Tolerance interpretation

Dr. Richard A. Wysk ISE316 Fall 2010

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

?
3.500.05

1.000.05

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 4

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

1.0.05

1.0.05 ?

1.0.05

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 DRILLING REAMING DIMENSIONAL ACCURACY + 0.008 - 0.001 + 0.003 POSITIONAL ACCURACY 0.010 (AS PREVIOUS)

SEMI-FINISH BORING
FINISH BORING COUNTER-BORING (SPOT-FACING) END MILLING

+ 0.005
+ 0.001 + 0.005 + 0.005

0.005
0.0005 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 1.05 D1-2 2.45 2.5 2.55

D1-2

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?