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
What is the expected dimension and tolerances?

D
1-4
= D
1-2
+ D
2-3
+ D
3-4
=1.0 + 1.5 + 1.0

t
1-4
= (.05+.05+.05) = 0.15
1.0.05 1.0.05
?
1.5.05
1
2
3
4
Case #1
TOLERANCE STACKING
What is the expected dimension and tolerances?

D
3-4
= D
1-4
- (D
1-2
+ D
2-3
) = 1.0


t
3-4
= (t
1-4
+ t
1-2
+ t
2-3
)

t
3-4
= (.05+.05+.05) = 0.15
1.0.05 1.5.05
1
2
3
4
3.5.05
Case #2
TOLERANCE STACKING
What is the expected dimension and tolerances?

D
2-3
= D
1-4
- (D
1-2
+ D
3-4
) = 1.5


t
2-3
= t
1-4
+ t
1-2
+ t
3-4


t
2-3
= (.05+.05+.05) = 0.15
1.0.05
?
1
2
3
4
3.500.05
Case #3
1.000.05
From a Manufacturing Point-of-View
Lets suppose we have a
wooden part and we
need to saw.
Lets further assume
that we can achieve
.05 accuracy per cut.
How will the part be produced?
1.0.05 1.0.05
?
1.0.05
1
2
3
4
Case #1
Mfg. Process
Lets try the following
(in the same setup)
-cut plane 2
-cut plane 3
Will they be of appropriate quality?
3
2


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

DIMENSIONAL
ACCURACY

POSITIONAL
ACCURACY

DRILLING

+ 0.008
- 0.001

0.010

REAMING

+ 0.003

(AS PREVIOUS)

SEMI-FINISH
BORING

+ 0.005

0.005

FINISH BORING

+ 0.001

0.0005

COUNTER-BORING
(SPOT-FACING)

+ 0.005

0.005

END MILLING

+ 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?


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 = D
1-2
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.
An Example
We know that
(as specified)
D
2-3
= 1.5 .05
If one uses a single set up, then
(as produced)
D
1-2

and
D
1-3

.95 1.0 1.05
D
1-2

2.45 2.5 2.55
D
2-3
= D
1-3
- D
1-2
What is the probability that D
2-3
is bad?
P{X
1-3
- X
1-2
>1.55} + P{X
1-3
- X
1-2
<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 D
2-3

1.4 1.5 1.6
The likelihood of a bad part is

P {X
2-3
> 1.55}-1 P {X
2-3
< 1.45}
(1-.933) + (1-.933) = .137

As a homework, calculate the likelihood that

D
1-4
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
= .9973
5
= .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?