Tolerance Analysis

for Non-rotational Parts

Team: Dr. X. Han, S. Yao, C. Fei
Advisor: Professor Y. Rong
Sponsor: NSF & Delphi Corp.
Tolerance Analysis in Production Planning
Tolerance analysis
- Part of setup planning
- Locating error coupled with process error
- Intra- and inter- setups
- Process verification and
quality control
- Integration in CAD/CAM

Four steps:
Tolerance stack-up analysis
Tolerance decomposition
Machining error analysis
Tolerance assignment
In process inspection
Quality control plan

In this project, the first step is studied.

CAD
Setup Planning
- DMG (Datum Machining feature relationship)
- Processes with tolerance specification
Part Information Model
- Manufacturing feature
- FTG (Feature tolerance graph)
Is error in
tolerance zone ?
Tolerance Decomposition
In-process Inspection
No
Yes
Machining Error Analysis
Best Practice
Quality Control Plan
End
Tolerance Assignment
Tolerance Stack-up Analysis
Tolerance stack-up analysis is to evaluate the machining error
effects in each setup on the feature tolerance specifications of the
final product
Tolerance stack-up analysis
For given setup plan as DMG
For given machining errors in each operation
Evaluate the machining error accumulation through setups
Tolerance decomposition
The feature tolerances specified in product design can be decomposed into
operation tolerances specified for each setup
The machining error in each setup can be decomposed into locating errors
(A
loc
) from machine tool and fixture, tool-fixture alignment errors and tool
wear errors (A
tool
), other deterministic (A
o
) and random (A
ran
) errors.
A = A
loc
+ A
tool
+ A
o
+ A
ran

Tolerance Achieved in One Setup
Symbol Tolerance type Machine error calculation in one set-up
Model1 Model2

Linear
dimensions
Two features have the same normal
and with the same tool

Two features have opposite normal
and with the same tool

Profile of a line



Two features have the same normal
and with the same tool



Two features have opposite normal
and with the same tool

Profile of a
surface
Circular runout
Total runout
Concentricity
Symmetry
Parallelism
Perpendicularity
Angularity
ran o
A + A = A
ran o tool
A + A + A = A 2
ran o
A + A = A
ran o tool
A + A + A = A
Tolerance decomposition model 2:
One of the features in the tolerance
relationship is the datum feature:
ran o
tool loc
A + A +
A + A = A
Tolerance decomposition model 1 :
Two related features are machined in
one datum frame:

Tolerance Achieved in Multiple Setups
Tolerance Decomposition Model 3
The features in the tolerance relationship are machined in different setups
A
N,N
= A
N, A
+ A
A,N

A
N, A
= A
ran

A
A,N
= A
ori
+ A
ran


Tolerance Stackup
Searching Algorithm
In order to identify the factors
that influence the machining
errors, two steps are needed:
Search the datum-feature
relationships that construct the
tolerance stackup chain
Calculate the total machining
errors
Tolerance within one setup:

Tolerance stackup in multi-setup:
radom Loc cutter mt
A + A + A + A = A
) (
radom Loc cutter
mt
A + A + A + A = A

Machining error calculation
Tolerance stackup chain searching
Searching features of target
tolerance in DMG
Two target features are machined
in one setup?
Begin with the target feature (I) in later set-up,
searching related features in stack-up, calculate the
variations of
i
A
Is the stack-up chain successfully
found?
Tolerance achieved in multiple setups
)
(
radom Loc
cutter
mt
A + A
+ A + A = A

End
Begin
No
Yes
No
Yes
Tolerance achieved in one setup
radom Loc
cutter mt
A + A
+ A + A = A
Locating Errors Analysis
Among the machine errors in one setup, the locating error
(A
loc
)can be calculated:
Six locating points(P
1
0
, P
2
0
, P
3
0
, P
4
0
, P
5
0
, P
6
0
) construct three orthogonal planes

CS
w
CS
f
) , ,
, , , (
0 0 0
0 0 0
| o A A A
A A A z y x
0
i
X
i
X
mt
T A
pl
T A
fb
T A
parallelism
profile
Workpiece
Fixture base
Pallet
Machine tool
Locator
CS
f

Actual fixturing coordinate reflects the

variation caused by locator errors
T = T
0
- AT
AT = (Ax, Ay, Az, Ao, A|, A). AT
comes from the given locator errors.

(
(

=
1 0 0 0
) ( ) (
0 0
0
T
X A
T
u
A
1
X + B
1
Y + C
1
Z + D
1
= 0
A
2
X + B
2
Y + C
2
Z + D
2
= 0
A
3
X + B
3
Y + C
3
Z + D
3
= 0
A theoretical fixturing coordinate is expressed as
X
0
is the position of the origin point
is the 33 orientation matrix

) (
0
u A
An Case Study on Knuckle

101
102
105
103
106
107
104
108
109
110
111
201
202
203
204
207
205
206
209
208
Machining feature GD&T of OP10: 101 Surface A
Theoretical fixture CS: Actual fixture CS
with given locator
errors( )

The worse case caused by locator errors: 0.654
Overall machining error
A
Total
= A
locating
+ A
mt
+ A
process
+A
tool
= 0.654 + 0.013 + 0.254 + 0 = 0.921 mm
A
mt,
A
process
and A
tool
are given parameters.

0.1 A

1.2 X Y Z

L1
L2
L3
L4
L5
L6

OP10
OP20
(
(
(
(

1 0 0 0
8312 . 73 1 0 0
7367 . 72 0 0 1
64 . 27 0 1 0
(
(
(
(

1 0 0 0
334775 . 0 99998 . 0 00124717 . 0 00614057 . 0
344082 . 0 00128144 . 0 999984 . 0 00558042 . 0
269581 . 0 00613351 . 0 00558818 . 0 999966 . 0
0254 . 0
+

A Case Study on Engine Block

W AA
XX
YY
X
A
B
M-S
J
K
D
DD
L
Cy1~4
Cy5~8
R
ZZ
|0.40 | M-S | A | R
|0.05/162 | M-S
M
| 0.25 | M-S | A | R
Datum frames:X-Y-Z, XX-YY-ZZ, A-B-C, M-S-A-R
X XX
YY Y
ZZ
XX
YY
ZZ
A
B
C
A
B
C
M-S
R
A
R
OP10 OP30~OP170 OP20 OP175~
M-S Cy
3 175 3 175 ,
2 30 2 ,
1 30 1 30 ,
proc mt OP tool loc OP Cy S M
proc mt OP tool R S M
proc mt OP tool loc OP A S M
A + A + A + A = A
A + A + A = A
A + A + A + A = A

Summary
A comprehensive tolerance analysis framework is established
for machining system planning and verification.
Tolerance stackup analysis has been studies for non-rotational
part.

Three tolerance decomposition models are developed for intra-
and inter-setup analysis.
An inter-setup tolerance stackup algorithm have been
implemented.
The calculation of locating errors has been implemented.
The analysis is integrated in CAD/CAM

Acknowledgement: Dr. Y. Zhang and Dr. W. Hu contributed to the earlier
work of the project.