Tolerance Analysis

for Non-rotational Parts

Team: Dr. X. Han, S. Yao, C. Fei

Advisor: Professor Y. Rong
Sponsor: NSF & Delphi Corp.
 Tolerance Analysis in Production Planning
Tolerance analysis CAD

- Part of setup planning Part Information Model

- Locating error coupled with process error
- Intra- and inter- setups
- Process verification and
quality control
- Integration in CAD/CAM
- Manufacturing feature
- FTG (Feature tolerance graph)
Setup Planning
Best Practice - DMG (Datum Machining feature relationship)
- Processes with tolerance specification
Tolerance Decomposition

Four steps: Tolerance Assignment

Machining Error Analysis
– Tolerance stack-up analysis
• Tolerance decomposition
• Machining error analysis Is error in
tolerance zone ?
– Tolerance assignment No

Yes
– In process inspection
– Quality control plan In-process Inspection

Quality Control Plan

In this project, the first step is studied.
End
 Tolerance Stack-up Analysis
• Tolerance stack-up analysis is to evaluate the machining error
effects in each setup on the feature tolerance specifications of the
final product
• Tolerance stack-up analysis
– For given setup plan as DMG
– For given machining errors in each operation
– Evaluate the machining error accumulation through setups
• Tolerance decomposition
– The feature tolerances specified in product design can be decomposed into
operation tolerances specified for each setup
– The machining error in each setup can be decomposed into locating errors
(∆ loc) from machine tool and fixture, tool-fixture alignment errors and tool
wear errors (∆ tool), other deterministic (∆ o) and random (∆ ran) errors.

∆ =∆ loc
+∆ tool
+∆ o+∆ ran
 Tolerance Achieved in One Setup
Symbol Tolerance type Machine error calculation in one set-up
•Tolerance decomposition model 1 : Model1 Model2
Two related features are machined in Two features have the same normal and
one datum frame:
Linear dimensions with the same tool
∆ = ∆ o + ∆ ran
Two features have opposite normal and
with the same tool

∆ = 2∆ tool + ∆ o + ∆ ran
Profile of a line

Profile of a surface ∆ = ∆ + ∆
loc tool Two features have the same normal and
+ ∆ o + ∆ ran
with the same tool
Circular runout
• Tolerance decomposition model 2: Total runout ∆ = ∆ o + ∆ ran
One of the features in the tolerance
relationship is the datum feature: Concentricity Two features have opposite normal and
with the same tool

Symmetry
∆ = ∆ tool + ∆ o + ∆ ran
Parallelism

Perpendicularity

Angularity
Tolerance Achieved in Multiple Setups
• Tolerance Decomposition Model 3
The features in the tolerance relationship are machined in different setups

∆ N,N’
=∆ N,A
+ ∆ A,N’
∆ N,A
= ∆ ran

∆ A,N’
=∆ ori
+∆ ran
 Tolerance Stackup
Begin

Searching Algorithm
Tolerance stackup chain searching

Searching features of target

tolerance in DMG

In order to identify the factors

that influence the machining Two target features are machined

errors, two steps are needed:

in one setup?

• Search the datum-feature No

No

relationships that construct the Yes Begin with the target feature (I) in later set-up,
searching related features in stack-up, calculate the
∆
tolerance stackup chain
variations of
i

• Calculate the total machining

errors Is the stack-up chain successfully
found?

Tolerance within one setup: Machining error calculation Yes

∆ = ∆ m t + ∆ cu tte r+ ∆ L o c + ∆ ra d o m Tolerance achieved in one setup Tolerance achieved in multiple setups

∆ = ∑ (∆ mt + ∆ cutter +
∆ = ∆ mt + ∆ cutter +
∆ Loc + ∆ radom ∆ Loc + ∆ radom )
Tolerance stackup in multi-setup:
∆ = ∑ ( ∆ mt + ∆ cutter + ∆ Loc + ∆ radom )
End
 Locating Errors Analysis
Among the machine errors in one setup, the locating error (∆ loc )can be
calculated:
• Six locating points(P1 , P2 , P3 , P4 , P5 , P6 ) construct three orthogonal planes
0 0 0 0 0 0

A1 X + B1 Y + C1 Z + D1 = 0
A2 X + B2 Y + C2 Z + D2 = 0
A3 X + B3 Y + C3 Z + D3 = 0

• A theoretical fixturing coordinate is expressed as

 A 0 (θ ) ( X 0 ) T 
T =
0
 X0 is the position of the origin point
0 0 0 1  A 0 (θ )
is the 3× 3 orientation matrix parallelism
CSf’
• Actual fixturing coordinate reflects the CSf

variation caused by locator errors (∆

x0 , ∆
y0 , ∆
z0 , Workpiece Xi profile
T = T0 • ∆ T α
∆ β0 , ∆
0,∆ γ0 )
X i
0

∆ T = (∆ x, ∆ y, ∆ z, ∆ α , ∆ β , Locator
Fixture base
∆
T fb
∆
Tpl
∆ γ ). ∆ T comes from the given Pallet
∆
Tmt
locator errors.
Machine tool

CSw
 An Case Study on Knuckle
L6

203 201
202
109 L3 L5
204
105 OP10
107
103

102 L2

110 L4
106 101

104 205
108 L1
208
207

111
0.1 A
OP20
209
206

Machining feature GD&T of OP10: 101 Surface A 1.2 X Y Z

Theoretical fixture CS: 0 1 0 − 27.64  Actual fixture CS  0.999966 − 0.00558818 − 0.00613351 0.269581
1 0 0 − 72.7367  − 0.00128144 0.344082
  with given locator 0.00558042 0.999984
0 0 − 1 − 73.8312 errors( + 0.0254 ) 0.00614057 0.00124717 0.99998 0.334775
  −
 
0 0 0 1   0 0 0 1 
The worse case caused by locator errors: 0.654
Overall machining error
∆ Total = ∆ locating + ∆ mt + ∆ process +∆ tool = 0.654 + 0.013 + 0.254 + 0 = 0.921 mm
∆ mt, ∆ process and ∆ tool are given parameters.
 A Case Study on Engine Block
| 0.25 | M-S | A | R |Φ0.40 M | M-S | A | R
AA X W |0.05/162 | M-S
Cy5~8
Cy1~4

YY
ZZ

L
XX
J K
M-S DD
R
D B
A

Datum frames:X-Y-Z, XX-YY-ZZ, A-B-C, M-S-A-R

OP10 OP20 OP30~OP170 OP175~

X XX XX A A M-S M-S Cy
∆ M − S , A = ∆ OP 30loc + ∆ tool 1 + ∆ OP 30 mt + ∆ proc1
Y YY YY B B A ∆ M − S , R = ∆ tool 2 + ∆ OP 30 mt + ∆ proc 2
ZZ ZZ C C R R
∆ ⊥ M −S ,Cy = ∆ OP175loc + ∆ tool 3 + ∆ OP175 mt + ∆ proc 3
Summary
A comprehensive tolerance analysis framework is established
for machining system planning and verification.
Tolerance stackup analysis has been studies for non-rotational
part.

Three tolerance decomposition models are developed for intra-

and inter-setup analysis.
• An inter-setup tolerance stackup algorithm have been
implemented.
• The calculation of locating errors has been implemented.
• The analysis is integrated in CAD/CAM

Acknowledgement: Dr. Y. Zhang and Dr. W. Hu contributed to the earlier

work of the project.