2012 QUALITY TIPS

TOLERANCE STACK-UP ANALYSIS

Tolerance stack-up when the part dimension and tolerances specified using
GD&T.

Tolerance stack-up analysis is very important for design engineers when they need analyse
whether each part dimensions and tolerances are adequate to meet the assembly or functional
requirement or performance requirements when they are assembled together. Manufacturing
engineeron the other hand must be able to perform tolerance analysis to resolve any
tolerance related problem encounter during production.
Tolerance stack-up analysis is especially crucial during the design verification/review process.
The Tolerance stack-up analysis approach is different when the part drawing is specified using
Geometric Dimensional and tolerances as opposed to traditional +/- drawings because of :
o Boundary Conditions (Worst case, Outer/inner and virtual) that present when the
features is specified, controlled, or modified with modifier
o Bonus Tolerances that becomes available under certain condition
o Datum shift that becomes available under certain condition.

For example consider the following scenario.

In this example, part A & B will be
fastened with part C using
fasterner D(2x). ( floating
Fastener).

When These four parts mate, the

following questions need to be
answered:
1. what is the maximum
and minimum gap between part
A and B?
2. Will there be any
interference between these two
parts?
3. If the the gap exceed the
engineering specification, how are
each Dimension/tolerance of each
part adjusted to meet the
requirement?

QBASE ENGINEERING SDN BHD

|Advanced Quality Engineering Series

2012 QUALITY TIPS

TOLERANCE STACK-UP ANALYSIS

4.What will be the strategy to adjust the tolerace, which one

is desirable?

This is another example where two parts mate (assembled)

Note the following:
1- The tab and slots centerplane are controlled with TOP with
Modifier. Therefore in this case the
boundary condition exist and
bonus tolerances applicable.
In this example the following
question need to be answered:
1- Maximum and minimum
distances (2X)
2. Maximum and
minimum width of the gaps ( 2X)
3. If there are specific
requirements for the distance and
gap, how do we adjust the
dimension or tolerances for the
part features? What strategy do
we use? Which is desirable?
To answer the above questions
Tolerance stack-up Analysis need
to be performed.

See: Tolerance Analysis Flow

QBASE ENGINEERING SDN BHD

|Advanced Quality Engineering Series