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Tolerance Stack-Up Analysis
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 Geometric Dimensioning and Tolerancing Tolerance Stack-Up Analysis
May 13-15, 2009 Updated for the New Y14.5-2009 Standard June 10-12, 2009
September 9-11, 2009 CEUs 1.8 October 21-23, 2009 CEUs 1.8
2. Analysis of an Eleven Part Assembly Using Plus
and Minus Tolerancing
Who Should Attend Course Outline: The Principles Presented Through This Course ◗ MIN and MAX axial separation
◗ Datum planes vs. datum features
These Courses? Class exercises with answers follow each section to in this Course Will Help You: Participants Will Be Able To: ◗ The calculations ◗ Separate requirements and accumulating tolerance
This course is designed for personnel whose work augment and illustrate the key concepts of each section. ◗ Interpret and apply ASME Y14.5-2009 ◗ The loop analysis chart ◗ Tolerances in degrees; trig functions introduction

◗ First Day
◗ Calculate minimum and maximum wall thicknesses,
requires them to communicate, interpret or manufacture ◗ The numbers analysis chart ◗ Composite positional tolerancing
◗ Reduce drawing changes airspaces and interferences for assemblies

9. Five Part Rotating Assembly Analysis

products through the use of engineering drawings ◗ Finding MIN and MAX gaps
◗ Reduce interpretation errors ◗ Create loop analysis/circuit diagrams for tolerance

3. Vertical vs. Horizontal Analyses for Features of Size

and/or CAD models that use Geometric Dimensioning - Introduction
◗ bid contracts with confidence stack-up analysis for both plus and minus toleranced
and Tolerancing. In this course participants will - Geometric Characteristic Symbols, Rules dimensions and geometric tolerances ◗ Position, perpendicularity, parallelism, profile, flatness
and Principles ◗ Design for maximum functionality and producibility
specifically learn the new ASME Y14.5-2009 standard ◗ Where to start and end ◗ Threaded holes with projected tolerance zones
◗ Increase part tolerances ◗ Create both simple and complex number charts
on Dimensioning and Tolerancing. It teaches the new - How to Construct and Read a Feature Control Frame ◗ Graphing the loop ◗ Mounted screws
◗ Assure mating parts will assemble for stack-up analysis using a variety of geometric
Y14.5 symbology, rules and basic principle revisions - Material Condition Symbols and the tolerances, basic dimensions, resultant conditions, ◗ Minimum and maximum gap analysis ◗ Part to part analysis (from two parts to an infinite number)
that took the Y14.5 committee 15 years to complete.
4. Assemblies with Plus and Minus Tolerances
New Material Condition Boundaries virtual conditions and plus and minus toleranced ◗ Runout, total runout, concentricity, positional coaxiality
The result of attaining this knowledge is that: product - New Symbols, Rules and Concepts dimensions ◗ Simplifying a complex assembly
representations are able to be more specific in conveying per ASME Y14.5-2009 ◗ Do tolerance stack-up analysis for floating fastener ◗ Multiple dimension loops ◗ Determining assembly housing requirements
tolerancing needs, products can be more easily situations for clearance holes, screws and shafts
- A Rotating Assembly is Toleranced, Projected ◗ Positive and negative values ◗ Radial clearance MIN and MAX calculations
manufactured, and appropriate inspection techniques

◗ Day Two
Tolerance Zones, Datum Feature Shift ◗ Do tolerance stack-up analysis for fixed fastener ◗ Airspace vs. interferences ◗ Interference calculations
are clarified. Products designers, manufacturing

5. Floating Fastener Five Part Assembly Analysis 10. Trigonometry and Proportions
situations using, screws, clearance holes, slots, tabs,
engineers, quality engineers, inspectors, product Instructor for both courses:
in Tolerance Stack-Up Analysis
overall dimensions and projected tolerance zones
engineers and process engineers are just a few of the - Geometric Characteristic Symbols; Uses, Tolerance
James D. Meadows is an ASME Certified Senior for threaded holes
job categories that can benefit from the course material. Zones, Boundaries and Measurement Techniques ◗ Resultant and virtual conditions
Even those who have been trained in GD&T will need Level Geometric Dimensioning and Tolerancing ◗ Calculate minimum and maximum gaps for assemblies ◗ Inner, outer, and mean boundaries ◗ Rocking datum features
- Bonus Tolerancing and Allowed versus Actual
to be trained in these vast and sweeping changes that Professional. He has been a full-time GD&T trainer that use a variety of datum structures ◗ Constructing a valid datum
Deviations from True Position ◗ Converting to radii
have been instituted in this latest Y14.5 revision. This and consultant since 1982. Mr. Meadows has written ◗ Learn a system of logic and mathematics ◗ Consideration of differing orientations
- A Variety of Mating Parts are Toleranced ◗ Mixing widths and diameters
course covers all of the basics on how to interpret, eleven best-selling GD&T books. He is nationally and to analyze tolerances from measurement to assembly
- Fixed and Floating Fastener Assembly ◗ Complex loop analyses with geometric dimensioning
apply and measure GD&T per ASME Y14.5-2009. internationally recognized as a GD&T expert and is and tolerancing ◗ An in-depth assembly analysis using trigonometric
Tolerancing Formulas an active member of 12 ASME/ANSI/ISO standards functions

6. Fixed Fastener Assemblies

◗ Day Three
- Datum Feature Selection committees, such as the Y14 Main Committee, the What This Course Will Cover: ◗ Computer programs versus personal analysis
Course Description: Y14.5.1 Subcommittee, the Y14.43 Subcommittee Course participants will be trained to apply tolerance
◗ Vertical stacking as it effects horizontal housing
(Chairman), the Y14.36 Subcommittee (Chairman) ◗ Calculating overall minimum and maximum requirements
This course is based on the ASME Y14.5-2009 In this half-day session, many of the new concepts in stack-up analysis techniques to a wide variety of assemblies, assembly dimensions
and two ISO Technical Advisory Groups. from the very simple to the more complex situations ◗ When stacked parts are not flat or parallel
Dimensioning and Tolerancing Standard, and Y14.5-2009 are discussed: ◗ Mixing holes, slots, tabs and shafts
He is an extremely knowledgeable and dynamic commonly faced in industry today. Both plus and minus and ◗ Formulae to calculate worst case fit conditions
concentrates on the new symbology, rules and basic - Datum Targets ◗ Calculating minimum and maximum gaps when trig is a factor
communicator, both in print and in person, and has geometrically toleranced assemblies will be examined
principle revisions that took the Y14.5 committee - Flexible Parts and stack-up analysis taught and practiced on each. within the assembly ◗ Using proportions and trigonometry to calculate
almost 15 years to complete. You’ll learn how to interpret trained thousands of engineering and technical
- Moveable Datum Target Symbol Many different datum structures will be discussed and ◗ Projected tolerance zones for total runout as a factor fit conditions beyond the GD&T formulae
design drawings and CAD representations of product professionals for major corporations, universities,

11. The Theory of Statistical Probability

- Datum Translation Symbol analyzed. The concepts taught in this course are: loop ◗ Determining if geometric tolerances are a factor
definitions that use the ASME Y14.5-2009 Standard. DOE, DOD, NASA and the military over the last 25 analysis (also known as circuit diagrams), number charting, ◗ Ruling out features and patterns as factors
You’ll review step-by-step procedures to apply the new - Specifying Degrees of Freedom Symbology years. You cannot find anyone more ‘expert’ on virtual condition, resultant condition, inner and outer

7. A Rail Assembly
Y14.5 practices and express design requirements more - Calculating the Correct Material Condition tolerancing issues that concern design, manufacturing, boundaries, minimum airspace, maximum wall thickness, ◗ Review of statistical concepts
clearly. The results are that: product representations - Boundaries (Maximum Material Boundary, Least quality and inspection professionals. maximum interference, minimum and maximum overall - Gaussian frequency curve, standard deviations,
Material Boundary and Regardless of Material dimensions, fixed and floating fastener assembly conditions, ◗ Threaded features plus or minus 3 sigma, root sum square formula
are able to be more specific in conveying tolerancing
projected tolerance zones, the logic of stack-up analysis, ◗ Multiple geometric controls - Steps to calculate and apply statistical tolerances
needs, products can be more easily manufactured, and Boundary)
and much more. ◗ Projected tolerance zones ◗ Statistical tolerancing applied
appropriate inspection techniques are clarified. - Datum Feature BASIC Symbology
◗ Gaps with and without perpendicularityas a factor - To plus and minus toleranced assemblies
This is a comprehensive GD&T course conducted to - Specifying the Desired Material Boundary
explain Geometric Dimensioning and Tolerancing per - Datum Feature Patterns Referenced at MMB Course Schedule (Both Courses): Course Outline:
◗ Calculating interference - To geometric toleranced assemblies
◗ Theoretically vs. physically worst case possibilities ◗ When best to allow statistical tolerances and when it
the new ASME Y14.5-2009 Standard. Some of the - LMB and RMB Registration on Day 1: 7:30 AM Class exercises with answers follow each section to ◗ When logic becomes an integral step should not be
concepts covered are: all of the new symbols, rules
- Oddly Configured Datum Features ◗ The logic of statistical tolerancing

8:00 am - 4:30 pm: Day 1 and Day 2

Seminar Format: augment and illustrate the key concepts of each section. ◗ Factoring in assembly conditions
and principles instituted by the ASME Y14.5-2009

1. The Basics of Tolerance Stack Up Analysis

- Datum Feature Simulators ◗ Maximum wall thickness vs. minimum airspace ◗ Modifying the root sum square formula with a safety/

8:00 am -12:00 pm: Day 3

standard and basic GD&T usage. It also includes correction factor
(Theoretical and Physical) for assemblies
lectures and real examples, discussions and applications
Adjournment at Noon on Day 3 (without lunch). 8. Single Part Analysis
- Irregular Datum Features of Size ◗ Where to begin a stack ◗ Reintegrating the statistical tolerance into the assembly
problems on the more difficult principles of GD&T.
- Repetitive Patterns ◗ Designating positive and negative routes
You’ll have the opportunity to learn and apply techniques
- Two and Three Level Composite Position Continental breakfast is provided each day. ◗ What are you calculating, what dimensions are factors ◗ Two-single segment positional controls
in datum selection and tolerancing optimization, It is recommended that you attend
and Profile Controls Breaks with coffee and soda are planned. ◗ How to push the parts to create the worst case ◗ Switching datum reference frames and accumulating
introducing more producible tolerances, practical
datum structures and measurement methods. Group luncheons are included on Day 1 and Day 2 ◗ Which geometric tolerances are factors? geometric tolerances Geometric Dimensioning and
◗ Finding the mean ◗ Datum features a MMC (pattern shift)
Do’s and don’ts of proper tolerancing are taught Tolerancing before Tolerance
◗ Calculating boundaries for GD&T, MMC, LMC ◗ Profile tolerances, flatness
and reinforced in every segment of the course Stack-Up Analysis.
and RFS material condition modifiers ◗ Envelopes of perfect form at MMC
by showing how they apply to realistic assembly
◗ Mean boundaries with equal bilateral tolerances ◗ Creating envelopes of perfect orientation at MMC
tolerancing conditions.

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