Department of Mechanical Engineering, The Ohio State University

Sl. #1
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Tolerance Design
Department of Mechanical Engineering, The Ohio State University
Sl. #2
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Design Specifications and Tolerance
- Develop from quest for production quality and
efficiency

- Early tolerances support designs basic
function

- Mass production brought interchangeability

- Integrate design and mfg tolerances
Department of Mechanical Engineering, The Ohio State University
Sl. #3
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Definition

The total amount by which a given
dimension may vary, or the difference
between the limits
- ANSI Y14.5M-1982(R1988) Standard [R1.4]
Source: Tolerance Design, p 10
Department of Mechanical Engineering, The Ohio State University
Sl. #4
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Affected Areas
Product Design Quality Control
Manufacturing
Engineering
Tolerance
Department of Mechanical Engineering, The Ohio State University
Sl. #5
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Questions
- Can customer tolerances be
accommodated by product?

- Can product tolerances be
accommodated by the process?
Department of Mechanical Engineering, The Ohio State University
Sl. #6
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Tolerance vs. Manufacturing Process
- Nominal tolerances for
steel
- Tighter tolerances =>
increase cost $
Department of Mechanical Engineering, The Ohio State University
Sl. #7
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Geometric Dimensions
- Accurately communicates the function of part

- Provides uniform clarity in drawing delineation
and interpretation

- Provides maximum production tolerance
Department of Mechanical Engineering, The Ohio State University
Sl. #8
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Tolerance Types
- Size
- Form
- Location
- Orientation

Department of Mechanical Engineering, The Ohio State University
Sl. #9
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Size Tolerances
Department of Mechanical Engineering, The Ohio State University
Sl. #10
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Form Tolerances
Department of Mechanical Engineering, The Ohio State University
Sl. #11
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Location Tolerances
Department of Mechanical Engineering, The Ohio State University
Sl. #12
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Orientation Tolerances
Department of Mechanical Engineering, The Ohio State University
Sl. #13
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Tolerance Buildup
Department of Mechanical Engineering, The Ohio State University
Sl. #14
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Statistical Principles
- Measurement of central tendency
Mean
Median
mode
- Measurement of variations
Range
Variance
Standard deviation
USL
LSL
tolerance
3o
X
Department of Mechanical Engineering, The Ohio State University
Sl. #15
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Probability
- Probability
Likelihood of occurrence

- Capability
Relate the mean and variability of the
process or machine to the permissible
range of dimensions allowed by the
specification or tolerance.
Department of Mechanical Engineering, The Ohio State University
Sl. #16
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Tolerance SPC Charting
Figure Source: Tolerance Design, p 125
Department of Mechanical Engineering, The Ohio State University
Sl. #17
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Tolerance Analysis Methods
- Worst-Case analysis
- Root Sum of Squares
- Taguchi tolerance design
Department of Mechanical Engineering, The Ohio State University
Sl. #18
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Figure Source: Tolerance Design, p 93
Initial Tolerance Design
Initial
Tolerance
Design
Department of Mechanical Engineering, The Ohio State University
Sl. #19
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References
- Handbook of Product Design for Manufacturing: A Practical Guide to
Low-Cost Production, James C. Bralla, Ed. in Chief; McGraw-Hill, 1986
- Manufacturing Processes Reference Guide, R.H. Todd, D.K. Allen & L.
Alting; Industrial Press Inc., 1994

- Standard tolerances for mfg processes
Machinerys Handbook; Industrial Press
Standard Handbook of Machine Design; McGraw-Hill
Standard Handbook of Mechanical Engineers; McGraw-Hill
Design of Machine Elements; Spotts, Prentic Hall
Figure Source: Tolerance Design, p 92-93
Department of Mechanical Engineering, The Ohio State University
Sl. #20
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Worst-Case Methodology

- Extreme or most liberal condition of tolerance
buildup

- tolerances must be assigned to the
component parts of the mechanism in such a
manner that the probability that a mechanism
will not function is zero
- Evans (1974)
Department of Mechanical Engineering, The Ohio State University
Sl. #21
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Worst-Case Analysis

WC
max
= N
p
i
+ T
p
i
( )
i=1
m

WC
min
= N
p
i
T
p
i
( )
i=1
m

Source: Six sigma mechanical design tolerancing, p 13-14.

- N
e
+ T
e
=> Maximum assembly envelope

- N
e
- T
e
=> Minimum assembly envelope

Department of Mechanical Engineering, The Ohio State University
Sl. #22
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Assembly gaps

G
max
= N
e
+ T
e
N
p
i
T
p
i
( )
i=1
m

G
min
= N
e
T
e
N
p
i
+ T
p
i
( )
i=1
m

G
nom
= N
e
N
p
i
( )
i=1
m

Department of Mechanical Engineering, The Ohio State University

Sl. #23
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Worst Case Scenario Example
Source: Tolerance Design, pp 109-111
Department of Mechanical Engineering, The Ohio State University
Sl. #24
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Worst Case Scenario Example
Source: Tolerance Design, pp 109-111
Department of Mechanical Engineering, The Ohio State University
Sl. #25
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Worst Case Scenario Example
Source: Tolerance Design, pp 109-111
Largest => 0.05 + 0.093 = 0.143

Smallest => 0.05 - 0.093 = -0.043
Department of Mechanical Engineering, The Ohio State University
Sl. #26
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Non-Linear Tolerances

y = f (x
1
, x
2
, x
3
,...x
n
)

Tol
y
=
cf
cx
1
tol
1
+
cf
cx
2
tol
2
+
cf
cx
3
tol
3
+ ...+
cf
cx
n
tol
n

Nom
y
~
cf
cx
1
x
1
+
cf
cx
2
x
2
+
cf
cx
3
x
3
+ ...+
cf
cx
n
x
n
Wource: Six sigma mechanical design tolerancing, p 104
Department of Mechanical Engineering, The Ohio State University
Sl. #27
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Root Sum-of-Square
- RSS
- Assumes normal distribution behavior

Wource: Six sigma mechanical design tolerancing, p 16

f (x) =
1
o 2t
e
(1/ 2)[x)/o ]
2
Department of Mechanical Engineering, The Ohio State University
Sl. #28
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RSS method
- Assembly tolerance stack equation

f (x) = T
1
2
+T
2
2
+T
3
2
+...T
n
2
Wource: Six sigma mechanical design tolerancing, p 128
Department of Mechanical Engineering, The Ohio State University
Sl. #29
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Pool Variance in RSS

o
adjusted
=
Tol
3Cp

o
gap
=
T
e
3Cp
|
\

|
.
|
2
+
T
pi
3Cp
i
|
\

|
.
|
i=1
m

2
Wource: Six sigma mechanical design tolerancing, p 128
Department of Mechanical Engineering, The Ohio State University
Sl. #30
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Probability

Z
Q
=
QG
nom
o
gap

Z
Q
=
Q N
e
N
pi
i=1
m

|
\

|
.
|
T
e
3Cp
|
\

|
.
|
2
+
T
pi
3Cp
i
|
\

|
.
|
i=1
m

2
Wource: Six sigma mechanical design tolerancing, p 128
Department of Mechanical Engineering, The Ohio State University
Sl. #31
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Probability for Limits

Z
Gmax
=
G
max
G
nom
T
e
3Cp
|
\

|
.
|
2
+
T
pi
3Cp
i
|
\

|
.
|
2
i=1
m

Z
Gmin
=
G
min
G
nom
T
e
3Cp
|
\

|
.
|
2
+
T
pi
3Cp
i
|
\

|
.
|
2
i=1
m

Wource: Six sigma mechanical design tolerancing, p 128

Department of Mechanical Engineering, The Ohio State University
Sl. #32
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Dynamic RSS

Z
Gmax
=
G
max
G
nom
T
e
3Cpk
|
\

|
.
|
2
+
T
pi
3Cpk
i
|
\

|
.
|
2
i=1
m

Z
Gmin
=
G
min
G
nom
T
e
3Cpk
|
\

|
.
|
2
+
T
pi
3Cpk
i
|
\

|
.
|
2
i=1
m

Wource: Six sigma mechanical design tolerancing, p 128

Department of Mechanical Engineering, The Ohio State University
Sl. #33
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Nonlinear RSS

Tol
y
=
cf
cx
1
|
\

|
.
|
2
tol
1
2
+
cf
cx
2
|
\

|
.
|
2
tol
2
2
+
cf
cx
3
|
\

|
.
|
2
tol
3
2
+ ... +
cf
cx
n
|
\

|
.
|
2
tol
n

o
adjusted
=
Tol
i
3Cpk
i
Wource: Six sigma mechanical design tolerancing, p 128
Department of Mechanical Engineering, The Ohio State University
Sl. #34
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RSS Example
Wource: Six sigma mechanical design tolerancing, p 128
Largest => 0.05 + 0.051 = 0.101

Smallest => 0.05 - 0.051 = -0.001
Department of Mechanical Engineering, The Ohio State University
Sl. #35
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Taguchi Method
Input from the voice of the customer and QFD processes
Select proper quality-loss function for the design
Determine customer tolerance values for terms
in Quality Loss Function
Determine cost to business to adjust
Calculate Manufacturing Tolerance
Proceed to tolerance design
Wource: Six sigma mechanical design tolerancing, p 21
Department of Mechanical Engineering, The Ohio State University
Sl. #36
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Taguchi
- Voice of customer
- Quality function deployment
- Inputs from parameter design
Optimum control-factor set points
Tolerance estimates
Initial material grades
Wource: Six sigma mechanical design tolerancing, p 22
Department of Mechanical Engineering, The Ohio State University
Sl. #37
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Quality Loss Function
- Identify customer costs for intolerable performance
- Quadratic quality loss function

Wource: Six sigma mechanical design tolerancing, p 208

L(y) = k(y m)
2
=
A
o
A
o
(y m)
2
Department of Mechanical Engineering, The Ohio State University
Sl. #38
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Cost of Off Target and Sensitivity
- Cost to business to adjust off target
performance
- Sensitivity, |
Wource: Six sigma mechanical design tolerancing, p 226-227

| =
A
o
A

A =
A
o
A
[|(x m)]
2
Department of Mechanical Engineering, The Ohio State University
Sl. #39
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Manufacturing Tolerance

A =
A
o
A
A
o
|
|
\

|
.
|
Department of Mechanical Engineering, The Ohio State University
Sl. #40
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Summary
- Importance of effective tolerances
- Tolerance Design Approaches
Worst-Case analysis
Root Sum of Squares
Taguchi tolerance method
- Continual process
- Involvement of multi-disciplines
Department of Mechanical Engineering, The Ohio State University
Sl. #41
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- This module is intended as a supplement to design classes in
mechanical engineering. It was developed at The Ohio State
University under the NSF sponsored Gateway Coalition (grant
EEC-9109794). Contributing members include:


- Gary Kinzel. Project supervisor
- Phuong Pham.. ... Primary author


Credits
Reference:
Six Sigma Mechanical Design Tolerancing, Harry, Mikel J. and Reigle
Stewart, Motorola Inc. , 1988.
Creveling, C.M., Tolerance Design, Addison-Wesley, Reading, 1997.
Wade, Oliver R., Tolerance Control in Design and Manufacturing,
Industrial Press Inc., New York, 1967.


Department of Mechanical Engineering, The Ohio State University
Sl. #42
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