Tolerance Stack-up Analysis

Tolerance Stack-up Analysis for Mechanical Design

Course outline and objective:
Mechanical designs can be complex involving numerous parts and sub-assemblies. In the manufacture of these parts and sub-assemblies, they are subjected to variation. Hence, a better understanding of their form, fit and function is vital. For better clarity and quality acceptance, more firms are now specifying their engineering drawings using GD&T symbols so as to better control its geometric and functional characteristics. 
Tolerance stack up methods are then used to ensure that the cumulative effects of these tolerances are acceptable to the functional aspects in a sub-assembly. 
Education wing of Quality Growth Services Pvt Ltd., has always been pioneer in assisting industries in elevating the competence of the personnel and promoting Operational Excellence and Quality Culture among the industries in India and abroad over the decade. 
We, pleasantly, take the opportunity to announce an one day basic training cum workshop on ‘Tolerance Stack-up Analysis for Mechanical Design’ 


Course Objective:
Explain various tolerances available in +/-system and GDT system such as part size tolerance, Bonus tolerance and datum shift.
Explain the relationship between piece-part tolerances and final part assembly tolerances and performance goal
Understand parts variation and source of variation and these variations affect assembly variation and cost
Explain the differences, the benefit, strength and weaknesses, and advantage/disadvantage between the various stack-up analysis methods.
Understand relationship between statistical distributions, nominal values, standard deviations and its effect to the final assembly tolerances.


Who should attend:
Engineering Managers
Product Designers
Process and Tooling Engineers and Technical Personnel 


• Knowledge or able to read technical drawing
• Able to read part drawings and assembly drawings
• Completed GD&T Training
• Calculators or Scientific Calculator

Course Content


Module 1: Basics
  • Overview of Dimensions and Tolerance Dimensions / Tolerance formats
  • Converting to equal bilateral format
  • Overview of Size Tolerances, Bonus Tolerances and Datum shift
  • Statistical Distribution-Nominal value and variation ( +/-3 sigma form mean)

Module 2: Analyzing Tolerance Stack-up for +/- Dimension
  • Establishing Performance/Assembly Requirements 
  • Loop Diagram
  • Converting Dimensions to Equal Bilateral 
  • Calculating the Mean Value (Gap) for the Requirements
  • Determine the Method of Analysis 
  • Calculating the Variation for the Requirement 
  • Worst Case Tolerancing Model 
  • RSS Model
  • Modified Root Sum of the Squares Tolerancing Model

Module 3: Analyzing Tolerance Stack up for Geometric Tolerances
  • Form Stackup 
  • Orientation Stackup 
  • Position Stackup and MMC and RFS 
  • Runout 
  • Concentricity/Symmetry 
  • Profile


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