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    Mechanical Tolerance Stackup and Analysis Muya PDF

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    Shaid Corona Herbert

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    © All Rights Reserved
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    Mechanical Tolerance Stackup and Analysis Mechanical Tolerance Stackup and Analysis a eo MECHANICAL ENGINEERING A Series of Textbook nd Reference Books Posing Eat LL. Faulkner Columbus Divison, Bane Memorta Instiute ‘an Deparoent of MochvielBngicering ‘he Ohio State Univers (Cantus, Oo ‘Soler Engheonng fer Dares Buldngs, Willan A. Hin ‘opted Engnceing Mecho: Sates and Dynarcs, G-Booboyd snd Sor ‘Genta Pomp Cin gor Kara ‘Gomputer dod Knees fr Masie Desi, Dane Ryan ‘Praies Posse Deg Handbak, Part A Matias and Components Part £8 Procnsee and Design fr Processes, ede by Ednars ‘Tubomoehinry: Base ery and Appleaton Eat Logan. J ‘ats of Sats and Plates, Wer Socda Flt and Corugatad Captrapr Desi Handbook, Mario Givens ‘races! Sess Anas Engoorng Desi, Aart Ble ‘a inroaicton tothe Desig and Bohavor of Bote Jos, JohnH. ‘esters Optial Engrg Deon Prieines and Agplcatons James N.S Shing Marufactuin Handbook Haris Caton ‘dutta se Cart: Pandan and Apaatns, to by Lows ‘Gears ond Tha Vivato: Base Approach fo Understanding Gear Nase, Dare Sm “Gini Yor Power Tranonisson and Mate! Hang: Design ard Apo ‘Salons Handbook, Amarcan Chai Assodabon {Carian "and Coneson Pretecion ‘Handbook, edted by Phiip A ‘Gear Ove Systm Desion and potato, Peer Lyewande inPlont Arbane ‘Consminants:Systams Design and Cal. catators, Joh D. Constance (GABCAi Syetns Planing end implementation, Chars S,Krox Protas Engineering Das: Poco and Appicatios, dames N Sisal Tracten Devs: Slecton and Application, Fredrick W, Helich Wand Eugene Shue Fine Element Metods: An Introduction, Ronald L. Huston and Chis E Pseore SeBEN 8 #8 3 seese # se Mechanical Fstanng o Pests: An Engneang Handbook, Brayen Lins Keneth Games, dsaras Facer Lbcatin i Proioa:Secnd Eaton, dtd by W. S. Robeson ‘nope of Autonet Gatig, Dail yen races! Sel Desi, eed by Loar art Engineing Docent fr CADICAM Applications, Carls S,Krox ‘Besgn Dinensioning wid) Computer Grophes Appicstons, Jone C ange cn Aa: Spied Gopi an ray Tce, yrn (CAOCAN Sytem: Juteaton, mpkmentaton, Proce vor Preston, Googe W. Cra, anda. Conia ‘Stoom Prt Catutons Manual, V.Gsnapany, Design Assurance or Engen and Managers, hn A Burgos Feat Tanstor Fluids and Syatoms for Procss and Eran Apleatons vase Singh Patel ows: Computor Graphic Solon, ober .Kre (Cemputer Aided Gapnics and Des: Second Eaton, Danial. Ryan tecroncaly Cowal Poperenal Vabes" Selecion and Appaton, Nehool J Tonan, ete by Tot Glitas Prceure Gauge Manaboot, ANETEX, U.S. Gauge Disien, eed by Pip “Fane Pivaton for Combuston Sources: Fundomaniai and Bask Tech Neaturee! Aptcatons na eta by Lawrence € Mur, Kat. Staugharsner, Hojo ‘Mogosium Peduts Design, Robert S Bk ‘Howe iogoe CADICAM Systems: Monomer ad Tecolay, Witla Dirge (am Bean end Menace: Second Eton: wh cam design soars forthe aM PC and compattls, dak nod, Praben W.Jonean Soldat AC eter Cantal Seectn and Aptcaton, Set Cartel FFundamerils of Rebates, Dave. Atayf0 [Ba Solacion and Appcatn for Enger, ested by Wallace D. Eton Devloing Three Demos! GAO Sofware whe OM PC, ©. Stan Wt ‘genta Data fr Gin Applicators. Charles. Krox, wy crtrutons Dpritomas © Boos, Ross S Coberouse, and Pol F. tlc @. os. @. n 2 i 6 n. 0. oF Computerides Simulation in Retivey Dynamics, by Rao V. Dutipt and ‘oaph Amt. Fteired Coposts Matra, Mando, and Des, PK. Picco and Cote Slcon and Applicaton, Soot M. Tite Ent Ansys wih Peon! Comper, Edvard R. Chapin Sevan). cael Eneming ‘Stoum Plant Coculsins Manus: Second Eston, Reed ond Expanded, V.Ganacaty Trust Nase Conta. Fundamentals and Agptcatens, Second Eaton, ‘Rowsed ond Expanded Low Ball ana Deals Hel ‘ite Esment’ Tht Design ard Porlomarce, Richard MecNost ‘Mochankal Pepertes of Palmers ard Gempostes:Sacond Eatin, Ro ise and Expande,Lawronce Nolen ang Reber FLandol chan Wear Pedeton and Peventon, Raymon Bayer i 16 16 42. 12 m Mechanical Powsr Tansmison Component, eed by Dav W. South fron Manco. Hansbook o Tursamachinen, ested by Ea Logan, Engncerns Documentation Conta Prctcee and’ Procedures, Ray E Monahan [sick Lies Temansctre asin ad Aare, Cos A Geamebie Dinensionng ad Teearce:Applcaton and Technigues fr ‘haf Soa or Dynami Apleatons, Las Howe Fitity-Based ecrantea Design etd by Thoms A. Cruse Mecrantal Fastening ania, and Assn) James A. Sack Turarachinery Fue Dynamics and Het Taner, edie by Cn Hah ighacaur Technolgy. A Practeal Gude, Second Eaten, Revised and + Expands arebodH Habanian CGeomeire: Dinensianing and Toleanchg: Werktook and Answerbook Find ais Stn tr Expr ets, eet anatcck of Tmoptastic Ping Systom Design. Themas Sbamit and Praca! Gaeta Fits Elements: A Sold Mechanics Approach, Steven Mt too ‘Aartied Computations Fu Dynamics, eed by Vy. Garg ‘Fa Seating Toetnatay Hens Kt and Berar Nas ‘Facto ana Lubicatonm Mechanea! Das, A See Inunoe Funtars ard Maiices, Yak. Neloe Mechanical Anais of Eleconc ‘Packaging Stems, Stephen A Nekeoun {Ceungs ard Joi: Design, Selec, and Agpstn,Socend Elon, Fovica and Expand, Jon Mancuso sa 12. 13. 134, 136. am 8 138 444 ae 4. us, 6, 7, 48, Me, 150. ie 1s 154 135 Designing fr Podut Sound Qusity, Rena, Lyon ‘Probably Apleatons in scars! Des, ra. Fisher and oy eke! Aya, etd by Uke Heute Fett cnr rte: Pim Anayis and Teutsocta Formals fr Dynan Anas, Renal. Huston and C.@. Ly Hanabooke Machinery Danis, yin Lule an Ea Logan Raped Prcyping Techraegy Scecton and Appleaton, Kemah G. Coorer FRecbrocatng Mechineyy Dymamice: Design and Anayie, Abdu S. Fargwaia Mabtenance Excelence: Opting Equpmart Life-Cycle Declsons, ed {edby seh. Campbel and Arrow KS are Praca! Gude to cst! Boor Systems, Raph Vandaptt abot Funcomertals: Socond Eaton, Ronsod and Expanded, OM Piro and ‘A ese stant! Lie Gye Handbook: Goad Envronmentl Design and Mans fectaing ates by wahenara 8. Funda Meremachiing of Engnceng laste, ete by Joseph MeGough Conte Sete for Dynami Systems: Design and implementa, Joba ilies, Praca Gi to Preseue Vessel Monuactung, Sul Pulecot Nendesbucive Evaliaton. Ther, Techniques, and Apoleatons, etd by Petr Shut Diesel Enane Engincerng: Themednenics, Oynamics, Design, ond Contes, Ana Marco andboot of Machine Too Anh, loan D. Mainescu, Contant aps, Implementing Goncurent Engineering in Smal Companies, Susan Cason Stal Fractal Guide othe Packaging of Elecroncs: Therma and Mechanical Design and ars, Al ara Bear Design Meine: Engineering Tribology and Lubrication, Nochencal Retbily Inprovement: Probably and States for Exper ‘mental Tsing RE. ute Inara Boles and Heat Recovery Stew Gonorats: Desig, Ap- pleatons, and Catuttons ¥. Canapaty ‘ihe CAD Gulseook A Bosie Manual or Understanding and inproing Cnputraied Desi, Sephen J Schooner Inga Nose Cont and Acoustics, Randa F. Baron Mechantal Prepares of Engoored teal Wole Saboyelo FRlaoley Veriton, Tesing, end Arajls Engneonng Desir Cay 8. ‘Waseomen Fodomnta Mechanics of Fis: Ti Elon, |G, Caio Intermost Heo Transfer Kaui vine Wong HVAC Water Chere ond Cosig Towers: Fundamentat, Appesten, and (peat Het W Star (Goer Noe and Viton’ Second Eton, Revised and Expanded, J Bere Sh 156, 189, 60 402. 1 10 1, 167, 18 470. am. we 173 174 175 1 178 178, $81 2 1. ancbock of Tubomachiery: Second Eten, Revised and Expanded, ‘oa by Ea Logan. and Ramona Roy Fog and Prine Engiroarng: Design, Constr, Maintenance, Ig- fy, and par, Gog A Arik Tubomactiney: Design end Theo, Rams S. R. Gata ané jae Arend Kan Target Costing: Market Oren Product Dasgn, M. Brat’ Cito, Hemy MB. Bi, Robert E Atiano, ana Wesley. Townsend ‘pated Conran, San la soning: AN Intodscten fo Paremeterahg Geamatic Mods Vig Sevasan Handrook ct Mechanical All Design, edited by Geog E. Tote, Ln Xe, {yoshi Fura ‘Stutal Analyse Polymone Compose Matris Mark Tale IMadetng and Simulation for Matorl Seccton and Mechants! Design, ‘ted by Gorge E- Toto, Lin Xe, ard Kyat Paclan ‘anabock ef Preumate Conveying Enghestng, David Mis, Nak G. ones end Vay Agar eas ond tas eson ant Sot, Secon Eat, lam C Randementls of Fld Flim Lubrcaton: Second Eon, Berard Hamer, StovenR Stn, and Bo 0. Jacobson ‘Handbook of Lead Free Solr Techie or Mcoeecoic Assembles, (doy Ka. Pats ond Katieen A Ser Vente Sty, Dean Kamo Mochoncal Wear Fundamotat and Testing: Second Eaton, Revised and Expanded, Rejtond 6. Bayer Lad Paine Phare, © Sash Meron Sold Fue Conbusion and Gasca ar de Soa-Sanoe MochantalTeleranes Sackup and Anais BR chee Engineering Doser Wear Rayong G Bayer \nvatons a Sets and Plates: Third Eso, Revised and Expanded, Wee et Soe Fetactones Handbook toby Chats A. Schacht Practica Enginerng Faure Anta Har MTavancy, Anwar Ube, Noredan Me xbbae ‘Mectantl Along and Meg, C. Suyanceayan. Mechanta! Vivato Analy, Uncotantes, and Cart, Second Eton, ‘Revised and Expande, tam Bosraya Der ofa tina, So Oty Practica Facue Mectants i» Desi Socond Eaton, Rewsed and Bx. Banded, Aun Sul ‘racial Gute to Desked Experiments, PaO. Frkontusch Adon! Volumes a Preparation ne Sore ‘Spring Desig wih an BHP, A Ditch esta Ded Fre ays: Wn alr Ara yt Sore Mechanical Tolerance Stackup and Analysis Bryan R. Fischer 4 7 aheE oy SR 1 Background ‘oleancing, Tolerance Analysis and Tolerance Stackups hve hee around In one form or another fora Longtime. Sometine inthe past it became ‘ees to determine whether a collin of pats woud together before ‘hey weremanofatired. A design eum may have nos t know bow tina part store coud become duriag manufacture, make sue the pat would Fenuissrong enough to work, They may have neded to know ho age ae ould be now frit ole fom it nominal potion to ake sie tee Was enough surface contact to properly dre the fa! fom 8 Jasener. Peeps the manufactring tum nooded t0 enderand Wi ah ‘stembly of prt that mat the drawing speiations dl not topthr at ‘stenbly. By performing Tolerance Amal and Tolerance Stackups, thse ‘nd many other important questions about the design canbe aster. ec thats why Tolerance Anls and Tolerance Stackups ae doae—t0 ‘onde answers to questions. The cchniqus inthis text wil belp you, he Teale, understand your tolerancng probes, answer your tolvanciag ‘ueton and vole sour tolrancig problems "ow can the designer envare tha prt wl together at asemby? ‘etry hw canbe deser nme that mere pat il ogsther at ‘sembly, as al parte are imperfect? How much imperfection or vations lomabe? Does tnt prt is mpulutured sit are ha noi ‘nd the mating part is manufactsad sealer than nominal? What both ‘ts are manafacrred on the smal side and mating Hoes i each part are lighted or out of poston? What fects the performance fhe seb 'Bore—vaiatonin iz or vrai in poston? What happens toaTeaure ot 2 nape ‘one parti surface onthe mating ar tite? These quetions al ead tos Tolerance Stactup “Tolerance Analysis and Tolerance Stackup techniques have evoied overtime increasing in comple tome! he ineresingl compa seed of hs prods they say. Inerestngy, a change in manuractrig pioeo- hiss ely the primary reson that Tolerance Stackps ae so portant foday. Design took and techniques bve changed the design comunity ad ‘he manufactuing community have econ separate cies and the ned 0 ‘erly and unamtaguoulycommanisate devin equiseneats between he two has driven the ned for Tolerance Sackups ‘The need for and the abiity Yo design ever more complex parts and sembly the need o guarantee taney and the wend to fuarantee interchangeably of pars have contbutt grey to the widespread neod for Tolerance Ansys. Comply san stresing iste it iat to determine if complex design il sats) is obptves even wheal parse thei nominal state Tow in varation and te problem can be ove hlming. Through the application of standardized Tolerance Analyst Tecigues, suchas te oes presented inset the problem an be reduced toa more manageable or and solved, The need fr interchangeable pars and the aed fr pats that wil without rowork adjustment tase an only be ented by Tolerance Anas Theefastrs ae hallmarks of oder manufactrig posi, andthe only way to ensure thee goals sate achive is through the proper we of Tolerance Anal ecigues Tolerance Anafss can be found today in nea all sanulactaing Indore, rom the very small geome found in ntepatd cee to the ‘erylarge geometry Found o rockets, the Space SbullesndtheInroatiol Spice tation. Anywhere that parts mus ttogetbar, anywhere the polis of accumulated triton may cave # problem, or merely needs to be lndersood and quanied, Tolerance Analysis and Tolerance Stak ‘echaiguor are being wed, “Although its ot the ely environment where Tolerance Anais is needed, Tolerance Analpis has founds greatest application it mass ‘production, where interchangeably of Sindy slsted prt sexsi ‘tine manufacturing ineases the demand for pat hat abot ‘mus a assmbly, as its mich eekly td Yo ve a stock of Spare arts wating inthe warehouse. Tolerance Analysis the oly way to eaute that the toleraoss pied on drawings wil lead to pars tha “Tolerance Anal equally benef in escuch and development (R&D) and for on-oFakind components and seen, as tere i 80 ‘thes way to ensre tat the acamlted variation of said pct fe. ‘acess nctionaly acceptable, Whether tithe to obi end eon ‘ona robotic am a cover that fs over a enlosie, a slerance hole thal sackourd 3 sus allow a fastener to pas, oF the location ofa bracket in an assembly, ‘Tolerance Analysis the only way to guaratce that pats wil it ogethe at sembly or milemi, mankind has heen doing and manufacturing parts, sssembboy and sractres Early onthe person that dened an sem treo reponse for manafcaring the pars hat made up the asienbl Td, tbe design wat’ complete unl fal asemy, where many pals ‘er ground, scraped, dled, Dnt and modified to mutch th ating pars. Such assenblis work well enough, but they were one of king. Tt vas eounon fal the parts ia such an assembly tobe easton Bt, This or of ‘aston, raftsman-orented mapufitring philosophy wasocessry back in tbe diy before automate, high-precision manufaetring machinery. twas {ben wy that the craftsman col be sre the parts oul be asiernble Sich anemblins, however, presented huge problem in tm of cot tine (both production tie and sembly ine) and matenance ‘Asallparswerecueatall) one of Kind, abd equed a great amount of abr by the eafsman, the cost Was high’ It ao took a fng tine 10 ‘manufacture such an assembly, as only afew could be made a any sven Sine Lastly, and ths is perhaps the gestest problem, was the problem of ‘ephcemeat parts, There was no easy way to replace a prt hat male ‘ona or broke in serie. Because the most oral of the pats had been custom at asembly, ther was bo guarantee hat replacement pat pled ‘ifthe shelf would work without more dling. grinding, nd modiction. Machinery dsened so manufactured sing thse methods Is subject to ‘xtende dowatime when 4 faire occurs The eration a te extra abor Feyuredin geting he replacement par to match the mating Parts us 0 ad the dowatime i the use of the machinery cas ead to potently large prot Tose ‘Overtime, designs mature, This yeu’ new desig borrowed bits and ces rm previous designs, improving upon eabetapproaches. As Sess ‘came more comple, designers develope ito spessizn! prop, ith Sls and aes unique to ther era Likewise, asthe process ad methods ‘wed to manufactze the pars and asembieshecame more comple, the frallsme that made the prs alo became more speed, evling ito 4 Sinn, highly skied and talented group. Eventually, the person that Signed the part and the person that made the prt were diferent people NNolongerwasit satisfactory for jst the designer fo know what was equed ‘ofthepartsmaking up theassembl)—eideas and requrerenisor the pars sod assembles had to be communicatd to someone els, communiaed fo ‘the caftsmen who were manufacturing the parts abd asembls, ‘Diag thi transtion it Bese evident that drawings were nde to ‘lce what wast he made, to communicate the designer eas to tose 4 haptr 1 manufctsing he componet. Drains i oe dincaions, alt Some infomation ad tbe speedo the Sawing, ina ltd decent conveyed vera Ont ame oon tht te best ‘ay tesa the part or seh being mafactre sts the eds of Uh deseo mas to completely dimension he ravi “Today, ritually al manfred tons ae dined by engineering deanings: Among or thigs, engecring Savings Jee ot dfn he eon: oranda ofall comer eatreron ar sual impo, ‘lowrg dings ads or dct losip beeen arn {Semb) fentues,coding th late srcnation and acon "Thee tn smpogets 0 the eon of par geome: esp on ofthe nominal state an destipion ofthe alowable aration Te ‘ode te ote wodiensonal GD) daving gentry nce btwn proves dexripion oe nomial sate Dinesonngis an “tension f the deseptin ofthe nomial sats, a dinenonng tal ‘sprees the nomial codon of pr geomet. Tleanng va dea ‘Soft alowabl anon ota erate at aur Tope these provide comple Sspon or enon of a one biesionsitvatsion pee "very fentre on» prt bold bs fly imensioned and tle, hich inclu ech etre’ form, se as apis) retton ad Iain relate othe ret of the part. The denoning system map we taditona psi dneesons and tla, my he Comets Di ‘Benning snd Tolsanng (ODEN) oritay wes cmbnton bath ‘rene, Alhoughallo the method recommoaa atta, isthe Atthorsopnon tht he sb bx metodo use GDR =i y fer ihe Gare, mos acct snd a problematic method fo dete the inenoning and folancng egurenents or prs and sci, the signers salt comply snd unambiguous dene te oie {omer retina betwee lat estore to onan hatte prt ome wil any non egestas soon, ten CDE s {tony way too. The protiens an aps he oyna se ‘AcrrteTolase Anas can oat el be done on parts and suc dmensonedand olrnsod wing D&T there ssfartoo any inconsistencies and sumptions reqare fo reba parts dened aa ineancd ng the plsfnnoe tom son. That sd th et covers ‘olernce Anaypug he plsminos tem and GDA, as many

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