The most fundamental, and perhaps most important, task in tolerance analysis is to test whether or not the components with tolerances are actually able to fit together. This problem doesn’t get much explicit attention because it is implicitly included in current tolerance analysis methods. However, for complex assemblies, especially for over-constrained assemblies, the implicit assumptions of assembly may not be valid. This paper proposes an assembly model, called GapSpace, which can capture the necessary and sufficient conditions needed to execute assembleability analysis. Assembleability analyses for both nominal components and those with tolerances are presented using the GapSpace model. Both worst case and statistical analyses are performed. The model and its attendant solution methods are more suitable to GD&T tolerancing than traditional plus/minus tolerancing.

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