Tolerance stack-up analysis is a method used to evaluate the cumulative effect of tolerances allocated on the features of components and to assure that the cumulative effect is acceptable to guarantee the functionality of a product after assembly processes.
Different names refer to the same tolerance stack-up analysis, such as: tolerance analysis, tolerance-chain analysis, variation stack-up analysis and assembly-chain analysis.
The main goal of tolerance analysis is to check that the dimensions and tolerances of components are correct so that after the components are assembled, the assembled product can function as desired.
Tolerance stack-up analysis is unique because this analysis is half-science and half-art (depends on how we determine a tolerance chain)
Tolerance allocation and tolerance stack-up analysis always come "hand-in-hand" and cannot be separated each other. Tolerance stack-up analysis and tolerance allocation are iterative processes that are carried out until the desired KC of an assembly is satisfied based on given geometrical and dimensional tolerances (GD&T) on parts.
A systematic approach on tolerance stack-up analysis is necessary to reduce the number of iteration processes to determine correct tolerance values on parts features.
The experience of design and manufacturing engineers play an important role on the first determination of tolerance values. Because, the value of tolerances are directly related to how difficult a part can be made and how much the cost to make the part.
The smaller the tolerance value, the tighter the tolerance, and then the higher the production and inspection cost, and otherwise.
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