Page 1Honeywell ProprietaryStack Up Training Stack Up Training Asia Group Asia GroupTraining for Stack-up on Turbo Drawing(REVISION_ A)Judy WangDesign EngineerAsia Support, SGTS 11/10/2003 Page 2Honeywell ProprietaryStack Up Training Stack Up Training Asia Group Asia Group1.What is Stack-up? 2.How to work out stack-up on a turbo drawing - Axial direction?3.How to work out stack-up on a turbo drawing? - Radial direction4.How to work out clearance holes and other customer attachment features on a turbo drawing? Page 3Honeywell ProprietaryStack Up Training Stack Up Training Asia Group Asia GroupWhat is Stack-up?When a turbo is assembled, there are many interfaces to customers for installation which are very important to them. So the dimension and tolerance between these interface are so crucial that they must be worked out on the drawing. Take 729995-1 for an example, the dim 34.87+/-1.10 shows the dimension and tolerance between oil outlet and turbine inlet hole.This dimension and tolerance can be called STACK-UP. Page 4Honeywell ProprietaryStack Up Training Stack Up Training Asia Group Asia Group1.What is Stack-up? 2.How to work out stack-up on a turbo drawing? - Axial direction3.How to work out stack-up on a turbo drawing? - Radial direction4.How to work out clearance holes and other customer attachment features on a turbo drawing? Page 5Honeywell ProprietaryStack Up Training Stack Up Training Asia Group Asia GroupHow to work out stack-up on a turbo drawing ? - Axial directionAxial Direction1. Find out how many components assembled into this stack-up. 2. Find the drawings on PDM system & print out the drawings. 1) THWA: 726381-21 - THS: 727981-1 2) CHRA: 726904-11 - CTS: 726364-8 (Item 1) BKP: 712339-2 4) CHS: 451963-87 Page 6Honeywell ProprietaryStack Up Training Stack Up Training Asia Group Asia GroupHow to work out stack-up on a turbo drawing ? - Axial direction3. Make sure contact surface for each components ( Generally, -A- datum on each part is the contact surface). Contact surfaces and components may be changed on different turbo! Check carefully!Contact SurfaceTHSCTSBKPCHSSKETCH 1 Page 7Honeywell ProprietaryStack Up Training Stack Up Training Asia Group Asia GroupHow to work out stack-up on a turbo drawing? - Axial direction4. Stack_up each dimension and tolerance of axis dimensions(See table followed) 1) Pay more attention to dimension direction. 2) Round off total tolorance per EDI4-8. 3) If the dimension is basic dimension, Form or Position tolerance should be added. 3) For each tolerance chain, the tolerance should be ascended to first machining datum per machining process. Page 8Honeywell ProprietaryStack Up Training Stack Up Training Asia Group Asia GroupHow to work out stack-up on a turbo drawing ? - Axial directionIn the table above:a) THS inlet hole to THS -A- 7.79 +/- 0.15 ( 11.00 +/-0.15) +/-0.25( Position of -K- to -A- at MMC) THSSKETCH 2 Page 9Honeywell ProprietaryStack Up Training Stack Up Training Asia Group Asia GroupHow to work out stack-up on a turbo drawing? - Axial direction b) 65.12+/-0.10 (on CTS) c) 32.21 (Oil inlet to -A- on CTS) +/- 0.25 ( 10.00+/-0.25 for default tol) +/- 0.125 ( Position of oil inlet to -A- at MMC on CTS) CTSSKETCH 3SKETCH 4 Page 10Honeywell Proprietary d) 22.46 +/- 0.25 ( Position of oil outlet to -A- on CTS) +/-0.175 (Per DS11000 SPIRALOCK M8 x 1.25 -6H minor is 6.65, so, 7- 6.65/2=0.175) e) 7.415+/-0.025Stack Up Training Stack Up Training Asia Group Asia GroupHow to work out stack-up on a turbo drawing? - Axial directionCTSSKETCH 5SKETCH 6 Page 11Honeywell ProprietaryStack Up Training Stack Up Training Asia Group Asia GroupHow to work out stack-up on a turbo drawing? - Axial direction f) 5.96+/-0.05 (on BKP) g) 50.61+/- 0.25 ( Dimension tolerance of 82.35 +/-0.25 on CHS) +/-0.125 ( Position of -S- to -A- on CHS) +/- 0.065 (Runout of 92.73 to -S- on CHS) +/- 0.065 (Runout of 107.00 to -S- on CHS)CHSBKPCHSSKETCH 7SKETCH 8SKETCH 9SKETCH 10 Page 12Honeywell ProprietaryStack Up Training Stack Up Training Asia Group Asia GroupHow to work out stack-up on a turbo drawing? - Axial direction h ) 95.95+/-0.13 CHSSKETCH 11 Page 13Honeywell ProprietaryStack Up Training Stack Up Training Asia Group Asia Group1.What is Stack-up? 2.How to work out stack-up on a turbo drawing ? - Axial direction3.How to work out stack-up on a turbo drawing? - Radial direction4.How to work out clearance holes and other customer attachment features on a turbo drawing? Page 14Honeywell Proprietary*Stack_up each dimension and tolerance of radial dimensions: 1) Round off total tolorance per EDI4-8. 2) For each tolerance chain, the tolerance should be ascended to first machining datum per machining process. 3) If the dimension is basic dimension, Form or Position tolerance should be added.See Turbocharger drawing 729995, 1. 100.52+/-*.* -D- (CTS ) to -C- (THS) on turbocharger 1). The tolerance caused by machining on CTS a)+/- 0.125 Surface Profile from -L- to -C- Stack Up Training Stack Up Training Asia Group Asia GroupHow to work out stack-up on a turbo drawing? -Radial DirectionCTSSKETCH 12 Page 15Honeywell Proprietary 2). The tolerance caused by CTS and THS attachment a) 170.78+/-0.03 (CTS) b) 170.86+/-0.03 (THS) So, the clearance between the attachment features should be: (170.86+/-0.03)-(170.78+/-0.03)=0.08+/-0.06. The maximum clearance is 0.14. The tolerance caused by attachment features is +/-0.07 Stack Up Training Stack Up Training Asia Group Asia GroupHow to work out stack-up on a turbo drawing? -Radial DirectionCTSTHSSKETCH 13SKETCH 14 Page 16Honeywell Proprietary 3) Tolerance caused by 170.78+/-0.03 machining on CTS) a) +/-0.05 ( Circular Runout of 170.78+/-0.03 to -C -) b) +/-0.125 ( Circular Runout of - C - to - J -) (See previous slider) 4) Tolerance caused by ) 170.86+/-0.03 machining onTHS a) +/- 0.05 (Circular Runout of 170.86+/-0.03 to -C -) b) +/-0.125 ( Circular Runout of - C - to - J -) 5) Tolerance caused by 146.00 machining on THS a)+/- 0.05 (Circular Runout of 146 to -J -)Stack Up Training Stack Up Training Asia Group Asia GroupHow to work out stack-up on a turbo drawing? -Radial Direction THSSKETCH 15SKETCH 16 Page 17Honeywell ProprietarySo, tolerance of 100.52 on turbocharger is: 100.52 +/- 0.125 +/- 0.07 +/- 0.125 +/- 0.05 +/- 0.125 +/- 0.05 100.52+/- 0. 47 Round off: 100.52+/- 0.50 per EDI4-82. 47.50+/-*.* - E -(CTS) to -C - (THS) on tubrocharger It is the same as 100.52+/-0.50Stack Up Training Stack Up Training Asia Group Asia GroupHow to work out stack-up on a turbo drawing? -Radial Direction Page 18Honeywell Proprietary3. 57.00+/-*.* - B -(THS) to - C - (THS) on turbocharger 1) +/-0.25 Position of 11.00+/-0.15 to -C-(THS) at MMC. 2) +/-0.15 Dimension tolerance of 11.00+/-0.15 due to the posion tolerance defined at MMC 3) +/- 0.05 Dimension tolerance of -C - due to posion tolerance defined at MMC 4) +/-0.125 Circular Runout of -C- to -J- . 5) +/- 0.05 Circular Runout of 146.00 to -J- . (See sketch2 on previous slider)Stack Up Training Stack Up Training Asia Group Asia GroupHow to work out stack-up on a turbo drawing? -Radial Direction Page 19Honeywell ProprietarySo, tolerance of 57.00 on turbocharger is: 57.00 +/- 0.25 +/- 0.15 +/- 0.05 +/- 0.125 +/- 0.05 57.00 +/- 0.625 Round off: 57.00+/- 0.65 per EDI4-8.4. 123.00+/-*.* - A -(THS) to - C - (THS) on turbocharger 1) +/-0.25 Surface profile of -D- to -C- on THS. 2) +/-0.125 Circular Runout of -C- to -J- on THS. (see sketch 15) Stack Up Training Stack Up Training Asia Group Asia GroupHow to work out stack-up on a turbo drawing? -Radial Direction THSSketch 17 Page 20Honeywell Proprietary 3) +/- 0.05 Circular Runout of 146.00 to -J- (see sketch 16)So, tolerance of 123.00 on turbocharger is: 123.00 +/- 0.25 +/- 0.05 +/- 0.125 123.00 +/- 0.425 x1.2 (Less than 4 dimensions 20% should be added per EDI4-8) 123.00 +/- 0.51 Round off: 57.00+/- 0.55 per EDI4-8.Stack Up Training Stack Up Training Asia Group Asia GroupHow to work out stack-up on a turbo drawing? -Radial Direction Page 21Honeywell Proprietary 5. 78.50.00+/-*.* - Outlet of CHS to - F - (CHS) on turbocharger 1) +/-0.065 Circular Runout of 107.00+/-0.13 to -S- on CHS. 2) +/-0.065 Circular Runout of 92.73.00+/-0.13 to -S- on CHS. 3) +/-0.125 Position of -S- to -C- at MMC on CHS. 4) +/-0.25 Dimention tolerance of 82.35+/-0.25 at MMC on CHS 5) +/-0.025 Dimention tolerance of -C- ( 177.875+/-0.025) at MMC on CHS 6) +/-0.065 Circular Runout of -C- to -J- on CHS (See sketch 8)Stack Up Training Stack Up Training Asia Group Asia GroupHow to work out stack-up on a turbo drawing? -Radial Direction Page 22Honeywell ProprietarySo, tolerance of 78.50+/-*.* on turbocharger is: 78.50 +/-0.065 +/-0.065 +/-0.125 +/-0.25 +/-0.025 +/-0.065 78.50 +/-0.595 Round off :78.50+/-0.60 per EDI4-8Stack Up Training Stack Up Training Asia Group Asia GroupHow to work out stack-up on a turbo drawing? -Radial Direction Page 23Honeywell ProprietaryStack Up Training Stack Up Training Asia Group Asia Group1.What is Stack-up? 2.How to work out stack-up on a turbo drawing ? - Axial direction3.How to work out stack-up on a turbo drawing? - Radial direction4.How to work out clearance holes and other customer attachment features on a turbo drawing? Page 24Honeywell ProprietaryTake the drawing 729995(Turbochrger) and 727981(THS) as example.According to EDI004-8, 1. Include 20% tolarence for the attachment features on outline drawing .2. Do not add 20% tolarence if the actual total tolerance specified on detail part drawing is less than 0.2mm.Stack Up Training Stack Up Training Asia Group Asia GroupHow to work out clearance holes and other customer attachment features on a turbo drawing? Sketch 18