Description
This workbook is divided into two main sections: Tolerance Stacks and Design Applications.
Tolerance Stacks
The first six units of this text are devoted to GD&T tolerance stack up concepts, guiding students through the essential techniques needed for effective calculations. It begins with foundational linear stacks on individual components in Units 1 and 2. Unit 3 shifts focus to linear stacks at the assembly level. Axial stack analysis is introduced in Unit 4 for detail parts and expanded to complex axial assemblies in Unit 5. Unit 6 explores orientation-based stacks, which are then integrated with axial boundary stacks to deliver a comprehensive understanding of stacking strategies. Learners will apply these concepts to real-world design scenarios to verify that specified design parameters are met through tolerance stack analysis.
Design Applications
Spanning Units 7 through 17, the second portion of this text focuses on practical design implementation. It opens in Unit 7 with a brief refresher on GD&T principles, followed by basic applications on simple part features. The remaining units present a variety of case studies where students practice establishing datum reference frames and applying GD&T to diverse component types, including sheet metal, castings, turned and milled parts, and welded assemblies. These case studies range from straightforward to more challenging problems, progressively increasing in complexity. Each unit begins with a contextual overview outlining key design objectives and performance criteria. Some examples come with full explanations, while others are intentionally left partially open-ended to encourage independent problem-solving. After applying GD&T, students will carry out stack analyses and reallocation exercises to confirm the designs satisfy the original functional goals.
Using This Workbook
This GD&T Advanced Applications and Stacks text offers a flexible learning path. Students may focus solely on tolerance stacks analysis, just the application section, or both. The stacks portion (Units 1–6) should be completed in sequence for best results. The application units (Units 7–17), however, can be explored in any order—students can choose problems based on part type or complexity. To keep the experience dynamic, it’s recommended to alternate between stack lessons and design case studies. This integrated approach reinforces theoretical understanding with hands-on practice. Note that some case study exercises involve stack problems that require prior completion of certain stack units; these prerequisites are listed at the top of each applicable exercise and at the start of each application section. A companion stacks solutions manual is available for this text.