this course, participants will be able to:
Calculate minimum and maximum wall thickness, airspaces and interferences
Create loop analysis/circuit diagrams for tolerance stack up analysis for
both plus and minus toleranced dimensions and geometric tolerances.
Create both simple and complex number charts for stack-up analysis using
a variety of geometric tolerances, basic dimensions, resultant conditions,
virtual conditions and plus and minus toleranced dimensions.
Do tolerance stack up analysis for floating fastener assemblies for
clearance holes, screws and shafts.
· Do tolerance
stack up analysis for fixed fastener assemblies using
screws, clearance holes, slots, tabs, overall dimensions and projected tolerance
zones for threaded holes.
Calculate minimum and maximum gaps for assemblies that use a variety of
Learn a system of logic and mathematics to analyze geometric tolerances.
Calculate the effects of angular stack-up using trigonometry and
Calculate statistical geometric tolerances using a variety of methods and learn
how to re-integrate these geometric tolerances back into the assemblys details.
GD&T Level 1
This course is directed to anyone with the professional
responsibility of analyzing or applying geometric tolerances to assemblies, or
anyone seeking a more thorough understanding of tolerance analysis.
Attendees should have a basic working knowledge of ASME
Y14.5. A knowledge of
GD&T principles is required to allow all participants to be
successful in learning the techniques of tolerance stack up analysis. [Each
course participant needs to bring a hand-held calculator.]
WILL THIS COURSE COVER?
participants will be trained to apply tolerance stack up analysis techniques to
a wide variety of assemblies, from the very simple to the more complex
situations commonly faced in industry today.
Both plus and minus and geometrically toleranced assemblies will be
examined and stack up analysis taught and practiced on each.
Many different datum structures will be discussed and analyzed.
The concepts taught in this course are:
loop analysis (also known as circuit diagrams), number charting, virtual
condition, resultant condition, inner and outer boundaries, minimum airspace,
maximum wall thickness, maximum interference, minimum and maximum overall
dimensions, fixed and floating fastener assembly conditions, projected geometric tolerance
zones, the logic of tolerance stack up analysis, statistical tolerancing , and much more.
Edition of the Tolerance Stack-Up Analysis (January 2010) text is easier to
understand, and (in the text as well as training sessions) includes more
discussion on what can go wrong, shows how to tell right from wrong stack-up
routes, and includes more on Statistical Analysis, as well as Worst Case
Tolerance Stack-Up Analysis. This revision reads smoother
and adds information that eases the learning process. The terminology in this
2nd Edition has been updated to comply with ASME Y14.5-2009.
length of 3 days.
Tolerance Stack Up Analysis [for Plus and Minus
and Geometric Tolerancing] 2nd Edition text/workbook-answerbook. This text is
per the ASME Y14.5-2009 and 1994 standards.
OUTLINE: The course
outline follows the Table of Contents listing, chapter by chapter.
TEXT CONTENTS (chapter by
#1 THE BASICS
Where to begin a stack
Designating positive and negative routes
What are you calculating?
What dimensions are factors
How to push the parts to create the worst case
Which geometric tolerances are and are not factors
Finding the mean
Calculating boundaries for GD&T, MMC, LMC and RFS Material Condition
Mean boundaries with equal bilateral tolerances
#2 STACK-UP ANALYSIS OF AN ELEVEN
PART ASSEMBLY USING PLUS AND MINUS TOLERANCING
The loop analysis chart
The numbers analysis chart
Finding MIN and MAX gaps
#3 VERTICAL vs. HORIZONTAL LOOP
ANALYSES FOR FEATURES OF SIZE
Where to start and end
Graphing the loop
Minimum and maximum gap analysis
#4 ASSEMBLIES WITH PLUS AND MINUS
Multiple dimension loops
Positive and negative values
Airspace vs. interferences
#5 FLOATING FASTENER FIVE PART
Inner and outer boundaries
Converting to radii
Mixing widths and diameters
Complex loop analyses with geometric dimensioning and tolerancing
#6 FIXED FASTENER ASSEMBLIES
Calculating overall minimum and maximum assembly dimensions
Mixing 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
Ruling out features and patterns as factors
#7 A RAIL ASSEMBLY
Multiple geometric controls
Projected tolerance zones
Gaps with and without perpendicularity as a factor
Theoretically vs. physically worst case possibilities
When logic becomes an integral step
Factoring in assembly conditions
Maximum wall thickness vs. minimum airspace for assemblies
#8 SINGLE-PART ANALYSIS
Two-single segment positional controls
Switching datum reference frames and accumulating geometric tolerances
Datum features at MMC (pattern shift)
Envelopes of perfect form at MMC
Creating envelopes of perfect orientation at MMC
MIN and MAX axial separation
Datum planes vs. datum features
Separate requirements and accumulating tolerance
Tolerances in degrees; Trigonometric function introduction
Composite positional tolerancing
#9 FIVE PART ROTATING ASSEMBLY
Threaded holes with projected tolerance zones
Part to part analysis (from two parts to an infinite number of parts
Simplifying a complex assembly
Determining assembly housing requirements
Radial clearance MIN and MAX calculations
#10 TRIGONOMETRY AND PROPORTIONS
IN TOLERANCE STACK-UP ANALYSIS
Rocking datum features
Constructing a valid datum
Consideration of differing orientations from measurement to assembly
An in-depth assembly analysis using trigonometric functions
Computer programs vs. a personal analysis
Vertical stacking as it effects horizontal housing requirements
When stacked parts are not flat or parallel
Formulae to calculate worst case fit conditions when trigonometry is a
Using proportions and trigonometry to calculate fit conditions beyond the GD&T
#11 THE THEORY OF STATISTICAL
Gaussian Frequency Curve
Plus or Minus 3 Sigma
Root Sum Square Formula
Steps to Calculate and Apply Statistical Tolerances
Statistical Tolerancing Applied to Plus and Minus Toleranced Assemblies
Statistical Tolerancing Applied to Geometric Toleranced Assemblies
When Best to Allow Statistical Tolerances and When it Should Not Be Allowed
The Logic of Statistical Tolerancing
Modifying the Root Sum Square Formula with a Safety/Correction Factor
Reintegrating the Statistical Tolerance into the Assembly