TOLERANCE STACK UP ANALYSIS

Introduction
 Tolerance analysis :
Study of individual tolerances
Process of determining the cumulative variation
possible between two or more features.
 Tolerance stack up analysis is one part of tolerance
analysis.
 Analyzes and predicts the variation between the
parts.
 Determines the maximum possible variation
between two components in an assembly.
Merits of Tolerance Stack Up Analysis

 Optimize the tolerances of parts and assemblies in a

new design
 Balance accuracy , precision and cost with
manufacturing process
 Determine the part tolerance required to satisfy a
final assembly condition
 Determine allowable part tolerance if assembly
tolerance is known
 Determine the effect changing a tolerance will have
on assembly component
Steps in Tolerance Stack Up Analysis

 The Distance to be studied is identified and labeled

 The positive and negative directions are identified
 A tolerance stack up sketch is created
 The dimensions in positive direction and negative
directions are added individually
 The nominal distance is found out by subtracting
negative direction total from the positive direction total
 The total possible variation is obtained by adding all
tolerances
 The maximum and minimum variations are obtained
from the nominal distance and total variation values.
Problem
 For an inseparable
assembly using
tolerance stack up
analysis find the
maximum and
minimum distance
between the part 5 and
6 in assembly.
Tolerance Stack Up Sketch
Tolerance Stack Up Report
Dimensional Chain Analysis
 Dimensional Chain is a consecutive series of interrelated
dimensions that contribute to the tolerance of a dimension and form
a closed loop.

 Two Basic tasks in tolerance design process :

Dimensional Chain analysis
Dimensional Chain synthesis
 In Dimensional analysis component tolerance are specified and
resulting assembly variation is calculated.
 Dimensional Synthesis involves allocation of specified assembly
tolerance between component dimension of the assembly.
Equivalent tolerance method
 All independent dimensions have same tolerance
Tx1=Tx2=.........=Txn=T
 Used when all independent dimensions in the analysed
dimensional chain have same nominal value.
 Deterministic approach formula is

 Stochastic approach formula is

 Equivalent Standard tolerance grade
method
 All independent dimensions are assigned tolerance
values from the same tolerance grade.
 Value of dimension tolerance is :

Txi = tolerance of ith independent dimension

Xi = nominal value of ith independent dimension
K =unknown tolerance grade factor
Deterministic Approach:
Stochastic Approach:
Problem
 Two holes are drilled in a plate. What are the
required tolerances of dimensions A,B,C,D if the
tolerance of the dependent dimension Z is required as
not greater than 140 µm and the nominal values of
the independent dimensions are A=124mm,
B=56mm,C=87mm,D=25.5mm
Solution
Solution
 Equivalent tolerance method
TA=TB=TC=TD=TW
Tz = 140 µm
=0.75*T A +0.66*TB +0.75*TC +0.66*TD =2.82*TW
TA=TB=TC=TD=TW = 50 µm
 Equivalent standard tolerance grade method
Tz = 140 µm
=K*(0.75* A 1/3 +0.66*B 1/3+0.75*C 1/3 +0.66* D 1/3)
K=12.11
TA=60 µm TB=47 µm TC=54 µm TD=35 µm
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