Worst Case Tolerance Analysis - What is it, why do it, and how?

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From the DCS Webinar on Worst Case: http://mkt.3dcs.com/worst-case-tolerance-analysis-webinar Worst Case tolerance analysis is where each individual tolerance is set to a point in its range (typically a tolerance limit) where it will result in either the maximum or minimum output at a specific measured location. A Worst Case analysis is the only way to guarantee that an assembly of good detail parts will not be out of specification. However, in most cases, a statistical analysis gives the results needed to make decisions and reduce manufacturing costs. Learn how 3DCS calculates, analyzes and answers Worst Case tolerance analysis. Find out about: -- What is Worst Case? -- Worst Case 1D vs Worst Case 3D -- Worst Case vs RSS -- GeoFactor Analyzer Worst Case -- Simple Example in 3DCS -- Worst Case User DLL -- Larger Example in 3DCS -- Q&A

Engineering

Dimensional Control Systems | 2017 All Rights Reserved | Confidential - Do not distribute.
Worst Case Analysis
What, Why and How

Dimensional Control Systems | 2017 All Rights Reserved | Confidential - Do not distribute.
Agenda
• What is Worst Case?
• Worst Case 1D vs Worst Case 3D
• Worst Case vs RSS
– Which One Should You Use?
• GeoFactor Analyzer Worst Case
• Simple Example in 3DCS
• Worst Case User DLL
• Larger Example in 3DCS
• Q&A

Dimensional Control Systems | 2017 All Rights Reserved | Confidential - Do not distribute.
What is Worst Case?
Worst Case Analysis - Each individual tolerance is set to a point in its range (typically a
tolerance limit) where it will result in either the maximum or minimum output at a
specific measured location.
A Worst Case analysis is the only way to guarantee that an assembly of good detail
parts will not be out of specification.

Dimensional Control Systems | 2017 All Rights Reserved | Confidential - Do not distribute.
Worst Case 1D Example
10 ± 1 12 ± 27 ± 1
Measure Nominal = 29 mm

Dimensional Control Systems | 2017 All Rights Reserved | Confidential - Do not distribute.
Worst Case 1D Example
Worst Case Variation
at Measure: 29 ± 4 mm
11 mm 14 mm8 mm
Measure Maximum = 33 mm
9 mm 10 mm6 mm
Measure Minimum = 25 mm

Dimensional Control Systems | 2017 All Rights Reserved | Confidential - Do not distribute.
1D vs 3D Worst Case
Worst Case Range: ???
Form Tolerance
Orientation Tolerance

Dimensional Control Systems | 2017 All Rights Reserved | Confidential - Do not distribute.
1D Worst Case vs 3D Worst Case
1D Worst Case Shortcomings:
• Assumes all tolerances have a 1:1 effect on measure
• Difficult to capture angular variation
• Limited in scope, can only look at the problem in 1 dimension
3D Worst Case:
• We can capture geometric effect and angular variation!
• Doing by hand requires rigorous hand-calcs and large possibility for human error.
• Luckily, 3DCS can help!

Dimensional Control Systems | 2017 All Rights Reserved | Confidential - Do not distribute.
Example 1D vs 3D Stack

Dimensional Control Systems | 2017 All Rights Reserved | Confidential - Do not distribute.
Worst Case vs RSS
Statistical Analysis - Each component’s variation is modeled as a statistical distribution
(typically Normal by default) and these distributions combine to predict a new
distribution that describes the assembly variation, not the extreme values of that
variation.
Statistical Analysis (RSS) carries some “risk” that bad assemblies will be made from
good parts, but using inspection to spot trends and adjusting accordingly is a far
cheaper solution to designing to incredibly tight part level tolerances (as a Worst Case
analysis would recommend).

Dimensional Control Systems | 2017 All Rights Reserved | Confidential - Do not distribute.
Worst Case vs RSS 1D Example
Apply a Normal Distribution to each
tolerance for our 3 blocks as our input
0.13% at or
below Minimum
0.13% at or
above Maximum

Dimensional Control Systems | 2017 All Rights Reserved | Confidential - Do not distribute.
Worst Case vs RSS 1D Example

Dimensional Control Systems | 2017 All Rights Reserved | Confidential - Do not distribute.
GeoFactor Analyzer Worst Case
Equation based solution to quickly report a Worst Case

Dimensional Control Systems | 2017 All Rights Reserved | Confidential - Do not distribute.
Basic Model Example

Dimensional Control Systems | 2017 All Rights Reserved | Confidential - Do not distribute.
Worst Case User DLL
dcsSimuWorstCase (dcu_simu_fn.dll)
Sets all tolerances in model to a Modal distribution and leverages Monte Carlo
simulations to determine Worst Case build

Dimensional Control Systems | 2017 All Rights Reserved | Confidential - Do not distribute.
How Many Simulations?

Dimensional Control Systems | 2017 All Rights Reserved | Confidential - Do not distribute.
Advanced Model Example

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2. Dimensional Control Systems | 2017 All Rights Reserved | Confidential - Do not distribute. Agenda • What is Worst Case? • Worst Case 1D vs Worst Case 3D • Worst Case vs RSS – Which One Should You Use? • GeoFactor Analyzer Worst Case • Simple Example in 3DCS • Worst Case User DLL • Larger Example in 3DCS • Q&A

3. Dimensional Control Systems | 2017 All Rights Reserved | Confidential - Do not distribute. What is Worst Case? Worst Case Analysis - Each individual tolerance is set to a point in its range (typically a tolerance limit) where it will result in either the maximum or minimum output at a specific measured location. A Worst Case analysis is the only way to guarantee that an assembly of good detail parts will not be out of specification.

5. Dimensional Control Systems | 2017 All Rights Reserved | Confidential - Do not distribute. Worst Case 1D Example Worst Case Variation at Measure: 29 ± 4 mm 11 mm 14 mm8 mm Measure Maximum = 33 mm 9 mm 10 mm6 mm Measure Minimum = 25 mm

7. Dimensional Control Systems | 2017 All Rights Reserved | Confidential - Do not distribute. 1D Worst Case vs 3D Worst Case 1D Worst Case Shortcomings: • Assumes all tolerances have a 1:1 effect on measure • Difficult to capture angular variation • Limited in scope, can only look at the problem in 1 dimension 3D Worst Case: • We can capture geometric effect and angular variation! • Doing by hand requires rigorous hand-calcs and large possibility for human error. • Luckily, 3DCS can help!

9. Dimensional Control Systems | 2017 All Rights Reserved | Confidential - Do not distribute. Worst Case vs RSS Statistical Analysis - Each component’s variation is modeled as a statistical distribution (typically Normal by default) and these distributions combine to predict a new distribution that describes the assembly variation, not the extreme values of that variation. Statistical Analysis (RSS) carries some “risk” that bad assemblies will be made from good parts, but using inspection to spot trends and adjusting accordingly is a far cheaper solution to designing to incredibly tight part level tolerances (as a Worst Case analysis would recommend).

10. Dimensional Control Systems | 2017 All Rights Reserved | Confidential - Do not distribute. Worst Case vs RSS 1D Example Apply a Normal Distribution to each tolerance for our 3 blocks as our input 0.13% at or below Minimum 0.13% at or above Maximum

14. Dimensional Control Systems | 2017 All Rights Reserved | Confidential - Do not distribute. Worst Case User DLL dcsSimuWorstCase (dcu_simu_fn.dll) Sets all tolerances in model to a Modal distribution and leverages Monte Carlo simulations to determine Worst Case build

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Default min and max are not Worst Case

Worst Case Tolerance Analysis - What is it, why do it, and how?

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