Tolerance Analysis

By Chiu Wing Chuen, Mar 9,2004

 Tolerance Analysis Models and
Practice
1. Worst Case Stack-Up

2. Statistical Stack-Up

3. Limitations of Worse Case and Statistical

4. Correction for Worse Case

5. Correction for Statistical Models

6. HybridEstimated Mean Shift Model

7. ExampleA285 Gear Box
1. Worse Case Model for Assembly Tolerance
Assembly tolerance, TASM, is determined by summing
component tolerances, Ti, linearly, assuming each
component dimension is at its max. or min. limit.
n f
TASM Ti
i 1 xi

Xi : nominal component dimension

f(xi): assembly function describing resulting dimension
of the assembly such as clearance or interference.
2. Statistical Model for Assembly Tolerance
TASM is determined by root sum squared component tolerances.
The low probability of worst case combination occurring is
taken into account statistically, assuming a normal distribution
for component variation.
2
n f 2
TASM Ti
i 1 xi

2
f
More general case : Ti / Zi 2
n
TASM Z
i 1 xi

Z: number of standard deviation expected for assembly, e.g., 3 , 4 , 6
Zi: number of standard deviation expected for component.
3. Limitations of Worse Case and Statistical
3.1 For the same assembly tolerance target, worse case
models results in component tolerances which are tight
and costly to produce, while statistical model allows
much looser component tolerance, but often predicts
higher assembly yield than actually occur in production.

3.2 For the same component tolerances, worst case

stacking underestimates assembly yield with too large
assembly tolerance , while statistical stacking
overestimates assembly yield with lower assembly
tolerance than actual.
So, correction factors are added to make the models more
applicable.
4. Corrections for Worse Case
Worst case model with correction:
n f
TASM K Ti
i 1 xi
K :correction factor n: number of components

K 1.6
n

n 2 3 4 5
K 1* 0.92 0.80 0.72

*: If n=2, K=1.0
5. Corrections for Statistical Models
Statistical model with correction:
2
n f 2
TASM Cf Ti
i 1 xi

Cf: correction factor for any non-ideal conditions. Typical

value: 1.4, 1.5
More general case :
2
f
Ti / Zi 2
n
TASM CfZ
i 1 xi

 6. HybridEstimated Mean Shift Model
6.1 Principles:
Statistical model assumes manufacturing variations follow a
Normal distribution, symmetrically positioned at the midpoint of
the tolerance limits, not taking into account possible bias which
are common in manufactured parts.

Virtually all manufacturing processes exhibit bias. Bias can occur

from tooling or fixture errors, setup errors or tool wear. It may
deliberately introduced during setup to compensate for tool wear.
Some process are more prone to bias than others. Bias results in
a shift of the nominal dimension.

Bias can accumulate in an assembly and cause unexpectedly

high rejection rate.

Estimated Mean Shift Model includes estimation of expected bias

for component manufacturing
 6. HybridEstimated Mean Shift Model
6.2 Approaches:
6.2.1 Define a zone about the midpoint of the tolerance range as
shown below, which is the probable location of the mean of a
typical batch of parts.
 6. HybridEstimated Mean Shift Model
6.2 Approaches:
6.2.2 The midpoint tolerance zone is expressed as Mean Shift
Factor, a fraction of the specified tolerance range for the
part dimension (a number between 0 and 1.0).
If the process to be used to produce the part is closely
controlled, a low mean shift factor may be selected, say 0.1
to 0.2.

For less well-known processes, such as a part supplied by

a new vendor, a larger factor, say 0.7 or .8, could be
selected to account for the uncertainty.

For common processes the factor could be selected on the

basis of prior history from quality assurance data.
 6. HybridEstimated Mean Shift Model
6.2 Approaches:
6.2.3 Once the range of mean shift has been estimated for
each component the assembly tolerance can be
calculated using the following model:

2
f f
mi 1 mi x Ti
2
TASM Ti
xi i
mi: mean shift factor for the ith component

The first term is the sum of the mean shifts added as a worst limit.
The second term is the sum of the component tolerances added
statistically. Summation of the mean shift or bias (term 1) and
part tolerance or variance (term 2) contribute to assembly
tolerance.
 6. HybridEstimated Mean Shift Model
6.3 Special cases:
when all the mean shifts of components are chosen as zero.
The resulting assembly tolerance reduces to the simple
statistical model
2
n f
TASM Ti 2
i 1 xi

If all the mean shifts of the components are chosen equal

to 1.0, it reduces to a worst limit model.
n f
TASM Ti
i 1 xi
Thus, the Estimated Mean Shift model can simulate the
entire continuum between these two extremes.
 6. HybridEstimated Mean Shift Model
6.4 Other advantages
Full flexibility to mix Mean Shift Factors in an assembly.
Some parts may be nearly worst case, while others nearly
straight statistical. Worst and statistical tolerancing can be
combined for more reasonable assembly tolerance analysis.

Flexibility to control component variance to hit assembly

target by fine-turn of Mean Shift Factors from EB to MS.
Early in design stage, when little manufacturing data are
available, conservative shift factors may be assigned. Later,
during production, as data becomes available, manufacturing
systems analysts may substitute more precise values. This may
allow tolerances to be loosened up so that production rates can
be increased. Mean Shift factors can vary from simple
worse limit to simple statistical as shown in the figure in
next page.
 7. ExampleA285 Gear Box
7. A285 Gear Box Tolerance Analysis
7.1 Component tolerances and assembly function
X2 X3 X4

Gap
X1
Front Housing Ring Gear Washer Rear Housing Assembly

Di Tolerance symmetrized
Spec(mm)
m spec(mm)
X1 23.60.1 23.60.1 Assembly function:
X2 19.8+0/-0.15 19.7250.075 Gap(x1, x2, x3, x4)=x1-x2-x3-x4
X3 0.70 0.03 0.700.03
X4 2.70.1 2.70.1
 7. ExampleA285 Gear Box
7.2 Gap Analysis
GAPnominal= X1-nominal - X2-nominal -X3-nominal - X4-nominal=0.475(mm)

7.2.1 Worst Case Scenario:

No correction:
TASM=T1+T2+T3 +T4=0.1+0.075+0.03+0.1=0.305(mm)
With correction ( correction factor=0.8):
TASM=K(T1+T2+T3 +T4)
=0.8x(0.1+0.075+0.03+0.1)=0.244(mm)
7.2.2 Statistical Scenario:
No correction:
TASM T1
2

T22 T32 T42 0.163(mm)
With correction (correction factor=1.5):

TASM C
f
T
1
2

T22 T32 T42 1.5 X 0.163 0.245(mm)
 7. ExampleA285 Gear Box
7.2.3 Estimated Mean Shift Scenario
7.2.3.1Engineering Sample Build

Mean Shift Factor

P/N Description Manufactured by as originally Tolerance(mm)
estimated
X1 Front Housing Die casting 0.8 0.1
X2 Ring Gear Powder metal 0.8 0.075
X3 Washer Stamping 0.8 0.03
X4 Rear Housing Plastic molding 0.8 0.1

TASM =0.8(T1+T2+T3 +T4 )+0.2SQRT (T12+T22+T32 +T42 )

=0.8*0.305+0.2*0.163=0.277(mm)

Gap=0.4750.277(mm)
 7. ExampleA285 Gear Box
7.2.3.2 Pilot Run and Initial Production
Unit:mm
Mean Shift Mean Shift
Mean as
P/N Description Manufactured by Spec CP Factor as Factor as re-
measured
calculated estimated
Front 23.60
X1 Die casting 23.63 1.82 0.15 0.2
Housing 0.1
19.725
X2 Ring Gear Powder metal 0.07 19.80 2.27 0.5 0.8
5
0.70
X3 Washer Stamping 0.71 3.33 0.16 0.2
0.03
Rear 2.70
X4 Plastic molding 2.75 1.15 0.25 0.4
Housing 0.1
TASM = (0.2*T1+0.8*T2+0.1*T3 +0.4*T4 )
+SQRT [(0.8*T1)2+ (0.2*T2)2 + (0.9*T3)2 + (0.6*T4)2]
=0.126 + 0.104 =0.230(mm)

Gap= 0.475 0.230 (mm)