Tolerance Stack-Up Analysis Tool
1D Tolerance Stack-up Analysis: Theoretical Foundation
In mechanical design, 1D Tolerance Stack-up is the process of calculating the cumulative effect of manufacturing variations along a single linear axis. This analysis ensures that parts will assemble correctly and function as intended despite unavoidable production inaccuracies.
Core Methodologies
- Worst Case (WC) Analysis: A deterministic model where all dimensions are assumed to be at their most unfavorable limit simultaneously. It provides 100% interchangeability but often leads to over-tightened, expensive tolerances.
- Root Sum Squares (RSS): A statistical model based on the Normal Distribution. It assumes that the probability of all parts being at their extreme limits is low. The total tolerance is the square root of the sum of the squares of individual tolerances.
RSS Total = √(Tol₁² + Tol₂² + ... + Tolₙ²)
Nomenclature
- Mean (Nominal): The ideal target dimension.
- Gap/Interference: The resulting space or overlap between components after assembly.
- Sensitivity: The impact of a single component's tolerance on the final stack-up.
Interactive Stack-up Laboratory
Input your dimensions below to visualize the chain and compare Worst Case vs. Statistical results.
ANALYSIS SUMMARY
Worst Case:
0.000 ± 0.000
0.000 ± 0.000
RSS Statistical (3σ):
0.000 ± 0.000
0.000 ± 0.000
| # | Nominal | Tol (±) | Dir |
|---|
Academic References & Standards
- ASME Y14.5-2018: Dimensioning and Tolerancing Standard.
- Fischer, B. R. (2011): Mechanical Tolerance Stackup and Analysis, Second Edition. CRC Press.
- Drake, P. J. (1999): Dimensioning and Tolerancing Handbook. McGraw-Hill Education.
- ISO 2768: General tolerances for linear and angular dimensions.
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