Design Life Cycle and fundamental design calculations Tolerance Stack up

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<30-09-09>

Tolerance Stack up
 Tolerance stackup analysis is used to deal with dimensional tolerances in one-dimension, the resultant tolerance is always the sum of the component tolerances. Analysis and control of dimensional tolerances are relatively well developed compared to those for geometric tolerances. The stackup of geometrical tolerances was usually ignored or replaced by the stackup of component tolerances.

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Addition of Tolerances
A and B two linear dimensions to be added a1 , a2 tolerance on A b1 , b2 tolerance on B A+B = C The tolerance on C to be analysed.

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Addition of Tolerances
C is max. when A and B are max. C is min. when A and B are min. Cmax Cmin Cmax (C + c2) Cmin (C - c1) = = = = A max + B A min + B
max min

(A + a2) + (B + b2) -------- ( 1 ) (A - a1) + (B - b1) -------- ( 2 )

c1, c2 tolerance on C Subtracting C min ( 2 ) from C max ( 1 ) c1 + c2 = (a1+a2) + (b1 + b2)

If , ( a1 ( b1 ( c1 + + + a2 ) b2 ) c2 ) = T = T = T
a b c

The Tolerance on the total length will be

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T c = Ta + Tb

Subtraction of Tolerances
A and B two linear dimensions to be subtracted a1 , a2 tolerance on A b1 , b2 tolerance on B A-B=C The tolerance on C to be analysed.

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Subtraction of Tolerances
C is max. when A is max. and B is min. C is min. when A is min. and B is max. C max C min A max B min A min B max C max C min = = = = = = A A
max min

- B min -B
max ;

A + a2 B - b1 A - a1 B + b2

= ( C + c2 ) = ( A + a2) - ( B - b1 ) ----------- ( 3) = ( C - c1 ) = ( A - a1) - ( B + b2 ) ---------- ( 4 ) Subtracting C

min

( 4 ) from Cmax ( 3 )

(c 2 + c 1 ) = ( a2 + a1 ) + ( b2 + b1) If ( a 2 + a 1 ) = Ta ( b 2 + b 1 ) = Tb ( c2 + c1 ) = Tc The Tolerance on the remaining length T c = Ta + Tb

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Addition & Subtraction of Tolerances

The tolerances are getting added both in addition and subtraction. Further slides deals with how to calculate unknown dimensions.

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Case - 1
The value of X and tolerances x1, x2 are un-known. x2 x1 X x2 x1 (X) Therefore, x 2 - a1 x2 x 1 - a2 x1 = = = = Therefore, x2 x1 X
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a2 a1 A = Z a2 a1 - (A)

z2 z1 x 2 - a1 x 1 - a2 (X -A) z2 z1 Z

z2 a1 + z2 z1 a2 +z1

a1 + z2 a2 + z1 (A + Z)

Example - 1
The value of X and tolerances x1, x2 are un-known. x2 x1 + 0.1 - 0.1 + 0.2 - 0.2

- 5

=
x2 - ( - 0.1 ) x2 + 0.1 x2 x1 - ( + 0.1 ) x1 - 0.1 x1

10
= = = = = = + 0.2 - 0.2 + 0.2 + 0.2 + 0.2 - 0.1 = + 0.1 - 0.2 - 0.2 - 0.2 + 0.1 = - 0.1

x2 + 0.1 x1 - 0.1

(X - 5 )

10
+ 0.2 - 0.2 = 10

Therefore ,

+0.1 + 0.1 - 0.1 - 0.1 (15 - 5 )

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Case 2
The value of X and tolerances x1, x2 are un-known. a2 a1 x2 x1 z2 z1 z2 z1

a2 - x 1 a1 - x 2

(A -X)

The tolerances of the equation can be equated. a2 x1 a1 x2 - x1 - x2 = z2 = a2 - z2 = z1 = a1 - z1

Therefore, x2 x1 (X )
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a1 - z1 a2 - z2 = (A- Z)

Example - 1
The value of X and tolerances x1, x2 are un-known.
+ 0.1 - 0.1 x2 x1 + 0.2 - 0.2 +0.1 - x1 - 0.1 - x2 +0.2 - 0.2

15

10

( 15 - X )

10

The tolerances of the equation can be equated. +0.1 x1 -0.1 x2 Therefore + 0.1 - 0.1 x2 x1 + 0.2 - 0.2 - x1 = = = = +0.2 +0.1 - 0.2 = -0.1 -0.2 -0.1 +0.2 = +0.1

- x2

15

X
+0.1 -0.1

10
+ 0.2 - 0.2

+ 0.1 - 0.1

15

10

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Example - 2
+ 0.05 - 0.03

Dimension A =

100 . 0

Dimension B =

60.0

- 0.13 - 0.20

Calculate the nominal size and the variation for the dimension C.

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Example - 2
Nominal size C C c2 c1 = = Nominal size A - Nominal size 100 - 60 = 40 a2 a1 b2 b1 B

C
c2 c1

B
- 0.13 - 0.20

40
c2 c1

=
= =

100

+ 0.05 - 0.03

60

+ 0.05 - ( - 0.20 ) = + 0.25 - 0.03 - ( - 0.13 ) = + 0.1 +0.25 +0.1

c2 c1

C
Verification:

40
Tc = Ta + Tb = = Tc = 0.15 = Ta +Tb + 0.05 - ( - 0.03 ) + ( - 0.13 ) - ( - 0.20) 0.15 0.15 0.15

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Example - 3
 Calculate the dimension x and tolerance on x with M-M and L-L as references.

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Example - 3
 Considering MM as reference
a2 a1 x2 x1 b2 b1

+ 0.0 - 0.1

X
x2 x1

B
0.1

30

- 8
+0.0- x1 -0.1 - x2

22
0.1

( 30 - 8 )
0.0 - x1 x1 -0.1 - x2 x2
x2 x1

=
= = = =
+ 0.0 - 0.1

22
0.1 - 0.1 0.1 0.0

The value of
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Example - 3
 Considering LL as reference
a2 a1 b2 b1 x2 x1

B
0.1

X
x2 x1

+ 0.0 - 0.1

30

- 22

x2 = + 0.0 - ( - 0.1) = + 0.1 x1 = - 0.1 - (+ 0.1) = - 0.2

x2 x1 + 0.1 - 0.2

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Multiplication & Division by a constant number

Any dimension with tolerances, if multiplied by a positive constant number, the tolerance of the result also increases proportionately. When divided by a constant number, the tolerance of the result, decreases proportionately similarly

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Multiplication by a constant number

a2 a1

When A

is multiplied by a constant K , it becomes

a2 a1 a2 * K a1 * K

(A)

* K

= (A*K)

Example :
+ 0.1 + 0.3 (+0.1) 3 (+0.3) 3

* (3)

= (4 * 3)
+0.3 +0.9

= 12

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Division by a constant number

a2 a1

When A is divided by a constant K , it becomes

a2 a1 a2 K a1 K

(A) Example :

(A K)

+ 0.3 + 0.9

0.3/3 0.9/3

( 12 )

( 12 / 3)
+0.1 +0.3

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Example : 1
Find out the variation of dimension x with reference to LL

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Example : 1
x2 x1 +0.0 -0.2 +0.1 -0.0 +0.0 -0.2 +0.0 -0.1 x2 x1

X x2 x1
x2 x1

= 50

- 5

- 38

- 5

= + 0.0 - ( - 0.0 ) - ( - 0.2 ) - ( - 0.1 ) = + 0.3 = - 0.2 - ( + 0.1 ) - 0.0 - 0.0 = - 0.3
+0.3 -0.3 0.3

= 2

Verification :

Ta + Tb + Tc + Td Ta + Tb + Tc + Td Tx 0.6

= = = =

Tx 0.2 + 0.1 + 0.2 + 0.1= 0.6 0.3+0.3 = 0.6 0.6

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Example : 2
+0.040 -0.040 -0.073 +0.013 -0.009 +0.012 +0.001 -0.000 -0.019 -0.006 -0.017 x2 x1

150

- 20

+ 95

- 15

+ 65

+ 15

= 290 = + 0.119 = - 0.017

x2 = (0.040)-(-0.073)+(0.013)-(0.001)+(0.000)+(-0.006) x1 = (0.000)-(-0.040)+(-0.009)-(0.012)+(-0.019)+(-0.017)
x2 x1 + 0.119 - 0.017

X Verification : Ta+ Tb+ Tc + Td + Te + Tf Ta+ Tb+ Tc + Td + Te + Tf

= 290 = Tx = 0.040 + [(-0.040)-(-0.073)] + [(0.013)-(-0.009)] + [(+0.012-(+0.001)] + [(-0.000)-(-0.019)] + [(-0.006)-( -0.017)] = 0.136

Tx = [0.119-(-0.017)] = 0.136 0.136 = 0.136

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Example : 2
+ 0.046 + 0.030 + 0.011 +0.021 +0.008 +0.030 +0.011 x2 x1

240
X x2 x1

+
= = =

75

20

60

X
= 235 = + 0.057 = - 0.040

(240 + 75 - 20 - 60) + 0.046 + 0.030 - ( + 0.008 ) - ( + 0.011 ) + 0.000 + 0.011 - ( + 0.021 ) - ( + 0.030 )
x2 x1 +0.057 - 0.040

235 Verification :
Ta + Tb + Tc + Td = Tx

235

Ta + Tb + Tc + Td = 0.046 + ( 0.030 - 0.011 ) + ( 0.021- 0.008 ) + ( 0.030 - 0.011 ) = 0.097 Tx = 0.097 0.097 = 0.097

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Example : 3
+0.012 - 0.007 +0.009 -0.004 +0.063 +0.013 -0.009 +0.008 -0.003 x2 x1

65
x2 x1 = =

- 20

+ 450

- 120

+ 12

387

+ 0.012 - (- 0.004) + 0.063-(-0.009) + 0.008 = + 0.096 - 0.007 - ( 0.009) + (0.000) - (0.013) + (-0.003) = - 0.032
x2 x1 +0.096 - 0.032

387 Verification :
Ta+Tb+Tc+Td+Te Ta+Tb+Tc+Td+Te Tx

387

= Tx = 0.012-(-0.007)+ 0.009 -(-0.004)+0.063+0.013 -(-0.009)+0.008-(-0.003) = 0.096- (-0.032) = 0.128 = 0.128

0.128 = 0.128
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Example : 4
Calculate the value of x to have the axial clearance between bearing and the shaft, as 1.25 0.25 mm

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Example : 4
  Considering LL as reference The value of X must lie as the difference between the sum of the dimension of B, C, D, and E to A.
L L

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Example : 4
Equation :
x2 x1 +0.0 -0.05 +0.00 -0.10 +0.25 - 0.25 +0.00 -0.05 +0.25 -0.25

X
x2 x1

= =
= =

+ 140
x2 x1

+ 1.25
x2 x1

+ 5

- 100

X
x2 x1

(151.25 - 100)

= (51.25)

+ 0.0 + 0.00 + 0.25 + 0.00 - ( - 0.25 ) = + 0.50 - 0.05 - 0.10 - 0.25 - 0.05 - ( + 0.25 )
x2 x1 +0.50 -0.70

= - 0.70

(51.25) Verification :

= 51.25

Tb+Tc+Td+Te+Ta Tb+Tc+Td+Te+Ta Tx 1.20

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= = = =

L Tx +0.05 + 0.1 + 0.25 +0.25+0.05 +0.25 + 0.25 =1.20 1.20 1.20

Example : 5
A hole 16H6 has to be drilled and reamed The dimension is 79 s 0.1 from one side of the component. Calculate the tolerance for the

dimension 12 from one end in a box jig plate to obtain the resultant dimension 79 s 0.1

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Example : 5
0.10 0.05 +0.00 - 0.05 x2 x1

79

111

20

- 12

Max. limit :

+ 0.10 = + 0.05 - ( - 0.05 ) - x1 x1 = 0.00 - 0.1 x2 = = - 0.05 - ( + 0.00 ) - x2 0.05

+0.00 - 0.05

Min. limit

The tolerance for the dimension 12 is

+ 0.05 + 0.00

12
Verification: Td

or

12.05
= Ta + Tb + Tc
0.05

0.10

+0.00 - 0.05

+0.05 - 0.00

79 Td Ta + Tb + Tc 0.20
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= = = =

111 20 - 12 0.20 (0.05)-(-0.05)+0.00-(-0.05)+(0.05)-(-0.00) = 0.20 0.20

Example : 6
A hole of 16H7 is to be made with reference to another predrilled and reamed hole 10H7 which lies on a perpendicular plane The dimension of the hole 10H7 with reference to one side of the box jig is given as 245 s 0.05 Calculate the tolerance for the dimension 97 to position the drill jig bush to drill and ream dia 16H7 hole.

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Example : 6
s 0.1 s 0.05 x1 x2

Dimension should be 148

s 0.1 x2 x1

= 245
s 0.05

97

148 + 97 +0.1 - ( x1 ) x1 -0.1 - ( x2 ) x2

= 245 = +0.05 = +0.05 = - 0.05 = - 0.05

The tolerances for the dimension 97 is s 0.05

Verification :
s 0.05 s 0.05 s 0.1

245

- 97
Ta +Tb Tc 0.2

= 148
= 0.1 + 0.1 = 0.2 = 0.2 = 0.2

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Example : 7
Case 1 : considering LL as reference
x2 x1 s 0.05 s 0.1 s 0.2

X x2 x1
x2 x1

= 180

50

100

The component shown in Fig. is dimensioned by two methods. Analyses the more practical one. In case 1 the dimensions, 50 s 0.1; 100 s 0.2 , and the overall dimensions 180 s 0.05 are toleranced. In case 2 , dimensions 100 s 0.2 , 130 s 0.05 and 30 s 0.05 are toleranced.

= + 0.05 - ( - 0.1 ) - ( - 0.2 ) = + 0.35 = - 0.05 - ( + 0.1 ) - ( + 0.2 ) = - 0.35

s 0.35

= 30

Case 2 : considering AA as reference

x1 x2 s 0.05 s 0. 2

X x2 x1
x1 x2

= 130

100

= + 0.05 - ( - 0.2 ) = + 0.25 = - 0.05 - ( + 0.2 ) = - 0.25

s 0. 25

= 30

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Example : 8
The dimension C from the functional reference LL . + 0.08 It is impracticable to measure the depth ( 20 - 0.14 ) of the hole having diameter D1 from the functional reference LL Hence the best auxiliary reference selected in this case is C and their tolerances are evaluated as follows. MM , which is also

reference for manufacturing. In view of this new reference the dimensions of A, B,

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Example : 8
Nominal dimension of A A A Total Tolerance of C The equation will be A - B
a2 a1 b2 b1

= Nominal dimension B + Nominal dimension C = B+C = 20 +10 = 30 = Total tolerance of A -Total tolerance of B = C
c2 c1

A a2 a1

B
s 0.0 5

= C

+0.08 -0.14

30 - 10 a2 - ( - 0.05 ) a2 a1 - ( + 0.05 ) a1

= 20

a2 a1

= + 0.08 = 0.08 - 0.05 = + 0.03 = - 0.14 = - 0.09

+0.03 -0.09

30
+0.03 -0.09

The depth of hole is = 30

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Tolerance on dimensions between centers of two holes

Case 1 : Sizes of the holes and shafts are identical. d is the diameter of the shafts. D is the diameter of holes in two plates.

A set up for the worst case of interchangeability.

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Tolerance on dimensions between centers of two holes

1-1 2-2 CC M m (D-d) = = = = = = Axis of holes in the plate1 Axis of the holes in the plate 2 Axis of the shafts mating the holes The distance between the centers of holes The tolerance on M on the respective holes Clearance between hole and shaft = L

Considering a datum line of no clearance from the figure: The following chain of dimension can be placed keeping in view the signs. An equation for the expression of tolerance is as 0 = D/2 - ( M+ m ) + D/2- d+ D/2 + ( M-m ) + D/2 -d 0 = 2D - 2m - 2d 2m = 2 ( D-d ) 2m = 2L m = L As this is a critical value, m can be less than L but not more, as 100% interchangeability is to be achieved. Therefore m=L
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Tolerance on dimensions between centers of two holes

Conclusion : If 100% interchangeability is to be achieved in the above case, the tolerance

on dimension between the two holes cannot be more than twice the diametrical clearance between the holes and shafts. It could be less or equal to the clearance.

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Tolerance on dimensions between centers of two holes

Case 2 : The size of the holes and shafts vary D1 be the diameter of the holes in plates 1 and 2, for the mating shaft d1. D2 be the diameter of the holes in plates 1 and 2 for the mating shaft d2 .

A worst case set-up for 100% interchangeability is shown.

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Tolerance on dimensions between centers of two holes

1-1 2-2 c1 -c1 c2 -c2 M m = = = = = = Axis of holes in the plate 1 Axis of holes in the plate 2 Axis of the shaft of diameter d1 Axis of the shaft of diameter d2 The distance between the centers of holes The tolerance on M.

( D1- d1 ) , ( D2 - d2 ). = The clearance between the holes and Shafts. Starting from a point of no clearance, a set of chain dimensions can be placed as follows, keeping in view the directional sign and equating it to zero. 0 0 2m 2m = = = = D2/2 - ( M+ m )+ D1/2 - d1 + D1/2 + ( M - m ) + D2/2 - d2 - 2m + ( D1 + D2 ) - ( d1 + d2 ) ( D1 - d1 ) + ( D2 - d2 ) ( L1 + L2 ).

Since ( D1 - d1 ) = L1 and ( D2 - d2) = L2 m = ( L1 + L2 ) 2

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Tolerance on dimensions between centers of two holes

Conclusion : The critical tolerance m on the centers of two holes in the above case should be equal to half the sum of clearances in both holes and could be less for 100% interchangeability between the two plates.

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Tolerance Stack up Case Study

Objective : To calculate the tolerance stackup on the clearance between the Reel Assembly and Bedbar-Bedknife assembly by Worst Case analysis and Statistical analysis. Need for Tolerance stack up : The clearance between the Reel Assembly and Bedbar-Bedknife assembly determines the quality of grass being cut.

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Tolerance Stack up Case Study

Reel Mower Cutting Unit :

Reel Assembly

Plate-Side Support

Bedbar-Bedknife Assembly

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Tolerance Stack up Case Study

Reel Mower Cutting Unit-side View :

Clearance

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Tolerance Stack up Case Study

Assumptions :  Reel sub assembly center axis is aligned to the mounting hole axis of Plate-Side Supports(107-3256).  Bedbar-bedknife assembly(107-3274) center axis is aligned to the mounting hole axis of Plate-Side supports(107-3256).   Title block tolerances are considered wherever applicable Clearance between the Reel sub assembly and Bedbar-Bedknife sub assembly is assumed to be .0008

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Tolerance Stack up Case Study

Shaft & Plate-support Dimensions

Bearing Dimensions

G2

A2

A1

D1

D2

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Tolerance Stack up Case Study

G1

F2

E1 F1 Clearance

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Tolerance Stack up Case Study

B1 C1

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Tolerance Stack up Case Study

Tolerance Stack up Calculations : Tolerance accumulated at the clearance = ( Tolerance accumulated at Bed knife cutting edge ) ( Tolerance accumulated at Reel cutting edge ) = (G1+E1+F1) F2

(G1 + E1 + F1) = Height between shaft axis to top of the Bed Knife. F2 = Height between shaft axis to bottom of Reel Assembly. Clearance between the Bed Knife and Bed Reel Assembly is : (G1 + E1 + F1) F2

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Tolerance Stack up Case Study

As per the Tolerance Stack - Calculation sheet : G1 E1 F1 F2 = = = = 1.5940 1.8317 0.1025 3.5274 = = = As per tolerance analysis :
0.0018

Tolerance Stack up calculations

G1 + E1 + F1 Therefore, Clearance

1.5940 + 1.8317 + 0.1025 = 3.5282 3.5282 - 3.5274 0.0008

G1 E1 F1 F2

= = = =

1.5940
0.0100

1.8317
0.0150

0.1025
+0.0160 -0.0190

1.5940

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Tolerance Stack up Case Study

0.0018 0.0100 0.0150 + 0.0160 - 0.0190 x2 x1

1.5940

+ 1.8317
0.0018 + 0.0100 + 0.0150 -0.0018 - 0.0100 - 0.0150

+ 0.1025
( - 0.0190 ) ( 0.0160 )

- 3.5274
x2 x1

0.0008 Therefore :

Nominal clearance Upper value Lower value Max clearance : Min clearance :

X x2 x1 X + x2 X + x1

= = = = =

0.0008 0.0458 -0.0428 0.0008 + 0.0458 0.0008 - 0.0428 = 0.0466 = -0.0420

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Tolerance Stack up Case Study

As per statistical analysis : Probable tolerance on G1 E1 F1 F2 (G1 + E1 + F1) Therefore, clearance
0.02680 +0 0.01745 +0 x2 x1 x2 x1

= = = = = =

0.00180 0.01000 0.01500 0.01745 0.00180 + 0.01000 + 0.01500 0.02680

3.5282

- 3.5274

0.0008

0.02680 -0.01745

= = = = =

Max clearance Min clearance Probable clearance

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0.0008+0.02680 = 0.0008-0.01745 =

0.02760 -0.01665

0.02760 (-0.01665) 0.04425

Tolerance Stack up Case Study

Conclusions : As per Worst Case Analysis :

Nominal Clearance between the Reel Assembly(107-4044) and the Bedknife Assembly(107-3274) is 0.0008

 

Maximum Clearance is 0.0466 Minimum Clearance is -0.0420

As per Statistical Analysis : Probable Clearance between the Reel Assembly and the Bedknife Assembly is 0.04425

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Reference Books

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Thank you

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