GeoTol Pro Advanced Applications and Tolerance Stacks Workbook


  • 170 pages
  • GD&T Advanced Applications and Tolerance Stacks based on ASME Y14.5-2009 standard
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This text is broken into two major sections: Tolerance Stacks and Design Applications.

Tolerance Stacks

The stacks section is contained in the first 6 units of this text, and is designed to teach students the fundamental principles of tolerance stacks.  The student will learn a variety of stack procedures, beginning with simple linear stacks on detail parts in units 1 and 2, and migrating to linear assembly stacks in Unit 3.  Unit 4 begins with axial detail stacks, and moves on to complex axial assembly stacks in unit 5.  Orientation tolerance stacks are covered in unit 6 and melded together with axial boundary assembly stacks to provide the participant with a complete understanding of the stacks process.  Students will use this knowledge to perform tolerance stacks to ensure the design criteria is met in the application case study problems.

Design Applications

The applications section is a total of 10 units, (7 thru 17). Unit 7 begins with a quick review of the fundamentals of geometric tolerancing and a few basic applications of geometric tolerancing on simple detail parts. The following units are a series of case study examples, where the students will learn to establish datum reference frames and apply geometric tolerancing to a variety of parts.  There are a multitude of simple to complex sheet metal, cast, turned and milled parts, and welded assemblies. The case study examples start out simple, but generally grow in complexity as the units progress.  In the beginning of each unit there will be an introduction explaining the issue at hand and the necessary functional requirements to be met.  Some examples provide detailed explanation, and in other instances, examples are incomplete by intent to make the problem less complex. After the parts are toleranced to achieve functional requirements, there are tolerance analysis stacks and reallocation exercises the student must perform to ensure the parts meet the established requirements detailed in each introduction.

How to use this book

This GD&T Advanced Applications and Stacks book provides complete flexibility in the learning process. Students can use this book to learn only tolerance stacks, only design applications or a combination of both. The tolerance stacks sections must be completed sequentially in order from unit 1 to 6.  The applications section may be taken in any order, applying tolerance to sheet metal, machined parts, simple or complex problems. To make the learning experience exciting, it is recommend the student alternately completes a lesson in the stacks units, and afterwards, solves a case study problem from the applications units. This format provides variety in the lessons and provides practical applications at the same time.  The student can work problems in any order in the application section.  In order to solve the stacks problems in the case study examples, there will be prerequisites from stacks units the student must first complete. The prerequisites for the stack exercises are shown after the title on the top of the exercise page, and following the title page of each application. There is an Advanced Applications and Stacks solutions manual available.

View Outline

Units in GeoTol Applications and Stacks
Unit 1 Plus/minus Stacks
Unit 2 Profile Detail Stacks
Unit 3 Profile Assembly Stacks
Unit 4 Boundary Detail Stacks
Unit 5 Boundary Assembly Stacks
Unit 6 Orientation Stacks
Unit 7 Introduction to Design Applications
Unit 8 Grommet Assembly
Unit 9 Powder Case Assembly
Unit 10 Fuel Cooler Assembly
Unit 11 Valve Assembly
Unit 12 Step Bracket Assembly
Unit 13 Regulator Mounting Bracket
Unit 14 Optic Connector Assembly
Unit 15 Mixer Assembly
Unit 16 Alternator Bracket
Unit 17 Link Assembly

Detailed Outline

  • Unit 1: Plus/Minus Stacks
    • Linear stacks on assemblies using plus/minus tolerancing
  • Unit 2: Profile Detail Stacks
    • Linear stacks on single parts using profile tolerancing
    • How to add flatness and perpendicularity tolerances to a stack analysis
  • Unit 3: Profile Assembly Stacks
    • Linear stacks on assemblies using profile tolerancing
    • When to add flatness and perpendicularity to a stack analysis
  • Unit 4: Boundary Detail Stacks
    • Axial stacks on single parts
    • Calculating boundaries for position, runout, profile
    • RFS, MMC and LMC datum and feature modifiers
    • Wall thickness calculations
  • Unit 5: Boundary Assembly Stacks
    • Axial stacks on assemblies using position and profile
    • Adding datum feature shift to a stack analysis
    • When not to add a geometric tolerance to a stack
    • Multiple datum reference frames
  • Unit 6: Orientation Stacks
    • Stacks affected by parallelism, perpendicularity, angularity
  • Unit 7: Introduction to Design Applications
    • Introduction to applications
    • Fixed and floating fastener formulas
    • Example parts and drawings
  • Unit 8: Grommet Assembly
    • Milling machined part exercise
    • Linear profile stack
    • Axial position stack
  • Unit 9: Powder Case Assembly
    • 2 part turned machined part exercise
    • Axial profile position stack
  • Unit 10: Fuel Cooler Bracket
    • Formed sheet metal part exercise
    • Functional gage exercise
  • Unit 11: Valve Assembly
    • 3 part round machined part exercise
    • Axial profile position stack
  • Unit 12: Step Bracket Assembly
    • 3 part formed sheet metal part exercise
  • Unit 13: Regulator Mounting Bracket
    • Formed sheet metal part exercise
    • Composite position discussion
  • Unit 14: Optic Connector Assembly
    • 2 part round machined part exercise
    • Linear profile stack
    • Axial position stack
    • Axial position profile stack
  • Unit 15: Mixer Assembly
    • 7 part round machined part exercise
    • Linear profile stack
    • Linear profile stack
    • Axial position stack
    • Axial profile stack
  • Unit 16: Alternator Bracket
    • Weldment assembly exercise
    • Piece part exercise
    • Weld fixture design
  • Unit 17: Link Assembly
    • Machined part exercise
    • Casting part exercise
    • Cast feature size calculations

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