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As a design and manufacturing principle the combination of the actual deformations in a designed mechanical part due to all of its service loads and the deviations due to all of its manufacturing and production uncertainties should be equal or less than its maximum acceptable total geometric and topological deviations that can satisfy its form, fit, and function requirements. Therefore, precise knowledge of the actual deformations of mechanical components under the applied loads and boundary conditions need to be used to allocate suitable tolerances. However, this process is optimized only if the minimum geometric zone that covers the evaluated deformations is studied properly. In order to achieve this goal, the concept of minimum deformation zone is introduced in this paper. Using this concept, a unified methodology is developed to find the optimum tolerances for the geometric parameters of mechanical frame structures. Validity of the developed procedure is studied by conducting case studies and ...

Tolerance allocation Based on the Minimum Deformation Zone of Finite Element Structural Frame Analysis