TOLERANCE ANALYSIS METHODS, PLATFORMS AND

TRENDS: COMPREHENSIVE OVERVIEW

The key objective of this blog is to understand tolerances analysis definition, methodologies, key attributes, statistical

parameter usage, advantages, software comparisons, and its latest trends. It also briefly covers tolerance allocation

methods and finally ends with Improvians take on the overall review.

TOLERANCE ANALYSIS
DEFINITION

Tolerance stack-up analysis calculates the overall effect of part tolerances on an assembly functionality requirement.
The term "stacking up" refers to the addition of tolerances to find the total part tolerance and then comparing that to
the available gaps or performance limits to ensure the design will meet its functional requirements. There are

different methods of doing a tolerance analysis. Let's understand each of them.

METHODS

1) Worst Case Analysis [WCA]

Worst-case analysis is a direct addition of part tolerances to determine assembly variation. Through this approach,
the individual part acceptance will be 100% and no interference will occur. This may also lead to over-design,
example preserved assembly gap is too large. This approach is advisable for extremely critical applications where
part per million (ppm) defects needs to be zero. It is also useful and appropriate for problems that involve just three

or four parts. This analysis is mostly done in one direction, i.e. a 1D analysis. If the analysis has part dimensions
which are not in the plane of the assembly measurement being studied, the stack-up approach needs to be modified

to 2D analysis to factor in angles, or any variation which is not parallel to the 1D direction.
 DAsm = DA + DB + DC
TAsm = TA + TB + TC
Figure 1: Assembly tolerance determination using Worst Case Analysis (WCA)

2) Root Sum Squared Analysis [RSS]

In this method, instead of adding up tolerances, as in worst-case analysis, assembly variation is the root sum square
of the individual component tolerance values. RSS assumes the dimensional distribution of each component is

normal which is typically the case in mass production. This allows comparison of the standard deviation to the

assembly limits which can help in the calculation of quality metrics like Cpk, Cp, Ppk, etc. This approach requires

distributions to be normal with all parts at the same quality level, i.e. +/- 3σ.
 Figure 2: Assembly tolerance determination using Root Sum Square Analysis (RSS)

3) Monte Carlo Analysis [MCA]

Monte Carlo analysis is an iterative method to calculate assembly variations by randomly changing possible values

of the dimension, each obtained by following a specific distribution. It is the most suitable method when assemblies
of parts have non-linear effects on the system or the individual components of the systems do not follow a normal

distribution.

DAsm = DA + DB + DC
TAsm = [ai + bj + ck] …Simulation Results
Figure 3: Assembly tolerance determination using Monte Carlo Analysis (MCA)

Worst Case Root Sum

Monte Carlo Analysis
Analysis Squared Analysis
It ensures that all It gives an Acceptance rate
assemblies will be acceptance rate of depends on number of
within limits if all the 99.73% of all the iterations, type of
 parts are between components are in distribution, random
tolerances. ±3σ range. number generator.
It generally requires The tolerances can
working with tight be loosened The tolerances can be
tolerances which depending on the loosened depending on
increase process the process capabilities.
manufacturing cost. capabilities.

Figure 4: Assembly tolerance variation comparison using different methods

As the figure shows the WCA range is always larger while RSS and MCA range depends on the input parameters of

the analysis.

Key Attributes in Tolerance Analysis:

Tolerance analysis gives the following key parameters as outputs to evaluate and validate your design.

Sensitivity: It is a measure of how the unit change in any dimension affects the final assembly dimension under

study. It is one of the key factors to determine which areas of geometry can be improved.

Contributors: It gives the percentage contribution of each component tolerance on the final assembly tolerance.

This helps in determining the targets for tightening or loosening the tolerances.
 Range: The range of assembly variation is derived based on the assembly tolerance as shown in figure 4.

Frequency Histogram: It is a graphical representation showing the probability of assembly variation and its

values. The type of distribution, mean and standard deviation can be calculated based on it.

USE OF STATISTICAL PARAMETERS IN TOLERANCE ANALYSIS

Root sum squared and other assembly variation analysis methods provide process capability and performance

indices that must be controlled to produce a part that meets the assembly requirements. Using these matrices such

as Cpk, Cp, Ppk, design engineer can allocate tolerance budgets tactfully.Manufacturing can then use this process

and performance indices to focus on developing and refining their manufacturing process to meet them. Typically, the

requirement for Cpk = 1.67 for key features which have ppm of 0.573 and Cp = 1.33 for non-key features which have

ppm of 63.34. These decisions ensure optimum product quality, performance and manufacturing cost.

ADVANTAGES OF TOLERANCE ANALYSIS

The assembly parts can be readily replaceable and interchangeable.

It reduces the manufacturing cost by reducing accuracy but maintaining functionality and design intent.

The control of manufacturing processes becomes easy.

It reduces part to part variations and improves quality.

With the data from manufacturing, individual component dimensional distribution can be updated to obtain more

realistic assembly variation tolerances.

TOLERANCE ANALYSIS PLATFORMS

1. 3DCS Variation Analyst

Type of Analysis: 1D, 2D, 3D

Methods of Analysis: Worst Case, RSS, Monte Carlo

CAD integration as Add-In: PTC Creo, Catia, NX, SolidWorks

Standalone Analysis with Supported Formats: STEP, IGES, STL, OBJ, CGR, Parasolid, JT

Additional Features:

1. Plant data and actual manufacturing data can be incorporated for validation.

2. Assembly process, tooling, fixture, clamping, locators, datums can be modeled and their added variations can

be taken into account.

3. FEA compliant analysis is available for flexible parts such as sheet metal parts, rubber components.
 4. Sensitivity or HLM (High-Low-Median) Analysis to analyze key contributors on the final assembly variation by
only changing one component tolerance at a time to its high, median and low value.

5. Geo Factor Analysis is used to analyze key tolerance contributors based on geometry of components and
assembly. Geo Factor can be used for deciding the changes in geometry to improve design.

Key Tolerance Analysis Output Parameters: Assembly variation, Distribution of Assembly Variation,

Sensitivities, Contributions, Geo Factor.

2. CETOL 6σ

Type of Analysis: 1D, 2D, 3D

Methods of Analysis: Worst Case, RSS, Monte Carlo

CAD Integration as Add-In: PTC Creo, Catia, NX, SolidWorks

Standalone Analysis with Supported Formats: None

Additional Features: Tolerance Advisor which guides for next steps or items which should be reviewed by the

user.

Key Tolerance Analysis Output Parameters: Assembly Variation, Distribution of Assembly Variation,
Sensitivities, Contributions.

3. Enventive

Type of Analysis: 1D, 2D, 3D

Methods of Analysis: Worst Case, RSS, Monte Carlo

CAD Integration as Add-In: None

Standalone Analysis with Supported Formats: STEP, IGES

Additional Features:

1. Performance modeling in which the values can be governed by an equation. It simultaneously solves equations

and computes tolerance. Any physical phenomenon which is governed by an equation such as friction, thermal
expansion, deflection due to force, etc. can be modeled.

2. Smart components and Smart Assemblies use engineering data for standard components such as springs,

bolts, bearings, shafts, etc. to compute their functional properties. The data canal so be customized according
to the required specifications.

Key Tolerance Analysis Output Parameters: Assembly Variation, Distribution of Assembly Variation,

Sensitivities, Contributions.
4. TolAnalyst

Types of Analysis: 1D, 2D, 3D

Methods of Analysis: Worst Case, RSS

CAD Integration as Add-In: SolidWorks

Standalone Analysis with Supported Formats: None

Additional Features: None

Key Tolerance Analysis Output Parameters: Assembly Variation, Distribution of Assembly Variation,

Sensitivities, Contributions.

5. Geometric StackUp

Types of Analysis: 1D

Methods of Analysis: Worst Case, RSS

CAD Integration as Add-In: SolidWorks & PTC Windchill

Standalone Analysis with Supported Formats: CAD files of SolidWorks, Solid Edge, NX, Inventor, Catia, Creo,

STEP, IGES, JT, Parasolid

Additional Features: None

Key Tolerance Analysis Output Parameters: Assembly Variation, Distribution of Assembly Variation,

Sensitivities, Contributions.

6. Inventor Tolerance Analysis

Types of Analysis: 1D

Methods of Analysis: Worst Case, RSS

CAD Integration as Add-In: Autodesk Inventor

Standalone Analysis with Supported Formats: None

Additional Features: None

Key Tolerance Analysis Output Parameters: Assembly Variation, Distribution of Assembly Variation,

Sensitivities, Contributions.

TOLERANCE ALLOCATION
This method works in reverse order wherein the tolerances on assembly are given and individual component
tolerances are assigned based on it. Tolerance analysis is then performed to validate the allocations. There are