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DimXpert and TolAnalyst Made Easy

Craig Therrien
Product Manager

Image courtesy of National Optical Astronomy


Observatory, operated by the Association of Universities
for Research in Astronomy, under cooperative
agreement with the National Science Foundation.
Topics

 GD&T Primer
 DimXpert
 TolAnalyst

© 2006 SolidWorks Corp. Confidential. 2


What is GD&T?

 Way of communicating dimensional


and tolerance requirements
 Allowable imperfection
 GD&T practices are governed by
standards manuals ASME Y14.5M-1994

ASME Y14.41-2003

© 2006 SolidWorks Corp. Confidential. 3


What is GD&T?

 ANSI - ASME Y14.5M-1994 ASME Y14.41-2003


– Y14.5M-1994: Application of GD&T
– Y14.41-2003: Display of GD&T in 3D
 ISO -
ASME
– ISO 1101: Application of GD&T
Completed
– ISO 16792: Display of GD&T in 3D –
just released December 2007

ISO
Under Construction

© 2006 SolidWorks Corp. Confidential. 4


What is GD&T?

Plus/Minus Tolerancing Geometric Tolerancing

© 2006 SolidWorks Corp. Confidential. 5


Typical Problem Solved by GD&T

More than one way to measure this hole location…


X

Surface Plate Surface Plate

Inspection Method 1 or Inspection Method 2

Proper GD&T provides critical information


necessary for manufacturing and inspection
© 2006 SolidWorks Corp. Confidential. 6
GD&T: Square vs. Cylindrical Tolerance Zones

 Plus-minus tolerancing typically locates holes using


square tolerance zones, whereas geometric
tolerancing utilizes cylindrical tolerance zones
GD&T yields
57% more
tolerance than
Plus/Minus!
Position Cylindrical Zone
Plus-minus Square Zone

© 2006 SolidWorks Corp. Confidential. 7


GD&T: Material Condition Modifier

Bonus Tolerance:
 Both
Maximum
MMC Material
(Maximum Condition
Material(MMC)
= largest shaft
Condition) in smallest
and LMC (Leasthole
Material
 Condition) allowCondition
Least Material a Bonus (LMC)
Tolerance
=
smallest shaft in largest hole
 Only GD&T emphasizes the
relationship between diameter
tolerance and center positional
Blue Area = Bonus tolerance
Tolerance!

© 2006 SolidWorks Corp. Confidential. 8


Who Needs GD&T?

 GD&T is for designers who:


– design high precision components
– design products to be produced in high
volume
– perform tolerance stack-up analyses
manually
– must correctly dimension and tolerance
designs
– anyone who currently suffers from
assembly fit problems

© 2006 SolidWorks Corp. Confidential. 9


Why You Should Care About GD&T

 DimXpert for automating


GD&T
 TolAnalyst for tolerance
analysis
 Proper GD&T saves time and
money
 “Lean manufacturing” requires
GD&T

© 2006 SolidWorks Corp. Confidential. 10


GD&T Elements: Datums

 Imaginary, geometrically perfect references for comparison


 Flat plane, point, line, circle, cylinder, cone, sphere
 Primary, Secondary and Tertiary - order for fixturing

Primary, Secondary, Tertiary


Datums

© 2006 SolidWorks Corp. Confidential. 11


GD&T Elements: Symbols

Geometric
Characteristic

© 2006 SolidWorks Corp. Confidential. 12


GD&T Elements: Tolerance Types and Zones

 Form Tolerances:

Flatness applied to a plane:

Conformance: all surface points lie within


Tolerance zone: two parallel planes
a flatness zone no greater than 0.25
separated by the specified tolerance

© 2006 SolidWorks Corp. Confidential. 13


GD&T Elements: Tolerance Types and Zones

 Orientation Tolerances:

Parallelism applied to a plane

Tolerance zone: two parallel planes separated Conformance: the smallest parallelism
by the specified tolerance that are parallel to zone to which the feature conforms
datum plane A

© 2006 SolidWorks Corp. Confidential. 14


GD&T Elements: Tolerance Types and Zones

 Location Tolerances:

Position applied to a hole pattern:

Tolerance zone: 2 cylindrical boundaries with a diameter Conformance: the smallest position
equal to the specified tolerance that are perpendicular to zone to which the features conform
datum plane A, and basically located to datum planes B
and C
© 2006 SolidWorks Corp. Confidential. 15
GD&T Elements: Tolerance Types and Zones

 Runout:

Circular runout applied to a boss:

Tolerance zone: two circles concentric Conformance: the smallest circular


with datum axis A whose radial runout zone to which the feature
separation is the specified tolerance conforms

© 2006 SolidWorks Corp. Confidential. 16


GD&T Elements: Tolerance Types and Zones

 Profile:

Surface profile applied to a part boundary:

Tolerance zone: two uniform boundaries Conformance: the smallest surface


equally disposed about the nominal surface profile zone to which the feature
separated by the specified tolerance conforms

© 2006 SolidWorks Corp. Confidential. 17


Remember this about GD&T…

 DECREASES manufacturing costs


 Reduces or eliminates physical prototypes
 Eliminates confusion for manufacturing and inspection – fixturing and
measurements
 GD&T yields bigger tolerance target than plus/minus
 New GD&T functionality in SolidWorks 2008
– DimXpert for Parts: automated 3D GD&T creation per ASME 14.41-2003
– TolAnalyst: automated tolerance stack-up analysis

© 2006 SolidWorks Corp. Confidential. 18


What is DimXpert?

 Intelligent, automated dimensioning


and tolerancing of 3D models
 Visual feedback on dimensional
completeness
 Automatically displays in 2D drawing
 Integrated with TolAnalyst

© 2006 SolidWorks Corp. Confidential. 19


What is DimXpert?

 2 DimXperts – don’t be confused


– 3D Part – DimXpert for Parts (New in
SW2008)
 Create DimXpert dims on the 3D part
 Dimensions appear pink
 Integrated with TolAnalyst DimXpert for Parts
 Integrated with drawings
– Automated 2D dimensioning – DimXpert for
Drawings (old 2D functionality in 2007)
 Just drawing dimensions
 Not integrated with TolAnalyst
 No geometric tolerancing capabilities
 Not in the DimXpert database

DimXpert for Drawings


© 2006 SolidWorks Corp. Confidential. 20
What is DimXpert?

 Applies and displays tolerance scheme ASME Y14.5M-1994 ASME Y14.41-2003


per industry standards
 “Spelling” and “Grammar” checks
 Completed - ASME
– Y14.5M-1994: Application of GD&T Completed
– Y14.41-2003: Display of GD&T in 3D
 Under Construction -
– ISO 1101: Application of GD&T
– ISO 16792: Display of GD&T in 3D –
just released December 2007
ISO
Under Construction

© 2006 SolidWorks Corp. Confidential. 21


Benefits of DimXpert
 DimXpert solves a HUGE problem:
 Most time spent in drawing creation is in dimensioning and
tolerancing
 Without DimXpert: manually dimension and tolerance, no way to
know if the drawing is complete or correct for manufacturing
 With DimXpert: dimension and tolerancing is automated and
ensured to be correct for manufacturing

© 2006 SolidWorks Corp. Confidential. 22


Benefits of DimXpert

 Automates part and drawing detailing per


industry standard specs
 No need to be an expert to apply correct
dimensioning and tolerancing
 Ensure design fit and function, and reduce
cost even when outsourcing designs
– Manufacturing won’t have to guess at
tolerances and datums

© 2006 SolidWorks Corp. Confidential. 23


Who Needs DimXpert?
 Companies who outsource product designs
– DimXpert provides clear and concise manufacturing
and inspection documentation

 Anyone who makes detailed drawings


 Inexperienced in GD&T
– DimXpert guides the user and automates the GD&T

 Experienced in GD&T
– DimXpert speeds GD&T creation

 Companies who want to go “drawingless”


– All geometric requirements are embedded in the part

© 2006 SolidWorks Corp. Confidential. 24


Who needs DimXpert?

 DimXpert is for designers who:


– Detail part drawings
– Annotate parts in 3D
– Want to know designs are completely
dimensioned
– Use +/- and/or geometric tolerances
– Design high precision components
– Currently have assembly fit problems

© 2006 SolidWorks Corp. Confidential. 25


DimXpert: Target Part Types

 Parts that are machined:


i.e., milled, drilled, and
turned parts
– Includes the machined and un-
drafted surfaces of castings and
forgings

© 2006 SolidWorks Corp. Confidential. 26


DimXpert: Part Types Not Targeted

 Part types not yet


specifically addressed:
– Sheetmetal
 Bends not yet supported
 BUT, prismatic type features are
supported: planes, holes, slots
– Molded/Cast parts
 Draft is not yet supported
 BUT, profile tolerancing is supported
– Special Geometries
 Includes gears, threads and cams

© 2006 SolidWorks Corp. Confidential. 27


DimXpert Functionality: UI

DimXpert
Feature Manager

DimXpert Toolbar

DimXpert Automatically
Recognizes and Creates
Manufacturing Features
© 2006 SolidWorks Corp. Confidential. 28
DimXpert Functionality: Manufacturing Feature
Types
Hole Cone Countersink Counterbore Plane

Slot Notch Boss Cylinder Width

Pocket Surface Chamfer Fillet

© 2006 SolidWorks Corp. Confidential. 29


DimXpert: Main Features

 Manufacturing Feature Recognition


– Automatically extracts, for tolerancing, the feature types consistent with
manufacturing and inspection processes
– Extraction can be done on SW modeling features and imported bodies

1 Extrude (modeling) Feature 10 (DimXpert) Manufacturing Features

=
Planes
Slot
Notch
Chamfer
© 2006 SolidWorks Corp. Confidential. 30
DimXpert: Manufacturing Feature Recognition

 The feature recognition process:


1. Start by recognizing a part’s complex features, e.g., pockets,
patterns, slots, and countersink holes
2. Then, recognize the remaining simple features, e.g., individual,
planes, simple holes, and cones

Applied to this part:


1. First, the pocket, 4X
countersink pattern,
4X fillet pattern, and Pocket
slot are recognized Countersink Pattern
2. Then, the simple Slot
hole and remaining Fillet Pattern
planes are Simple Hole
recognized
Plane

© 2006 SolidWorks Corp. Confidential. 31


DimXpert Functionality: Intersection Feature
Types

Intersect Plane Intersect Line Intersect Point

Plane intersection Point intersection


Line intersection
between a cylinder and between a cylinder and
between a two planes
a cone a plane

© 2006 SolidWorks Corp. Confidential. 32


DimXpert Functionality: Schemes

 Supports both geometric and plus-minus


dimension and tolerance schemes
Geometric Plus-Minus

© 2006 SolidWorks Corp. Confidential. 33


DimXpert Functionality: Automatic
Dimensioning

 Auto Dimension Scheme


– Automation tool for creating dimension and tolerance schemes (patent
pending)
– User can specify Plus-Minus or Geometric

1. Select a primary, secondary, and 2. Automatic Dimension and Tolerance


tertiary datum/reference feature Scheme is created

Note: Coloring the faces green indicates


they have been fully constrained
© 2006 SolidWorks Corp. Confidential. 34
DimXpert Functionality: Other Functionality

© 2006 SolidWorks Corp. Confidential. 35


DimXpert Functionality: Show Tolerance
Status

 Show Tolerance Status Before

– Informs user when the dimension


and tolerance scheme is complete
– Each face is colored based on its
status:
 Green = Fully constrained
 Yellow = Under constrained
 Red = Over constrained
 Native color = Not Recognized by
DimXpert
After

© 2006 SolidWorks Corp. Confidential. 36


DimXpert: Integration

 Integrated with Drawings


– Annotation Views can be imported into drawings

© 2006 SolidWorks Corp. Confidential. 37


DimXpert: Integration

 Integrated with TolAnalyst


– DimXpert dimensions and tolerances are used in the computation of the
worst case conditions

© 2006 SolidWorks Corp. Confidential. 38


DimXpert: Sketch vs. DimXpert Dimensions

 Sketch dimensions:
– Primary purpose are to facilitate the
creation of the part, configurations, and
design tables
– Are often linked to construction geometry,
which aren’t present on the finished part
– Aren’t always consistent with the methods
used for dimensioning manufacturing
features, e.g., pockets, slots, and notches
– Don’t always meet the requirements
necessary to support geometric tolerancing

© 2006 SolidWorks Corp. Confidential. 39


DimXpert: Sketch vs. DimXpert Dimensions

 DimXpert Dimensions:
– Primary purpose is to communicate
a part’s functional requirements for
assembly, manufacturing and
inspection
– Are always associated with
manufacturing features
– Are always associated with a
tolerance
– Dimensions (basic) associated with
geometric tolerances originate from
and are oriented to the datum
reference frame

© 2006 SolidWorks Corp. Confidential. 40


DimXpert Functionality: Document Properties

© 2006 SolidWorks Corp. Confidential. 41


DimXpert Functionality: Document Properties

Method for tolerancing General Tolerance Model


dimensions without Units = mm
tolerance indications

Tolerance values
based on decimal
precision

Tolerance value for


angle dimensions Block Tolerance Model
without tolerance Units = inch
indication

Part classification per


ISO 2768

Note: This information is used by TolAnalyst, can be accessed


through the API or system variables
© 2006 SolidWorks Corp. Confidential. 42
DimXpert: Document Properties – Size
Dimension
Tolerance type and values for dimensions
created by Size Dimension and Auto Dimension
Scheme

The tolerance of each dimension


corresponds to its document property

© 2006 SolidWorks Corp. Confidential. 43


DimXpert: Document Properties – Location Dimension

Tolerance type and


values for dimensions
created by Location
Dimension and Auto
Dimension Scheme

© 2006 SolidWorks Corp. Confidential. 44


DimXpert: Document Properties – Chain Dimensioning

Methods for dimensioning hole


patterns and pockets created by
Auto Dimension Scheme

Chain Baseline

© 2006 SolidWorks Corp. Confidential. 45


DimXpert: Document Properties – Chain Dimensioning

Tolerance type and values for chain


dimensions created by Auto
Dimension Scheme

© 2006 SolidWorks Corp. Confidential. 46


DimXpert: Document Properties – Geometric
Tolerance

Option to reference datums at MMC,


and tolerance values used in geometric
tolerances created by Auto Dimension
Scheme to interrelate the datum
features

© 2006 SolidWorks Corp. Confidential. 47


DimXpert: Document Properties – Geometric
Tolerance

Options and tolerance values for geometric


tolerances created by Auto Dimension Scheme

Position at MMC Position with Composite option

Profile with Composite option Runout

© 2006 SolidWorks Corp. Confidential. 48


DimXpert: Document Properties – Geometric
Tolerance
Chain Dimension Scheme

Option and method for basic dimensions


created by Auto Dimension Scheme and
the Recreate Basic Dim command

Note:
1. Option applies to Position
tolerances only Baseline Dimension Scheme
2. The Recreate Basic Dim is an
RMB option given when a
position tolerance is selected in
the DimXpertManager

© 2006 SolidWorks Corp. Confidential. 49


DimXpert: Document Properties – Chamfer
Controls

Values used by Feature Recognition to determine if For the orange face to be


a face is to be dimensioned as a chamfer considered a chamfer:
1. W must be > 10
2. A1/W and A2/W must be > 2
Note: SW Chamfer features are automatically
recognized as chamfers regardless of the settings

Dimensioned as Chamfer Dimensioned as Plane

© 2006 SolidWorks Corp. Confidential. 50


DimXpert: Document Properties – Chamfer
Controls
Distance - Distance

Tolerance type and values for chamfer


dimensions created by Size Dimension and Auto
Dimension Scheme
Distance - Angle

Note: SW Chamfer features are dimensioned


distance-distance or distance-angle based on their
definition. All other chamfers are dimensioned
distance-distance

© 2006 SolidWorks Corp. Confidential. 51


DimXpert: Document Properties – Display
Options
Method for dimensioning the width and
length of slots created by Size Dimension
and Auto Dimension Scheme

Combined Dimension
Separate Dimensions

© 2006 SolidWorks Corp. Confidential. 52


DimXpert: Document Properties – Display
Options
Options to eliminate duplicate dimensions and
show instance counts on combined
dimensions.

Options are applied to dimensions created by


Auto Dimension Scheme and re-create pattern
and basic dimension commands.

Eliminate duplicates and


Show instance counts Eliminate duplicates only Both options unchecked

© 2006 SolidWorks Corp. Confidential. 53


DimXpert vs. the Competition

 Inventor, PTC, SolidEdge do


not have functionality DimXpert
– No automated tolerancing based
on manufacturing feature
recognition
– No automated tolerance
verification

© 2006 SolidWorks Corp. Confidential. 54


DimXpert Packaging

DimXpert:
All SolidWorks

© 2006 SolidWorks Corp. Confidential. 55


Things to Remember

 Using DimXpert results in:


– Correct application and display of
tolerances without having to be an expert
– DECREASED manufacturing costs - less
prototypes and looser tolerances
– Assemblies that fit and function better
– Eliminating manufacturing and inspection
guesswork

© 2006 SolidWorks Corp. Confidential. 56


DimXpert: Examples

 Example 1 – ADS (Automatic Dimensioning Scheme) and


Geometric Tolerancing
 Example 2 – ADS and Plus-Minus Tolerancing
 Example 3 – ADS and Selected Features
 Example 4 – ADS and the Wedge
 Example 5 – ADS and Concentric Features
 Example 6 – Feature Selector
 Example 7 – Manual Tolerancing
 Example 8 – More Feature Selector

© 2006 SolidWorks Corp. Confidential. 57


DimXpert #1 - ADS and Geometric Tolerancing

 Steps:
– Automatic
Dimension
Scheme
 Tolerance type: Geometric
 Scope:
All features
– Show Tolerance
Status
– Review
DimXpertManager

© 2006 SolidWorks Corp. Confidential. 58


DimXpert #2 - ADS and Plus-Minus Tolerancing

 Steps
– Automatic
Dimension
Scheme
 Tolerance type: Plus and
Minus
 Scope:
All features
– Show Tolerance
Status
– Create Drawing

© 2006 SolidWorks Corp. Confidential. 59


DimXpert #3 - ADS and Selected Features

 Steps
– Automatic Dimension
Scheme
 Tolerance type:
Plus and Minus
– Selected Features
 Dimension the center hole, top
and right hand plane from the
bottom and left hand plane
 Dimension the 4 hole pattern
from the center hole

© 2006 SolidWorks Corp. Confidential. 60


DimXpert #4 - ADS and the Wedge

After ADS
 Steps
– Automatic Dimension
Scheme
 Tolerance type:
Plus and Minus
– Location Dimension
After Location Dimension is used to
 Create the 30 dimension create the 30 and 80 dimensions
 Create the 80 dimension

© 2006 SolidWorks Corp. Confidential. 61


DimXpert #4 – ADS and the Wedge
(continued)
 How to create the 30 dimension
1. Location 2. Select the
Dimension, Intersect Line
select the left option
hand plane and
then the angled
plane

3. Select the
top face, and
4. Place the
then OK
dimension

© 2006 SolidWorks Corp. Confidential. 62


DimXpert #5 - ADS and Concentric Features

 Steps Plus and Minus

– Auto Dimension Scheme


 Create plus and minus dimension
Scheme
– Concentric features are under
constrained
 Create geometric dimension
scheme
– Position tolerances are Geometric
applied to fully constrain
concentric features

© 2006 SolidWorks Corp. Confidential. 63


DimXpert #6 - Feature Selector

 Step 1  Step 2
– Create left 40 dimension – Combine the 2 Dimensions
 Show tolerance status

– Create right 40 dimension


 Show tolerance status

© 2006 SolidWorks Corp. Confidential. 64


DimXpert #6 – Feature Selector (continued)

 Step 3  Step 4
– Change length of left leg – Create dimension from the
 Dimensions are automatically broken bottom plane to a compound
plane containing the two top
faces
– Show tolerance status

© 2006 SolidWorks Corp. Confidential. 65


DimXpert #6 - Feature Selector (continued)

 Step 5
– Dimension the hole location and size
 Face selection must be used

© 2006 SolidWorks Corp. Confidential. 66


Demo #6 - Feature Selector (cont.)
 Step 6  Step 7
– Create Location dimension – Create Size dimension

Resultant Tolerance Zone Resultant Tolerance Zone

© 2006 SolidWorks Corp. Confidential. 67


DimXpert #7 – Manual Tolerancing

 Create the
tolerance
scheme as
shown using:
– Datum
– Size
Dimension
– Geometric
Tolerance
– Location
Dimension

© 2006 SolidWorks Corp. Confidential. 68


DimXpert #7 – Manual Tolerancing

 Datum Command
– Create datums A, B, and C

© 2006 SolidWorks Corp. Confidential. 69


DimXpert #7 – Manual Tolerancing (cont.)

 Size Dimension
– Create the hole
callouts for the
two counterbore
patterns

© 2006 SolidWorks Corp. Confidential. 70


DimXpert #7 – Manual Tolerancing (cont.)

 Geometric
Tolerance
– Create the
two position
tolerances

© 2006 SolidWorks Corp. Confidential. 71


DimXpert #7 – Manual Tolerancing (cont.)

 Location
Dimension
– Create the 60
and 25
dimensions

© 2006 SolidWorks Corp. Confidential. 72


DimXpert #7 – Manual Tolerancing (cont.)

 Show
Tolerance
Status

© 2006 SolidWorks Corp. Confidential. 73


DimXpert #8 – Feature Selector

 Create the 3 dimensions as shown

© 2006 SolidWorks Corp. Confidential. 74


DimXpert #8 – Feature Selector (cont.)

 Create Datum A
– Include both
front faces

© 2006 SolidWorks Corp. Confidential. 75


DimXpert #8 – Feature Selector (cont.)

 Create the size


dimension

© 2006 SolidWorks Corp. Confidential. 76


DimXpert #8 – Feature Selector (cont.)

 Create the
location
dimension

© 2006 SolidWorks Corp. Confidential. 77


TolAnalyst Overview

 What is Tolerance Stack-up Analysis?


 Who needs Tolerance Stack-up Analysis?
 What is TolAnalyst?
 Target Market
 Competition
 Main Features
 Use Case
 Packaging
 Things to Remember

© 2006 SolidWorks Corp. Confidential. 78


What is Tolerance Stack-up Analysis?

 Tolerance stack-up analysis is the study of dimension and


tolerance schemes to determine potential form, fit, and
function problems in parts and assemblies

What the permissible gap (G)


between Part1 and Part4 ?

© 2006 SolidWorks Corp. Confidential. 79


What is Tolerance Stack-up Analysis?

 Worst-case analysis
– Assumes dimensions vary within the entire range of their tolerance
zones and that the accumulation of tolerances will experience all
possible variations

Performing worst-case analysis using a tolerance graph and hand calculation to


determine the smallest permissible gap (G)

Gmin = L1 + L2 + L3 + L4… + Ln
= L1 + L2 + L3 + L4
= 152.75 + (-60.75) + (-42) + (-50.5)
= -0.5 Interference

© 2006 SolidWorks Corp. Confidential. 80


What is Tolerance Stack-up Analysis?

 RSS (Root Sum of Squares) statistical analysis


– Assumes dimensions vary randomly within a normal distribution (±3σ)
centered about midpoint of the tolerance zone.

Using statistical RSS to compute the minimum and maximum gap (G)

G = Gnominal ± √ T12 + T22 + T32… TN2


= 2 ± √ 0.252 + 0.752 + 12 + 0.52
= 2 ± 1.369
Gnominal = 153 - 60 - 41 - 50
=2
Gmin = 0.631, Gmax = 3.369

© 2006 SolidWorks Corp. Confidential. 81


What is Tolerance Stack-up Analysis?

 Worst-case tolerance analysis is dependent on how parts are


actually assembled in real life
 It is incorrect to think max worst case is when the parts are
at their largest and min worst case is when they are at their
smallest
Nominal Worst-case Worst-case
Part Assembly Maximum Minimum

© 2006 SolidWorks Corp. Confidential. 82


Who Needs Tolerance Stack-up Analysis?

 Companies concerned with or having form, fit, and function


problems with parts or assemblies
– Form
 Will the allowable gap and/or offset between parts fall within requirements
for aesthetics?
– Fit
 Will the assembly go together without interference?
– Function
 Will the allowable clearance or distance between surfaces meet
operational requirements?

© 2006 SolidWorks Corp. Confidential. 83


What is TolAnalyst?

 TolAnalyst is a tool for performing tolerance stack-up


analysis on parts and assemblies

Note: Single part analysis can be accomplished


by creating a one part assembly
© 2006 SolidWorks Corp. Confidential. 84
TolAnalyst: Target Customers

 Target Customers are Those Who:


– Perform tolerance analysis on paper or spreadsheets, or using simple
3rd party applications
– Do not perform tolerance analysis, but are having problems with
existing assemblies or are wanting to perform analysis on new design
work
– Are contractually required to perform tolerance analysis. i.e.
aerospace contractor
– Want a tolerance analysis product that can be easily used by all
design and manufacturing engineers
 High-end products typically require specialists, and in many cases use consultants
contracted from the product supplier

© 2006 SolidWorks Corp. Confidential. 85


TolAnalyst: TolAnalyst Does Not Do…

 TolAnalyst Does Not Do


– Statistical Monte-Carlo type analyses
 Allows users to control the distribution types applied to the features and
tolerances
– Runtime access to the analysis engine
 Allows users to apply their own logic and sources of variation within the
tolerance analysis
– Consideration for other (non-tolerance) sources of variation
 Gravity
 Temperature
 Deflection
– Kinematic solutions
 linkages

© 2006 SolidWorks Corp. Confidential. 86


TolAnalyst: Main Features

 Analysis results include Worst-Case and statistical RSS


(Root Sum of Squares)

© 2006 SolidWorks Corp. Confidential. 87


TolAnalyst: Main Features

 Orientation tolerances can be considered

Worst-case maximum with Worst-case maximum with


orientation tolerances disabled orientation tolerances enabled
© 2006 SolidWorks Corp. Confidential. 88
TolAnalyst: Main Features

 DimXpert is used to drive analysis


– Items not currently supported:
 Form Tolerances (Flatness, Cylindricity, and Circularity)
 Intersect Features (Plane, Line, Point)

Dimension to
Intersect line

Note: Intersect features are under


Form Tolerance construction

© 2006 SolidWorks Corp. Confidential. 89


TolAnalyst: Main Features

 Contributor list
– Priority ranks tolerances based on their total contribution to the
tolerance stack

© 2006 SolidWorks Corp. Confidential. 90


TolAnalyst: TolAnalyst vs. the Competition

TolAnalyst

Inventor
ProE

© 2006 SolidWorks Corp. Confidential. 91


TolAnalyst: Use Case

Functional Requirement: D >= 39

© 2006 SolidWorks Corp. Confidential. 92


TolAnalyst: Use Case

 Apply DimXpert to each component


– Only those feature impacting the study need to be dimensioned and
toleranced
 TolAnalyst give warnings should the dimension and tolerance schemes be insufficient or
“broken”

Top Plate Angle Bracket Bushing

© 2006 SolidWorks Corp. Confidential. 93


TolAnalyst: Use Case

 Create a Study
– A TolAnalyst Study includes all information required to perform the
tolerance analysis

TolAnalyst Study

Note: Assemblies may have multiple studies


© 2006 SolidWorks Corp. Confidential. 94
TolAnalyst: Use Case

 Define the Measurement


– A Measurement is defined by creating a dimension between two
DimXpert features

© 2006 SolidWorks Corp. Confidential. 95


TolAnalyst: Use Case

 Define the “actual” Assembly Sequence


– The sequence may differ than that used to create the assembly

© 2006 SolidWorks Corp. Confidential. 96


TolAnalyst: Use Case

 Define the Assembly Constraints for each part

© 2006 SolidWorks Corp. Confidential. 97


TolAnalyst: Use Case

 Review the Results


The minimum worst-case result
of 38.2 is less than required
minimum of 39

The contributor list shows that the


top 3 sources of variation are
dimensions applied to the assembly
component “Top_plane-1”

© 2006 SolidWorks Corp. Confidential. 98


TolAnalyst: Use Case

 Options to consider to achieve a minimum worst case of 39


– Reducing the part tolerances
– Changing the part’s model dimensions
– Changing the dimension and tolerance scheme

© 2006 SolidWorks Corp. Confidential. 99


TolAnalyst: Use Case

 Reducing the tolerances of the 3 main contributors

To reduce the tolerance stack by 0.8 (39 –


38.2) the tolerance of each dimension would
have to be changed to ± 0.1

Before After

Note: In order for this option to be acceptable consideration should


be given to the added cost to produce the part at tighter tolerances
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TolAnalyst: Use Case

 Changing the part’s model dimensions.

By increasing the width between the faces locating the


two angle brackets by 1 mm the results for the minimum
worst-case gap would be 39.2 (38.2 + 1)

Before After

Note: In order for this change to be acceptable consideration should be


given to the maximum worst-case gap, which would increase by 1 to 42.8
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TolAnalyst: Use Case

 Changing the dimension scheme


By adding a dimension between the planes which locate the axel
supports and removing the 40 dimension on the right side of the part
the tolerance stack between the planes is reduced from ± 1.1 to ±
0.3. As a result the new worst-case minimum dimension would be 39.

Before After

Dimensions would no contribute


in the tolerance stack
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TolAnalyst: Use Case

 Export the Results

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TolAnalyst Packaging

TolAnalyst: SolidWorks Office Premium

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Things to Remember

 Maximum/minimum tolerance
stack-up
 Identifies key contributors
 Graphically displays result
 Reduces prototyping and testing
for assembly fit
 Leverages DimXpert
 Eliminates error-prone hand
calculations
 Enables fast tolerance optimization

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