Intro To Tol Stack Up March2014 PDF

Introduction To Tolerance Stack Up
March 2014
January 2013
3/31/2014 Footer
Agenda
• Introduction
– What is tolerance stack up
– Why tolerance stack up
– Type of tolerance stack up
– Tolerance stack up process
• Worst case Tolerance Stack Up Analysis with Plus and Minus
Tolerance and Assembly Shift
• Case Study: ST Tool
• Tolerance Stack Up Analysis with GD&T
• Case Study
What is Tolerance Stack
Up?
Tolerance stack up is a process of determining the

cumulative variation possible between two or more
features. In other words, the cumulative effect of
multiple tolerances.
Typically a distance or displacement is chosen as

the subject of study, which usually represents a
nominal gap or interference.
Why Tolerance Stack Up?
•Assemblies are comprised of variable
parts. Additional variation may also occur
as part of assembly process.
•Tolerance stack up allows designer to determine the

maximum possible variation between components in an
assembly. It helps to:
−Optimizes the tolerance of parts and assemblies
−Balance accuracy, precision and cost with manufacturing process
capability.
−Determine part tolerances required to satisfy a final assembly
condition
−Determine allowable part tolerance if the assembly is known
−Determine if the parts will work at their worst case condition
−Trouble shoot malfunctioning existing parts or assemblies.
Types Of Tolerance Stack Up
•2 types of tolerance stack up:
−Worst – case tolerance stack up analysis which represents the
largest possible variation, and is a simple summation of all
tolerances.
−Statistical tolerance stack up analysis which uses one of many

techniques for determining the likely maximum variation. Most
common technique is the root-sum-square. (RSS)
−Only worst-case tolerance stack up will be covered in this session.

Tolerance Stack Up Process
• A single part with missing dimension
Stack Up process steps:
•Step1: Determine subject of study-> In
this case, solve for max/min Gap
•Step 2: Identify all dimensions that
Loop contribute to the subject of study. All the
dimensions including the subject of study
should form a loop.
•Step 3: Convert all tolerance to equal
bilateral, if necessary and assign each
dimension a +ve and –ve value.
Left –ve, Right +ve
Down –ve, Up +ve
Use of Standard ST Report recommended.
•Step 4: Loop analysis. Perform the
Tolerance stack up analysis based on the
loop identified. Tolerance Stack Up
Analysis is also referred as Loop Analysis.
Worst-Case Tolerance Stack Up with Plus and minus
tolerance
• A single part with missing

dimension
tolerance
• A simple assembly
tolerance – Assembly Shift
• Assembly shift – represents the amount that parts can
move from its nominal position during the assembly due to
clearance. For example, clearance between a hole and a
fastener, and hole and a shaft, a width and a slot etc.
• This clearance must be accounted for in tolerance stack up.
• Assembly shift is the greatest when the hole and the
fastener at their LMC. The difference represent the worst-
case assembly shift.
• Assembly shift within threaded hole is normally omitted and
assumed to be fixed as the clearance is considered
negligible compared to the subject of study.
tolerance
• Assembly shift
tolerance
• A simple assembly with assembly shift
tolerance
• A bolted assembly with assembly shift
tolerance
Tolerance Stack Up Case Study: ST Tools (P134000-0021)
Critical Features that

requires tolerance
stack up study:
Lift pin to pick up energizing

mandrel
Packoff lock pin to retract just
before packoff is set
Trash seal to be in the bore

1.Lock ring to be in the groove
Mandrel to backup lock ring but
not bottom out
Anti-rotation key to be in the slot
Seal to be in the bore of hanger
14
Tolerance Stack Up Case Study: ST Tools
Step 1: Determine the subject of study for feature 1
To ensure lock ring to be in the groove of casing hanger
body once the ST tool lands on Casing Hanger
ST tool
lands on
Casing
Hanger
15
Step 1: Determine the subject of study
2 Conditions:
1. Point G on Lock Ring must be to the left of Point B on Casing
Hanger i.e. determine the Gap G-B.
2. Point H on Lock Ring must be to the left of Point C on Casing
Hanger i.e. determine the Gap C-H LANDING SHOULDER
Casing Hanger
C H B
G
Lock Ring Inner Body
16
Step 2 & 3: Identify all the parts and dimensions that
form a loop and contribute to subject of study and
convert all tolerance to equal bilateral
Parts Involved
Casing Hanger
Lock Ring Inner Body
17
18
Step 2 & 3: Identify all the parts and dimensions contribute to subject of
study and convert all tolerance to equal bilateral
CH3
X.XXX ± 0.005
10.650
CH1
(13.74 - 13.0425)/2 ± (0.015+(13.045-13.040))/2
CH2 0.34875 ± 0.00875
6.36 ± 0.015
CH4 1.30 ± 0.015
45o 2 x 45o
C
CH1 B
∅13.040/13.045 Casing Hanger

∅13.74 1046DU1069356
19
20
Step 2 & 3: Identify all the parts and dimensions contribute to
subject of study and convert all tolerance to equal bilateral
IB2
22.87 ± 0.015 IB1
1.600 ± 0.005
IB3
17.25 ± 0.015
Inner Body
LOCK Ring
1105DU2006364
22
1.80 ± 0.015
LR2
H G Tolerance Stack Up
Case Study: ST Tools
LR3 (12.810 - 12.34)/2 ± 0.005*2
0.235 ± 0.01 (12.810 - 12.20)/2 ± 0.005*2
0.305 ± 0.01 LR1
Step 2 & 3:
Identify all the ∅12.34 ∅12.20
parts and
dimensions
contribute to ∅12.810
subject of study
and convert all
tolerance to
equal bilateral
Assumption:
No angular
tolerance for 45°
2 x 45o Lock Ring
23
Step 4: Loop Analysis Gap G-B IB1
CH3
CH2 CH1
Casing Hanger
B #
G
Inner Body LR1
IB3
IB2
Note: At Point #, it is assume same point for casing hanger and

inner body as diametric difference is negligible. Actual condition
there is a slight difference.
24
Step 4: Loop Analysis Gap C-H IB1
CH3
CH2
CH4
Casing Hanger CH1

C
H #
LR3
Inner Body LR2
IB3
IB2
Note: At Point #, it is assume same point for casing hanger and

inner body as diametric difference is negligible. Actual condition
there is a slight difference.
26
Tolerance Stack Up Exercise:
MQC Couplers Tolerance Stack Up Analysis
MQC: Critical Features
Find the max and min gap between the end of the male coupler and
the crevice of the female coupler when the male coupler is securely
bolted using tolerance stack up analysis
28
Tolerance Stack Up Exercise:
MQC Couplers Tolerance Stack Up Analysis
MQC Plate Female Coupler
DWG-0212241-001 DWG-0214703-001
Male Coupler
DWG-0214703-001
Coupler Plate
DWG-0212243-001
29
Worst-Case Tolerance Stack Up with GD&T
• Parts and assemblies that have been properly
dimensioned and toleranced with GD&T must also
be converted to equal bi-lateral tolerances before a
tolerance stack up can be completed.
• Care must be taken when converting the geometric
tolerance to ± equal bi-lateral tolerance as the
material condition modifier (MMC,LMC,RFS) must be
considered.
• This session will concentrate on RFS only.
• Converting the geometric tolerance to ± equal bi-lateral
tolerance.
– Determine worst case Outer Boundary and Inner
Boundary
– Boundaries are generated by the collective effects of
size and geometric tolerances.
Hole
Tolerance Zone
Inner Boundary
Outer Boundary
Center Point
Video 1 : Boundary
THE IB;OB FOR THE RFS CONCEPT This is applicable
Alternative method
0.495±0.005
for RFS only!
±0.010 For external feature
±0.015 WCIB= LMC - GT
WCOB=MMC+GT
Bi-Equal Tolerance:
(WCOB+WCIB)/2 , ± (WCOB-WCIB)/2
(CONTINUES)
Bi-Equal Tolerance : (0.51+0.48)/2, ± (0.51-0.48)/2
=> 0.495 ± 0.015
THE IB;OB; FOR THE RFS CONCEPT This is applicable
Alternate Method for RFS only!
0.505±0.005 For internal feature
±0.010 WCIB= MMC - GT
±0.015 WCOB=LMC+GT
Bi-Equal Tolerance:
(WCOB+WCIB)/2 ± (WCOB-WCIB)/2
Bi-Equal Tolerance : (0.52+0.49)/2 ± (0.52-0.49)/2

=> 0.505 ± 0.015
Convert GD&T to
Bi-Equal Lateral:
6±2
Note: For MMC modifier,

WCIB= MMC-GT=5.4-1.4=4
WCOB= LMC+(GT+BT)=6+1.4+2*0.3)=8
Thus (8+4)/2 ± (8-4)/2 => 6 ± 2
tolerance
Note: MMC modifier for the holes (x4) allow more tolerance (Bonus
tolerance), thus resulting in bigger tolerance range.

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Introduction To Tolerance Stack Up

Tolerance stack up is a process of determining the

Typically a distance or displacement is chosen as

•Tolerance stack up allows designer to determine the

−Statistical tolerance stack up analysis which uses one of many

−Only worst-case tolerance stack up will be covered in this session.

• A single part with missing

Critical Features that

Lift pin to pick up energizing

Trash seal to be in the bore

Seal to be in the bore of hanger

Lock Ring Inner Body

Lock Ring Inner Body

CH4 1.30 ± 0.015

∅13.040/13.045 Casing Hanger

2 x 45o Lock Ring

Note: At Point #, it is assume same point for casing hanger and

Casing Hanger CH1

Inner Body LR2

Note: At Point #, it is assume same point for casing hanger and

Bi-Equal Tolerance : (0.52+0.49)/2 ± (0.52-0.49)/2

Note: For MMC modifier,

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