TOLERANCE

STACK-UP
ANALYSIS
 INTRODUCTION
MERITS OF TOLERANCE STACK-UP ANALYSIS
STEPS IN TOLERANCE STACK-UP ANALYSIS
PROBLEM
TOLERANCE STACK-UP EXAMPLE
CONTENTS TOLERANCE STACK-UP REPORT
DIMENSIONAL CHAIN ANALYSIS
EQUIVALENT TOLERANCE METHOD
EQU. STD. TOLERANCE GRADE METHOD
PROBLEMS
SOLUTIONS
Introduction
What Is a Tolerance?
Option 1
A tolerance specifies how close to the nominal (or exact) location, size,
form or orientation a feature on a part must lie.
Option 2
A tolerance specifies the range of acceptable deviation for a feature on a
part.
Option 3
According to Merriam–Webster’s Collegiate Dictionary (11th edition):
“The allowable deviation from a standard; especially the range of
variation permitted in maintaining a specified dimension in machining
a piece.”

Final Answer:
A tolerance is the specified amount a feature is allowed to vary from
nominal. This may include the form, size, orientation or location of
the feature as applicable.
Tolerance Stack-up

 Tolerance Analysis is a,
o is a study of individual tolerances
o process of determining the cumulative variation
possible between two or more features
 Tolerance stack up analysis is one part of
tolerance analysis
 It analyzes and predicts the variation between
the parts
 Determines the maximum possible variation
between two components in an assembly
Merits of Tolerance Stack-
up
 Optimize the tolerances of parts and assemblies in a design
 Balance accuracy, precision and cost with mfg. processes
 Determine the part tolerance required to satisfy a final assembly condition
 Determine allowance part tolerance if assembly tolerance is known
 Determine the effect changing a tolerance will have on assembly component
 Steps of Tolerance Stack-up
The nominal distance is found out
The distance to be studied A tolerance stack up by subtracting -ve direction total The maximum and
is identified and labelled sketch is created from the +ve direction total minimum variation are
obtained from the
nominal distance and
total variation values

The nominal
The maximum and
The dimensions in distance is found
The distance to be The total possible minimum variation
The positive and A tolerance stack positive direction out by subtracting
studied is variation is are obtained from
negative directions up sketch is and negative negative direction
identified and obtained by adding the nominal
are identified created directions are total from the
labelled all tolerances distance and total
added individually positive direction
variation values
total

The positive and negative The dimensions in +ve and -ve The dimensions in +ve and -ve
directions are identified directions added individually directions added individually
 Tolerance Stack-up
1 = Identified and Labelled

2 = +ve and –ve Directions

3 = Tolerance Stack-up Sketch

4 = Dimns in +ve and –ve directions

5 = Find nominal distance: subtract –ve totals from +ve totals

6 = Add all tolerances to get total possible variation

7 = Obtain Max and min variations from nom. Distance and total
variation values
Tolerance Stack-up
Problem - 1
Tolerance Stack-up
Problem – 1 > Solution
Tolerance Stack-up
Problem – 2A

Inseparable Assembly
(Weldment)
Tolerance Stack-up
Problem – 2A > Solution
Tolerance Stack-up
Problem – 2B

Bolted Assembly
Tolerance Stack-up
Problem – 2B > Solution
Tolerance Stack-up
Problem – 2B > Solution