Geometric Dimensioning & Tolerance (GD&T) – Tolerance Stack-up Analysis


Seminar Content

This two-day course focuses on the application of tolerance stack-up analysis techniques to a wide variety of assemblies per GD&T requirements of ASME Y14.5M-1994 and ISO1101, from the very simple to the more complex situations commonly faced in industry today. Both plus/minus and geometrically toleranced assemblies are examined, with stack-up analysis taught and practiced on each. Many different datum structures are discussed and analyzed. The concepts taught in this course are: loop analysis (also known as circuit diagrams), number charting, virtual condition, resultant condition, inner and outer boundaries, minimum airspace, maximum wall thickness, maximum interference, minimum and maximum overall dimensions, fixed and floating fastener assembly conditions, projected tolerance zones, the logic of stack-up analysis, statistical tolerancing , and much more.

Who Should Attend

This seminar is designed for Design Engineers, Product Engineers, Quality and Technical Staff.

Recommended Training and/or Experience

Attendees should have a basic working knowledge of ASME Y14.5M-1994. A knowledge of GD&T principles is required to allow all participants to be successful in learning the techniques of tolerance stack-up analysis. [Each participant needs to bring a hand-held calculator.].

Seminar Materials

Each participant will receive a seminar manual with case studies.

Seminar Goals

  • Calculate minimum and maximum wall thickness, airspaces and interferences for assemblies.
  • Create loop analysis/circuit diagrams for tolerance stack-up analysis for both plus/minus toleranced dimensions and geometric tolerances.
  • Create both simple and complex number charts for stack-up analysis using a variety of geometric tolerances, basic dimensions, resultant conditions, virtual conditions and plus/minus toleranced dimensions.
  • Conduct tolerance stack-up analysis for floating fastener situations for clearance holes, screws and shafts.
  • Conduct tolerance stack-up analysis for fixed fastener situations using screws, clearance holes, slots, tabs, overall dimensions and projected tolerance zones for threaded holes.
  • Calculate minimum and maximum gaps for assemblies that use a variety of datum structures.
  • Learn a system of logic and mathematics to analyze tolerances.
  • Calculate the effects of angular stack-up using trigonometry and proportions.
  • Calculate statistical tolerances using a variety of methods and learn how to re-integrate these tolerances back into the assembly’s details.

Seminar Outline

  • Tolerance Stack-up Introduction
  • Dimensioning and Tolerancing
  • Tolerancing Format and Decimal Places
  • Tolerancing Converting
  • Sources of Variation
  • Tolerance Analysis
  • Worst Case Tolerance Stack-up
  • Statistic Tolerance Stack-up
  • Geometric Dimensioning and Tolerancing
  • Converting Plus/Minus Tolerancing to Positional Tolerancing and Projected Tolerance Zones
  • Diametral Tolerancing Stack-up
  • MMC/LMC Tolerancing Analysis
  • Tolerance Stack-up Sketch
  • Tolerance Stack-up Report
  • Tolerance Stack-up with Trigonometry
  • Advanced Tolerance Stack-up
  • Component Tolerance Calculation
  • Floating/Fixed Fastener Calculation
  • Fit Classification
  • Form Tolerance Stack-up


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