Part mating gaps need to be effectively adjusted during the assembly of products and greatly affect the working performance. This paper develops an algorithm to calculate the dimensional and aerodynamic indexes affected by part mating gaps. Mating gaps are expressed by displacements of one contact surface, and indexes are evaluated by displacements of key surface, when the surface is ready to compare with the other. A graph that denotes contacts as nodes and related paths through the physical domain as lines is proposed to express assembly sequences and hierarchies. A variable is defined to combine the time set with the displacement set. Boolean algebraic theorems are extended to derive a compact expression for the contact graph that supports the organization of accumulations at different surfaces with propagations through physical domains. Demonstrations of this method using three products exhibit the general applicability, and the application shows that the performance deviations of the centrifugal fan and axial turbine are apparent. In particular, the isentropic efficiency is good with a certain probability, despite turbines having mating gaps. The algorithm benefits both design and assembly: design can be performed through the fluid domain, which is affected by the mating gaps, and when the parts are being adjusted, the selected tolerance limit allows engineers to monitor key surfaces to ensure good aerodynamic performance.

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