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ToleranceDesign

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DesignSpecificationsandTolerance

Developfromquestforproductionqualityand
efficiency

Earlytolerancessupportdesignsbasicfunction

Massproductionbroughtinterchangeability

Integratedesignandmfgtolerances
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Definition
Thetotalamountbywhichagiven
dimensionmayvary,orthedifference
betweenthelimits
ANSIY14.5M1982(R1988)Standard[R1.4]

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Source:ToleranceDesign,p10

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AffectedAreas
Engineering
Tolerance
ProductDesign

QualityControl

Manufacturing

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Questions

Cancustomertolerancesbe
accommodatedbyproduct?

Canproducttolerancesbe
accommodatedbytheprocess?

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Tolerancevs.ManufacturingProcess

Nominaltolerancesfor
steel

Tightertolerances=>
increasecost$

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GeometricDimensions

Accuratelycommunicatesthefunctionofpart

Providesuniformclarityindrawingdelineation
andinterpretation

Providesmaximumproductiontolerance

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ToleranceTypes

Size
Form
Location
Orientation

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SizeTolerances

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FormTolerances

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LocationTolerances

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OrientationTolerances

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ToleranceBuildup

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StatisticalPrinciples

Measurementofcentraltendency
Mean
Median
mode

Measurementofvariations
Range
Variance
Standarddeviation

LSL

USL

X
3

tolerance
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Probability

Probability
Likelihoodofoccurrence

Capability
Relatethemeanandvariabilityofthe
processormachinetothepermissible
rangeofdimensionsallowedbythe
specificationortolerance.

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ToleranceSPCCharting

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FigureSource:ToleranceDesign,p125

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ToleranceAnalysisMethods

WorstCaseanalysis
RootSumofSquares
Taguchitolerancedesign

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InitialToleranceDesign

Initial
Tolerance
Design

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FigureSource:ToleranceDesign,p93

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References

HandbookofProductDesignforManufacturing:APracticalGuideto
LowCostProduction,JamesC.Bralla,Ed.inChief;McGrawHill,1986
ManufacturingProcessesReferenceGuide,R.H.Todd,D.K.Allen&L.
Alting;IndustrialPressInc.,1994

Standardtolerancesformfgprocesses

MachinerysHandbook;IndustrialPress
StandardHandbookofMachineDesign;McGrawHill
StandardHandbookofMechanicalEngineers;McGrawHill
DesignofMachineElements;Spotts,PrenticHall

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FigureSource:ToleranceDesign,p9293

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WorstCaseMethodology

Extremeormostliberalconditionoftolerance
buildup

tolerancesmustbeassignedtothe
componentpartsofthemechanisminsucha
mannerthattheprobabilitythatamechanism
willnotfunctioniszero

Evans(1974)
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WorstCaseAnalysis
m

WCmax = ( N p i + Tp i )
i=1
m

WCmin = ( N p i Tp i )
i=1

Ne+Te=>Maximumassemblyenvelope
NeTe=>Minimumassemblyenvelope

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Source:Sixsigmamechanicaldesigntolerancing,p1314.

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Assemblygaps
m

Gmax = N e + Te ( N p i Tp i )
i=1
m

Gmin = N e Te ( N p i + Tp i )

i=1
m

Gnom = N e ( N p i )

i=1

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WorstCaseScenarioExample

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Source:ToleranceDesign,pp109111

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WorstCaseScenarioExample

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Source:ToleranceDesign,pp109111

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WorstCaseScenarioExample

Largest=>0.05+0.093=0.143
Smallest=>0.050.093=0.043
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Source:ToleranceDesign,pp109111

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NonLinearTolerances
y = f (x1, x 2 , x 3 ,...x n )
f
f
f
f
Toly =
tol1 +
tol2 +
tol3 + ...+
toln
x1
x 2
x 3
x n

f
f
f
f
Nomy
x1 +
x2 +
x 3 + ...+
xn
x1
x 2
x 3
x n
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Wource:Sixsigmamechanicaldesigntolerancing,p104

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RootSumofSquare

RSS
Assumesnormaldistributionbehavior
1
(1/ 2)[x )/ ]2
f (x) =
e
2

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Wource:Sixsigmamechanicaldesigntolerancing,p16

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RSSmethod

Assemblytolerancestackequation

2
1

2
2

2
3

2
n

f (x) = T + T + T + ...T

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Wource:Sixsigmamechanicaldesigntolerancing,p128

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PoolVarianceinRSS
adjusted

gap

Tol
=
3Cp
2

Tpi
Te
= +

3Cp i=1 3Cpi

m

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Wource:Sixsigmamechanicaldesigntolerancing,p128

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Probability
Q Gnom
ZQ =
gap

ZQ =

Q N
e N pi

i=1
2

Te
Tpi

+
3Cp i=1 3Cpi
2

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Wource:Sixsigmamechanicaldesigntolerancing,p128

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ProbabilityforLimits
ZG min =

ZG max =

Gmin Gnom
2
Te 2 m Tpi

+
3Cp i=1 3Cpi

Gmax Gnom
2
Te 2 m Tpi

+
3Cp i=1 3Cpi

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Wource:Sixsigmamechanicaldesigntolerancing,p128

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DynamicRSS
ZG min =

ZG max =

Gmin Gnom
2
Te 2 m Tpi

+
3Cpk i=1 3Cpk i

Gmax Gnom
2
Te 2 m Tpi

+
3Cpk i=1 3Cpk i

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Wource:Sixsigmamechanicaldesigntolerancing,p128

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NonlinearRSS
f 2 2 f 2 2 f 2 2
f 2
Toly = tol 1 + tol 2 + tol3 + ...+ toln
x
1
x
2
x
3
x
n

adjusted

Toli
=
3Cpki

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Wource:Sixsigmamechanicaldesigntolerancing,p128

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RSSExample

Largest=>0.05+0.051=0.101
Smallest=>0.050.051=0.001
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Wource:Sixsigmamechanicaldesigntolerancing,p128

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TaguchiMethod
InputfromthevoiceofthecustomerandQFDprocesses
Selectproperqualitylossfunctionforthedesign
Determinecustomertolerancevaluesforterms
inQualityLossFunction
Determinecosttobusinesstoadjust
CalculateManufacturingTolerance
Proceedtotolerancedesign
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Wource:Sixsigmamechanicaldesigntolerancing,p21

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Taguchi

Voiceofcustomer
Qualityfunctiondeployment
Inputsfromparameterdesign
Optimumcontrolfactorsetpoints
Toleranceestimates
Initialmaterialgrades

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Wource:Sixsigmamechanicaldesigntolerancing,p22

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QualityLossFunction

Identifycustomercostsforintolerableperformance
Quadraticqualitylossfunction

Ao
L(y) = k(y m) =
(y m) 2
o
2

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Wource:Sixsigmamechanicaldesigntolerancing,p208

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CostofOffTargetandSensitivity

Costtobusinesstoadjustofftarget
performance
Sensitivity,

Ao
A

Ao
A = [(x m)]2

DepartmentofMechanicalEngineering,TheOhioStateUniversity

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Wource:Sixsigmamechanicaldesigntolerancing,p226227

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ManufacturingTolerance

Sl.#39

Ao o

A

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Summary

Importanceofeffectivetolerances
ToleranceDesignApproaches
WorstCaseanalysis
RootSumofSquares
Taguchitolerancemethod

Continualprocess
Involvementofmultidisciplines
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Credits

Thismoduleisintendedasasupplementtodesignclassesin
mechanicalengineering.ItwasdevelopedatTheOhioState
UniversityundertheNSFsponsoredGatewayCoalition(grant
EEC9109794).Contributingmembersinclude:

GaryKinzel.Projectsupervisor
PhuongPham.....Primaryauthor

Reference:
SixSigmaMechanicalDesignTolerancing,Harry,MikelJ.andReigle
Stewart,MotorolaInc.,1988.
Creveling,C.M.,ToleranceDesign,AddisonWesley,Reading,1997.
Wade,OliverR.,ToleranceControlinDesignandManufacturing,
IndustrialPressInc.,NewYork,1967.
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completeinformation,OhioStateUniversityandGatewaydonot
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heldliableforanyimproperorincorrectuseoftheinformation
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