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Tolerance interpretation. Dr. Richard A. Wysk IE550 Fall 2008. Agenda. Introduction to tolerance interpretation Tolerance stacks Interpretation. Tolerance interpretation. Frequently a drawing has more than one datum How do you interpret features in secondary or tertiary drawing planes?
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Tolerance interpretation Dr. Richard A. Wysk IE550 Fall 2008
Agenda • Introduction to tolerance interpretation • Tolerance stacks • Interpretation
Tolerance interpretation • Frequently a drawing has more than one datum • How do you interpret features in secondary or tertiary drawing planes? • How do you produce these? • Can a single set-up be used?
Case #1 1 4 2 3 1.0±.05 1.5±.05 1.0±.05 ? TOLERANCE STACKING What is the expected dimension and tolerances? D1-4= D1-2 + D2-3 + D3-4 =1.0 + 1.5 + 1.0 t1-4 = ± (.05+.05+.05) = ± 0.15
Case #2 1 4 2 3 1.0±.05 1.5±.05 3.5±.05 TOLERANCE STACKING What is the expected dimension and tolerances? D3-4= D1-4 - (D1-2 + D2-3 ) = 1.0 t3-4 = (t1-4 + t1-2 + t2-3 ) t3-4 = ± (.05+.05+.05) = ± 0.15
Case #3 1 4 2 3 ? 1.0’±.05 1.00’±0.05 3.50±0.05 TOLERANCE STACKING What is the expected dimension and tolerances? D2-3= D1-4 - (D1-2 + D3-4 ) = 1.5 t2-3 = t1-4 + t1-2 + t3-4 t2-3 = ± (.05+.05+.05) = ± 0.15
Case #1 1 4 2 3 1.0±.05 1.0±.05 1.0±.05 ? From a Manufacturing Point-of-View Let’s suppose we have a wooden part and we need to saw. Let’s further assume that we can achieve .05 accuracy per cut. How will the part be produced?
Let’s try the following (in the same setup) -cut plane 2 -cut plane 3 3 2 Mfg. Process Will they be of appropriate quality?
So far we’ve used Min/Max Planning • We have taken the worse or best case • Planning for the worse case can produce some bad results – cost
PROCESS DIMENSIONAL ACCURACY POSITIONAL ACCURACY DRILLING + 0.008 - 0.001 0.010 REAMING + 0.003 (AS PREVIOUS) SEMI-FINISH BORING + 0.005 0.005 FINISH BORING + 0.001 0.0005 COUNTER-BORING (SPOT-FACING) + 0.005 0.005 END MILLING + 0.005 0.007 Expectation • What do we expect when we manufacture something?
2.45 2.5 2.55 Size, location and orientation are random variables • For symmetric distributions, the most likely size, location, etc. is the mean
What does the Process tolerance chart represent? • Normally capabilities represent + 3 s • Is this a good planning metric?
An Example Let’s suggest that the cutting process produces (, 2) dimension where (this simplifies things) =mean value, set by a location 2=process variance Let’s further assume that we set = D1-2 and that =.05/3 or 3=.05 For plane 2, we would surmise the 3of our parts would be good 99.73% of our dimensions are good.
.95 1.0 1.05 2.45 2.5 2.55 D1-2 We know that (as specified) D2-3 = 1.5 .05 If one uses a single set up, then (as produced) and D1-2 D1-3 D2-3 = D1-3 - D1-2
1.4 1.5 1.6 What is the probability that D2-3 is bad? P{X1-3- X1-2>1.55} + P{X1-3- X1-2<1.45} Sums of i.i.d. N(,) are normal N(2.5, (.05/3)2) +[(-)N(1.0, (.05/3)2)]= N (1.5, (.10/3)2) So D2-3
The likelihood of a bad part is P {X2-3 > 1.55}-1 P {X2-3 < 1.45} (1-.933) + (1-.933) = .137 As a homework, calculate the likelihood that D1-4 will be “out of tolerance” given the same logic.
What about multiple features? • Mechanical components seldom have 1 feature -- ~ 10 – 100 • Electronic components may have 10,000,000 devices
Suppose we have a part with 5 holes • Let’s assume that we plan for + 3 s for each hole • If we assume that each hole is i.i.d., the P{bad part} = [1.0 – P{bad feature}]5 = .99735 = .9865
Success versus number of features 1 feature = 0.9973 5 features = 0.986 50 features = 0.8735 100 features = 0.7631 1000 features = 0.0669