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Tolerance Stackup Analysis Statistics By Dr N Dr. N. Ramani
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At the end of this Training, the participant should be able to: 1. Master basic Tolerance Types & Tolerance Concepts 2. To do basic Stack-up Analysis Techniques for 100% & 99.7% Interchangeability 3. Do a formal Tolerance stack-up analysis for Documenting d i C design Conditions diti 4. Determine if statistical Interchangeability will give a lower cost product 5. Determine if larger tolerance zones can meet Design requirements 6. Understand the Principle of ‘Robust Design’
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Case of 100% infallible interchangeability no matter the cost : Safety is of paramount importance
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Whyy do we require to do Tolerance Analysis? y
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Why do we require to do Tolerance Analysis? 1. To determine whether the parts will assemble 100% of the time or only 99.7% of the time statistically? 2. To determine if the parts will function properly att worstt condition diti 3. To determine if the drawing tolerances could be larger 4. To complete p the design g p process 5. To provide a record of the dimensional design requirements that can be reviewed at a later date in case of a product problem 5
Assumptions while doing Tolerance Analysis: 1.All dimensions apply at 20oC 2.All 2 All manufactured f t d parts t meett dimensional requirements of drawing 3.All parts are rigid in free state & in asse b y assembly 4.For , parts are manufactured ST with ith th the mean di dimension i as T Targett
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What are the Types of Tolerance Analysis?
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What are the Types of Tolerance Analysis? 1. Radial Stack – 2 Linear Stack – 2. 3. Assembly Stack – What do they do?
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What are the Types of Tolerance Analysis? 1. Radial Stack – Involves diameters or radial directions 2. Linear Stack – Involves dimensions that are in X,Y , or Z direction 3. Assembly Stack – Involves radial or linear directions of several parts Give a pictorial example for each type
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•Example of a Radial Stack , •R,Θ 10
X
Find the Dimension & Tolerance of ‘X’ for +/-3 +/100% 3 Sigma IInterchangeability t conformance h bilit Example of a Linear Stack
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?
Assemblyy Stack 12
100 $ 100 $
?$
COST
100% Interchangeability
99.7% Interchangeability
Estimate E ti t the th costt for f 99.7% 99 7% interchangeability i t h bilit Please write down your answer
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100 $ 100 $
?$
COST
100% Interchangeability
99.7% Interchangeability
Estimate the cost for 99.7% interchangeability
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1. Let us say that there is a possibility to reduce cost substantially, if you are prepared to accept 99.7% Interchangeability, in place of 100% 2. Let us say that cost saving will more than offset the loss of 0.3% Interchangeability (3 out of 1000 assemblies)) 3. Please answer the question, at what reduced cost, you will accept 99.7% Interchangeability
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100 $ 100 $
Cost Saving
?$ COST
100% Interchangeability
99.7% Interchangeability
At what reduced cost, you will accept 99.7% Interchangeability?
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100 $
COST
< 20 $
100% Interchangeability
!
99.7% Interchangeability
Based on Statistical Principles!
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100% Interchangeability 18
Assumption “Extreme assembly conditions can and will be met in practice”
100% Interchangeability 19
Effect of component tolerances upon the assembly Assumption “Extreme assembly conditions can and will be met in practice”
100% Interchangeability 20
Effect of component tolerances upon the assembly
Functioning g of finished product
Assumption “Extreme assembly conditions can and will be met in practice”
100% Interchangeability 21
Highest
Si off ‘B’ P Size Partt Lowest ‘B’
Lowest ‘A’
Highest
Size of ‘A’ Part 22
C min
C max
B min
B max
A min i
A max
Assemblyy of 3 Parts
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How does Insurance Business function?
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Effect on Assembly
1 2 3 4 5 6 7 8 9 10 Number of Parts / Feature Dimensions Affecting Assembly 25
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•Assembly tolerance = Sum of all tolerances of the individual parts (OK for 2 or 3 parts…)
•One One method is to provide the widest practical component tolerances based upon the statistical fact that it is unlikely that all maximum-tolerance parts or all minimum-tolerance parts would ever be brought together in the same assembly.
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Objectives of this presentation: 1
Preferred component tolerances (Based on p & Cpk) p ) Cp
Worst case assembly variation for 100% & 99 99.7% 7% Interchangeability
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?*
* For 100% Interchangeability 30
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X
Find the Dimension & Tolerance of ‘X’ for +/-3 Sigma conformance 100% Interchangeability
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Stage 1. Covert all Dimensions to be Median values & Tolerances into Bilateral ones 34
Start
End 2 4
3
1
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Plus Minus Direction Direction +/Distance Distance Tolerance A# 'B' 'C' 'D' 1
Stage3: Tabulate Analysis
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0.2175 2.62
0.0025 0.01
3
0.42
0.01
4
1.8985
0.0025
2.536
0.025
2.62
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0.084
0.025
Introduction to Normal Distribution
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100% Successful Interchangeability
X σ?
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Please remember the value of tolerance!
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6 100% Success
6σ (?)
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6σ
2.63 / 2.61
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Cf 100% Vs 99.7% Interchangeability
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Comparison bet between een 6 6σ &3σ &3 Limits #
Sigma g Value
Tolerance
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6 (100% I t h Interchangeability) bilit ) 3 ((99.7% Interchangeability)
+/-0.0250
2
+/-0.0146
Which is better from Assembly point of view? Lesson? 47
Compare the g two drawings A
B 48
X
Calculate the Dimension & Tolerance for the Circlip Groove @ 100% & 99.7% 99 7% Interchangeability
B
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Cf between 100% & 99.7% Interchangeability
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Comparison bet between een 6 6σ &3σ &3 Limits #
Sigma g Value
Tolerance
1
6 (100% I t h Interchangeability) bilit ) 3 ((99.7% Interchangeability)
+/-0.0500
2
+/-0.0250
Which is better from Assembly point of view? Cf Cost also 51
#
Sigma Value
Tolerance
1
6 (100% Interchangeability) 3 (99.7% Interchangeability)
+/-0.0500
2
+/-0.0250
Determine the relationship between Assembly (resultant) tolerance of +/-0.025 & four tolerances of part viz.0.0125
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(Assembly Tolerance)2 { Number of Parts * (Part Tolerance)2 } Part Tolerance = Assembly Tolerance / Sq.Rt of N, where N is the number of parts or dimensions involved Very Important to note: Assembly Variance = Arithmetic sum of Variances of Parts σ2 Assembly A bl
=Σ (n ( 1 * σ12) off Parts P vide id CLT
∴ Assembly Tol
= Part Tolerance *√n 53
#
Sigma Value
Tolerance
1
6 (100% Interchangeability) 3 (99.7% Interchangeability)
+/-0.0500
2
+/-0.0250
Assembly tolerance of +/-0.025 = 2 * 0.0125 =
(√4
*0 0.0125) 0125)
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TSA Vs STA
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ST? Super Structure
ST ?
Foundation 57
Assigning of Tolerances to related components p of an assembly Super Structure
ST Assembly Tolerance = RMS value of Individual Tolerances
Foundation 58
Process Control: 1. Must be maintained on any statistical tolerance vide ASME Y14.5 standard 2. Symbol drawn next to dimension 3 Not shown in our drawings 3. 4. Operations / QC will maintain Statistical control t l off process
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What are the benefits of Statistical Tolerancing?
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Benefits of ST: 1. Reduced costs 2. Closer average Fits 3. Improved Quality / Performance of Product • Sony USA Vs Sony Japan Story
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When should we apply ST?
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When should we apply ST? 1. Limited Space requires a close assembly tolerance 2. Fits with a narrow range of Clearance required 3 100% Interchangeability not possible 3. 4. Means of reducing manufacturing cost 5. To reduce Tolerance Accumulation • Selective assembly required • Adjustments / complex designs required • Tighter tolerances on components required 63
When should we apply ST? •What if Analysis? •You want to know what will be the condition for 99.7% of parts if manufactured around the mean of dimensions
TSA Vs STA
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When will ST succeed?
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When will ST succeed? 1. Manufacturing is done to the middle of the dimension 2. Use of proper controls to produce parts to a near normal distribution within drawing specification
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Responsibility for achieving ST: 1. Engineers understand that parts are to be produced with the ‘Target on the mean’ 2. Tools are designed & produced to achieve the above target* 3. Necessary inspection equipment are available ((In process p gauging..) g g g ) to determine Cp & Cpk *Reamer Design Example
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Normal Distribution: 1. Formed where manufacturing processes produce in a random manner about the mean with a majority of the dimensions close to the mean & a decreasing number occurring away from the mean 2. If dimensions from a stable process are measured & recorded according to size, a plot of resulting frequency distribution will approximate the Gaussian curve
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0.084+/-0.05 @ 100% Interchangeability
0.084+/-0.025 @ 99.7% Interchangeability
You cant have something…….
CLT?
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Conclusion?
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• Four tolerance zones can be increased & still meet original design requirements of 0.084+/-0.025 using g 99.7% p probability y
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1 Four tolerance zones can be increased & still 1. meet original design requirements of 0.084+/-0.025 using g 99.7% p probability y 2. How did we get to suggest +/-0.0125 tolerance?
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1 Four tolerance zones can be increased & still 1. meet original design requirements of 0.084+/-0.025 using g 99.7% p probability y 2. How did we get to suggest +/-0.0125 tolerance? 3. From CLT formula: 4. Tol of p parts / features = Tol of Assy y / ((Sq.rt q of number of parts or features)
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100%
99 7% 99.7%
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Is it possible to relax manufacturing tolerances on all 5 di dimensions* i * & still till achieve hi assembly bl ttargett off 0.034 +/-0.022, thereby reducing cost * +/- 2,3,4,5 & 8 thous
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1. We have relaxed original tolerances of +/- 2,3,4,5 & 8 thous to +/ +/- 0.010 0 010 2. Check correctness of Calculations 3. How did we get proposed tolerance of 0.010?
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Dim.Tolerance = (assembly Tolerance / Sq.rt of number b off di dimensions i iinvolved) l d) = 0.022 / √ 5 = 0.010
Very Important
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Part 3
P t1 Part Part 2 •You are the designer of this assembly •The top surface of part 1 is to be proud of the top surface of part 3 by 0.0005 – 0.018 •Determine the Unknown Length & fix tolerances of the di dimensions i off parts t 2 & 3 tto achieve hi th the objective bj ti ffor 100% interchangeability 80
1. Average Axial Clearance = (0.0005+0.018) / 2 = 0.00925 Nominal 2. Total Tolerance = (0.018 - 0.0005) = 0.0175 = +/- 0.00875 3. Target Clearance = 0.00925 +/- 0.00875 (Check max & min values) 4. Nominal Unknown Length = (0.250+0.125+0.00925) = 0.384(approx) 5. Tolerance of Dimensions 0.384, 0.250 & 0.125 = +/- 0.00875 / 3 = +/- 0.0029
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Part 3
P t1 Part Part 2 •You are the designer of this assembly •The top surface of part 1 is to be proud of the top surface of part 3 by 0.0005 – 0.018 •Determine the Unknown Length & fix tolerances of the di dimensions i off parts t 2 & 3 tto achieve hi th the objective bj ti ffor 99 99.7% 7% interchangeability 82
Part Tolerance = Assembly tolerance / √ n = 0.0175 / √3 = 0.010 0 010 = +/- 0.005 Rechecking:
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Determine Assembly Gap for 100% of cases
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T Transition iti b between t Max Clearance
0.0275
Max Interference 0.0035 88
Determine Assembly Gap for 99.7% of cases
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Thank You
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