Tolerancestacks

In the picture below you can find examples of different types of tolerance. For the purpose of tolerance analysis, all of these are equivalent and Equal Bilateral Tolerancing must be used.

The calculator also does a Root Sum Square (RSS) type of analysis, which is essentially calculating a standard deviation for the assembly, thus creating a bilateral tolerance for the assembly: Toleranceassembly = ±3σassembly. This shows that in most cases both blocks will fit inside the pocket, and interference is not likely.

Use a plunge rate of 50% or less of the feed rate. So for a feed rate of ... ft/min, use a plunge rate of ... ft/min or less.

Assign a positive direction. In this case positive will be towards the right, so that vector 1 will have a positive value, and vectors 2 and 3 will have negative values.

Tolerance stackcalculation

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Starting from one end of the target dimension, draw vectors through each relevant dimension, in order to create a loop so that you reach the other end of the target dimension. Assign a number to each vector.

Tolerance stackupexamplePDF

Chip loads are provided as ranges. In order to extend the life of your tool, use the lower value in the range. If need to get your job done quickly then you can a higher chipload within the specified range.

All tolerances must be symmetric bilateral. In this example, dimension 1 is given as unilateral. In order to convert it, we must center the nominal value and give it an equal bilateral tolerance. This results in: 35.95 ± 0.05

Toleranceloopexample

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Worst Case scenario, as expected, predicts the largest range of variation. That is, under Max Condition, the clearance could be up to 0.95, however, under Min Conditions, there would be interference (blocks won’t fit in the pocket), as shown by the negative sign.

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Note: To perform a meaningful RSS (Root Sum Square) stack-up tolerance analysis, some assumptions are made: Independent Variations, Normally Distributed Variations, and Tolerance Accumulation Linearity

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Tolerancestack-up loop diagram

Additionally, the adjusted RSS analysis is performed. This analysis is more suitable for high-volume production processes where the mean value of a process may be shifted by 1.5σassembly

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Tolerance stackup analysis Excel

Two blocks are to be inserted in a pocket, as shown below. We would like to understand what is the clearance that we will have between the blocks and the pocket. Dimensions and tolerances are provided in the image.

Make sure to use the converted bilateral tolerance, and make sure to use the correct signs per the loop diagram. Columns in blue will be automatically calculated.

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Note about Sigma Level: This allows you to specify the manufacturing capability for a specific dimension. For example, if the manufacturer of a part can achieve 6sigma production, this column would allow you to specify this by entering a value of ‘6’. However, if left blank, a standard sigma level of ‘3’ is used. This means that “Tolerance = ±3σ”

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The ‘Nominal’ column shows the nominal value of the gap that we will have between the blocks and the pocket. Max and Min Condition show the extreme cases for each analysis type.

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Feed Rate = Spindle Speed (RPM) * Number of Flutes * Chip Load (inches) = Spindle Speed * Number of flutes * Chip Load = Answer inches/min