exercise OBJECTIVE: -EINDTHEMAX&MINDISTANCEX STACK. 4-6 : SHEET_1_OF_1 » ® > 52.0 x E i Feces oO cera i Ei ~ 80 DIA-2 HOLES {ied cae 7 g ole 8 PART NO. | REV DESCRIPTION FROM TO ‘COMMENTS ‘SUB TOTALS resorcon Qa) NAME ___ DATE 47Unit4 Part Stacks Using Coordinate Dimensions Summary To do a stack, we follow four simple steps. First, identify the problem by describing the stack features and determining whether we are calculating a max condition, a min condition or both. We also determine whether any special conditions exist which supercede our set of default conditions. Next, we place a large dot at the start point of the stack, and another large dot at the ‘end point, Axial stacks start at the left; radial stacks start om the bottom. Also specify the positive and negative directions of the stack path by placing a stack indicator at the start point; positive is toward the end point and negative is away from the end point. Second, select a design goal, Choose the desired answer which meets the functional needs of the design. Now, identify the stack path, This is the shortest possible continuous chain of dis- tances, based on known dimensions and/or calculations derived from known dimensions, from the start point to the end point of the stack. Each distance begins where the previous one ends. The final step is to perform the math, We list the dimensions for each segment of the stack path on the stack form, being careful to observe all + and - signs. We do the arith- metic and check our work to make sure the stack balances. If it does not balance, we debug our work until the stack does balance ‘Then, analyze the answer. A positive answer indicates clearance; a negative answer indicates interference. This step-by-step procedure, applies to part stacks.