ToleranceCalc
ToleranceCalc FAQ

Question: What is ToleranceCalc?

ToleranceCalc is an "available anytime" assistant that helps users to perform quick and easy 1D and 2D tolerance analysis of parts and assemblies in any CAD application at any stage of the product development process. ToleranceCalc is a self-contained tool that works off-line with geometry saved in any CAD application in the DXF R14 (or above) format.

Question: What are the key benefits of ToleranceCalc?

ToleranceCalc makes 1D/2D statistical tolerance analysis of CAD parts and assemblies at any stage of the design process as easy as "spell checking". With ToleranceCalc you will avoid costly redesigns caused by arbitrary allocation of tolerances.

Specifically, ToleranceCalc wizard will help you to:

ToleranceCalc assures strategic success that results from including tolerance considerations as an integral and early part of the overall design process.

Question: What are the system requirements to run ToleranceCalc?

ToleranceCalc can be used in conjunction with any DXF compliant CAD application on any computer running Vista, XP, Windows 7, Windows 8, or Windows 10. Disk requirement < 2MB.

Question: How does ToleranceCalc work?

ToleranceCalc incorporates a groundbreaking graphical calculation technology that eliminates tedious statistical calculations from the tolerance analysis process. Here are the steps for performing tolerance stack-up analysis of CAD parts and assemblies using ToleranceCalc:

1. Start by selecting a new layer in your CAD application and using the sketching tools in CAD draw the tolerance vector chain representing the tolerance propagation within a part or assembly using the model or drawing geometry as overlay - the process is simple as connecting a set of dots to create head to toe connected lines starting from the datum to the point-of-interest. There is no limit to the number of contributors that you can include in the vector chain. Then you explode the vector chain into individual entities and save the sketch geometry containing the tolerance vector loop in the DXF file format in CAD.

2. Load the saved DXF file in ToleranceCalc. ToleranceCalc automatically assumes the unit system set in CAD - you need to simply enter linear and angular tolerances for the individual contributors using the next and previous button with the vector highlighted in the graphic window to guide you (contributor tolerances maybe values from manufacturing process capability tables, vendor supplied tolerances, values from GD&T tables, or any other value that will cause a deviation from the nominal value of the contributor).

Next, you specify the number of iterations and the distribution (choice of Uniform, 3-Sigma, 4.5-Sigma, or 6-Sigma) for the Monte Carlo analysis in the setup window and click a button.

3. ToleranceCalc delivers the effects of the stack-up on the X and Y co-ordinates of the point-of-interest and the resultant assembly dimension that is the distance of the point-of-interest from the datum. A sensitive analysis report containing sorted "percent contribution" for each vector is also automatically generated for each analysis run that helps designers and production people to decide where to concentrate their quality improvement efforts.

Analysis results from each run can be saved in the .csv standard file format that can be read by Excel for consolidation.

Question: Who should use ToleranceCalc?

ToleranceCalc does not require any specialized knowledge of dimensional engineering and has a learning curve of minutes. Which means all engineers as well as designers using CAD can quickly benefit from ToleranceCalc to participate in quality-driven product development.

Question: I use spreadsheets for tolerance analysis. How will ToleranceCalc help me?

Spreadsheet based solutions first require you to convert geometry data into numerical information that you enter manually in the spreadsheets - a tedious process subject to errors. Then you have to define and setup complex formulae to calculate tolerances, a process, which requires specialized knowledge of statistical analysis. Whereas ToleranceCalc works directly on geometry saved in CAD. All analysis calculations are already built-in. ToleranceCalc does the tedious work for you to automatically deliver high value answers in seconds.