i2
- Course Outline –
Tolerance Stack-up Analysis using Co-ordinate system of Dimensioning
and GD&T (GD&T as per ASME Y14.5M:1994)
Two Days Course For
Maruti Suzuki Limited, INDIA
By
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(InterOperability & InterChangeability Solutions, Pune)
Course Objectives:
The course is designed to introduce the Tolerance Stacks and analysis through goal setting and initiatives
and is recommended for those who are already familiar with fundamentals of GD&T. The Tolerance Stack
up analysis course has following objectives:
Increasing designer’s understanding of part functioning, assembly relationships.
Predict and Solve assembly build problems well in advance than at prototype or production stage.
Appreciating Tolerance Stack-up as decision making tool at early design stage
Evaluating various proposals and ECRs / ECNs
Increasing Designers understanding of Geometric Dimensioning & Tolerancing (GD&T)
Ability to calculate stack-ups for single part and multi part assemblies having +/- tolerances as well as
GD&T
It is expected that the participants have basic knowledge of engineering drawing practices/
fundamental rules and Fundamentals of GD&T.
Course Duration:
Two Full Days (16hrs).
Courseware:
We recommend you to purchase a a book “Tolerance Stack-up Analysis” by James Meadows. You can
purchase the same directly from publisher in USA or we can arrange to purchase the book on your behalf.
One soft/hard copy of the courseware will be provided to you to duplicate at your end. Relevant examples
and exercises of single part and assembly stacks using co-ordinate dimensioning and GD&T shall be
covered in the training.
The Basics of Tolerance Stacks:
Definition of Stacks
Where to begin a stack?
Positive and negative routes
Objectives (what are we calculating?)
Which dimensions are factors?
Arranging parts to create the worst case configuration
Which geometric tolerances affect or don’t affect goals?
Calculating mean dimensions
Calculating boundaries for GD&T controls having MMC, LMC and RFS Material Condition modifiers
Converting dimensions to Mean boundaries with equal bilateral tolerances
Loop Analysis: Creating Vertical and Horizontal Loops for FOS (Feature of
Size):
Where to start and end?
Creating the loop
Minimum and maximum gap analysis
Assemblies with parts having Plus/Minus (+/-) Tolerances:
Multiple dimension loops
Positive and negative values
Airspace vs. material interferences
Studying an Assembly with Floating Fastener:
Understanding Resultant conditions
Understanding Virtual conditions
Understanding Inner and outer boundaries
Mean boundaries
Converting to radii
Combining planer features and diameters
Complex loop analyses with GD&T
Studying an Assembly with Fixed Fastener:
Calculating overall minimum and maximum assembly dimensions
Combining slots, tabs, holes and shafts
Calculating minimum and maximum gaps within the assembly
Projected tolerance zones for total runout as a factor
Determining if geometric tolerances are a factor
Analyzing an Assembly having:
o Threaded Fixed features
o Multiple geometric controls
o Projected tolerance zones
Gaps with and without perpendicularity as a factor
Calculating interference
Theoretically vs. Physically worst case possibilities
Applying assembly logic and Factoring in assembly conditions
Understanding Part Stacks:
Performing a single part analysis. The part consists of various controls such as:
o Two-single segment positional controls,
o Switching datum reference frames and accumulating geometric tolerances,
o Datum features at MMC (pattern shift),
o Profile tolerances, Flatness,
o Envelopes of perfect form at MMC,
o Creating envelopes of perfect orientation at MMC
o MIN and MAX axial separation
o Datum planes vs. datum features
