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Are you not designing only with IEB (intuition, experience, and boldness)?
Here you can get an easy-to-understand explanation of the advantages of tolerance design, and the requisite knowledge.
Tolerance design has recently received renewed attention. This will explain the advantages of tolerance design.
The following shows some examples of tolerance calculations. Let us consider, for example, this device.
Let us study a case where gap f is a very important value and a design standard of 0.5 ±0.3 must be achieved.
This gap f is composed of all parts from A to H.
The key point is whether or not the design standard can be satisfied even if all parts from A to H vary to the limit of tolerance, and how to set the tolerance of each part is important for this reason.
Let's consider a few things here in a simple model.
Given the condition in the figure below that the χ gap must be designed in the range of 0.5 ±0.4 and the dimension of part A is 9.5 ±0.3, how would you go about calculating the dimensions and tolerances for parts B, C and D if they were the same part?
The dimensional values of B, C, and D are (9.5-0.5)/3 = 3, right? Tolerance calculations are then performed, but there are 2 major methods for calculating tolerances. Compatibility and incomplete compatibility methods.
The calculation method for the worst-case (maximum or minimum) tolerance of all parts assembled is called the compatibility method.
In contrast, the method of calculation based on statistical theory, which comes from variation and its treatment, is called the incomplete compatibility method.
In the compatibility method, the following formula is used to calculate the result, which is ±0.033.
On the other hand, the incomplete compatibility method yields a result of ±0.15.
Compatibility method
0.3+(T+T+T)=0.4
3T=0.1
T=0.033
Incomplete compatibility method
0.32+T2+T2+T2=0.42
3T2=0.42-0.32
T2=0.0233
T=0.15
In other words, whether the tolerance is ±0.033 or ±0.15 depends on how the tolerance is calculated.
In this example, the difference is approx. 5-fold, and naturally, there will be a significant difference in cost.
Whichever calculation method is adopted is the company's policy and should be thoroughly confirmed; but in any case, it is important to be fully aware of this theoretical background.