Tolerance interpretation

Agenda
Introduction to tolerance interpretation
Tolerance stacks
Interpretation

Tolerance interpretation
Frequently a drawing has more than one
datum
How do you interpret features in secondary or
tertiary drawing planes?
How do you produce these?
Can a single set-up be used?

TOLERANCE STACKING
Case #1
1

1.0.05

1.5.05

1.0.05

What is the expected dimension and tolerances?

D1-4= D1-2 + D2-3 + D3-4
=1.0 + 1.5 + 1.0
t1-4 = (.05+.05+.05) = 0.15

TOLERANCE STACKING
Case #2
1

1.0.05

1.5.05
3.5.05

What is the expected dimension and tolerances?

D3-4= D1-4 - (D1-2 + D2-3 ) = 1.0
t3-4 = (t1-4 + t1-2 + t2-3 )
t3-4 = (.05+.05+.05) = 0.15

TOLERANCE STACKING
Case #3
1

1.0.05

1.000.05

3.500.05

What is the expected dimension and tolerances?

D2-3= D1-4 - (D1-2 + D3-4 ) = 1.5
t2-3 = t1-4 + t1-2 + t3-4
t2-3 = (.05+.05+.05) = 0.15

From a Manufacturing Point-of-View

Case #1
1

1.0.05

1.0.05
?

1.0.05

Lets suppose we have a

wooden part and we
need to saw.
Lets further assume
that we can achieve .
05 accuracy per cut.

How will the part be produced?

Mfg. Process
3
2

Lets try the following

(in the same setup)
-cut plane 2
-cut plane 3

Will they be of appropriate quality?

So far weve used Min/Max

Planning
We have taken the worse or best case
Planning for the worse case can produce
some bad results cost

Expectation
What do we expect when we manufacture
something?
PROCESS
DRILLING
REAMING
SEMI-FINISH
BORING
FINISH BORING

DIMENSIONAL
ACCURACY
+ 0.008
- 0.001
+ 0.003
+ 0.005
+ 0.001

POSITIONAL
ACCURACY
0.010
(AS PREVIOUS)
0.005
0.0005

COUNTER-BORING
(SPOT-FACING)

+ 0.005

0.005

END MILLING

+ 0.005

0.007

Size, location and orientation are

random variables
For symmetric distributions, the most likely
size, location, etc. is the mean

2.45 2.5

2.55

What does the Process tolerance

chart represent?
Normally capabilities represent + 3 s
Is this a good planning metric?

An Example
Lets suggest that the cutting process produces (,
2) dimension where (this simplifies things)
=mean value, set by a location
2=process variance
Lets further assume that we set = D1-2 and that
=.05/3 or 3=.05
For plane 2, we would surmise the 3of our parts
would be good 99.73% of our dimensions are good.

We know that
(as specified)
D2-3 = 1.5 .05
If one uses a single set up, then
(as produced)
and
.95 1.0

D1-2

1.05
D1-2

2.45 2.5

2.55

D1-3

D2-3 = D1-3 -

D1-2

What is the probability that D2-3 is bad?

P{X1-3- X1-2>1.55} + P{X1-3- X1-2<1.45}
Sums of i.i.d. N(,) are normal
N(2.5, (.05/3)2) +[(-)N(1.0, (.05/3)2)]= N (1.5, (.10/3)2)
So D2-3

1.4

1.5

1.6

The likelihood of a bad part is

P {X2-3 > 1.55}-1 P {X2-3 < 1.45}

(1-.933) + (1-.933) = .137

As a homework, calculate the likelihood that

D1-4 will be out of tolerance given the same

logic.

What about multiple features?

Mechanical components seldom have 1
feature -- ~ 10 100
Electronic components may have
10,000,000 devices

Suppose we have a part with 5 holes

Lets assume that we plan for + 3 s for each
hole
If we assume that each hole is i.i.d., the
P{bad part} = [1.0 P{bad feature}]5
= .99735
= .9865

Success versus number of features

1 feature = 0.9973
5 features = 0.986
50 features = 0.8735
100 features = 0.7631
1000 features = 0.0669

Should this strategy change?