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Understanding Statistical Tolerance Analysis - by Sigmetrix

Statistical tolerance analysis accounts for the variation in inputs to calculate the expected variation in an output. A 1D tolerance stackup analyzes variation in a single dimension. Worst-case analysis uses maximum input ranges while RSS statistical analysis considers input distributions and probabilities. Second order tolerance analysis incorporates skewness and kurtosis to better model real-world manufacturing scenarios where relationships may be non-linear. Sigmetrix software integrates with CAD systems to enable engineers to perform precise statistical tolerance analysis early in design.

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Vishwasen Khot
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160 views

Understanding Statistical Tolerance Analysis - by Sigmetrix

Statistical tolerance analysis accounts for the variation in inputs to calculate the expected variation in an output. A 1D tolerance stackup analyzes variation in a single dimension. Worst-case analysis uses maximum input ranges while RSS statistical analysis considers input distributions and probabilities. Second order tolerance analysis incorporates skewness and kurtosis to better model real-world manufacturing scenarios where relationships may be non-linear. Sigmetrix software integrates with CAD systems to enable engineers to perform precise statistical tolerance analysis early in design.

Uploaded by

Vishwasen Khot
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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UnderstandingStatisticalToleranceAnalysisby

Sigmetrix
DefinitionofStatisticalToleranceAnalysis
Astatisticaltoleranceanalysisiswhenyoutakethevariationofasetofinputstocalculatetheexpected
variationofanoutputofinterest.Inmechanicalengineering,aproductdesigniscomposedofmultiple
features,eachwithtolerancevaluesthatcontrolthevariableaspectsofthosefeatures.Statistical
toleranceanalysisisusedtounderstandhowthesetolerancescontributethevariousperformance
characteristicsofthedesign.
1DToleranceStackup
Thesimplestformoftoleranceanalysisisthesingledirection,1DToleranceStackup.A1DTolerance
Stackupiscreatedbycreatingacrosssectionofamodelandaddingthetolerancevaluesforeach
featureinastraightline.Thevariationineachcontributestotheoveralloutput/outcome.

WorstCaseAnalysisvsRSS(RootSumSquared)StatisticalAnalysis
InaWorstCaseAnalysis,eachdimensionwillhaveaminimumandmaximumvaluethatrepresentsthe
rangeofacceptabilityforthatdimension.WorstCaseanswersthequestion,ifItakethemaximumrange
oneachinput,whatisthemaximumrangeforthemeasurementofinterestorstackup?Weare
thereforedealingwiththelimitsofacceptabilityandnotprobability.
RSS(RootSumSquared)StatisticalAnalysisdoesnotfocusontheextremevalues,butfocusesonthe
distributionofthevariationforeachdimension.Eachdimensionwillhaveauniquedistributionofvalues
basedonthemanufacturingprocess.Toolwear,operatordifferences,changesinmaterialand
environmentallcontributetovariationinthedimensionvalue.Eachdimensionhasitsowndistribution
curve.
Whenyoucombinetheprobabilitiesforeachdimension(eachseparatecurve)yougettheprobabilityfor

thetotalandthereforethedistributioncurveofthetotal.Statisticalanalysisanswersthequestion,given
thedistributionofvariationoneachdimensionwhatistheprobabilitythatmyperformancecharacteristic
willfallwithindefinedacceptablelimits.ThelimitationofRSSisthatitassumesallinputsarenormally
distributedandallperformancecharacteristicshavealinearrelationshipwiththedimension.These
assumptionsdonotaccountforthebreadthofconditionsthatexistintypicalscenariosfoundin
manufacturing.
SecondOrderToleranceAnalysis
Becausemanufacturingmethodsvaryfordifferenttypesofparts,thedistributionmomentsor
parameterschangeaswell.RSSonlyusesstandarddeviationanddoesnotincludethehighermoments
ofskewnessandkurtosisthatbettercharacterizetheeffectstoolwear,formagingandothertypical
manufacturingscenarios.SecondOrderToleranceAnalysisincorporatesalldistributionmoments:

SecondOrderToleranceAnalysisisalsoneededtodeterminewhatyouroutputisgoingtobewhenthe
assemblyfunctionisnotlinear.Intypicalmechanicalengineeringscenarioskinematicadjustmentsand
otherassemblybehaviorsresultinnonlinearassemblyfunctions.Secondordercalculationsaremuch
morecomplexsohandcalculationsarenotadvisablebutthecomputationaccuracyisgreatlyimproved
andbecomesviablewithinatoleranceanalysissoftwarepackage.

SummaryofStatisticalToleranceAnalysisforpracticaluseage
Thechoiceintoleranceanalysismethodisbasedonmanyfactors,butthecanbesummarizedas
Whichmethodbestmatchesthemanufacturingandinspectionprocessoftheassembly.Forsimplefit
problems,a1Dstackupmaybesufficient.RSSissufficientforthesmallnumberofscenarioswherethe
inputsarenormalandtheassemblyrelationshipsarelinear.Forallotherscenarios,SecondOrder
ToleranceAnalysisisrequiredtoaddresstherealworldofmanufacturing.

HowdoesSigmetrixSoftware&Trainingsolutionsenableengineers&designersto
calculatepreciseStatisticalToleranceAnalysis?
Oursystemsaredesignedtointegratewithintheprimary3Dcadenvironmentsinwhichmanufacturers
designpartsandassemblies.EnablingthemtoutilizeGeometricDimensions&Tolerancingreportingto
createefficientToleranceAnalysisandVariationsforviableproducts.Thuscreatinganearlymodeling
methodpriortoproductionandassemblyforincreasedROIcreatingtheneedforaworld
renownedGD&Tsoftware.Formoreinformationtherelationshipofqualityandprofitabilityin
manufacturingclickhere,orreadthroughourwhitepapersandcasestudiesthroughoutthewebsite.
Beforeyournextprojectbegins
ContactSigmetrixTeam
USAPH:972.542.7517

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