Tolerance Analysis Techniques

Tolerance Path Recognition Is a process of analyzing all contributing tolerances, as inputs, that will ultimately affect a feature, part or sub-assemblys final location. This in essence establishes a point-to-point relationship through the parts and processes involved and will describe the overall additive effect of the system as a total resultant. Establishing the path, through contributing factors, is a careful process that requires a thorough knowledge of how parts are toleranced, fabricated and assembled. Factors such as tooling tolerance, stress relief, and metal springback must sometimes be investigated. Tolerance path recognition becomes more difficult as system complexity increases. Method-Straight / Limit Stack A straight limit stack dimensional analysis (reference Figure 1) is a one directional evaluation of the upper and lower limits of accumulating individual sizes, and corresponding tolerances, in an assembly build. The resulting value represents a worst-case build scenario in which all included tolerances are assumed to be at their extreme limits simultaneously. Pros: It is quick and relatively inexpensive to perform. Cons: It can only be performed in one direction at a time and ignores geometric skewed effects. The statistical nature of tolerances is ignored. It can ignore assembly methods and sequences. The probability that the worst-case scenario would occur is 1 in 400,000,000 assemblies.

Method-Root Sum Square (RSS) An RSS probability study (reference Figure 2) is a progression of the limit stack method that takes into account the statistical nature of tolerances by using the Root Sum Square method of analyzing each tolerance. The resulting output value, for the limit desired, is the square root of the sum of the squares of each contributing tolerance. Pros: It is quick and relatively inexpensive to perform. Cons: It can only be performed in one direction at a time and ignores geometric skewed effects. Non Normal distributions are not considered. It can ignore assembly methods and sequences. The probability that this case scenario would occur is 740:1. Method-Assembly Variation Analysis Computer aided analysis, or 3D modeling such as Vis VSA, is also a technique commonly used today to predict and quantify assembly build variation. These software systems are capable of taking into account, three dimensionally, factors such as assembly processes; assembly sequence; geometric effects; non-normal tolerance distributions and the like, that could not previously be considered in a tolerance analysis process. Many build simulations can be performed for more accurate results.

Tolerance Analysis Techniques

Limit Stack
(Limits occur once every 400 million assemblies)

Upper Limit

5.0 + 0.5

Lower Limit
16.5

5.0 + 0.7

13.5

5.0 + 0.3

Calculation of Limit Stack Min = 4.5 + 4.3 + 4.7 = 13.5 Max = 5.5 + 5.7 + 5.3 = 16.5

Limit Stack typically accounts for variation in one direction & ignores the statistical nature of tolerances.

Figure 1

Tolerance Analysis Techniques

R.S.S.

(Limits occur once every 740 assemblies)

5.0 + 0.5

Upper Limit

Lower Limit
5.0 + 0.7 15.91 14.09

5.0 + 0.3

Calculation of Root Sum Square (R.S.S.)

Min = 15.0 0.52 + 0.72 + 0.32 = 14.09 Max = 15.0 + 0.52 + 0.72 + 0.32 = 15.91

RSS typically accounts for variation in one direction & includes the statistical nature of tolerances.

Figure 2

Study Example
Objective Determine the misalignment (up/down variation) of the Hood Assembly hinge pivot hole-to-Body hinge pivot hole for an adjustable hinge design. Perform an R.S.S. calculation on the assembly Hood hinge process to determine the required adjustable range. Components Hood assembly (geometry not shown for clarity) Hood hinge Body hinge Cowl top outer Fender (geometry not shown for clarity) Shotgun

Assembly Process Hood hinge mating surface (Datum) moves to hood assembly datums on hood inner. Fender mating surface (Datum) moves to shotgun mating surface Cowl top outer mating surface moves to shotgun mating surface Body hinge mating surface (Datum) moves to Cowl top outer mating surface

Assumptions The final resultant output of this study is for training purposes only. It identifies the range of adjustability required for the hinge design The study evaluates the Right Hand side and takes into consideration only the following up/down linear tolerance contributors and stated assembly sequence.

Tolerance Assumptions Hood outer surf profile (surface flushed to fender point): +/-0.7 Hood hinge Pivot hole positional tolerance: +/-0.7 Body hinge pivot hole positional tolerance: +/-0.7 Cowl top outer mounting surface for hinge: +/-0.5 Cowl top outer mounting surface to shotgun: +/-0.7 Shotgun mounting surface for Cowl top outer: +/-0.7 Shotgun mounting surface for fender: +/-0.70 Fender flush point surface profile (flush out point for hood): +/-0.7

1) Define the tolerance path and associated tolerance.

Right Hood / Body Hinge Pivot Hole

Tol.+/- ____

Tol.+/-____

Tol. +/-____

Tol. +/-_____

Tol. +/-_____ Tol.+/-_____

Partial Front End Assembly

Tol. +/-____ Required output Tol.+/-_____

2) Calculate the Root Sum Square (R.S.S)

R.S .S = + / Tol12 + Tol 2 2... + Tol 8 2

3) Solution Tolerance Path:

Right Hood / Body Hinge Pivot Hole

Shotgun ms for Fender Tol.+/-0.7

Shotgun ms Cowl Top Otr. Tol.+/-0.7

Fender flush Surface profile Tol. +/-0.7

Cowl Top outer ms to shotgun

Tol. +/-0.7

Tol. +/-0.7

Hood Otr Surface profile

Cowl Top ms for Hinge body

Tol.+/-0.5

Hood Hinge Pivot hole pos Tol. +/- 0.7 Required output R.S.S= +/-1.92

Hinge body pivot hole pos Tol.+/-0.7

Calculated the Root Sum Square (R.S.S.)

R.S .S . = + / 0.7 2 + 0.7 2... + 0.7 2 = + / 1.92