Tolerance analysis of linear dimensional chains.

The program is designed for tolerance analysis of linear (1D) dimensional chains. The program solves the
following problems:
1. Tolerance analysis, synthesis and optimization of a dimensional chain using the arithmetic "WC" (Worst
case) method, possibly the statistical "RSS" (Root Sum Squares) method.
2. Analysis of a dimensional chain deformed as a result of temperature change.
3. Extended statistic analysis of dimensional chain using the "6 Sigma" method.
4. Tolerance analysis of a dimensional chain during selective assembly including optimization of the number
of assembled products.
All solved tasks enable work with standardized tolerance values, both in designing and in optimization of the
dimensional chain.
Data, methods, algorithms and information from professional literature and ANSI, ISO, DIN and other standards
are used in calculation. List of standards: ANSI B4.1, ISO 286, ISO 2768, DIN 7186

Control, structure and syntax of calculations.

Information on the syntax and control of the calculation can be found in the document "Control, structure and
syntax of calculations".

Information on the project.

Information on the purpose, use and control of the paragraph "Information on the project" can be found in the
document "Information on the project".

Theory - Fundamentals.
A linear dimensional chain is a set of independent parallel dimensions which continue each other to create a
geometrically closed circuit. They can be dimensions specifying the mutual position of components on one part
(Fig. A) or dimensions of several parts in an assembly unit (Fig. B).

A dimensional chain consists of separate partial components (input dimensions) and ends with a closed
component (resulting dimension). Partial components (A, B, C,) are dimensions either directly dimensioned in
the drawing or following from previous manufacturing, possibly assembly operations. The closed component (Z)
in the given chain represents the resulting manufacturing or assembly dimension, which is the result of
combining partial dimensions as a scaled manufacturing dimension, possibly assembly clearance or interference
of a component. The size, tolerance and limit deviations of the resulting dimension depend directly on the size
and tolerance of partial dimensions. Depending on how the change of partial component affects the change of
the closed component, two types of components are distinguished in dimensional chains:
- increasing components - partial components, the increase of which results in an increase of the closed
component
- decreasing components - partial components, the increase of which results in a decrease of the closed
component
When solving tolerance relations in dimensional chains, two types of problems occur:
1. Tolerance analysis - direct tasks, control
Using known limit deviations of all partial components, the limit deviation of the closed component is set.
Direct tasks are unambiguous in calculation and are usually used for checking components and assembly
units manufactured according to the specific drawing.

2. Tolerance synthesis - indirect tasks, designing

Using known limit deviations of a closed component given by the functional demands, limit deviations of
partial components are designed. Indirect tasks are solved when designing functional groups and
assemblies.
The choice of method of calculation of tolerances and limit deviations of dimensional chain components affects
manufacturing accuracy and assembly interchangeability of components. Therefore, economy of production and
operation depends on it. To solve tolerance relations in dimensional chains, engineering practice uses three
basic methods:

arithmetic method of calculation

statistical method of calculation

method of group interchangeability

Arithmetic method of calculation - WC method (Worst Case).

The most often used method, sometimes called the maximum - minimum calculation method. It works on the
condition of keeping the required limit deviation of a closed component for any combination of real dimensions
of partial components, i.e. also upper and lower limit sizes. This method guarantees full assembly and working
interchangeability of components. However, due to the demand of higher accuracy of the closed component, it
results in too limited tolerances of partial components and therefore high manufacturing costs. The WC method
is therefore suitable for calculating dimensional circuits with a small number of components or in case that
broader tolerance of the resulting dimension is acceptable. It is most often used in piece or small-lot production.
The WC method calculates the tolerance of the resulting dimension as an arithmetic sum of tolerances of all
partial dimensions. The dimensions of a closed component are therefore determined by its mean value:

and total tolerance:

Boundary dimensions of the closed component are set by the relations:

with:

i - mean dimension of ith component

Ti - tolerance of ith component
n - total of partial components
i=1,..,k - number of increasing components
i=k,..,n - number of decreasing components
Statistical methods of calculation - RSS, 6 Sigma methods.
Statistical methods of calculation of dimensional chains are based on the calculus of probability. These methods
assume that in a random selection of components during assembly, the limit values of deviations only rarely
occur with more partial components simultaneously, as is the case of combined probability. The probability of
the occurrence of limit value of deviations in manufacturing individual dimensions on one component will be
similarly small. With a certain, pre-selected risk of rejection of some components, the tolerances of partial
components in the dimensional chain can be increased.
The statistical method guarantees only partial assembly interchangeability, with a low percentage of
unfavourable cases (spoilage). With respect to larger tolerances of partial dimensions, however, it results in a
decrease in manufacturing costs. It is mainly used in mass and large-lot production, where savings in
manufacturing costs outbalance increased assembly and operating costs resulting from incomplete assembly
interchangeability of components.

The dimensions of a closed component show certain variation from the mean of the tolerance field. The
frequency of occurrence of individual dimensions follows the rules of mathematical statistics and in the outright
majority of cases it matches normal distribution. This distribution is described by the Gauss curve of
probability density, for which the frequency of occurrence of "x" dimension follows the relation:

determines the position of

maximum frequency of the resulting dimension occurrence; standard deviation defines the curve
The shape of the Gauss curve is characterized by two parameters. Mean value
"slenderness".
Gauss curve for various values of standard deviation

The area defined by the intersection of the Gauss curve with the required closed component limit dimensions
represents the expected yield of the process. Parts of the curve lying outside the tolerance interval define the
area which represents spoilage in the process.
Yield of process for centric and non-centric design

In general engineering, the manufacturing process is usually considered satisfactorily efficient on the level 3 .
That means that the upper limit UL and lower limit LL of the resulting dimension is at 3 distance from the

mean value . The area of the Gauss curve between both limits then equals 99.73% of the total area and
represents the portion of products meeting the specification requirements. The area outside these limits equals
0.27% and represents off-size products.
Expected yield of a process for various widths of the closed component tolerance field
Limit sizes

Process yield [%]

Number of rejects per

million components
produced

68.2

317310

95.4

45500

99.73

2700

 3.5

99.95

465

99.994

63

4.5

99.9993

6.8

99.99994

0.6

99.9999998

0.002

RSS (Root Sum Squares) method

This method of calculation is a traditional as well as the most widespread method of statistical calculation of
dimensional chains. The RSS method is based on the assumption that individual partial components are
manufactured with the level of process capability (quality) 3 .

Their limit values therefore match tolerance interval

3 , and standard deviation is set by the relation:

The dimensions of a closed component are determined by its mean value:

and standard deviation:

with:

i - standard deviation of ith component

i - mean dimension of ith component
Ti - tolerance of ith component
n - total of partial components
i=1,..,k - number of increasing components
i=k,..,n - number of decreasing components

"6 Sigma" method

In general engineering, the manufacturing process was traditionally considered satisfactorily efficient on level
3 . That means an estimated 2700 rejected products per one million produced. Although such portion of off-size
products seems very good at first sight, it is considered ever more and more insufficient in some spheres of
production. Besides, it is almost impossible to keep the mean value of the process characteristic curve exactly in
the middle of the tolerance field in the long term. In case of large production volumes, the mean value of the
process characteristic shifts in the course of time due to the influence of various factors (erroneous set-up, wear
of tools and jigs, temperature changes, etc.). A shift of 1.5 from the ideal value is typical. In case of

traditionally approached processes with 3 level of capability, that represents an increase of the off-size product
ratio to approx. 67000 per one million produced.

It is obvious that a manufacturing process with such level of spoilage is unacceptable. Therefore, recently the
modern "6 Sigma" method has been used more and more frequently to assess the quality of manufacturing
processes. The concept of the method is to achieve such target that the mean value of the process

characteristic is at 6 distance from both tolerance limits. In such efficient manufacturing process, the ratio of
3.4 off-size products per one million produced is achieved even after the expected mean shift of 1.5 .

The "6 Sigma" method is relatively new; it became popular rather broadly only in the 1980s and 1990s. It was
put into practice for the first time by Motorola and it is considerably used mainly in the USA. Its utilization is
suitable in case a higher quality of manufacturing processes is required and for large production volumes where
the mean value of the process characteristic may be shifted.
The "6 Sigma" method is a modification of the standard "RSS" method and introduces two new parameters, (Cp,
Cpk), called process capability indexes into the problems of dimensional chain solutions. These capability
indexes are used to assess the manufacturing process quality.
The Cp capability index assesses the quality of the manufacturing process using the comparison of specified
tolerance limits with the traditional capability level 3 .

For the process with tolerance interval

3 , Cp will equal 1. With high quality processes where tolerance

limits are at 6 distance from the mean value, the capability index will be Cp=2.

The Cpk index is a modified Cp index for mean shift of the process characteristic.

where the mean shift factor k ranges between <0..1> and determines the relative value of the mean shift
related to half of the tolerance interval. In case of a typical mean shift of process characteristic of 1.5 , the
mean shift factor for the process with "6 Sigma" quality will be k=0.25 and the capability index Cpk=1.5.

The effective standard deviation of the process may then be estimated as:

After the application of capability indexes on all partial components of the dimensional chain, the dimensions of
the closed component can be described similarly to the "RSS" method by its mean value
deviation:

and standard

with:

ei - effective standard deviation of ith component

In case of the "6 Sigma" method, a manufacturing process with resulting 4.5 capability ratio is typically
considered satisfactory.
Group interchangeability method (selective assembly).
The selective assembly method is used in mass and large-lot production of precise products which do not require
working interchangeability of components inside the product. The assembly of the product is preceded by
sorting of individual components into tolerance subsets. Manufacturing dimensions of components may be
prescribed with a larger tolerance. The narrowed resulting dimensional tolerance is achieved by the functional
matching (combination) of sorted subsets. To determine the resulting dimension of the closed component, the
above-specified "WC" method is used, except that the calculation does not include all manufacturing tolerances
of partial components, but only narrowed tolerances applicable for the selected tolerance subset.
The selective assembly method is a very effective method of solving dimensional chains, enabling a substantial
increase in manufacturing tolerances of partial components and thus a significant reduction in manufacturing
costs. On the other hand, application of this method places increased demands on product assembly. Operating
costs will also increase, as it is usually necessary to replace the whole assembled component in case of wear or
damage of a partial component.
If the selective assembly method is to be effective, it is necessary to solve the problem of optimum selection
(combination) of components. The components have to be matched so that it is possible to assemble the
maximum possible number of products meeting the functional requirements with the given number of
manufactured components. This task can be divided into two parts:
1. Designing part of the task
Finding all combinations of individual subsets of partial components for which the functional requirements are
met by the closed component.
This task has to be solved before the beginning of production, in the process of designing the dimensional chain.
The number of suitable combinations will depend on the overall manufacturing tolerance of partial components,
as well as the selected number of tolerance subintervals. The dimensional chain should be designed so that the
number of acceptable assembly combinations ranges within reasonable limits.
For small numbers of suitable combinations, it will probably not be possible to use all manufactured parts during
the assembly. That is why the assembly yield of the process decreases and the production becomes more
expensive. The critical index is represented by the state when some of the subsets appear unacceptable already
in the design stage.
On the other hand, a large number of suitable combinations signal an ineffective design. The tolerance chain
could probably be designed in a more optimal way, with larger tolerances of partial components or with a
smaller number of tolerance subintervals.
2. Technological part of the task
Optimization of the number of assembled products for the given numbers of manufactured components in
individual tolerance subintervals.
This task has to be solved repeatedly during production, always before replenishing the stock before the
beginning of assembly itself. The main aim of the task is to determine the optimum assembly procedure in order
to achieve the biggest possible number of assembled products. When solving the task, we have to choose the
optimum set of combinations from the subset of acceptable combinations used in assembly and at the same
time determine the number of products assembled within each used combination.
The algorithm of optimization is based on gradual assembly of individual products by retracting the components
from selected subsets. In the first stage, the calculation estimates the minimum and maximum possible number
of assembled products. In further stages it retracts the parts from the selected subsets according to a preselected scheme so that the lower estimate of the number of assembled products increases as fast as possible
and the upper estimate decreases as slowly as possible.
The solution to the task usually is not unambiguous. Several different assembly procedures leading to an
identical number of assembled products can often be found. That is why the number of used assembly
combinations is used as another optimization criterion. The minimization of the number of used combinations

results in simplification and speeding-up of assembly, i.e. in the reduction of manufacturing costs. In some
practical applications, both criteria are identically important.

Units of calculation, standardized tolerances.

This line is used to switch over the system of units for calculation and to select standardized tolerances.
Units of calculation.
In the list box, select the required system of units for calculation. After switching the units, all values will be
automatically recalculated.
Warning: If you use optimization functions of program [1.11, 8.10], it is necessary to restart optimization after
changing the units.
Standardized tolerances.
When defining the dimensional chain in paragraphs [1.1, 3.2, 5.1, 7.1], the tolerance is also set for each
dimension. To simplify work, the program is provided with a tool for automatic selection of standardized
tolerances.
The program includes a set of basic dimensional tolerances according to ISO, or ANSI. With respect to the type of
deviation and applied standard, the tolerances are divided into 5 subsets:

standardized deviations of length dimensions according to ISO 286

standardized deviations of length dimensions according to ANSI B4.1

standardized bearing fits according to ISO 286

preferred fits according to ANSI B4.1

non-prescribed limit deviations of length dimensions according to ISO 2768

Each subset contains a set of list boxes and buttons in the heading of the workbook. Set the required
parameters of tolerance, possibly fits (accuracy level, tolerance field, ..) in the list boxes. Using the buttons,
insert the dimensions of the required deviation into the appropriate place in the input table - the line with the
active cell.
Tolerances according to ISO are defined by the standard in [mm] and are intended for calculation in SI units.
Tolerances according to ANSI are defined in [in] and are intended for calculation in Imperial units. In case of use
of standardized tolerances defined in units other than those set in the calculation, the deviations of the
dimension will be automatically recalculated and rounded.
Warning: The program enables setting standardized tolerance only for one dimension in one step. If more cells
in several lines are selected in the input table, the automatic tolerance set-up will not be performed.
Note: If the selected tolerance is not defined by the standard for the given nominal dimension, zero values of
deviation are set in the input table.
Hint: For more detailed information on standardized tolerances, see workbook "Tolerances and fits".

A. Basic tolerance analysis.

This chapter enables the tolerance analysis, synthesis and optimization of dimensional chain using the
arithmetic "WC" method, possibly statistic "RSS" method to be performed.
The "Worst Case" method is used in case full assembly and working interchangeability of components is
required and is suitable for solving dimensional circuits with a small number of components or if rougher
tolerance of the final dimension is acceptable. The statistical "Root Sum Squares" method guarantees only
partial assembly interchangeability and is used to decrease manufacturing costs in mass and large-lot
production.
Designing procedure.
The task of designing and optimization of a dimensional chain consists of the following steps:
1. Define dimensions and tolerances of all partial components in table [1.1].
2. In column 8 of table [1.1] mark the partial components with tolerances to be optimized.
3. Set required limit sizes of the closed component [1.3].
4. Set required optimization parameters [1.7 - 1.10].

5. Start optimization [1.11].

6. Check the dimensions of the closed component in paragraph [2].
7. Save the workbook with the suitable solution under a new name.
Hint: You can find an illustration of the procedure in designing a dimensional chain for the "Worst Case" method
in example 1, for the "Root Sum Squares" method in example 2.

Design and optimization of dimensional chain. [1]

This paragraph is intended for the design of a dimensional chain and optimization of tolerances of selected
partial components.
1.1 Design of dimensional chain,
This table is used to define the dimensions of individual partial components of a dimensional chain. Each line of
the table belongs to one partial component. The meaning of the table is obvious from the following description:
Column 1 - Name of component is an optional parameter.
Column 2 - Set the nominal dimension of partial component. "Increasing" components are positive,
"decreasing" components are set with negative value.
Column 3 - Set upper and lower deviation of the dimension. Press the selected button in the heading of the
workbook to insert the deviations appropriate to the selected tolerance into the table.
Column 4..7 - These columns contain the calculation of limit sizes, mean dimension and standard deviation of
all partial components.
Column 8 - Set the switches to mark all partial components with tolerances to be optimized. Checking the field
marks fixed tolerance, which will remain without changes after optimization.
Column 9,10 - After optimization, these columns contain designed (optimized) deviations. The left column
contains results of optimization using the arithmetic "WC" method; the right one contains the results using the
statistical "RSS" method. Press the button located on the bottom line of the table to transfer the designed
deviations into the input column.
Note: On the bottom line of the table, the basic dimensions of the closed component are calculated in real time.
For detailed parameters of the closed component, see paragraph [2].
1.2 Optimization of dimensional chain.
This paragraph is used to optimize tolerances of selected partial components of the dimensional chain defined in
table [1.1]. Before the beginning of optimization, set the required limit sizes of the closed component [1.3] and
set optimization parameters [1.6]. Start optimization using the button in line [1.11].
Optimization is performed for both calculation methods (WC, RSS) simultaneously. Designed deviations are listed
in table [1.1], for resulting dimensions of the closed component see paragraph [2].
1.3 Limit sizes of closed component.
This paragraph defines required limit sizes of the closed component determined by functional requirements of
the product.
1.7 Optimization process.
Select one of the following optimization modes in the list box:
1. Design centring
With the size of tolerance preserved, the calculation will adjust limit deviations of selected partial components
so that the mean dimension of the closed component is as close to the mean of the required tolerance interval
determined by limits [1.3] as possible. Depending on the set-up of tolerance accuracy [1.8], the calculation
works in two modes:

Calculation of limit deviations

Position of limit deviations of optimized dimension is set by calculation. Accuracy of calculation (number of
decimal places) follows the choice in line [1.8]. In this mode, the calculation enables use of tolerances with
both positive, possibly negative deviations.

Design of standardized deviations

In this mode, the program tries to use preferentially symmetric or one-sided deviation. Upper deviation of
optimized dimension always remains positive, lower deviation remains negative.

2. Optimization of tolerances
With the mean value of the tolerance interval preserved, the calculation adjusts the tolerance of selected partial
components so that the resulting dimensions of the closed component meet the requirements of the
specification determined by limits [1.3].

3. Centring and optimization

Combination of both previous procedures
1.8 Tolerance accuracy.
In the list box select the type and accuracy of tolerances used during optimization.
In case any of first five items in the list box are selected, the size of the optimized tolerance will be set by the
calculation, with a predetermined level of accuracy (number of decimal places). For optimized tolerances, the
mutual ratio of their sizes is kept.
In case the remaining two items in the list box are selected, the size of optimized tolerances will match
standardized values. For calculation in SI units, standardized tolerances according to ISO 286 are used, for
calculation in Imperial units they are used according to ANSI B4.1. In case the "Same tolerance grade" item is
selected, the standardized tolerances from the same tolerance grade will be used for all optimized dimensions.
Warning: The choice of tolerances affects the size of optimized tolerances as well as the method of design
centring (see [1.7]).
1.9 Minimum tolerance size.
Set the minimum size (accuracy grade) of tolerances which can be used during optimization.
Note: For calculation in SI units, the minimum tolerances are set according to ISO 286, for calculation in
Imperial units according to ANSI B4.1.
1.10 Required yield.
Choose the minimum required yield of the manufacturing process from the list box.
Hint: Traditionally, a manufacturing process with resulting capability rate 3 (yield 99.73 %) is considered
satisfactorily capable.
Note: This parameter is significant only for the statistical RSS method of calculation.

Parameters of closed component. [2]

This paragraph presents in a well-arranged form the detailed parameters of a closed component for the
dimensional chain defined in paragraph [1]. For comparison, it contains the resulting dimensions of closed
components for both original and optimized tolerances of partial components.
2.1 Required limit sizes.
In this paragraph, define the required limit sizes of the closed component given by functional requirements of
the product.
Note: If the check box is checked, the limit sizes defined during optimization in [1.3] will be used.
2.5 Arithmetic calculation ("WC" method).
This paragraph shows resulting dimensions of the closed component in case the arithmetic "Worst Case"
calculation method is used.
Note: Graphic presentation of resulting dimensions, see line [2.19].
2.10 Statistical calculation ("RSS" method).
This paragraph shows parameters of the closed component in case the statistic "Root Sum Squares" calculation
method is used.
Productive yield [2.13] specifies the expected ratio of products meeting the specification requirements, i.e.
products with a resulting closed component dimension within the interval specified by limit sizes [2.1]. Rejection
of the manufacturing process [2.14] represents the estimated number of off-size products per million produced
products.
Note: Graphic presentation of resulting dimensions, see line [2.20].
2.15 Limit sizes.
This paragraph contains the calculation of limit sizes of the closed component for the selected yield of the
manufacturing process.
Hint: Traditionally, a manufacturing process with resulting rate of capability 3 (yield 99.73 %) is considered
satisfactorily capable.

B. Deformation of system due to temperature change.

The calculation used in chapter [A] is based on the assumption that the designed component will work at
temperatures close to the basic temperature of 20C (68F) that the dimensions and tolerances of partial
components were set at. If the components operate permanently at higher working temperatures, their
dimensions are deformed during operation. This chapter is therefore meant to analyse the linear dimensional

chain deformed as a result of the working temperature change. To check the resulting dimension of the closed
component, the arithmetic "WC" or statistic "RSS" methods can be used.

Design of dimensional chain. [3]

In this paragraph, define the dimensional chain and working temperature for the operation of the designed
component.
3.1 Working temperature.
Set the expected working temperature for the operation of the designed component.
3.2 Design of dimensional chain.
This table is used to define the dimensions of individual partial components of the dimensional chain. One line of
the table belongs to each partial component. The meaning of columns in the table is obvious from the following
description:
Column 1 - Name of component is an optional parameter.
Column 2 - Set the nominal dimension of the partial component. "Increasing" components are positive; set the
"decreasing" components with negative value.
Column 3 - Set the upper and lower deviation of the dimension. Press the selected button in the workbook
heading to insert the deviations appropriate to the selected tolerance into the table.
Column 4,5 - Manufacturing (assembly) dimensions of partial components are calculated in these columns.
Column 6 - Select the material of the component in the list box.
Column 7 - Set the heat expansion coefficient. If the check box in the table heading is checked, the values will
be set automatically according to the selected material and working temperature [3.1].
Column 8,9 - In these columns, dimensions of partial components at working temperature are calculated.
Note: In the bottom line of the table, the basic dimensions of the closed component are calculated in real time.
For detailed parameters of the closed component, see paragraph [4].
Warning: Automatically designed values of heat expansion coefficient are calculated for the proper working
temperature using empirically obtained coefficients common to the selected group of materials. Although the
values obtained in this way are close to the values obtained by measuring the specific materials, we recommend
that the values according to the material sheet or manufacturer's specifications be used for the final
calculations.
Hint: In case you only perform a check of the dimensional chain designed in chapter [A], use the function of
automatic data transfer.

Parameters of closed component. [4]

This paragraph shows in a well-arranged form the detailed parameters of a closed component for the
dimensional chain defined in paragraph [3]. For comparison, the resulting dimensions of the closed component
during assembly (20 C) and at working temperature are given here.
4.2 Heat expansion coefficient.
Set the coefficient of heat expansion of the closed component material.
Hint: If the check box in line [4.1] is checked, the coefficient will be set automatically according to the selected
material and working temperature [3.1].
4.3 Required limit sizes.
In this paragraph define the required assembly dimensions of the closed component. Limit sizes of the closed
component at working temperature are calculated automatically in dependence on the selected heat expansion
coefficient [4.1].
4.7 Arithmetic calculation ("WC" method).
This paragraph shows resulting dimensions of the closed component in case the arithmetic "Worst Case"
calculation method is used.
Note: Graphic presentation of resulting dimensions, see line [4.21].
4.12 Statistical calculation ("RSS" method).
This paragraph shows parameters of the closed component in case the statistic "Root Sum Squares" calculation
method is used.
Productive yield [4.15] specifies the expected ratio of products meeting the specification requirements, i.e.
products with a resulting closed component dimension within the interval specified by limit sizes [4.3]. Rejection
of the manufacturing process [4.16] represents the estimated number of off-size products per million produced
products.
Note: Graphic presentation of resulting dimensions, see line [4.22].

4.17 Limit sizes.

This paragraph contains the calculation of limit sizes of the closed component for the selected yield of the
manufacturing process.
Hint: Traditionally, a manufacturing process with resulting rate of capability 3 (yield 99.73 %) is considered
satisfactorily capable.

C. Extended statistical analysis (6 Sigma).

This chapter enables tolerance analysis of a linear dimensional chain using the statistical "6 Sigma" method to
be performed.
The "6 Sigma" method is a modern statistical method used for the assessment of manufacturing process quality.
It is especially suitable in case of a requirement for higher quality manufacturing processes and for large
volumes of production, where the mean value of the process characteristic may be shifted. The objective of the
method is to achieve the mean value of the process characteristic at 6 distance from both tolerance limits. For
such capable manufacturing process, the rate of 3.4 off-size products per million manufactured is achieved even
at the expected mean shift.

Hint: Detailed description of the "6 Sigma" method, see theoretical part of user's guide.

Design of dimensional chain. [5]

This paragraph is meant for the design of a dimensional chain.
Hint: The meaning and a detailed description of parameters used in this paragraph can be found in the
theoretical part of the user's guide.
5.1 Design of dimensional chain.
This table is used to define the parameters of individual partial components in a dimensional chain. One line of
the table belongs to each partial component. The meaning of columns in the table is obvious from the following
description:
Column 1 - Name of component is an optional parameter.
Column 2 - Set nominal dimension of partial component. "Increasing" components are positive; set the
"decreasing" components as a negative value.
Column 3 - Set upper and lower deviation of the dimension. Press the selected button in the heading of the
workbook to insert the deviations appropriate to the selected tolerance into the table.
Column 4 - In the list box choose the type of theoretical frequency distribution. As a standard, normal
distribution, which best matches the real distribution of random process quantities in the outright majority of
cases, is used to describe the manufacturing processes.
Diagram of theoretical frequency distribution for normal distribution

Diagram of theoretical frequency distribution for uniform and triangular distribution

Column 5 - Set the capability index of the manufacturing process. If the check box in the table heading is
checked, the values appropriate to the selected type of theoretical frequency distribution will be used
automatically.
Column 6 - Set the factor of the process characteristic mean shift. This factor determines the relative value of
mean shift related to half the tolerance interval. For a manufacturing process with "6 Sigma" quality, the mean
shift factor k=0.25 is usually used.
Column 7 - In this column, the modified index of capability is calculated for the mean shift of the process
characteristic.
Column 8,9 - In these columns, the mean value and effective standard deviation of the process are calculated.
Hint: The meaning and a detailed description of parameters used in this paragraph can be found in the
theoretical part of the user's guide.
5.2 Parameters of selected input component.
In this paragraph, the detailed parameters of the selected input component are presented numerically and
graphically in the way it was defined in table [1.1].
Hint: The meaning and a detailed description of parameters used in this paragraph can be found in the
theoretical part of the user's guide.

Parameters of closed component. [6]

This paragraph shows in a well-arranged form the detailed parameters of a closed component for the
dimensional chain defined in paragraph [5].
6.1 Required limit sizes.
In this paragraph, define the required limit sizes of the closed component given by functional requirements of
the product.
6.5 Statistical calculation ("6 Sigma" method).
This paragraph shows the parameters of a closed component using the statistical "6 Sigma" calculation method.
Productive yield [6.11] specifies the expected ratio of products meeting the specification requirements, i.e.
products with a resulting closed component dimension within the interval specified by limit sizes [6.1]. Rejection
of the manufacturing process [6.12] represents the estimated number of off-size products per million produced
products.
Hint: A detailed description of the "6 Sigma" method can be found in the theoretical part of the user's guide.
6.13 Limit sizes.
This paragraph contains the calculation of limit sizes of the closed component for the selected yield of the
manufacturing process.
Hint: For the "6 Sigma" method the manufacturing process with a resulting capability rate 4.5 is considered
satisfactory.

D. Selective assembly.
This chapter enables tolerance analysis of a linear dimensional chain using the group interchangeability
(selective assembly) method to be performed.
The selective assembly method is used in mass and large-lot production of precise products which do not require
working interchangeability of components within the product. Product assembly is preceded by the sorting of
individual components into tolerance subsets. Manufacturing dimensions of components can be prescribed with
bigger tolerance. Narrowed tolerance of the resulting dimension is achieved by practical matching (combination)
of sorted subsets.
Designing procedure.
The task of designing the dimensional chain consists of the following steps:
1. In table [7.1] define the number, dimensions and tolerances of components that the resulting product
will be assembled from. Further select the number of tolerance subsets (subintervals) here for each
component, which the components will be sorted into before assembly.
2. In paragraph [8.1] set assembly parameters.
3. Set the required limit sizes of the closed component [8.4].
4. Search for all suitable assembly combinations [8.10].
5. Check the search results in paragraph [8.11]. You can assess the quality of the dimensional chain design
from the number of suitable assembly combinations [8.13]. A further guide for the assessment of design
quality is possible unsuitability of a tolerance subset (table [8.14]).
6. Adjust the dimensional chain parameters for the ineffective design in table [7.1] and repeat the search
for suitable assembly combinations [8.10].
7. Save the workbook with the suitable solution under a new name.
Besides the dimensional chain design itself, the optimization of a number of assembled products for the
specified numbers of manufactured components [9] is usually a part of the solution. This task has to be solved
repeatedly during production, whenever the stock is replenished before the beginning of assembly.
Hint: You can find an illustration of the procedure in designing a dimensional chain using the selective assembly
method in "example".

Design of dimensional chain. [7]

This paragraph is intended for designing and check of dimensional chain.
In table [7.1] define the number, dimensions and tolerances of all components that the final product will be
assembled from. Further select the number of tolerance subsets (subintervals) for each component that the
component will be sorted into before the assembly. In paragraph [7.2] you will find the limit sizes of the closed
component for any assembly combination of sorted component subsets.
7.1 Design of dimensional chain.
This table is used to define the dimensions of individual partial components (parts) of the dimensional chain.
One line of the table belongs to each component. The meaning of columns in the table is obvious from the
following description:
Column 1 - Set the number of identical components joining the dimensional chain.
Column 2 - Name of component is an optional parameter.
Column 3 - Set the nominal dimension of the partial component. "Increasing" components are positive; set the
"decreasing" components as a negative value.
Column 4 - Set the upper and lower dimensional deviation. Press the selected button in the workbook heading
to insert deviations appropriate to the selected tolerance into the table.
Column 5 - Set the number of tolerance subsets (subintervals) that the component will be sorted into. You will
set the identical number of subsets for all components using the selection from the list box in the table heading.
Column 6..11 - In these columns the limit sizes of all tolerance subintervals are calculated. Individual subsets
are marked with a numerical index in the heading of table. Together with the component marking, the index is
used to unambiguously describe the selected assembly subset (A1, A2, B1, B2, B3, ...).
7.2 Dimensions of closed component.
In the first line of the table, the limit dimensions of the closed component determined by the "Worst Case"
method for full tolerances of partial components are specified. This data is only informative and is significant
mainly for design centring. In case of well and efficiently performed design of a tolerance chain, the mean
dimension specified here should be as close to the required dimension [8.7] as possible.

In the second line you will find the limit sizes of the closed component for any assembly combination of sorted
component subsets. You can set the required assembly combination using the appropriate tolerance subsets in
list boxes.

Component pairing. [8]

Solving the task of correct component pairing is an inseparable part of designing a dimensional chain. The
purpose of this task is to find such assembly combinations of individual component subsets for which the closed
component meets the functional product requirements. The total of found combinations is the criterion for
assessment of the design quality. The dimensional chain should be designed so that the number of suitable
assembly combinations ranges within reasonable limits.
For small numbers of suitable combinations, it will probably not be possible to use all manufactured parts during
assembly. That way the assembly yield of the process decreases and production becomes more expensive. The
critical index is the state when some subsets seem unacceptable already in the design stage.
On the other hand, a large number of suitable combinations signal an ineffective design. The tolerance chain
could probably be designed in a more optimal way, with larger tolerances of partial components or with a
smaller number of tolerance subintervals.
8.1 Assembly parameters.
The selective assembly method guarantees only partial (group) assembly interchangeability within the selected
assembly combinations. In case of wear or damage of a partial component during operation, it is necessary to
replace the whole assembled component. That is why the selective assembly method is used especially in the
production of precise products, when working interchangeability of components inside the product is not
required.
Although it will result in increased manufacturing costs, it may still be more economically advantageous in case
of some products to ensure complete working interchangeability of at least one component. For such defined
requirement, we can apply two different solutions (methods) when solving the task of selective assembly:

Ensuring full interchangeability of the selected component while keeping functional

requirements of the product set during assembly
This task is already solved during the design of the dimensional chain. In table [7.1] set the number of
tolerance subsets equal to one for the selected component. In list box [8.2] select "No".

Ensuring full interchangeability of the selected component in case variable functional criteria
are required
More often in cases when less strict functional criteria are required from the product after replacing the
component than during assembly. When solving this task, select "Yes" in line [8.2] and select the appropriate
component in list [8.3] for which full working interchangeability should be ensured. In paragraph [8.4] set
the adjusted limit sizes of the closed component for the case of component replacement.

8.4 Required limit sizes.

In this paragraph, define the required limit sizes of the closed component determined by the functional
requirements of the product. The first column shows limit sizes of the closed component during product
assembly. The second column shows limit sizes when the selected component is replaced.
8.8 Search of suitable assembly combinations.
This paragraph is used to search for all assembly combinations for which the closed component meets the
functional requirements of the product specified in paragraphs [8.1, 8.4]. The program works in two modes:

search of all suitable assembly combinations

search of acceptable combinations for product assembly with one pre-selected subset

Set the search mode in list box [8.9]. Run the search using the button in line [8.10], results are specified in
paragraph [8.11].
8.12 Total possible combinations.
This parameter specifies the total of all assembly combinations that can be used in assembly of the product.
8.13 Number of suitable combinations.
This parameter specifies the number of all found assembly combinations for which the closed component meets
the functional requirements of the product specified in paragraphs [8.1, 8.4]. The total of found combinations is
then the criterion for the design quality assessment. The dimensional chain should be designed so that the
number of suitable assembly combinations ranges within reasonable limits.
For small numbers of suitable combinations, it will probably not be possible to use all manufactured parts during
assembly. That way the assembly yield of the process decreases and production becomes more expensive.

On the other hand, a large number of suitable combinations signal an ineffective design. The tolerance chain
could probably be designed in a more optimum way, with larger tolerances of partial components or with a
smaller number of tolerance subintervals.
8.14 Table of suitable combinations / Unused subsets.
The table of suitable combinations shows assembly combinations with the closed component meeting the
functional requirements of the product specified in paragraphs [8.1, 8.4]. The resulting dimensions of close
component for the selected combination are specified in paragraph [8.15].
The table of unused subsets shows all tolerance subsets (subintervals) for which no acceptable assembly
combination can be found. Products sorted into these subsets cannot be used during assembly. The assembly
yield of the process decreases and production becomes more expensive. For a correctly designed dimensional
chain, this table should remain empty.
Note: The table of suitable assembly combinations contains maximally 1000 found combinations and provides
initial information for optimization of the number of assembled products in paragraph [9].
8.15 Dimensions of closed component.
This paragraph numerically and graphically presents the resulting dimensions of the closed component for the
assembly combination selected in table [8.14]. The first column shows limit sizes of the closed component
during assembly. The second column gives the limit sizes in case the selected component is replaced.

Optimization of number of completed products. [9]

If the selective assembly method is to be effective, it is necessary to solve the problem of optimal choice
(combination) of components. The components have to be matched so that it is possible to assemble the
maximum possible number of products meeting the functional requirements using the given number of
manufactured components.
This task has to be solved repeatedly during production, whenever the stock is replenished before assembly
itself is started. The main part of the task is to determine an optimum assembly procedure in order to achieve
the largest possible number of assembled products. When solving the task, we have to choose the optimum set
of combinations from the subset of acceptable combinations [8.14] used in assembly and at the same time
determine the number of products assembled within each used combination.
The solution to the task is not usually unambiguous. It is often possible to find several different assembly
procedures leading to an identical number of assembled products. That is why the number of used assembly
combinations is used as another optimization criterion. The minimization of the number of used combinations
results in simplification and speeding-up of assembly, i.e. a reduction in manufacturing costs. In some practical
applications both criteria are identically important.
Warning: The list of suitable assembly combinations [8.14] provides initial information for solving the
optimization problem. For correct functioning of the calculation, the data in this list have to be up-to-date and
match the designed dimensional chain [7.1]. Before running the optimization it is necessary to run the search of
suitable assembly combinations in line [8.10] at least once.
9.1 Number of components in individual subsets.
Set numbers of manufactured components in individual tolerance subintervals in the table.
Note: You can find limit sizes of all tolerance subintervals in table [7.1].
9.3 Optimization method.
Select the required optimization method from the list box.

Optimization of number of assembled products - methods A, B, C

The task of optimization of the number of assembled products can be highly time-consuming. The speed of
solution depends on the number of components set in individual tolerance subintervals [9.1] and the
number of suitable assembly combinations [8.13]. Especially in case of large numbers of components, the
common optimization method results in an unreasonably slow solution, even on a fast computer. That is why
in practice simplified optimization methods are often used. As opposed to the basic method, these modified
methods do not guarantee that the absolute maximum number of assembled products can be found;
however they result in a significant speeding up of the calculation.

Minimization of number of used combinations - method D

Besides the demand for assembling the maximum number of products, the demand for minimization of the
number of assembly combinations which will be used for assembly of the product often occurs in practice.
Minimization of the number of used combinations results in simplification and speeding up of the assembly,
which means a reduction in manufacturing costs. In some practical applications both criteria are identically
important. Set the mutual rate of importance of both criteria in line [9.4].

Note: Although the primary request in case of methods A, B and C is to find the maximum number of assembled
products, even these methods enable, to a certain limited degree, minimization of the number of used
combinations to be performed.
9.4 Optimization criterion.
Besides the demand to assemble the maximum number of products, the demand to minimize the number of
assembly combinations which will be used for assembly of the product often occurs in practice. With a
decreasing number of used combinations, however, the total of assembled products also decreases. It is obvious
that both these demands are antagonistic. Therefore, the parameter specifying the weight (importance) of
individual criteria has to be specified during optimization. Set the mutual rate of importance of both criteria
using the scroll bar.
Note: This parameter is important only if the last optimization method "D" in line [9.3] is selected. In case of
other methods, the primary request is to find the maximum assembled products and minimization of assembly
combinations is used only as an additional criterion.
9.5 Optimization.
The solution of the problem of optimization of the number of assembled products is not usually unambiguous.
Several different assembly procedures resulting in the same number of assembled products can often be found.
Therefore, the calculation offers the choice of selecting from several different solutions put together using
different optimization schemes (algorithms). Select the solution in the list box before running the optimization.

Solutions 1 to 10
Basic solutions assembled according to the set, pre-selected optimization scheme.

Random scheme
If you choose this item, you will obtain other solutions assembled using a randomly selected optimization
scheme.

Batch processing
If you choose this item, the program will gradually perform optimization for all 10 basic solutions. The most
suitable solution will then be chosen with respect to the maximum number of assembled products and
minimum number of used assembly combinations.

Warning: The list of suitable assembly combinations [8.14] is initial information for the solution to the
optimization problem. For proper functioning of the calculation, the list has to include updated information and
meet the designed dimensional chain [7.1]. Before running the optimization, it is therefore necessary to perform
a search of suitable assembly combinations in line [8.10] at least once.
9.6 Optimization results.
In this paragraph you can find the basic qualitative parameters of the designed assembly procedure. A detailed
specification of the optimized assembly procedure can be found in table [9.12].
9.12 Summary of used assembly combinations.
This table shows the detailed specification of an optimized assembly procedure. The left column shows all
assembly combinations used for the product assembly. The right column gives the number of products
assembled within each combination.
9.13 Number of unused components.
This table shows the numbers of remaining (unused) components which could not be used in product assembly.

Examples.
For the illustration of problems of tolerance analysis of linear dimensional chains, the user's guide is provided
with several practical examples of utilization of this calculation:

"Example 1" - Design and optimization of linear chain using "Worst Case" method

"Example 2" - Design and optimization of linear chain using statistical "Root Sum Squares" method

"Example 3" - Production and assembly of roller bearings using selective assembly method

Setting calculations, change the language.

Information on setting of calculation parameters and setting of the language can be found in the document
"Setting calculations, change the language".

Workbook modifications (calculation).

General information on how to modify and extend calculation workbooks is mentioned in the document
"Workbook (calculation) modifications".

Design and optimization of linear dimensional chain using "Worst Case"

method.
For the example of fit of the shaft in the case (see the picture), design manufacturing tolerances of individual
components so that 0.05 - 0.80 mm clearance in fit is ensured. The designed tolerances have to match the
following technological production requirements:
- contact areas of the case will be machined using milling
- turning will be used to machine the shaft and bearing bushings

with:
A ....... Shaft
B ....... Retainer ring 40 DIN 471
C,G .... Bearing 6308 DIN 625 SKF
D,F .... Bearing sleeve
E ....... Case
Z ....... Clearance in fit <0.05 to 0.80> mm

Solution of problem.
If we start from the dimensional chain diagram

we can describe clearance in fit for the given problem using the relation Z = A - B - C + D - E + F - G
In the design of manufacturing tolerances itself we have to proceed from the technological demands of
production. The size of designed tolerances of individual components has to range within the manufacturing
accuracy achievable with the selected machining method. In case of milling, commonly achieved manufacturing
accuracy ranges between tolerance levels 9 and 13, in case of turning it ranges between tolerance levels 6 and
12.
Hint: You will find a table of achieved manufacturing accuracies for various methods of machining in the
workbook "Tolerances and fits".
Design of dimensional chain.
We can divide the solution of the task of designing and optimization of a dimensional chain into the following
steps:
1) Using the above-mentioned relation, we will define the dimensional chain in table [1.1]. Partial components of
the chain are formed by individual components; required clearance in fit is the closed component of the
dimensional chain.
2) In case of components with fixed tolerance prescribed by the manufacturer (bearings, retained ring), we will
set the appropriate dimensional deviations in the input table.

3) Contact areas of the case will be machined by milling; in the first design we will therefore select the size of
tolerance at accuracy level 11 for the width of the case.
4) By checking appropriate switches in column 8 of the table, we will mark all components with fixed tolerance.

5) In paragraph [1.3] we will set limit values of the required clearance in fit.
6) In list box [1.7] select the "Centring and optimization" method, in list [1.8] choose "Standard tolerances".
7) Turning will be used to machine all components for which we want to design tolerances in the next step. In
the list box [1.9] we will therefore set the minimum allowed number of tolerance to accuracy level 6.

8) Using the button in line [1.11] we will start optimization of the dimensional chain.
9) Parameters of the resulting clearance achieved for the optimized design of tolerances are shown in paragraph
[2.5],

optimized deviations of manufacturing dimensions are listed in column 9 of table [1.1].

10) For the example specified herein, a functionally suitable solution was found during optimization; however
from the practical point of view such design is not suitable. The program designed the width of the bearing
sleeves in lines D and F with different tolerances. For the sake of production and assembly efficiency, it is
necessary to secure interchangeability of both bearing sleeves. The next step in the design deals with removing
this fault.
11) Use the button on the bottom table line to transfer the designed tolerances to the input part of the table,
then unify the tolerance for both sleeves using the higher of the designed values.

12) In column 8 of the table, further check the switches in lines D and F, and restart optimization using the
button on line [1.11].

13) This time the design will result in a fully suitable solution of the problem with bearing sleeve tolerance at
accuracy level 9 and accuracy level 7 for shaft tolerance.
Final note.
The solution designed herein will not of course be the only suitable solution to the problem and it need not be
the ideal solution either. Therefore, it is appropriate (especially in case of lot production) to design several
different solutions with varying accuracy of manufacturing of individual components.
We will obtain another solution to the problem if we choose the lower of the originally designed values for the
bearing sleeve tolerance in step 11).

We will obtain further suitable solutions in case of selecting a different case width in step 3). The following table
shows a comparison of several suitable designs:
Solution 1

Solution 2

Solution 3

Solution 4

Tolerance grade
Case
Bearing
sleeves
Shaft
Clearance in
fit [mm]

11

11

10

10

10

0.053 - 0.793

0.061 - 0.789

0.062 - 0.788

0.073 - 0.777

The resulting solution has to be chosen so that the total manufacturing costs are as low as possible.

Design and optimization of linear dimensional chain using statistical

"RSS" method.
For the component (see picture), design the manufacturing tolerances of dimensions so that the permissible
deviation 0.0013 in for the technologically resulting dimension is not exceeded.

Solution of problem.
If we start from the diagram of the dimensional chain

we can describe the resulting dimension for the given component using the relation Z = C - A - B.
If the problem were solved using the common "Worst Case" method, it would be necessary to use tolerance at
approx. accuracy level 4 for dimensions B and C to keep the required tolerance of the resulting dimension. It is
obvious that production with such accuracy level would be unreasonably expensive. In this case it will therefore
be much more advantageous to use the statistical method of calculation. This method enables manufacturing of
a component with significantly greater tolerances, at the cost of a low (pre-selected) percentage of spoilage.
Design of dimensional chain.
The solution to the task of dimensional chain design and optimization can be divided into the following steps:
1) Using the above-mentioned relation, we will define the dimensional chain in table [1.1].
2) We will further set the required manufacturing tolerances for individual dimensions. We will set the
appropriate deviations for dimension A required by the task.

For the remaining dimensions we will tentatively select symmetrical tolerance at accuracy level 8.
Note: Although this step is not absolutely essential, it will ensure that the optimized tolerances are designed to
the proper ratio. During the design of individual tolerances, the mutual ratio of their dimensions given by values
set in the input part of the table will be kept.
3) In column 8 of the table, check the switch with dimension A, the tolerance of which is strictly given.

4) In paragraph [1.3] set the required limit values of the resulting dimension.
5) In list box [1.7] choose the "Centring and optimization" method, in list [1.8] set the required accuracy
(number of decimal places) designed by the tolerance.
6) With respect to the various methods of machining applicable during production of the component, set the
minimum allowed tolerance to accuracy level 6 in the list box [1.9].
Hint: You will find a table of achieved manufacturing accuracies for different methods of machining in the
workbook "Tolerances and fits".
7) In list box [1.10] choose the required production yield 99.9%, i.e. manufacturing process with maximum
number of 1000 rejects per million manufactured components.

8) Start optimization of the dimensional chain using the button in line [1.11].
9) The resulting design parameters are shown in paragraph [2.10],

optimized deviations of manufacturing processes are shown in column 10 of table [1.1].

10) The designed tolerances can of course be further adjusted. Using the button on the bottom line of the table,
transfer the optimized values of tolerances into the input part of the table. There, while keeping the tolerance
sizes, we can e.g. finely tune the designed deviations to a more suitable shape.

Calculation results for this adjustment will be the same as the result achieved for the optimized tolerances.
Final note.
The solution designed here will not of course be the only suitable solution to the problem and need not therefore
be the ideal solution. When choosing a suitable solution, it is necessary to assess the relationship between the
chosen sizes of manufacturing tolerances and expected manufacturing process yield. By increasing the applied
tolerances we will achieve a decrease in direct costs connected with machining of the components, but it will
result in an increase in losses due to the increased occurrence of faulty products. It is necessary to choose the
resulting solution so that the total manufacturing costs are as low as possible.
For comparison, the following table shows the values of expected production yield for normalized tolerances of
dimensions B and C.
Tolerance grade

Expected production yield

[%]

Number of rejects per

million manufactured
components

99.99

125

99.77

2324

97.54

24640

Production and assembly of roller bearings using selective assembly

method.
Problem assignment.
For a roller bearing assembled from three components with dimensions:
1. Outer ring - diameter D=160 mm
2. Inner ring - diameter d=120 mm
3. Rollers - diameter dr=20 mm
design the manufacturing tolerances of all components and parameters of the selective assembly so that a
radial clearance ranging from 60 m to 90 m is kept during the bearing assembly. The bearing further requires
interchangeability of the inner ring so that a radial clearance ranging from 40 m to 105 m is guaranteed
during replacement of the ring in case of repair of the bearing.
Note: In actual practice, the selective assembly method is normally used only in manufacturing products that do
not require working interchangeability of components inside the product. The requirement of ensuring the
interchangeability of any of the components reduces the advantages of selective assembly significantly. The
problem described herein has only a theoretical nature and is meant to demonstrate the wider possibilities of
using the program.

Solution to problem.
Production of roller bearings is a typical example suitable for use of the selective assembly method. Using the
traditional "Worst Case" method for the solution of the specified example will secure full assembly and working
interchangeability of all components, however it would be necessary to manufacture the components of the
bearing with accuracy level 3 to keep the required radial clearance. It is obvious that production with such
accuracy level would be unreasonably expensive. Using the selective assembly method, the components can be
made with significantly lower accuracy. The solution to the selective assembly problem itself consists of two
parts:
Design of dimensional chain.
The size of radial clearance for roller bearings is specified by the relation c = D - d - 2*dr.

The solution to the task of dimensional chain design and optimization can be divided into the following steps:

1) Using the above-mentioned relation, we will define the dimensional chain in table [7.1]. Individual
components used during assembly of the bearing are partial components of the chain. The required radial
clearance is then the closed component of the dimensional chain.

2) Next set the required manufacturing tolerances for individual dimensions. In the initial design, use tolerances
at accuracy level 7 for all components. For the roller diameter, choose symmetric tolerance, H7 for the outer
ring diameter tolerances and h7 for the inner ring.
3) For all components, initially set 10 tolerance subsets for the manufactured components to be sorted into.

4) In paragraph [8.1] set the requirement of working interchangeability of the inner bearing ring.
5) In paragraph [8.4] set limit sizes of the required radial clearance during assembly of the bearing and
replacement of the inner ring.
6) In list box [8.9] choose search for all assembly combinations. Start the search for combinations using the
button on line [8.10].

7) The design quality can be assessed from the results in paragraph [8.11]. It is obvious that in this case the
design is not suitable. From the table of "Unused subsets" in line [8.14] it is clear that it was not possible to use
more than half of the manufactured outer rings and rollers for assembly of the bearing.
8) For the unsuitable design, the next logical step could be decreasing the sizes of used manufacturing
tolerances. On closer scrutiny of the design, however, we will find out that the main problem is not the selected
size of tolerances, but rather wrong centring of the design. The standard indicator for better assessment of this
design aspect is the mean dimension of the closed component calculated in paragraph [7.2].

For the optimum design of the tolerance chain, the specified dimension should be as close to the required value
as possible [8.7].
9) In the repeated design, adjust the position of the tolerance field of all components while keeping the sizes of
tolerances. For the outer ring diameter, use G7 tolerance, and g7 for the inner ring diameter.

Next adjust the upper and lower deviation of the diameter of the rollers so that the resulting design is centred as
well as possible.

10) For such adjusted design of a dimensional chain repeat the search for all suitable assembly combinations.

11) From the search results it is obvious that all manufactured components will be usable in the bearing
assembly. However, the design is not that efficient as the number of suitable assembly combinations is
unnecessarily high. We can decrease the number of suitable combinations e.g. by decreasing the number of
tolerance subsets which the manufactured components will be sorted into.
12) While gradually decreasing the number of subsets, we will come to the resulting design of the dimensional
chain,

which seems optimum for the selected example.

The resulting 75 suitable assembly combinations are acceptable for the purpose of selective assembly.
Optimization of number of assembled products.
In the previous part of the task we designed manufacturing tolerances of components and searched for all
suitable assembly combinations which can be applied during assembly of the bearing with suitable parameters.
However, during the assembly itself it is not practical to assemble the bearings by mere random choice of
components within permissible assembly combinations. If the selective assembly method is to be efficient, it is
necessary to solve the problem of optimum selection (combination) of components. The components have to be
matched so that it is possible to assemble the maximum possible number of products which meet the functional
requirements with the given number of manufactured components.
This task has to be solved repeatedly during production, whenever the stock is replenished before assembly
itself is started. The main part of the task is to determine the optimum assembly procedure in order to achieve
the largest possible number of assembled products. When solving the task, we have to choose the optimum set
of combinations from the previously found subset of acceptable combinations used in assembly and at the same
time determine the number of products assembled within each used combination.
The solution to the task of optimization of the number of assembled products is performed in the following steps:
1) In table [9.1] set the number of manufactured components in individual tolerance subsets.

Note: Limit sizes of all tolerance subintervals are shown in table [7.1].
2) In list box [9.3] choose a suitable optimization method. For the selected example choose "Basic method",
which gives the best results. Although this method is rather slower than the other methods for the small
numbers of components which the bearing should be assembled from in the given example, we can use it even
on less efficient computers.
Note: The comparison of results and speed of calculation achieved for the given example using various
optimization methods is specified at the end of the example.
3) Select "Batch processing" in list [9.5]. After this item has been chosen, the program will gradually perform
optimization for all 10 basic solutions. The most suitable solution will then be chosen with respect to the
maximum assembled products and minimum used assembly combinations.

4) Press the button on line [9.5] to start optimization.

5) Basic qualitative parameters of the design procedure are specified in paragraph [9.6]

a detailed specification of optimized assembly procedure is shown in table [9.12].

The left column of the table shows all assembly combinations used for assembly of the product. The right
column shows the number of products assembled within each combination.
Comparison of optimization results and speed of calculation achieved with the given example using
various optimization methods:

Number of
assembled
bearings

Number of used
assembly
combinations

Speed of
calculation

A. Basic method

762

29

6 min 20 s

B. Modified method

760

34

1 min 30 s

C. Simplified method

759

32

55 s

Optimization method

Note: "Batch processing" was used with all optimization methods. The calculation was made using a computer
with x86 processor, 1800 MHz, 256MB.