Tolerance Study for Almirah

Tushar Zala : - 171173119146

Devarsh Kaka : - 171173119507
Kaivalya Kavi : - 171173119030
➢ Problem Statement:
• As per the assembly sequence, It is possible that Door of the Almirah
cannot fit properly with casing of the Almirah while assembling the door
with the casing.
So, for this problem we will perform Tolerance study. This study will provide
us actual problem with product.
• Assembly Sequence:
Hinge is bolted with casing and support hinge is bolted with Door.
So Casing Hinge will be assemble with Door Support Hinge.

Approach: Here, answering the problem statement we will be perform two study
between the casing Hinges and Door Support Hinges.
1. Worst case gap between mounting surface of between Casing Hinge and Door Support
Hinge.
2. Axial Variation and Acceptable Criteria between Casing Hinge and Door Support Hinge.

Door Support
Hinge
Casing Hinge
1. Worst case gap between mounting
surface of between Casing Hinge and
Door Support Hinge.
Approach: Worst case gap between mounting surface of between Casing Hinge and Door Support Hinge.

➢ In this tolerance study we will be finding out worst case gap between Mounting Surface of Casing Hinge and Door
Support Hinge. As per nominal CAD Condition this gap is 0.25 mm as shown in below image.
➢ From this study we will come to know that at worst case condition is there will be any problem with Door Support
Hinge and Casing Hinge during the assembly in vertical Direction.
Nominal Cad Clearance = 0.25 mm

PNT B
Worst Case Gap
= 0.25 mm
PNT A

PNT A: On the surface of Casing Hinge.

PNT B: On the Surface of the Door Support Hinge.

Target: To Find worst case gap between PNT A & B

Loop Diagram: To find worst case gap between mounting surface of between Casing Hinge and Door Support Hinge.

PNT B
Worst Case Gap ?
D
PNT A

A C

PNT A: On the surface of Casing Hinge.

PNT B: On the Surface of the Door Support Hinge.

B Target: To Find worst case gap between PNT A & B

Tolerance Stack Report: To find worst case gap between mounting surface of between Casing Hinge and Door Support Hinge.
CONCEPT
No. Part Process Tol Source Dist Nominal ± 3σ Tol % Loop Diagram
Casing
A PNT A to Lower Mounting Surface of Casing Hinge Print N -59.75 0.25 26%
Hinge
Flatness Tolerance Print N 0.25 26%
Door
Lower Hinge Mountig surface of Door Support Hinge
B Support Print N -2.00 0.10 11%
to Datum B of Door Support Hinge
Hinge
Door
Datum B of Door Support Hinge to Upper Surface of
C Support Print N 64.00 0.25 26%
Door Support Hinge
Hinge
Door
D Support Upper Surface Door Support Hinge to PNT B Print N -2.00 0.10 11%
Hinge
Flatness Tolerance Print N 0.25 26%
WC RSS
WC RSS Mean = 0.25 0.25
Mean = 0.25 0.25 Tolerances = 1.20 0.52
Standard Deviation = 0.40 0.17 Upper Limit 1.45 0.77
Stack Result = ± 1.20 ± 0.52 Lower Limit -0.95 -0.27

Result:
So as per worst case, Tolerance variation is ±1.20 mm due to which Maximum Clearance possibility is of 1.45 mm whereas
Maximum Interference Possibility of 0.95 mm between mounting surface of between Casing Hinge and Door Support
Hinge in vertical direction
Suggestions: To avoid Interference at worst case between mounting surface of between Casing Hinge and Door Support Hinge.

Suggestions:
For avoiding interference at worst case we need to decease to total Tolerance or we need to increase nominal CAD
Clearance. So here are two suggestion as per design point of view.
1. Define surface to surface Dimension for Door Support Hinge: This will reduce Tolerance variation by reducing tolerance
two major Contributor i.e. ‘C’ & ‘D’. So resulting Tolerance Variation will be 0.75 mm (0.25 mm + 0.25 mm + 0.25 mm)
from 1.20 mm.
2. Also we need to decrease the length of Casing Hinge up to 59.25 mm from 59.75 mm.

So with these two suggestions, at worst case interference possibility will be neglected.

X.XX ±X.XX
Loop Diagram: To find worst case gap between mounting surface of between Casing Hinge and Door Support Hinge.

PNT B
Worst Case Gap ?

PNT A

A B

Suggested

PNT A: On the surface of Casing Hinge.

PNT B: On the Surface of the Door Support Hinge.

Target: To Find worst case gap between PNT A & B

Tolerance Stack Report: To find worst case gap between mounting surface of between Casing Hinge and Door Support Hinge.
Suggested
CONCEPT
No. Part Process Tol Source Dist Nominal ± 3σ Tol % Loop Diagram
Casing
A PNT A to Lower Mounting Surface of Casing Hinge Print N -59.25 0.25 50%
Hinge
Flatness Tolerance Print N 0.25 50%
Door
B Support Lower Hinge Mountig surface to PNT B Print N 60.00 0.25 50%
Hinge
WC RSS
WC RSS Mean = 0.75 0.75
Mean = 0.75 0.75 Tolerances = 0.75 0.43
Standard Deviation = 0.25 0.14 Upper Limit 1.50 1.18
Stack Result = ± 0.75 ± 0.43 Lower Limit 0.00 0.32

Result after Suggestions:

So as per Suggestions at worst case, Tolerance variation is ±0.75 mm due to which Maximum Clearance possibility is of
1.45 mm whereas Maximum Interference Possibility is 0.00 mm between mounting surface of between Casing Hinge and
Door Support Hinge in vertical direction
 2. Axial Variation and Acceptable
Criteria between Casing Hinge and Door
Support Hinge.
Approach: Axial Variation and Acceptable Criteria between Casing Hinge and Door Support Hinge.

➢ In this tolerance study we will be finding out Axial variation & Acceptable criteria between Casing Hinge and Door
Support Hinge. Where
❑ Axial variation: It is maximum possible variation possibility between Casing Hinge Hole Axis to Door Support Hinge
Axis considering other hinges are perfectly aligned.
❑ Acceptable Criteria: It is Float at MMC condition between Casing Hinge and Door Support Hinge. This MMC Float will
accommodate axial variation between Casing Hinge and Door Support Hinge.

➢ So at the end of the study, for no fitment issue of the assembly, Axial variation between Casing Hinge and Door
Support Hinge should be equal to the Acceptable criteria.

Door Support
PNT B Hinge Axis

PNT A
Acceptable Criteria
PNT A: On the surface of Casing Hinge.
Casing Hinge Axis
Axial variation= ? PNT B: On the Surface of the Door Support Hinge.

Target: To Find axial variation between PNT A & B

Acceptable Criteria: Axial Variation and Acceptable Criteria between Casing Hinge and Door Support Hinge.

Acceptable Criteria

Item Process Part Dia + - MMC LMC

1 Acceptable Criteria Casing Hinge 2.50 0.20 0.20 2.30 2.70
Bolt 2.00 0.00 0.00 2.00 2.00
Door Support Hinge 3.00 0.20 0.20 2.80 3.20

Acceptable Criteria 1:
= {(MMC of Hole 1 – MMC of Shaft 1) + (MMC of Hole 2 – MMC Shaft 2)}
= {(2.30 -2.00 ) + (2.80 – 2.00)} / 2
= {(0.30) + (0.80)}/2
= ±0.55 mm

So acceptable criteria for the Assembly of Casing Hinge & Door Support hinge is ±0.55 mm
➢ So if for no Fitment issue, Axial Variation should be less than or equal to this acceptable Criteria i.e. ±0.55 mm.
Loop Diagram: To find Axial Variation and Acceptable Criteria between Casing Hinge and Door Support Hinge.

D Clarification of “C & D”

F
Enlarged View
Aligned Side Assembly Float 2
(Not Considered as
E used for Adjustability) D
Datum A Datum A
Casing Hinge Casing Hinge
C

B
G

Assembly Float1
(Not Considered as
Enlarged View used for Adjustability) B
A
Datum A
Casing Hinge
Datum A
Casing Hinge
Clarification of “B”
Tolerance Stack Report: Axial Variation and Acceptable Criteria between Casing Hinge and Door Support Hinge.
CONCEPT
No. Part Process Tol Source Dist Nominal ± 3σ Tol % Loop Diagram
Casing
A Axis of Casing Hinge to Datum A of Casing Hinge Print N -20.82 0.00 0%
Hinge
Postional Tolerance + Bonus Tolerance Calculated N 0.33 16%
Casing Datum A of Casing Hinge to Casing Mounting Hole of Casing
B Print N 23.07 0.00 0%
Hinge Hinge Bracket
Postional Tolerance + Bonus Tolerance Calculated N 0.33 16%
Not Considered Assembly Float 1 as it is used for Adjustability N
Lower Hinge Mounting Hole to Upper Hinge Mounting hole of the
C Casing CAD N 0.00 0.00 0%
Casing
Composite Position Tolerance Print N 0.13 6%
Not Considered Assembly Float due it use for Adjustability Print N
Casing
D Upper Casing Hinge Mountig Hole to Datum A of Casing Print N -23.07 0.00 0%
Hinge
Postional Tolerance + Bonus Tolerance Print N 0.33 16%
Casing
E Datum A of Casing Hinge to Casing Hinge - Door Hinge Mounting Print N 20.82 0.00 0%
Hinge
Postional Tolerance + Bonus Tolerance Print N 0.33 16%
Not Considered Assembly Float as considred aligned Print N

F Door Axis of Door Support Hinge to Datum B of Door Support Hinge Print N -7.64 0.00 0%

Postional Tolerance + Bonus Tolerance Print N 0.33 16%

Door Suppot Surface of Door -Door support Hinge Mounting to Axis of Lower
G Print N 7.64 0.00 0%
Bracket Door Support Hinge Mounting

Postional Tolerance + Bonus Tolerance Print N 0.33 16%

WC RSS
WC RSS Mean = 0.00 0.00
Result: Mean = 0.00 0.00 Tolerances = 2.10 0.81
So per tolerance study, at worst case Axial variation Standard Deviation =
Stack Result =
0.70
± 2.10
0.27
± 0.81
Upper Limit
Lower Limit
2.10
-2.10
0.81
-0.81
is ±2.10 mm between axis of Casing Hinge and Door
Support Hinge.
Conclusion.
Result:
So per tolerance study, at worst case Axial variation is ±2.10mm between axis of Casing Hinge and Door Support Hinge,
whereas our acceptable criteria is ±0.55mm,
Thus in this case there will be fitment issue with the existing design.

To avoid fitment issue, below are the suggestions for design changes.
• We can provide slot in Door hinge support Bracket of Ø3.00 ± 0.2 X 6.5 mm
• This will increase our acceptable criteria from ±0.55mm to ±2.30mm
• Below is the calculation, with suggested dimension of the slot
Item Process Part Dia + - MMC LMC
1 With Suggested Acceptable Criteria Casing Hinge 2.50 0.20 0.20 2.30 2.70
Bolt 2.00 0.00 0.00 2.00 2.00
Door Support Hinge 6.50 0.20 0.20 6.30 6.70

Range
Float to A 0.50
Float to B 4.50
Size of A 0.40
Size of Fast 0.00
Size B 0.40
WC Float +/- 2.30