Lear Tolerance Stackup Course PDF

Welcome to a Course On
Tolerance Stack-up Analysis using Co-ordinate

System of Dimensioning and GD&T
For
Lear Corporation Philippine Engineering and

Technology Center, Cebu
1
How is Course Organized?
Total 12 Sessions; 3days

Pre-defined objectives at the beginning of each
session
Classroom exercises at the end of each session
Homework
Extended hours as necessary
Assumption : Understanding of GD&T controls
Feel free to interrupt and ask Questions
11
Classical Approach to Tolerance Stack-up
Analysis
12
What is Tolerance Stack-up Analysis?
Tolerance Stack-up Analysis (also called as Gap

Analysis / Loop Diagrams / Circuit Analysis or COD
(Chain of Dimensions)) is the process of calculating minimum
and maximum airspaces or wall thickness or material
interferences in a single part or assemblies.
Its a Decision making tool and helps designer to answer one or

more questions shown in next slides.
It is a logical process divided in few steps
13
Typically, Tolerance Stack-up Provides
answers to
Will these two surfaces touch in their worst case? If so, how much they
will interfere?
What is maximum thickness of the two parts that must fit in the slot?
Will the pin fit within the hole?
How do I know if the worst case assembly will satisfy its dimensional
objectives.
If we reduce the size of clearance hole, will the parts still assemble?
Will the dimensioning and tolerancing scheme used on the parts, allow
too much variation at assembly? Should the drawing be re-dimensioned
and re-toleranced to reduce the accumulation of tolerances?
.
.
14
Why Perform Tolerance Stack-up?
A Tolerance Stackup allows the designer to:
Optimize the tolerances of parts and assemblies in a new design.

Balance accuracy, precision and cost with manufacturing process capability
Determine part tolerances required to satisfy a final assembly condition.
Determine the allowable part tolerances if the assembly tolerance is known.
Determine if parts will work at their worst-case or with the maximum statistical
variation.
Troubleshoot malfunctioning existing parts or assemblies.
Determine effect of changing a tolerance will have on assembly function
Explore design alternatives using different or modified parts or tooling/fixturing
methods.
15
Factors affecting Tolerance Stack-up
Analysis
There are four major factors that determine which dimensions and tolerances
are included in a Tolerance Stack-up:
The geometry of parts and assemblies that contribute to the distance (objective)
being studied in the Tolerance Stack-up.
The Dimensioning and Tolerancing schemes on the drawing of the parts and
assemblies in the Tolerance Stack-up.
The assembly process: how and and which order the parts are assembled?
The direction of tolerance stack-up and direction of the dimensions and tolerances.
16
Basic Assumptions in Tolerance Stack-up
Analysis : Problem Idealization
Tolerance Stack-ups are preformed with following assumptions:
All parts are considered in a static state. The tolerance stack-up allows parts
to adjust (translate/rotate) relative to one another during assembly process,
but the analysis is performed in a static condition.
If more than one position or configuration of part/assembly to be studied (such as linkage or
mechanism), then, tolerance stack-up should be done for the considered parts at each
required position or orientation/configuration.
Tolerance Stack-ups are performed at a specified temperature. Unless

specified otherwise, Tolerance stack-ups are performed at ambient
temperature the temperature at which the parts are assembled or inspected.
If parts are assembled at one temperature and operate at different temperatures, it is
important to study both conditions, as the parts must be assembled before they can operate.
17
Steps in Tolerance Stack-up Analysis
Step #1:
Identify objectives: what are your end requirements? Such as
flushness between features or gaps around a feature or
alignment of features
Step #2:
Identify all dimensions that contribute to your objectives as
defined in step #1 and convert them to equal bilateral
toleranced dimensions; as necessary
18
Step #3:
Assign each dimension a +ve or ve value. For Radial stacks
(going up and down); start at the bottom of gap and end up at
the top of gap
Down direction is ve (top of gap to bottom)
Up direction is +ve (bottom of gap to top OR towards end)
Stacks that go left and right in the assembly, start at the left
side of gap and end up at the right side of the gap.
Left direction is ve (right of gap to left)
Right direction is +ve (left of gap to right OR towards end)
Remember to work on one part at a time; so deal with that parts pertinent
features before moving to next part. This approach is best to work with
assemblies having many parts
19
Step #4 (tips):
Remember that one set of mating features between parts creates the variable
or objective you are working for. Variables are either minimum gap or
maximum gap or maximum overall assembly dimension. One set mating
features creates it. So, though multiple routes may have to be evluated to find
this most significant set of features, only one set creates worst case, from one
part to next.
Errors could creep in if you follow one route from one set of mating features
(hole/pin pairs) then continue the same route through another set. Only one of
these sets shall create the smallest or largest gap or maximum/minimum
overall dimension, Once you spot it, others become non-factors in analysis.
While reaching end objectives or goals, using more than one set of features
within same two parts, will most likely produce incorrect results and
tolerances from other features may contribute to the critical set you are
searching for. For example: when datum features are referenced at MMC or
when more than one set of datum features are assembly features.
20
Step #5 (Basic Rules):

When a single feature or a pattern of features are controlled by
multiple Geometric Tolerances (such as orientation refined
with position), the analyst must determine which, if either is
contributing factor to variable. It is likely that none of geometric
tolerance is a factor and instead size dimensions are factors.
The Designer must evaluate which factors are relevant through

diagrams and logical reasoning.
The judgment of designer is critical in these determinations.
21
Beginning Tolerance Stack-up Analysis
Its important to arrange all the features and parts in the directions
that will create the max or min gap / or variable you are searching
for. This is to allow your loop always pass through material and
you do not jump over an air space unnecessarily in analysis
You should position the features of the parts against each other so
that you will get extreme configurations and make clear to you the
correct path with +ve v/s ve designations for each dimension.
22
Session #1 : The Basics
Objectives:
Calculating mean dimensions with equal Bilateral

Tolerances
Calculating Inner and Outer Boundaries
Virtual and Resultant Condition of features
23
Finding Mean Dimensions
Few Important Concepts of Tolerance Stack-up Analysis:
There is NO difference between equal, unequal or unilaterally

toleranced dimension.
There is NO difference between a limit dimension and a plus
or minus toleranced dimension.
They all have extremes and they all have means. So, first thing
is to change any dimension to an equal bilateral toleranced
dimension.
24
Limit dimensions:
n22-n20
Upper limit = n22, Lower limit = n20

Now, sum the limits : n22 + n20 = n42. Take the mean of sum = n21
Take the difference of limits: n22 - n20 = n2. Take the mean of difference = n1
Therefore, limit dimension of n22-n20 is expressed as equal bilateral toleranced dimension

as n21`1
25
Unequal bilateral toleranced dimensions:
n50
+1
-3
So, Upper limit = n50+1= n51

Lower limit = n50-3= n47
Now, sum the limits : n51 + n47 = n98. Mean of sum is n98/2 = n49
Then, take the difference of limits : n51 - n47 = n4. Mean of difference is n4/2 = n2
n50
+1
Therefore, unequal bilateral toleranced dimension of -3
converted to equal bilateral toleranced dimension is n49`2
26
Finding Mean Dimensions : Exercise
Convert following Dimensions to an equal bilateral toleranced dimensions
3
1. 100 1
2. 150 155
2
3. 200 0
0
4. 30 0.47
0.26
5. 500 0.37
27
Boundaries
Boundaries are generated by collective effects of size and

Geometric tolerances applied to feature(s) and often
referred to as simply inner and outer boundaries
There are two types of boundaries:
Virtual Condition Boundary (VCB)

Resultant Condition Boundary (RCB)
28
Virtual Condition Boundaries (Refer ASME Y14.5M-1994
section 2.11)
FCFs that use m (MMC symbol), generate constant

boundaries (VCB) for features under consideration and
are calculated as:
VCB for internal FOS such as hole = MMC Size Boundary

Geometric Tolerance value
VCB for external FOS such as pin = MMC Size boundary +

Geometric Tolerance
VC Boundaries are Constant and do not vary based upon actual

mating size of the feature
29
Virtual Condition Boundaries (Refer ASME Y14.5M-
1994 section 2.11)
FCFs that use l (LMC symbol), generate constant

boundaries (VCB) for features under consideration and
are calculated as:
VCB for internal FOS such as hole = LMC Size Boundary +

VCB for external FOS such as pin = LMC Size boundary -

Geometric Tolerance.
VC Boundaries are Constant and do not vary based upon actual

mating size of the feature
30
Resultant Condition Boundaries (Refer ASME
Y14.5M-1994 section 2.11)
RC Boundaries are non constant in nature and are

generated on opposite side of the virtual conditions.
When RFS (Regardless of Feature Size) concept

applies to FOS, they generate only non-constant or RC
boundaries.
31
Case#1: Internal FOS controlled at MMC
Hole MMC Concept

32
Case#1: Calculating VC & RC boundaries
Hole
Size GTol VirtualCondition( FixedBoundary )
49 1 48
50 2 48
51 3 48 Worst case inner boundary
Hole
Size GTol Re sul tan tConditon(VariableBoundary)
49 1 50
50 2 52
51 3 54 Worst case outer boundary
VCB for internal FOS (such as hole) controlled at MMC = MMC Size Boundary Geometric
Tolerance value
VCB for external FOS (such as pin) controlled at MMC = MMC Size boundary + Geometric
Tolerance value
33
Case#1: Creating equal Bilateral Toleranced
Dimension from VCB and RCB
Resultant condition of hole

54
+ Virtual condition of hole 48
SUM 102

54
- Virtual condition of hole 48
DIFFERENCE 6
Then, So, 51 3
6 Is an equal bilateral expression
102 & 3 of the dimension and its
51 2 tolerance
2
34
Case#2: Internal FOS controlled at LMC
Hole LMC Concept

35
Hole
51 1 52
50 2 52
Hole
51 1 50
50 2 48
VCB for internal FOS (such as hole) controlled at LMC = LMC Size Boundary
+Geometric Tolerance value
VCB for external FOS (such as pin) controlled at LMC = LMC Size boundary -
36

46
+ Virtual condition of hole 52
SUM 98

46
- Virtual condition of hole 52
DIFFERENCE 6
Then, So, 49 3
49 2 tolerance
2
37
Case#3: Internal FOS controlled at RFS
Hole RFS Concept

38
Case#3: Calculating RC boundaries
Since its a RFS Callout, no virtual condition

boundaries exist and all boundaries are non-constant
Hole
Size GTol InnerBoundry
49 1 48 Worst case Inner boundary
50 1 49
51 1 50
Hole
Size GTol OuterBoundary
49 1 50
50 1 51
51 1 52 Worst case Outer boundary
39
Dimension from Inner and Outer Boundaries
Outer Boundary of hole

52
+ Inner Boundary of hole 48
SUM 100
Outer Boundary of hole

52
- Inner Boundary of hole 48
DIFFERENCE 4
Then, So, 50 2
50 2 tolerance
2
40
Case#4: External FOS Controlled at MMC
Shaft MMC Concept

41
Shaft
47 1 48
46 2 48
Shaft
47 1 46
46 2 44
VCB for internal FOS (such as hole) controlled at MMC = MMC Size Boundary Geometric
Tolerance value
VCB for external FOS (such as pin) controlled at MMC = MMC Size boundary + Geometric
Tolerance value
42
Resultant Condition of Shaft

42
+ Virtual Condition of Shaft 48
SUM 90

42
- Virtual Condition of Shaft 48
DIFFERENCE 6
Then, So, 45 3
45 2 tolerance
2
43
Case#5: External FOS controlled at LMC
Shaft LMC Concept

44
Shaft
45 1 44
46 2 44
Shaft
45 1 46
46 2 48
VCB for internal FOS (such as hole) controlled at LMC = LMC Size Boundary
+Geometric Tolerance value
VCB for external FOS (such as pin) controlled at LMC = LMC Size boundary -
45

50
+ Virtual Condition of Shaft 44
SUM 94

50
- Virtual Condition of Shaft 44
DIFFERENCE 6
Then, So, 47 3
47 2 tolerance
2
46
Case#6: External FOS controlled at RFS
Shaft RFS Concept

47
Case#6: Calculating RC boundaries
Since its a RFS Callout, no virtual condition

boundaries exist and all boundaries are non-constant
Shaft
Size GTol OuterBoundry
45 1 46
46 1 47
47 1 48 Worst case Outer boundary
Shaft
Size GTol InnerBoundary
45 1 44 Worst case Inner boundary
46 1 45
47 1 46
48
Dimension from Inner and Outer Boundaries
Outer Boundary of Shaft

48
+ Inner Boundary of Shaft 44
SUM 92
Outer Boundary of Shaft

48
- Inner Boundary of Shaft 44
DIFFERENCE 4
Then, So, 46 2
46 2 tolerance
2
49
Formulae to Remember
For Internal FOS controlled at MMC / LMC:

VCB at MMC (IB) = MMC Size Boundary Geometric Tolerance value at MMC
VCB at LMC (OB) = LMC Size Boundary + Geometric Tolerance value at LMC
For External FOS controlled at MMC / LMC:

VCB at MMC (OB) = MMC Size boundary + Geometric Tolerance value at MMC
VCB at LMC (IB) = LMC Size boundary - Geometric Tolerance value at LMC
50
Finding Inner & Outer Boundaries : Exercise
Calculate Inner and Outer boundary for features having following specifications
51
Session #2: Analyzing a C Channel
Assembly
Objectives:
To determine min and max gap for a simple eleven parts

assembly.
Perform the calculations

Create a Loop Analysis Diagram
Create a Number Chart
52
C Channel Assembly
53
C Channel Assembly : Loop Analysis
Diagram
Up Down
Direction Direction
(+ve) (-ve) ` Tolerance Remarks
GAP
188.4 1.5 All 10 blocks

188.4+/-1.5 255.67 0.1 Channel inner
255.67 188.4 1.6 Totals

255.67 188.4 67.27 1.6 = 65.67 Min GAP
255.67+/-0.1 67.27 + 1.6 = 68.87 Max GAP
54
Session #2: Exercises
55
3
5 4
2 1
56
Up Direction / Down Direction /
Right Direction Left Direction
Loop # (+ve) (-ve) ` Tolerance Remarks
1 56.62 0.1
2 34.74 0.1
3 10 0.1
4 90 0.15
5 30 0.15
6 230.58 0.2
240.58 211.36 0.8 Totals

(29.22 - 0.8) = 28.42 Min GAP / Max GAP
(29.22 + 0.8) = 30.02
57
58
5 4
2 1 9
7 6
8
3
59
1 26 0.1
2 23 0.15
3 235 0.2
4 23 04.35.15
5 51 0.5
6 22 0.1
7 60.2 0.1
8 28 0.1
9 39 0.15
285 222.2 1.55 Totals

(62.8 1.55) = 61.25 Min GAP / Max GAP
(62.8 + 1.55) = 64.35
60
Session #3: Loop Analysis for Box and Cavity
Objectives:
Using Loop Analysis Technique; determine Max and Min gap

in Horizontal and Vertical Directions
Determine proper start and End points for stack-ups
Graph the numbers calculated into Loop Diagram
61
Problem Description
Calculate:
MIN / MAX Horizontal Gap
MIN / MAX Vertical Gap
62
Loop Diagram
1
2
1
2
Horizontal Direction Vertical Direction
63
Number Chart
Horizontal Direction

1 25.9 0.1
2 26.75 0.5
26.75 25.9 0.6 Totals

(0.85 0.6) = 0.25 Min GAP / Max GAP
(0.85 + 0.6) = 1.45
Vertical Direction

1 24.425 0.575
2 26.75 0.5
26.75 24.425 1.075 Totals

(2.325 1.075) = 1.25 Min GAP / Max GAP
(2.325 + 1.075) = 3.4
64
Session #4: Analysis of an assembly with Limit
tolerancing
Objectives:
Calculate the airspaces and interferences for a plus and

minus toleranced assembly
Performing multiple loop analyses on an assembly
65
Assembly with limit tolerancing : Problem
Description
66
Assembly with limit tolerancing : Loop
Diagrams
1
2
1 2
67
Assembly with limit tolerancing : Number
Chart
Horizontal Direction
Up Direction Down Direction
1 20.84 0.66
2 15.8 0.75
3 32.7 1.2
36.64 32.7 2.61 Totals

(3.94 2.61) = 1.33 Min GAP / Max GAP
(3.94 + 2.61) = 5.55 Max / Min Overall Dim
Vertical Direction
1 25.125 0.375
2 25.975 0.575
25.975 25.125 0.95 Totals

(0.85 0.95) = -0.1 Min GAP / Max GAP
(0.85 + 0.95) = 1.8 Max / Min Overall Dim
68
Session #5: Analyzing a Floating Fastener
Assembly
Objectives:
Calculate Virtual and Resultant conditions (Inner / Outer

Boundaries) for GD&T callouts
Determine mean of all these boundaries
Convert all FOS (diameters and widths) to mean radii with
equal bilateral tolerance
Mixing FOSs (widths and diameters) in number chart
Graph the numbers in tolerance stack-up diagram
Determine all unknown gaps in the assembly
69
Floating fastener assembly sketch with
GD&T
70
Floating fastener Part sketches with GD&T
140
140

6-7 6-7
3.5+/-0.5 5.5+/-0.5

300
71
Floating fastener Assembly with parts
shoved towards center
VCB of holes in top plates = (MMC Gtol) = (6-0.5) = 5.5 VCB of holes in base plate = (MMC Gtol) = (5.5-0.5-0) = 5
RCB of holes in top plates = (LMC + Gtol + Btol) = (7+0.5+1) = 8.5 RCB of holes in base plate = (LMC + Gtol + Btol) = (5.5+0.5+0+1) = 7
Mean Dia with equal bilateral representation of these holes is: 7+/-1.5 Mean Dia with equal bilateral representation of these holes is: 6+/-1
72
Loop Diagram with values printed
2 1 9
3 7
4
6 Up Direction / Down Direction /
5
(+ve) (-ve) ` Remarks
Loop # Tolerance
1 140 0 Basic dimension
2 3.5 0.75 Over radius of top plate hole
3 3.5 0.5 Over pin dia
4 3 0.5 Over radius of base plate hole
6 3 0.5 Over radius of base plate hole
7 3.5 0.5 Over pin dia
8 3.5 0.75 Over radius of top plate hole
9 140 Basic dimension
307 293 3.5 Totals

10.5 Min GAP / Max GAP
73
Can you imagine a configuration for MAX Gap? And then calculate MAX Gap

Totals
Min GAP / Max GAP
Max / Min Overall Dim
74
Session#6: Analyzing an Assembly for Gaps and Overall
Dimensions (Fixed Fastener Case)
75
Session#6: Analyzing an Assembly for Gaps and
Overall Dimensions (Fixed Fastener Case)
76
Session#6: Analyzing an Assembly for Gaps and
Overall Dimensions (Fixed Fastener Case)
Objectives:
Calculate assembly overall MAX and MIN dimensions

Calculate MAX and MIN gaps within assembly as shown
Calculate boundaries using various GD&T controls
77
Min Gap and Min Overall Dimensions
Configuration
VCB of hole = (MMC Gtol) = (13-0.03-0.05) = 12.92 VCB of pin = (MMC Gtol) = (12.5-0.03-0.05) = 12.22
RCB of hole = (LMC + Gtol + Btol) = (13+0.03+0.05+0.06) = 13.14 RCB of pin= (LMC + Gtol + Btol) = (12.5+0.03+0.05+0.06) = 12.64
Mean Dia with equal bilateral representation of this hole is: 13.03+/-0.11 Mean Dia with equal bilateral representation of this pin is: 12.43+/-0.21
Start Point of Loop Min overall Dimension Loop diagram (4)

End Point of Loop
Min Left bottom gap Loop diagram (6)
Min Right top gap Loop diagram (6)
78
Chart the values (Min overall Dim)


2 6.515 0.055 Over radius of hole
3 6.215 0.105 Over radius of pin
176.215 6.515 0.16 Totals

169.54 Min Overall Dim
79
Chart the values (Min left bottom gap)

1 15 0.1

6 143.5 0.7
176.215 165.015 0.96 Totals
10.24 Min left bottom gap
80
Chart the values (Min Right top gap)

1 140 0.7

6 15 0.1
176.215 161.515 0.96 Totals
15.66 Min right top gap
81
Max Gap and Max Overall Dimensions
Configuration
Start Point of Loop Max overall Dimension Loop diagram (4)

End Point of Loop
Max Left bottom gap Loop diagram (6)
Max Right top gap Loop diagram (6)
82
Chart the values

Totals
Min GAP / Max GAP
83
Session #7: Calculating MAX overall Diameter for a
Revolving Assembly
MAX?
84
Detailed Part Drawing with GD&T Controls
Part2
Part 1
Determine factors and non-factors affecting objectives with logical reasoning
85
Step#3: Create a Loop Diagram
OB = MMC + Gtol = 250+0.2+0.15 = 250.35

IB = LMC Gtol = 250-0.2-0.15 = 249.65
Mean dia with equal bilateral tolerance = 250+/-0.35
OB = MMC + Gtol = 250+0.2+0.15 = 250.35

IB = LMC Gtol = 250-0.2-0.15 = 249.65
Mean dia with equal bilateral tolerance = 250+/-0.35
86
Step#4: Chart the values

1 125 0.175
2 25.11 - LMC of hole / 2
3 25.035 - LMC of spigot / 2
4 125 0.175
275.11 25.035 0.35 Totals

250.425 Max Assembly Dia
87
Session #8: Analyzing a Guide Assembly with Fixed
fasteners
Assembly
88
Part #1 & #2: Detailed Drawing
89
Session #7: Analyzing a Guide Assembly with Fixed
fasteners
Objectives:
Calculate Boundaries for Threaded features

Work with multiple Geometric Controls on a single feature
GD&T Controls affecting and non-affecting stack-up
Calculate desired gaps
Use product knowledge / experience and Assembly
conditions in stack-up analysis
90
Locating parts to create MIN Gap
Configuration
One line contact
CL of clearance hole in block

CL of threaded hole in slot
91
Chart the values

1 13.5 0.15 Over 50% width of slot

2 3.95 0.12 Over radius of screw
3 4.1325 0.055 Over radius of clearance hole
4 12.25 0.15 Over 50% width of block
17.45 16.3825 0.475 Totals

0.5925 Min GAP / Max GAP
OB of Slot = LMC + Gtol =27.2+0.1 = 27.3 OB of Block = MMC + Gtol =24.7+0.1 = 24.8
IB of Slot = MMC Gtol = 26.8-0.1 = 26.7 IB of Slot = LMC Gtol = 24.3-0.1 = 24.2
Mean width of slot with equal bilateral tolerance = 27+/-0.3 Mean width of block with equal bilateral tolerance = 24.5+/-0.3
OB of threaded hole/screw = MMC + Gtol =8+0.14 = 8.14 OB of clearance hole = LMC + Gtol =8.25+0.05+0.06 = 8.36
IB of threaded hole/screw = LMC Gtol = 7.8-0.14 = 7.66 IB of clearance hole = MMC Gtol = 8.19-0.05 = 8.14
Mean dia with equal bilateral tolerance = 7.9+/-0.24 Mean dia with equal bilateral tolerance = 8.265+/-0.11
92
Locating parts to create MAX Gap
Configuration
One line contact
CL of clearance hole in block

CL of threaded hole in block
93
Chart the values

Totals
Min GAP / Max GAP
94
Form Tolerances in Tolerance Stack-up
Min Max
MIN / MAX?
96
Orientation Tolerances in Tolerance Stack-up
Min Max
MIN / MAX?
97
Part Stacks using Position (RFS)
Min Max
Find MAX and MIN Distance (1) between edges of two small holes.
(10.5)
98
Min Max
Find MAX and MIN Distance X.

(10.6)
99
Min Max
Find MAX and MIN Distance between Centerlines of Hole and Slot.
(10.9)
100
Part Stacks using Position (Bonus)
Min Max
Find MAX and MIN Distance between Edges of two small holes.
(11.7)
101
Min Max
Find MAX and MIN Distance (2)

between Centerlines of the
two small holes.
(11.8)
102
Min Max
Find MAX and MIN wall thickness.
(11.9)
103
Part Stacks using Position (Bonus & Shift)
Min Max
Find MAX and MIN horizontal distance between edges of datum G and n8.6-8.2 hole.
(12.6)
104
Part Stacks using Position (Bonus & Shift)
Min Max
Find MAX and MIN distance between edge of the groove and side of the part.
(12.8)
105
Part Stacks using Profile
Min Max
Find the MAX and MIN distance.
106
Part Stacks using Profile
Min Max
Find the MAX and MIN distance
107
Part Stacks using Form/Orientation/Profile
Min Max
109
Min Max
110
Min Max
111
Part Stacks Composite Position Control
113
Part Stacks Composite Position Control
MIN / MAX?
MIN / MAX?
Min Max
MIN?
MIN?
114
Session #10: Tolerance Stack-up Analysis of an
Assembly with Revolving Parts
GAP?
Part 1
Part 4
Part 2
Part 5
Part 3
115
Tolerance Stack-up Analysis of an Assembly
with Revolving Parts
Objectives:
Calculating tolerance stack-ups on a five part rotating

assembly with a variety of geometric controls such as:
position, perpendicularity, parallelism, profile, flatness,
projected tolerance zones, runout, total runout,
concentricity, positional coaxiality
Learn Simplifying a complex situation
Calculate radial clearance and interference
116
Part #1: Detailed Drawing

117
Part #2,3 : Detailed Drawing

118

119
120
Session #11: Trigonometry and Proportions in
Tolerance Stack-up Analysis
121
Trigonometry and Proportions in Tolerance
Stack-up Analysis
Objectives:
Understanding the role of trigonometry and proportions in

tolerance stack-up and geometric tolerancing
Understanding the effect of Unstable Datums features
Know how vertical stacks affect horizontal envelope
requirements.
Mixing trigonometry and algebra determining stack-up
results
Consider the rules in Y14.5.1 (Math Standard) for
constructing a valid Datum
122
Example of Rocking Datum and proportions

Out of flatness is shown on datum A on one

side of part center; since this is worst case
than flatness tolerance being evenly spread
on entire surface
Y14.5.1 states that in order to be a valid
primary datum feature, the points used to
construct a datum plane (3 high points of
contact minimum) must not lie solely in one
of the outer thirds of the surface. So its
possible to conceive of slightly worse
situation than this, but we are restricting to
rocking at center point of part
The illustration shows that flatness
tolerance allows datum A to lean by an
amount equal to flatness tolerance = 0.002. If
the part is inspected on surface that does not
lean; but assembled on surface that leans,
the pin will be forced to lean with with it, by
an amount = 0.006
126

Normally this is ignored while

calculating worst mating
conditions of features like 80
length pin. We normally calculate
worst mating condition diameter
= MMC size + geo tol at MMC =
20.2+0.4 = 20.6.
But with additional radial lean of
0.376, the worst mating condition
can be seen as 20.4 +
2x0.376=21.352
Also, while calculating the
minimum gap between this shaft
and the housing into which it fits,
as per procedure we used in
Simple Proportions: previous sessions, we would
0.2/42.5 = X/80 probably be working with radii,
80*0.2 = 45.5*x therefore of 21.352 = R10.676
0.376 = x
127

Parallelism is also a factor that can be

related to the problems that flatness creates.
Parallelism when used on planer surfaces,
controls flatness and angle to datums
referenced.
In the illustration on left, produced part has
crest in middle (rock point) and surfaces
sloping on either side of rock point.
So, when two or more such parts are
stacked on top of one another, and each
having problem as shown, such assembly
would exhibit a problem of not fitting other
assemblies/housings or closing holes on parts
into which pins ore screws had to fit. (see next
slide)
128

Initially,
the three parts were aligned with
center, left edge and right edge aligned,
then the parts are either to left or right
This would assume that interior part
features such as holes (not shown here)
have been positioned from one of these
features as secondary datum feature.
Each part during inspection has been
adjusted 9shimmed up) to allow high point
shown at the bottom center of part 1 and
2 to establish the datum plane, but during
assembly parts have been rocked instead
of equalized.
This is just one speculation as what can
happen due to out of flatness of bottom of
parts 1,2. Many such scenarios are
possible.
This much space would be

needed if parts were
stacked this way and
allowed to rock this way
129

Unlike previous configuration, this

configuration calculates the space needed to
house these parts if they were stacked with
their edges aligned and then rocked in either
direction.
This much space would be

needed if parts were stacked
this way and allowed to rock in
either direction
130
Session#12: The Theory of Statistical
Probability
132
The Theory of Statistical Probability
Objectives:
Convert arithmetically calculated tolerances to statistically

calculated tolerances.
Use Root Sums Square (RSS) formula
Comparing Worst-case and Statistical tolerances
Reintegrating statistical tolerances into the assembly
133
Background
The dispersion of dimensions

under the curve is described as
standard deviation and often
represented by letter (sigma),
and calculated as:
The arithmetic mean +or- one

standard deviation (`1 ) is often
described as containing 68.26% of the
produced parts under this normal curve.
By the same logic `2 is 95.46% of
the total production and `3 is
99.73%
137
Root Sum Squares (RSS) Method
The statistical probability can be applied to tolerance stack-up analysis for

assemblies both with and without geometric tolerances.
Thus the tolerance of an assembly is expressed as square root of the sum of
squares of the individual component tolerances and is called as RSS
formula:
2 2 2 2
TA T 1
T 2 T 3 ......T n
Statistical probability has been practiced for several years and well
documented. Statistical approaches are more reliable for volume production.
For small production runs, the frequency curve tends to be skewed from its
normal shape.
138
Applying RSS: Steps Involved with Example
Method: once the worst case calculations are

performed,
1. Using the RSS formula, calculate assembly tolerance

2. Determine the percentage (%) ratio between statistical
probability tolerance and 100% assembly tolerance
3. Determine the increased statistical probability tolerances
to be re-assigned to the assemblys individual part
features.
139
RSS Calculations: Example#1
Worst case table

Up Down
Direction Direction
(+ve) (-ve) ` Tolerance Remarks
188.4 1.5 All 10 blocks

255.67 0.1 Slot inner
255.67 188.4 1.6 Totals

255.67 188.4 67.27 1.6 = 65.67 Min GAP
67.27 + 1.6 = 68.87 Max GAP
RSS case table
Up Direction Down ` Tolerance ` Tolerance Remarks

(+) Direction (-) Squared
188.4 1.5 2.25 All 10 blocks
255.67 0.1 0.01 Channel Inner
255.67 188.4 1.6 2.26 Totals
1.5033 Sqrt of total

tolerance
140
Previous slide shows that the worst case assembly tolerance is +/-1.6, while the assembly tolerance
based on RSS calculations is +/-1.5033
It states that if the parts are produced under statistical control, the likely tolerance on assembly is +/-
1.5033 and NOT +/-1.6.
If we calculate the ratio of worst case tolerance to RSS tolerance = 1.6/1.5033 = 1.064.
This ratio can be used to increase the individual part level tolerance, in short, you can multiply part
tolerances by factor of 1.064.
Therefore the individual blocks will receive a new tolerance of 0.15 * 1.064 = 0.1596 and the channel will
receive a new tolerance of 0.1 * 1.064 = 0.1064
141
Suggested Readings & References
ASME Y14.5M-1994 Geometric Dimensioning and Tolerancing

ASME Y14.5.1M-1994 Mathematical Definition of Dimensioning and Tolerancing
Principals
Geometrics IIIm - Lowell W. Foster
Tolerance Stack up Analysis Alex Krulikowski
Geometric Dimensioning and Tolerancing: Applications and Techniques for Use in
Design, Manufacturing, and Inspection - James D. Meadows
Tolerance Design: A Handbook for Developing Optimal Specifications Clyde M.
Creveling
CAD/CAM Theory and Practice : Ibrahim Zeid (Dedicates a chapter on Mechanical
Tolerancing) A good reference book.(< Rs.500/-)
Interpretation of Geometric Dimensioning and Tolerancing : Daniel Puncochar.
Tolerance Stack up Analysis James Meadows
Dimensioning & Tolerancing Handbook : Paul Drake Jr.
All books are priced in US$ 40-US$125 range.
149

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Welcome to a Course On

Tolerance Stack-up Analysis using Co-ordinate

Lear Corporation Philippine Engineering and

Total 12 Sessions; 3days

Tolerance Stack-up Analysis (also called as Gap

Its a Decision making tool and helps designer to answer one or

A Tolerance Stackup allows the designer to:

Optimize the tolerances of parts and assemblies in a new design.

Tolerance Stack-ups are preformed with following assumptions:

Tolerance Stack-ups are performed at a specified temperature. Unless

Step #5 (Basic Rules):

The Designer must evaluate which factors are relevant through

The judgment of designer is critical in these determinations.

Calculating mean dimensions with equal Bilateral

Few Important Concepts of Tolerance Stack-up Analysis:

There is NO difference between equal, unequal or unilaterally

Upper limit = n22, Lower limit = n20

Therefore, limit dimension of n22-n20 is expressed as equal bilateral toleranced dimension

Unequal bilateral toleranced dimensions:

So, Upper limit = n50+1= n51

converted to equal bilateral toleranced dimension is n49`2

Convert following Dimensions to an equal bilateral toleranced dimensions

Boundaries are generated by collective effects of size and

There are two types of boundaries:

Virtual Condition Boundary (VCB)

FCFs that use m (MMC symbol), generate constant

VCB for internal FOS such as hole = MMC Size Boundary

VCB for external FOS such as pin = MMC Size boundary +

VC Boundaries are Constant and do not vary based upon actual

FCFs that use l (LMC symbol), generate constant

VCB for internal FOS such as hole = LMC Size Boundary +

VCB for external FOS such as pin = LMC Size boundary -

VC Boundaries are Constant and do not vary based upon actual

RC Boundaries are non constant in nature and are

When RFS (Regardless of Feature Size) concept

Hole MMC Concept

Resultant condition of hole

Resultant condition of hole

Hole LMC Concept

Resultant condition of hole

Resultant condition of hole

Hole RFS Concept

Since its a RFS Callout, no virtual condition

Outer Boundary of hole

Outer Boundary of hole

Shaft MMC Concept

Resultant Condition of Shaft

Resultant Condition of Shaft

Shaft LMC Concept

Resultant Condition of Shaft

Resultant Condition of Shaft

Shaft RFS Concept

Since its a RFS Callout, no virtual condition

Outer Boundary of Shaft

Outer Boundary of Shaft

For Internal FOS controlled at MMC / LMC:

For External FOS controlled at MMC / LMC:

To determine min and max gap for a simple eleven parts

Perform the calculations

188.4 1.5 All 10 blocks

255.67 188.4 1.6 Totals

240.58 211.36 0.8 Totals

285 222.2 1.55 Totals