_top_ — Tolerance Stack Up Calculator

Assign a “+” if the dimension increases the gap/stack, “-” if it decreases.

| Part | Nom | Upper | Lower | Mean | Half-tol | Direction | Contrib (mean×dir) | Tol WC | Tol RSS² | |------|-----|-------|-------|------|----------|-----------|---------------------|--------|----------| | Spacer A | 10 | 10.1 | 9.9 | 10.0 | 0.1 | + | 10.0 | 0.1 | 0.01 | | Spacer B | 10 | 10.1 | 9.9 | 10.0 | 0.1 | + | 10.0 | 0.1 | 0.01 | | Gap (target) | - | - | - | - | - | - | 20.0 | 0.2 | 0.02 | tolerance stack up calculator

| Method | Formula (for additive tolerances) | Best for | |--------|----------------------------------|-----------| | | (T_total = \sum \vert T_i \vert) | Safety-critical, low volume | | Root Sum Square (RSS) | (T_total = \sqrt\sum T_i^2) | High-volume manufacturing (Cpk≥1.0) | Rule of thumb: Use RSS when you have 4+ parts in the stack and assume normal distribution. Use worst-case when human life or mandatory clearance is at stake. How to Build a Basic Calculator in Excel (5 Steps) You don’t need expensive software. Here is a manual setup: Assign a “+” if the dimension increases the

If you aren’t calculating it, you’re gambling with your production schedule. In this post, I’ll show you how to build a simple (and why you need more than just worst-case math). What Is Tolerance Stack-Up? Tolerance stack-up is the cumulative effect of individual part tolerances on an assembly’s final dimension (gap, interference, or total length). How to Build a Basic Calculator in Excel

The culprit? .

Worst-case or RSS? Learn how to build a tolerance stack-up calculator in Excel or use our free web tool to predict assembly fit before you cut metal.

Include nominal dimensions, upper tolerance, and lower tolerance.