1D-2D-3D Tolerance Analysis

With some Worst Case

What, Why and How

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 Agenda
• What is a 1D Stack (Worst Case)?
• Worst Case 1D vs Worst Case 3D
• Simple Example in 3DCS
• Worm Model
• Worst Case vs RSS
– Which One Should You Use?
• Larger Example in 3DCS
• Headlamp Model
• Q&A

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 What is Worst Case?
Worst Case Analysis - Each individual tolerance is set to a value 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.

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Worst Case 1D Example
Measure Nominal = 29 mm

10 ± 1 7±1 12 ± 2

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 Worst Case 1D Example
Measure Minimum = 25 mm

9 mm 6 mm 10 mm

Worst Case Variation

at Measure: 29 ± 4 mm
Measure Maximum = 33 mm

11 mm 8 mm 14 mm

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 1D vs 3D Worst Case
Worst Case Range: ???
Worst Case Range: ???

Form Tolerance
Orientation Tolerance
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 1D Stacks vs 3D Stacks
1D 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 Advantages:
• Can capture geometric effect and angular variation!
• Doing by hand requires rigorous hand-calcs and large possibility for human error.
• Luckily, 3DCS can help!

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Example 1D vs 3D Stack

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 1D Worst Case vs RSS
Statistical Analysis - Each component’s variation is modeled as a statistical distribution
(typically Normal) and these distributions combine to predict a new distribution that
describes the assembly variation, not the extreme values (outliers) 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 than manufacturing to incredibly tight part level tolerances (as a Worst Case
analysis would recommend).

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Worst Case vs RSS 1D Example

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 What is RSS
RSS stands for (Root Sum Squared)
It is the method of adding normally distributed variation
Using the example below

𝑅𝑆𝑆 𝑆𝑡𝑎𝑐𝑘 = 22 + 22 + 42 = 4.88

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 Basic Model Example

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 Basic Model Results
1D 2D 3D

Range 3.42mm Range 4.31mm Range 5.26mm

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 Questions?
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