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ToleranceCalc is breakthrough wizard that enables users to perform linear and angular stack-up and statistical analysis of parts and assemblies created in any popular CAD application with unprecedented ease, speed, and accuracy. Quick and extensive information from ToleranceCalc saves costly redesigns and retooling.

Results in three easy steps!

To illustrate we will analyze the tolerances of a gear assembly mechanism as shown in the following figure.

Step 1. Identify tolerance contributors in CAD

In this step user identifies and draws the tolerance vector chain in CAD starting from the datum on the left ending with the point of interest on the right, by connecting the centers.  The resultant lines, representing the tolerance vector chain, are saved in CAD in the DXF (R 14) format. 

Note : The tolerance chain can be extracted from CAD models aligned to appropriate 2D plane as well as from drawings. In most CAD applications this step is easy as drawing lines by connecting dots. Often it is easier to draw the contributors in a separate layer and save the layer in DXF format.

There are three contributors in the tolerance chain as shown in the following figure.  The nominal value of the distance of the point of interest (D) from the datum (A) is L.

The user wants to know the worst-case value of L and the co-ordinates of D will be when linear and angular tolerances stack-up.  Also, given an acceptable delta in the value of L within which the assembly will perform (OK Delta-L) user wants to perform manufacturability and quality analysis of the assembly.

Step 2. Setup ToleranceCalc

ToleranceCalc is launched and the DXF file containing the tolerance chain, saved in CAD in the previous step, is loaded and shown in ToleranceCalc Setup pane window as illustrated below.

Step 3. See Results

In a split second, ToleranceCalc develops the results and displays the answers in the Stack-Up pane including Max, Min, Worst, and Mean value of L (the distance from the datum to the point of interest) as shown in the following illustration.

Here X and Y represent the co-ordinates of the point of interest (D).

Next, user clicks on the Sigma panel and receives the quality report developed using the Monte Carlo analysis, assuming a normal distribution, as shown in the following figure.

The user can now save the results for the particular tolerance setting and go back to the Setup pane and tweak tolerances to receive instantaneous sensitivity feedback. This way user can make intelligent decisions to tweak part and assembly tolerances to make sure the assembly will work as expected and can be manufactured to meet the quality goal.

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