SOLIDWORKS DIMXPERT and TOLERANCE STACKUP ANALYSIS
The DimXpert and TolAnalyst tools that are built into SOLIDWORKS software. The purpose of the tool is to meet the information we use to create our designs is same as the information we provide to manufacturing. But it isn’t same in many scenarios, that’s why the DimXpert and TolAnalyst are used widely.
DESIGN INFORMATION ≠ MANUFACTURING
Why DimXpert?
In Engineering, detailing a model is always challenging due to manual dimensioning. Which leads to inaccuracies and inconsistencies. Managing geometric tolerances and updating designs manually become tedious and its leading to potential errors. High complex detail drawing documentation requires more manual efforts without a tool like DimXpert.
DIMXPERT
DimXpert is a feature in SOLIDWORKS that speed up the process of dimensioning a 3D models, even if the model is imported body or has a large number of complicated features. DimXpert capabilities quickly define the Size, Location and Tolerance of the model for manufacturing.
Where to Find: From DimXpert Manager (or) Command Manager > MBD Dimension
DimXpert Commands:
Measure the length of the Model by specifying the location of a feature relative to a datum, such as a plane
The Location dimension specifies the position of a dimension or tolerance relative to a reference point or plane on the selected feature. This helps define the exact position of the dimension on the feature.
Measure and insert Geometric dimensions & tolerances for specific features such as Boss, Chamfer, Cone, Cylinder, Fillet, Intersect Circle, Counterbore Hole, Countersink Hole, Simple Hole, Notch, Width, Sphere
Measure the angle between the hole, face or plane with the defined tolerance.
To create a DimXpert angle dimension, select two or three DimXpert featured Face/Plane/Axis/Vertex, where the first two selections define the origin and the third selection will be the reference Face/Plane/Axis/Vertex.
Tool used to create or edit pattern features and collection features
The “Pattern” feature allows you to replicate dimensions of features, bodies, or components in a specified manner.
Datum used to create reference for inspecting the part after dimensioned.
In the context of DimXpert, datum features are specific geometric entities chosen to establish reference frames for dimensioning and tolerancing. These datum features can include planes, axes, cylinders, and cones.
Feature that allows for specifying precise tolerances and controls on dimensions for 3D models, ensuring accurate manufacturing.
Tool shows whether or not a feature is fully dimensioned.
Tool lets us automatically to create dimension for the entire model with reference to specific datums.
Automatically generate dimensions based on chosen features & dimensioning scheme and generated dimensions as needed to meet requirements. Update dimensions when part designs change, maintaining consistency between model and dimensions.
Step 1: Define the part and tolerance type for dimensioning.
Step 2: Specify datum to use as reference points to dimension the model
Step 3: Specify which features to include or exclude.
Step 4: After selecting the desired features, click “ok”.
Step 5: SOLIDWORKS will analyze the selected features and automatically add dimensions and tolerances according to predefined rules and settings.
Step 6: Review the automatically generated dimensions and tolerances to ensure they meet your design requirements.
DimXpert Options
Within the DimXpert Document Properties, you’ll find various settings that control the behavior and appearance of dimensions created with DimXpert. Some common properties include:
- Dimension Units: Sets the units for DimXpert dimensions.
- Tolerance Format: Controls how tolerances are displayed.
- Precision: Specifies the number of decimal places displayed for dimensions.
- Annotation Font: Allows you to select the font used for DimXpert dimensions.
- Leader Arrow Display: Specifies whether or not leader arrows are displayed with dimensions.
- Arrowhead Style: Sets the style of arrowheads for dimension lines.
Why Tolerance Stack-Up Analysis
When we design a model to its nominal size in SOLIDWORKS and going for manufacture. It might not be the exact nominal size we have created, whatever the manufacturing technique we use it might not fit. We will find the tolerance stacked up through the components, it will either too big or too small and will end up with a clearance issue.
TOLANALYST
The TolAnalyst or tolerance Stack-up analysis tool automatically checks the effects of tolerances on parts and assemblies to ensure consistent fit of components and to verify the Maximum/minimum worst-case and RSS results before a product goes into manufacturing.
TolAnalyst tool used to evaluate how manufacturing variations affect part and assembly, with these reports and information, we get to know max and min tolerance measurements of the component. So that we get a good clearance fit to a pretty tight press fit depending on the specifications with TolAnalyst with much less errors.
Where to Find:
From DimXpert Manager > TolAnalysis (or) Command Manager > SOLIDWORKS Add-ins > TolAnalysis
If you want to run TolAnalyst, every single part that going to involve in tolerance analysis study must have already run through a DimXpert on it.
That this model is going to function properly before going to manufacturing using Tolerance Stack-up Analysis.
Step 1: MEASUREMENT
Establish the measurement, which is a linear distance between two DimXpert features.
Measure the distance between the DimXpert featured parts you want to involve in TolAnalyst Study to its (Center or Min/Max distance).
Example: In this scenario, I want to measure the clearance between the Knuckle and Pin Shaft both the parts are involved to DimXpert feature.
Step 2: ASSEMBLY SEQUENCE
Select the assembly order of the parts to establish a tolerance chain between the two measurement features “simplified assembly”.
Assembly order affects the results
Example: First select the Base part of the assembly, once selected the remaining part goes to wireframe and add the components in sequence like how the assemblies are put together in production.
Step 3: ASSEMBLY CONSTRAINTS
Define how each part is placed or constrained into the simplified assembly.
Constraints are used to define the relationships between components within an assembly. Constraints ensure that components are positioned and oriented correctly relative to each other.
Example: The base part shows as constrained, because it is fixed as the origin part. The remaining relative part needs to be constrained to the assembly using constrain callouts box before running the study.
Step 4: ANALYSIS RESULTS
Evaluate and review the minimum and maximum worst case tolerance stacks and RSS.
TolAnalyst results are displayed visually in the graphics area. Warning messages appear if there are potential problems with the setup and evaluation.
Example: Once the assembly is set up with tolerances, run the TolAnalyst. SOLIDWORKS will automatically calculate the maximum and minimum dimensions for each part based on the defined DimXpert tolerances.
If necessary, we can modify the Analysis Parameter options under Min/Max Contributors. By double-clicking the listed dimensions and tolerances to modify their tolerance values and click Recalculate to compute new results.
After the analysis is complete, we can export the results in a report format with various parameters such as:
Worst-case stack-up: Max deviation in assembly dimensions considering all possible combinations of tolerance values.
RSS (Root Sum Square) stack-up: Calculates the root sum square of all tolerance variations to determine the overall variation in the assembly.
Individual part variations: Information on how each part’s tolerance contributes to the overall variation in the assembly
BENEFITS OF USING DIMXPERT AND TOLANALYS
DIMXPERT and TOLANALYST are two powerful tools in SOLIDWORKS that are primarily used for dimensioning and tolerance analysis respectively.
Benefits of DIMXPERT:
1.Automated Dimensioning: Automates the process of adding dimensions to your 3D models. This saves time and reduces errors compare to manual dimensioning.
2.Associativity: Maintains associativity between the dimensions and the model. If the model gets change, DimXpert updates the dimensions accordingly, ensuring that your design is preserved.
3.Standard Compliance: Ensure your designs met the industry standards for dimensioning, such as ASME Y14.5.
4.Dimensioning for Manufacturing: Capability of adding dimensions that are crucial for manufacturing processes, such as hole callouts, geometric tolerances, and annotations.
5.Enhanced Communication: Clear and accurate dimensioning improves communication between designers, engineers, and manufacturers, reducing misunderstandings and errors during production.
Benefits of TOLANALYST:
1.Tolerance Stack-Up Analysis: Predict how variations in component dimensions and tolerances will affect the overall assembly’s performance and functionality.
2.Identify Critical Dimensions: Identify critical dimensions and tolerances that have the most significant impact on product performance, reliability, and manufacturability.
3.Optimize Tolerances: By simulating different tolerance scenarios, optimize tolerances to meet performance requirements while minimizing manufacturing costs.
4.Reduce Scrap and Rework: By identifying potential issues early in the design phase, reduce the rework due to dimensional variations during manufacturing.
5.Improved Quality and Reliability: By ensuring the product quality and reliability, leads to customer satisfaction and reduced warranty claims.
Overall, DIMXPERT and TOLANALYST are indispensable tools in SOLIDWORKS for streamlining the design process, improving communication, and ensuring that your designs meet quality and performance requirements while being manufacturable within specified tolerances.
Have questions or need assistance? Feel free to reach out!
Email: mktg@egs.co.in
Phone: +91 94454 24704
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