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The document discusses assembly tolerance stack up analysis, which calculates the tolerance of an entire assembly based on the tolerances of its individual components. It provides an example of using the worst case method to analyze an assembly of four plates with different thickness tolerances. By summing the lower and upper specification limits of each plate, it determines the overall lower and upper limits of the assembly. Taking the difference between these limits and dividing by two provides the tolerance of the entire assembly. The analysis allows determining the tolerance value of an assembly when the component tolerances are known.

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79 views3 pages

Stack Up

The document discusses assembly tolerance stack up analysis, which calculates the tolerance of an entire assembly based on the tolerances of its individual components. It provides an example of using the worst case method to analyze an assembly of four plates with different thickness tolerances. By summing the lower and upper specification limits of each plate, it determines the overall lower and upper limits of the assembly. Taking the difference between these limits and dividing by two provides the tolerance of the entire assembly. The analysis allows determining the tolerance value of an assembly when the component tolerances are known.

Uploaded by

oddball64
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOC, PDF, TXT or read online on Scribd
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All the machining process produces the components within certain amount of tolerance to its

desired dimensions. As the precision of the machining process increases, the tolerance gets
reduced, but no practical machine can produce components with zero tolerance. Due to this
tolerance only, the concept of MMS, LMS and bonus tolerance is developed.

The situation become even more complicated when multiple components with different
tolerances form an assembly. For such an assembly, what will be the tolerance? How to calculate
the whole assembly tolerance? Assembly tolerance chain analysis or tolerance stack up analysis
is the answer.

What is Assembly Tolerance Stack up Analysis?


In short, assembly tolerance stack up analysis will tell you the tolerance value of the whole
assembly or a specific gap of the assembly when you know the tolerance values of all its
components.

Assembly tolerance chain stack up analysis can be performed in many ways. The simplest
method is the worst case method, which we are going to discuss here.

Worst Case Method of Assembly Tolerance Stack Up


Say, we have an assembly of four thick plates like below:

The thickness and tolerance of the four plates are shown in the above figure. We have to find out
the dimension “X” and its tolerance value. Proceed as below:

For PLATE-1:

LSL= 27-0.4 = 26.6

For PLATE-2:

LSL= 15-0.3 = 14.7

For PLATE-3:
LSL= 15-0.3 = 14.7

For PLATE-4:

LSL= 15-0.5 = 14.5

• Sum up the LSL thickness values of all the plates, and you will get the LSL thickness of
the whole assembly as below:

TL = 26.6 +14.7 + 14.7 + 14.5 = 70.5

• Calculate the upper specification limit (USL)size for each of the plates like below:

For PLATE-1:

USL= 27+0.4 = 27.4

For PLATE-2:

USL= 15+0.3 = 15.3

For PLATE-3:

USL= 15+0.3 = 15.3

For PLATE-4:

USL= 15+0.5 = 15.5

• Sum up the USL thickness values of all the plates, you will get the USL of the whole
assembly as below:

TU = 27.4 + 15.3 + 15.3 + 15.5 = 73.5

• Tolerance of the whole assembly can obtained as:

± (TU – TL) / 2 = ± (73.5-70.5)/2 = ± 1.5

• Sum up the nominal thickness dimensions of all the plates to get the nominal thickness
value of the whole assembly, like below:

TN = 27 + 15 + 15 + 15 = 72

• So, by the worst case method we got the overall dimension (X) of the assembly as:

X = 72 ± 1.5
Conclusion
Assembly tolerance chain stack up analysis is used for calculating the tolerance value of the
overall assembly (or a gap in the assembly) from the tolerance values of the individual
components. The worst case method of the stack up analysis is the simplest among all the
methods used in industry

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