2/17/2017 WorstCaseAssemblyToleranceStackUpAnalysisCalculationExampleTutorial

WORST CASE METHOD ASSEMBLY TOLERANCE STACK UP CALCULATION FOR NON-

SYMMETRIC DIMENSIONAL TOLERANCES WITH EXAMPLE
1
shares Gopinath K (http://blog.mechguru.com/author/gopinath/) December 30, 2014

No comments (http://blog.mechguru.com/machine-design/worst-case-method-assembly-tolerance-stack-calculation-non-symmetric-dimensional-tolerances-
example/#respond)
1
Ifyouarewonderingwhatisstackupanalysis/calculation,theansweris

determiningworstcasescenario.Moreover,theproblemcansortedoutinearly
1092OakridgersinTop
stagesofdesignratherthanundergoingprototypingandfindingouttheissue.
Universities
0

Wehavealreadydiscussedhowtodoworstcasemethodassemblytolerancestackupcalculationforsymmetricdimensionaltolerances
0
(http://blog.mechguru.com/machinedesign/assemblytolerancestackcalculation4stepsexample/),inthistoleranceanalysistutorialwewilldiscussabout
nonsymmetrictolerances.

Adimensionrepresentedonanengineeringdrawinghasnominaldimensionswithtolerances.(Ex:250.2).Inthissimplifiedexample,maximumlimitofthe
partdimensioncanbeupto25.2mmandminimumcanbeupto24.8mm,providedthematingcomponentisdesignedtocatertothisrequirement.

Tolerancebasissystem:

Therearecertainterminologiesassociatedwithtolerancestackupsuchasbasicsize,allowance,interference,deviation(http://blog.mechguru.com/machine
design/diniso286standardtolerancezonesizetabledifferentgradesnominalsize/)etc.,Letustakealookaboutthelimitsystemwhichdetermineswhatto
changeandwhattonot.

Typically,therearetwotwolimitsystems.

1.BasicHolesystem

2.Basicshaftsystem (http://blog.mechguru.com/machine-design/din-iso-286-tolerance-fundamental-deviation-tables-shaft/)

Outoftheseanyoneofthesystemmaybeadopted.

Boththesesystemsimplicatethat,tolerances/fitscanbeobtainedbykeepingtoleranceononematingsurfaceunchangedwhilechangingthetoleranceonthe
other.

Inabasicholesystem,theholedimensioniskeptunchangedwhilethetoleranceontheshaftischangedandisthecaseinbasicshaftsystem,keepingthe
shaftdimensionunchanged.

Tolerancegrades(http://blog.mechguru.com/machinedesign/diniso286standardtolerancezonesizetabledifferentgradesnominalsize/):

IndianStandardofLimits&Fitsinclude16gradesoffundamentaltolerance.ThesegradesarerepresentedasIT01,IT02..IT16.

WorkedoutExample:

Letustakeasimpleexampletofindouthowthisisdone.

Consideracomponentwhichneedstohavesomeoverhang(min.3mm)afterassembled.

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2/17/2017 WorstCaseAssemblyToleranceStackUpAnalysisCalculationExampleTutorial

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WorstCaseAssemblyToleranceStackUp
1 CalculationforNonSymmetricTolerance
shares

1 Table.1: Calculation table for worst case tolerance stack up for the above example

Tolerance

Descripon Basicsize Maximum Minimum
0 Max. Min.

0 A 50 +0.3 -0.5 50.3 49.5

B 28 +0.2 -0.4 28.2 27.6

C 15 +0.2 +0.1 15.2 15.1

D 98 +0.5 0 98.5 98

Calculated Overhang Value 6.3 4.3

Requiredformulas:

MaximumOverhangofthepart=[Max.D(Min.A+Min.B+Min.C)]

MinimumOverhangofthepart=[Min.D(Max.A+Max.B+Max.C)]

Inthiscase,minimumoverhangistheworstcasescenarioandwhichmeetsourintendedlength.

ThisisthesimplestwayofstatisticalapproachtowardsStackupcalculation.

However,stackupcalculationshassomeshortcomingssuchas

1. Temperautre/Pressureofthepartatwhichitisoperayed
2. Nottakingintoaccountwear&tear
3. Afterassemblydeviations/deflections

AZNanoparticles/Nanopowders
Element,Carbide,Nitride&OxideCarbonNanotubes,
Graphene&Dispersions.Gotonanoamor.com

AboutGopinath K (http://blog.mechguru.com/author/gopinath/)
Gopinath is a Design Engineer by profession and a writer by passion.
One who always wanted to share the knowledge gained of both technical and non-technical aspects.

Posted in Engineering design (http://blog.mechguru.com/category/machine-design/)

Tagged Tolerance StackUp (http://blog.mechguru.com/tag/tolerance-stackup/)

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