University of Houston

Industrial Engineering Department

Engineering Design and Prototyping
Professor: Ali K. Kamrani

PROTOTYPING PROJECT

Balasubramanian, Pradeep
Kalaveena, Harideep
Sarcina, Adriana

Table of Content

List of Figures ................................................................................................................................. 4

List of Tables .................................................................................................................................. 5
Abstract ........................................................................................................................................... 6
Chapter I. Introduction .................................................................................................................... 7
Chapter II. Procedures .................................................................................................................... 8
II.1 Gear Part I.......................................................................................................................... 8
II.1.1 Design of gear components and assembly structure in CATIA software ...................... 8
II.1.2. DFA analysis ................................................................................................................. 8
II.1.3. D-Chains and D-Trees ................................................................................................ 10
II.1.4. Worst Case Arithmetic Method for Missing pieces .................................................... 13
II.1.5. Tolerances calculation for X-115 and X-104, X-104 and X-108, X-103 and X-104
using the limits FN2, LC10 and LC11 respectively .............................................................. 14
II.1.6. Specifications for positional control for features X-115 and X-104, X-104 and X-108,
X-103 and X-104 ................................................................................................................... 15
II.1.7. Process plan ................................................................................................................ 15
In order to create the process planning, Kamrani the next list of machine are going to be
used and evaluated to find the best one based in an information analysis. ........................... 15
II.1.8. Statistical Process Control .......................................................................................... 15
II.2 Drilling Jig Part 2 ............................................................................................................ 16
II.2.1. DFA Analysis.............................................................................................................. 16
II.2.2. Modular System Characteristics based in physical attributes ..................................... 16
Chapter III. Results ....................................................................................................................... 17
III.1 Gear Part I ...................................................................................................................... 17
III.1.1 Design of gear components and assembly structure in CATIA software................... 17
IIII.1.2. DFA analysis ............................................................................................................ 18
III.1.3. Components D-Chains and D-Trees ........................................................................ 21
III.1.4. Worst Case Arithmetic Method for Missing pieces .................................................. 26
III.1.5. Tolerances calculation for X-115 and X-104, X-104 and X-108, X-103 and X-104
using the limits FN2, LC10 and LC11 respectively .............................................................. 28
2

III.1.6. Specifications for positional control for features X-115 and X-104, X-104 and X108, X-103 and X-104 ........................................................................................................... 30
III.1.7. Process plan ............................................................................................................... 32
III.1.8. Statistical Process Control ......................................................................................... 36
III.2 Drilling Jig Part 2 ........................................................................................................... 41
III.2.1. Analysis ..................................................................................................................... 41
III.2.2. Modular System Characteristics based in physical attributes ................................... 48
Chapter IV. Conclusions ............................................................................................................... 50
Chapter V. Appendix .................................................................................................................... 51

List of Figures
Figure 1 - D-Chain Shaft (Horizontal Axis) ................................................................................. 21
Figure 2 - D-Tree Shaft (Horizontal Axis) ................................................................................... 22
Figure 3 - D-Chain Input Gear (Vertical Axis)............................................................................. 23
Figure 4 - D-Tree Input Gear (Vertical Axis) ............................................................................... 23
Figure 5 - D-Chain Cover (Vertical Axis) .................................................................................... 24
Figure 6 - D-Chain Cover (Horizontal Axis) ................................................................................ 25
Figure 7 - D-Tree Cover (Vertical Axis) ...................................................................................... 25
Figure 8 - D-Tree Cover (Horizontal Axis) .................................................................................. 25
Figure 9 - X-Chart for giving Input Gear data .............................................................................. 37
Figure 10 - R-Chart for giving Input Gear data ............................................................................ 37
Figure 11 - Scenario after first correction ..................................................................................... 38
Figure 12 - Scenario after second correction ................................................................................ 39
Figure 13 - Scenario after modify designer specification for Input Gear ..................................... 40
Figure 14 - Center Plate ................................................................................................................ 44
Figure 15 - Base ............................................................................................................................ 44
Figure 16 Bolt ............................................................................................................................ 45

List of Tables

Table 1 - DFA Components 0, 1, 2 ............................................................................................... 18

Table 2 - DFA Components 3, 4 ................................................................................................... 19
Table 3 - DFA ............................................................................................................................... 20
Table 4 - Machine Specifications ................................................................................................. 32
Table 5 - Surface groups specifications ........................................................................................ 33
Table 6 - CNC Automated Machine Selection Software .............................................................. 35
Table 7 - Final list of machines selected ....................................................................................... 35
Table 8- Statistical data for Input Gear ......................................................................................... 36
Table 9 - DFA B&D Method for Drill Jig .................................................................................... 41
Table 10 - DFA Lucas Method for Drill Jig ................................................................................. 42
Table 11 - DFA B&D Method for Redesign ................................................................................ 46

Abstract

In the next report, it can be found the complete analysis and develop of two different
prototypes. The first one, is a gear that was design in CATIA software and completely studied,
including its dimensions and tolerances, estimated time of manual insertion and handling,
specifications of positional control, and other important features in the develop of the
components of the gear. The second prototype is a design with the mainly function of provide
precision to users when drilling a piece. Equally to the first prototype, it was calculated the
estimated time for manual insertion and handling, considering different methods to do the
calculations of it; also for this second piece it was created a new design, reducing the
components that create high assembly estimated times.

Chapter I. Introduction

In the next report, it will be cover all the analysis and related study for the design and the
manufacture of a gear and a drilling jig. The work will be divided in two chapters: the procedures
which explain the steps used for the development of each section, and the results that shows the
final proceeds and solutions obtained. Both chapters will be divided in two sections, the first one
will cover all the analysis and results of the gear and the second of the drilling jig.

For the gear analysis, it will be included nine subdivisions that will cover the following
points:

The design and assembly of the parts in CATIA V5 software

The design for assembly analysis

The D-Chain and D-Tree for the parts required

The calculation of the sizes for the missing pieces, using the worst-case arithmetic
method

The calculation of tolerances for the parts required

The specification for positional control for the same parts of the previous subdivision

Other methods of form control

The process plan for the parts including cost with manufacturing of the components

Check if Statistical Process Control was used for the data collected as part of quality
control for outer diameter of input gear

For the drilling jig analysis, it will be included two subdivisions that will cover the
following points:

The design for assembly analysis using the M&D method and Lucas method

Identify the components in production and functional modules

Finally, it will be included a conclusion and the appendix, with some assumptions made for
the parts not required and the other tolerances calculations.
7

Chapter II. Procedures

II.1 Gear Part I

II.1.1 Design of gear components and assembly structure in CATIA software

Before starting to draw the parts with the software, it was necessary to do required
calculations for those pieces which their dimensions werent presented in the original
documentation. To do so, the width of some of them was calculated by the worst case arithmetic
method, which will be better explained in the section II.1.4, and other sizes were estimated based
on the graphics given, or were calculated with the Geometric Dimensioning and Tolerance
tables, which can be found in the chapter 11 of the textbook Engineering Design and Rapid
Prototyping.

II.1.2. DFA analysis

In order to perform the DFA analysis, it was necessary to come up with the order of
assembly first. The first step was to check the best way to disassemble the gear, and then how to
assembly it, based in the backward order. After doing these, there were obtained five
components that are going to be assembly separately from the rest of the pieces:

Component 0 / X-120 Speed Sensor Assembly:

X-124 Speed sensor

X-122 O Ring

Component 1/ X-108 Assy-Input Gear:

X-110 Gear Input

X-109 Bushing

X-124
X-122

X-110
X-109

X-106

Component 2 / X-103 Cover Assembly:

X-102 Cover

X-105 Shaft Seal

X-106 Seal O Ring

X-109 Bushing

X-105
X-109
X-102
X-112

Component 3 / X-101 Housing Assembly:

X-111

X-108

X-100 Housing

X-111 Plug Cup

X-109 Bushing

X-104 Shaft

X-112 Washer Thrust

X-108 Assy-Input Gear (Component 1)

X-113 Hub

X-125 Shaft Control

X-128 Sleve Control

X-129 Ring Retainer

X-113

X-104
X-109

X-100

X-129
X-128
X-125

Component 4 / X-126 Shift Fork Assembly:

X-126 Shift Fork

X-127 Pin-Shift Fork

X-114 Collar Shift

X-127
X-114

X-126

The final assembly will be considered in the order below:

X-101 Housing Assembly (Component 3)

X-126 Shift Fork Assembly (Component 4)

X-130 Spring

X-129 Ring Retaining

X-115 Gear-Speed Sensor

X-117 Ring Retaining

X-120 Speed Sensor Assembly (Component 0)

X-121 Ring Retaining

X-116 Washer Thrust

X-103 Cover Assembly (Component 2)

X-107 Bolts

X-118 Gear Output

X-119 Spacer Gear

X-117 Ring Retaining

II.1.3. D-Chains and D-Trees

To solve tolerance relations in dimensional chains and dimensional trees, engineering
practice uses three basic methods:

arithmetic method of calculation

statistical method of calculation

method of group interchangeability

As it was mentioned before, in the section II.1.4, it was used the arithmetic method of
calculation (Worst-Case method) to calculate all the dimensions related with the parts not
specified in the graphics given. Based on this, and the sizes given, the d-chains and d-trees were
created for the pieces that are shown below:
10

X-104 Shaft

X-110 Gear Input

11

X-102 Cover

12

II.1.4. Worst Case Arithmetic Method for Missing pieces

Since the dimensions of some pieces were not specified in the graphics given, they were
calculated with the worst case arithmetic method. Having the width of the hub, input gear,
bushing, and gear speed sensor, it was calculated the width of the washer thrust. Same as the
washer thrust, it was calculated other pieces, as it is shown in the section III.1.4.

In order to complete the calculations, it was used the dimensions given on the graphics,
and the formulas shown next:

Nominal dimension:

=1

=+1

=
Maximum dimension:

=1

=+1

=
Minimum dimension:

=1

=+1

=
Tolerance:

T(positive) = Fmax Fn
T(negative)= Fmin - Fn

13

II.1.5. Tolerances calculation for X-115 and X-104, X-104 and X-108, X-103
and X-104 using the limits FN2, LC10 and LC11 respectively
To calculate the tolerances required in this section, the parts were identified and
analyzed as it is shown next:

X 115 and X -104

The diameter of the shaft in the area where the speed sensor is located is equal to
27 mm, and this was converted to inches and, using the tables FN2, the
dimensions and tolerances for the shaft and speed sensor were calculated.

X 108 and X -104

X-108 is a component which includes three pieces, the gear input (X-110) and
two bushings (X-109). For the tolerances of the assy-input gear and the shaft, it
was considered the shaft diameter as it is shown on the given graphics (25 mm),
and was calculated the dimensions and tolerances for bushings and shaft.

X-103 and X-104

X-103 is a component which includes four pieces, the cover (X-102), shaft seal
(X-105), the seal O Ring (X-106) and the bushing (X-109). For the tolerances
of the cover assembly and the shaft, it was considered the shaft diameter as it is
shown on the given graphics (25 mm), and was calculated the dimensions and
tolerances for bushing, shaft seal and shaft.

14

II.1.6. Specifications for positional control for features X-115 and X-104, X104 and X-108, X-103 and X-104
In order to protects the parts function and minimize the lowers production costs, it
is important to calculate the positional control of the holes and shaft mentioned in the
previous section. In order to do so, the diameter values of hole and shaft are subtracted.
The formula, for maximum material condition or minimum material condition, is the
diameter of the hole minus the diameter of the shaft. If the fit is clearance, the result
obtained will be positive, but if it is interference, the result will be negative. After making
the subtraction, it is assigned a value for the shaft and a value for the hole, to establish
their positional control.

II.1.7. Process plan

In order to create the process planning, Kamrani the next list of machine are going
to be used and evaluated to find the best one based in an information analysis.
Shaper

Vertical Milling Machine

Horizontal Surface Grinding Machine

Lathe

High Precision Lathe

Horizontal Milling Machine

Cylindrical Grinding Machine

II.1.8. Statistical Process Control

The statistical control will calculate the upper control limits and lower control limits and
based on the results on the X and R Chart and it will be submit to corrections in order to find a
better process capability that allows the company to produce output within the specification
limits.
15

II.2 Drilling Jig Part 2

II.2.1. DFA Analysis

To complete the design for assembly analysis, it will be used two methods, the B&D
method, which is the same that will be used in the first section for the evaluation of the gear, and
a second method, called Lucas. The last one mentioned will include a functional, feeding and
fitting analysis.
For the functional analysis, it will be considered the essential parts for the products
function and the non-essential parts. The formula required for the calculation is:
Ed(efficiency of the design) = A / (A+B) * 100,

where A represents the essential parts and B

the non-essential

It is expected to obtain an efficiency of 60%.

On the other hand, in the feeding analysis, it will be analyzed the handling and insertion
process using the provided table and it is expected a 1.5 value for each part; it will be calculated
the total feeding ratio with the following formula:
Feeding Ratio = ( feeding index) / (Number of Essential Components A)
In this case, the ideal ratio will be 2.5.
Finally, it will be calculated the fitting analysis for each part, taking the values from the
automation manual, where it is expected a 1.5 value for each part; and again the fitting ratio will
come from the next formula:
Fitting Ratio = ( fitting index) / (Number of Essential Components A)
The target for the fitting ratio is 2.5.
After doing the analysis mentioned, a redesign will take part if necessary.

II.2.2. Modular System Characteristics based in physical attributes

Given the physical characteristics of the drill jig, there is going to be identifying the
function modules and the production modules.

16

Chapter III. Results

III.1 Gear Part I

III.1.1 Design of gear components and assembly structure in CATIA

software
The dimensions given in the graphics were convert into inches, and were used to compare
and find the tolerance table to make the corresponding calculations, which can be found on the
appendix (Chapter V), in the last part of this document, as well as all the assumptions made for
the estimated sizes.

The DVD that is attached below includes all the components designed with CATIA V5
software:

Note: The DVD includes also a copy of this report, presentation made in the class, and the design of the Drill Jig in
CATIA.

17

IIII.1.2. DFA analysis

1

Part ID
No.

Number of
time the
operation is
carried out
consecutively

Two-digit
manual
handling
code

Manual
handling
time per
part

Two-digit
manual
insertion
code

Manual
insertion
time per
part

Operation
Time, in
seconds
(2)*[(4)+(6)]

Operation
cost, in
cents
0.4*(7)

Figures for
estimation
of theorical
minimum
parts

Name of Assembly

360

180

COMPONENT 0 - X-120 SPEED SENSOR ASSEMBLY

X-124
X-122

1
1
1

10

1,5

03

1,69

00
98
31

1,5
9
5

3
9
6,69
18,69
TM

1,2
3,6
2,676
7,476
CM

1 SPEED SENSOR
0 SEP. OPERATION
0 "O" RING
1
NM

Design Efficiency

0,161

COMPONENT 1 - X-108 ASSY-INPUT GEAR

X-110
X-109

1
1
2

10

1,5

00

1,13

00
98
11

1,5
9
5

10,5
5
12,26
27,76
TM

4,2
2
4,904
11,104
CM

1 GEAR INPUT
0 SEP. OPERATION
0 BUSHING
1
NM

Design Efficiency

360

180

0,108

COMPONENT 2 - X-103 COVER ASSEMBLY

X-102
X-105
X-106
X-109

1
1
1
1
1

30

1,95

00
00
00

1,13
1,13
1,13

00
98
00
01
11

1,5
9
1,5
2,5
5

10,95
1,5
3,63
3,63
6,13
25,84
TM

4,38
0,6
1,452
1,452
2,452
10,336
CM

1
0
0
0
0
1
NM

COVER
SEP. OPERATION
SHAFT SEAL
SEAL 'O' RING
BUSHING
Design Efficiency

360

36
0

180

180

180

0,116

Table 1 - DFA Components 0, 1, 2

18

Part ID
No.

Number of
time the
operation is
carried out
consecutively

Twodigit
manual
handling
code

4
Manual
handling
time per
part

Two-digit
manual
insertion
code

Manual
insertion
time per
part

Operation
Time, in
seconds
(2)*[(4)+(6)]

Operation
cost, in
cents
0.4*(7)

Figures for
estimation
of theorical
minimum
parts

Name of Assembly

COMPONENT 3 - X-101 HOUSING ASSEMBLY

X-100
X-111
X-109
X-104
X-112
X-108
X-113
X-125
X-128
X-129

1
1
1
1
1
1
1
1
1
1
1

30

1,95

13
00
10
00
10
10
10
00
03

2,06
1,13
1,5
1,13
1,5
1,5
1,5
1,13
1,69

00
98
98
11
06
00
00
00
06
00
31

1,5
9
9
5
5,5
1,5
1,5
1,5
5,5
1,5
5

3,45
9
11,06
6,13
7
2,63
3
3
7
2,63
6,69
61,59
TM

1,38
3,6
4,424
2,452
2,8
1,052
1,2
1,2
2,8
1,052
2,676
24,636
CM

1
0
0
0
1
0
1
1
1
1
0
6
NM

HOUSING
SEP. OPERATION
PLUG-CUP
BUSHING
SHAFT
WASHER-THRUST
ASSY-INPUT GEAR (COMPONENT 1)
HUB
SHAFT CONTROL
SLEEVE CONTROL
RING REATINING
Design Efficiency

360 360
360
180
360
180
360
360
360
180
180

0
0
0
0
0
0
0
0
0

0,292

COMPONENT 4 - X-126 SHIFT FORK ASSEMBLY

X-126
X-127
X-114

1
1
2
1

00

1,13

10
00

1,5
1,13

00
98
31
06

1,5
9
5
5,5

10,13
5
13
6,63
34,76
TM

4,052
2
5,2
2,652
13,904
CM

1
0
0
1
2
NM

SHIFT FORK
SEP. OPERATION
PIN-SHIFT FORK
COLLAR SHIFT
Design Efficiency

180

360

180

0,173

Table 2 - DFA Components 3, 4

19

Part ID
No.

Number of
time the
operation is
carried out
consecutively

Twodigit
manual
handling
code

4
Manual
handling
time per
part

Two-digit
manual
insertion
code

Manual
insertion
time per
part

Operation
Time, in
seconds
(2)*[(4)+(6)]

Operation
cost, in
cents
0.4*(7)

Figures for
estimation
of theorical
minimum
parts

Name of Assembly

360

360

360

180

180

180

180

180

360

180

360

360

360

360

360

180

180

DFA

X-101
X-126
X-130
X-129
X-115
X-117
X-120
X-121
X-116
X-103
X-107
X-118
X-119
X-117

30

1,95

00

1,5

3,45

1,38

1
1
1
1
1

20
00
03
00
03

1,8
1,13
1,69
1,13
1,69

06
00
31
00
01

5,5
1,5
5
1,5
2,5

7,3
2,63
6,69
2,63
4,19

2,92
1,052
2,676
1,052
1,676

1
1
1

10
03
10

1,5
1,69
1,5

00
31
00

1,5
5
1,5

3
6,69
3

1,2
2,676
1,2

1
4
1
1
1

30
10
10
00
0,3

1,95
1,5
1,5
1,13
1,69

38
92
00
00
31

6
5
1,5
1,5
5

7,95
26
3
2,63
6,69
85,85
TM

3,18
10,4
1,2
1,052
2,676
34,34
CM

HOUSING ASSEMBLY
1 (COMPONENT 3)
SHIFT FORK ASSEMBLY
1 (COMPONENT 4)
0 SPRING
0 RING REATINING
1 GEAR-SPEED SENSOR
0 RING REATINING
SPEED SENSOR
ASSEMBLY (COMPONENT
1 0)
0 RING REATINING
0 WASHER-THRUST
COVER ASSEMBLY
1 (COMPONENT 2)
0 BOLTS
1 GEAR OUTPUT
0 SPACER GEAR
0 RING REATINING
6
NM

Design Efficiency

0,210

Table 3 - DFA

20

III.1.3. Components D-Chains and D-Trees

X-104 Shaft
P3
P4
P6
P5
P8
P7
P1

P11
P10
P9

P2

3
27
1.56
58.1
4
3

20
1.56

94

4
156.1
Horizontal axis
Figure 1 - D-Chain Shaft (Horizontal Axis)

21

P1
P3

1.56

156.1

P4

20
58.1

P5
P6

-3

P2

-4

-94
P7
-1.56

P10

P9

P8

Figure 2 - D-Tree Shaft (Horizontal Axis)

X-110 Input Gear

P2
P7 P6

Using the worst-case arithmetic

method, i.e. 101.9 (nominal value of
highest diameter) minus 95 (nominal
value for teeth diameter), equal 6.9

P3 P4
P1 P5

22

61.183
101.9
35.535
23.55

20.845

Vertical Axis
3.45

Figure 3 - D-Chain Input Gear (Vertical Axis)

3.45

P3

P1

20.845
P4

101.9

23.55

P5

35.535
P6

61.183

P2

P7

Figure 4 - D-Tree Input Gear (Vertical Axis)

23

X-102 Cover
P6

P2
P9
P6
P5

P7

P8 P7

P4

P2

P3
P1
Horizontal Axis

P4 P5
P3

P1
Vertical Axis

13.45

15.415
10.585
164
34

36.2

Vertical Axis

28

Figure 5 - D-Chain Cover (Vertical Axis)

24

11.5
3.45
3.5
12
11
30.5

Horizontal Axis

Figure 6 - D-Chain Cover (Horizontal Axis)

P3

P1

28

164

P4

34

36.2

P5

P2
10.585

P7

P6

-13.45
P8

15.415

P9

Figure 7 - D-Tree Cover (Vertical Axis)

P1
11

P3
P5

30.5

12

3.5
11.5

P4

P2

3.45
P7
P6

Figure 8 - D-Tree Cover (Horizontal Axis)

25

III.1.4. Worst Case Arithmetic Method for Missing pieces

As it was mentioned in the previous chapter, the dimensions given in the graphics are
used to calculate the sizes that were not given. Below, it is shown an example and explanation of
the calculations of worst case arithmetic method:
+0.05
-0.05

+0.05

40 mm -0.05
6.0 mm

+0.05
26.6mm -0.05
+0.1
-0.1

+0.05

13mm -0.05

For the nominal dimension of the washer thrust, the nominal values of the gear speed
sensor, hub, gear input and bushing are subtracted from the shaft nominal value:

NomVal(washer-thrust) = (94-3) (6 + 26.6 + 40 +13) = 5.4 mm

For the maximum dimension, it is required to use the maximum value of the shaft minus
the minimum value for the last part of the shaft. Then, also it is necessary to subtract the
minimum values for all the parts given.

MaxVal(washer-thrust) = (94.05 2.95) (5.9 + 26.55 + 39.95 + 12.95) = 5.75 mm

For the minimum value dimension, it is required to use the minimum value of the shaft
minus the maximum value for the last part of the shaft. Then, also it is necessary to subtract the
maximum values for all the parts given.

26

MinVal(washer-thrust) = (93.95 3.05) (6.1 + 26.65 + 40.05+ 13.05) = 5.05 mm

The last calculation required is the tolerances, where the nominal value is subtracted from
the maximum value for positive tolerance and from the minimal value for the negative one.

Positive tolerance = 5.75 5.4 = + 0.35 mm

Negative tolerance = 5.05 5.4 = -0.35 mm
5.4 mm

+0.35
-0.35

The same process is applied to calculate the dimensions of the hub.

Nom Val = (60.31 27.035)/2 = 16.6375 mm
MaxVal = (60.36 27.01)/2 = 16.675 mm
MinVal = (60.26 27.06)/2=16.6 mm
NomVal = (60.31 47.00)/2 = 6.655 mm
MaxVal = (60.36-46.96)/2 = 6.7 mm
MinVal = (60.26 47.04)/2 = 6.61 mm
NomVal=27-6 = 21 mm
MaxVal = 27.05 5.9 = 21.15 mm
MinVal = 26.95 6.1 = 20.85 mm

27

III.1.5. Tolerances calculation for X-115 and X-104, X-104 and X-108, X-103
and X-104 using the limits FN2, LC10 and LC11 respectively

X 115 and X -104

1.0611 in
26.95 mm

+0.0008
-0.0000
+0.02
-0.00

X-115

/ X-104 (FN2)
Diameter of Shaft = 1.063 in
ds(max)= d a = d = 1.0611 in

1.063 in
27.00 mm

Range
0.951.19

+0.0000
-0.0005
+0.00
-0.01

a
0.6
1.9

h
+0.8
0

L
+1.9
+1.4

dh(max) = d+h = 1.0611 + 0.0008 = dh(max) = 1.0619 in

For interference fit, the allowance is the

higher value, the hole tolerance is the nonzero value and for the shaft, is used the
next formula:

ds(min)= d-a-s = ds(min)= 1.0625 in

s=|Lmin + a|=|0.0014-0.0019|= 0.0005 in

dh(min) =d = dh(min) = 1.0611 in

28

X 108 and X -104

0.9850 in
25.02 mm

+0.0008
-0.0000
+0.02
-0.00

+0.0000
-0.0008
+0.00
-0.02

0.9843 in
25.00 mm

X-109/

X-104 (LC10)

a
7.0
23.0

Range
0.71
1.19

Diameter of Shaft = 0.9843 in

ds(max)= d a = 0.9843 in

h
+8.0
0

L
-7.0
-15.0

dh(min) =d = dh(min) = 0.9850 in

For clearance fit, the allowance is the lower

value, the hole tolerance is the non-zero
value and for the shaft, is used the next
formula:

dh(max) = d+h = dh(max) = 0.9858 in

s=|Lmin + a|=|-0.0015+0.0007|= 0.0008 in

Since a =0.0007, d = 0.9850 in

ds(min)= d-a-s = ds(min)=0.9835 in

X-103 and X-104

0.9853 in +0.0012
-0.0000
25.03 mm +0.03
-0.00

0.9843 in

+0.0000

-0.0012
25.00 mm +0.00
-0.03

X-105

/ X-104 (LC11)
Diameter of Shaft = 0.9843 in
ds(max)= d a = 0.9843 in

Range
0.711.19

a
10
34

h
+12
0

L
-10
-22

dh(min) =d = dh(min) = 0.9853 in

For clearance fit, the allowance is the lower

value, the hole tolerance is the non-zero
value and for the shaft, is used the next
formula:

dh(max) = d+h = 0.9833 + 0.0012 = dh(max) = 0.9865 in

s=|Lmin + a|=|-0.0022+0.0010|= 0.0012 in

Since a =0.001, d = 0.9853 in

ds(min)= d-a-s = ds(min)= 0.9831 in

29

III.1.6. Specifications for positional control for features X-115 and X-104, X104 and X-108, X-103 and X-104

X-115 and X-104

1.0611 in
26.95 mm

+0.0008
-0.0000
+0.02
-0.00

1.063 in
27.00 mm

+0.0000
-0.0005
+0.00
-0.01

-A-

-0.02 mm
-0.03 mm M
-0.01 mm

M
M

-0.01 mm L

X 108 and X -104

0.9850 in
25.02 mm

+0.0008
-0.0000
+0.02
-0.00

0.9843 in
25.00 mm

+0.0000
-0.0008
+0.00
-0.02

30

-A-

0.01 mm M
0.03 mm L

A
A

0.01 mm

0.03 mm

X-103 and X-104

0.9853 in +0.0012
-0.0000
25.03 mm +0.03
-0.00

0.9843 in
25.00 mm

+0.0000
-0.0012
+0.00
-0.03

-A-

0.02 mm M
0.05 mm

A
A

0.01 mm

0.04

mm

31

III.1.7. Process plan

As it was mentioned on the previous chapter, the machines that are going to be used are:
1.
2.
3.
4.
5.
6.
7.

Shaper
Vertical Milling Machine
Horizontal Surface Grinding Machine
Lathe
High Precision Lathe
Horizontal Milling Machine
Cylindrical Grinding Machine

Now these machines have different levels of tolerances and surface finish values:

Tolerance
Machine Name

Surface Finish

Power
(KWH)

Efficiency

Labor and
Depreciation

lower

upper

lower

upper

1 Shaper

-75

750

10

100

0.58

2 Vertical Milling Machine

-75

750

80

3.7

0.5

-2.5

25

0.5

0.65

4 Lathe

-20

200

40

0.7

5 High Precision Lathe

-10

100

20

0.75

2.5

6 Horizontal Milling Machine

-75

750

10

100

3.7

0.5

1.5

7 Cylindrical Grinding Machine

-2.5

25

0.5

0.65

Horizontal Surface Grinding

Machine

Table 4 - Machine Specifications

32

Consider The Input Gear:

The surface groups that have been identified on this input gear are:

Sequence 1
Tolerance

Surface Finish

Description

Surface Groups

lower

upper

lower

upper

Length cut

Surface Group 1

-50

50

19

Diameters

Surface Group 2

300

12

Shaft Hole

Surface Group 3

60

20

Undercutting

Surface Group 5

-30

30

15

Teeth

Surface Group 6

30

10

Table 5 - Surface groups specifications

Using the formulae for the Information Axiom to decide the best machine for each job to
be done:

Creating a program in MS Excel to automatically choose machines form the available

ones based upon the information axiom.

33

An instance of the excel sheet is:

Surfac
e
Group
1

Recommended

Surfac
e
Group
2

Recommended

Surfac
e
Group
3

Recommended

Surfac
e
Group
4

Recommended

Shaper
Vertical Milling
Machine
Horizontal Surface
Grinding Machine
Lathe
High Precision
Lathe
Horizontal Milling
Machine
Cyllindrical
Grinding Machine
Shaper
Vertical Milling
Machine
Horizontal Surface
Grinding Machine
Lathe
High Precision
Lathe
Horizontal Milling
Machine
Cyllindrical
Grinding Machine
Shaper
Vertical Milling
Machine
Horizontal Surface
Grinding Machine
Lathe
High Precision
Lathe
Horizontal Milling
Machine
Cyllindrical
Grinding Machine
Shaper
Vertical Milling
Machine
Horizontal Surface
Grinding Machine

Information
Sequence 1
Surface
Tolerance
Finish
Total
2.1102132 2.302585093 4.41279829
2.1102132

Min Value
0.72391884

Activate
1

1.878770846 3.98898405

0
0.810930216 0.81093022
1.145132304 0.875468737 2.02060104

1
1

0.606135804 0.117783036 0.72391884

2.1102132

2.302585093 4.41279829

0
0.810930216 0.81093022
1.011600912 3.80666249 4.8182634

1
1

0.9062404

1.011600912 2.890371758 3.90197267

0.09531018
0.09531018

1.504077397 1.59938758
1.504077397 1.59938758

1
1

0.09531018

0.810930216

0.9062404

1.011600912

3.80666249

4.8182634

0.09531018 1.504077397 1.59938758

2.621038824 2.197224577 4.8182634

1
1

0.72391884

2.621038824 1.791759469 4.41279829

0.09531018 1.504077397 1.59938758

1.299282984 0.810930216 2.1102132

1
1

0.606135804 0.117783036 0.72391884

2.621038824 2.197224577

4.8182634

0.09531018 1.504077397 1.59938758

2.621038824 2.890371758 5.51141058

1
1

3.314186005 3.583518938 6.89770494

0

1
34

Surfac
e
Group
5

Recommended Lathe
High Precision
Recommended Lathe
Horizontal Milling
Recommended Machine
Cyllindrical
Recommended Grinding Machine
Shaper
Vertical Milling
Machine
Horizontal Surface
Recommended Grinding Machine
Lathe
High Precision
Lathe
Horizontal Milling
Machine
Cyllindrical
Recommended Grinding Machine

0
0
0
2.621038824 2.890371758 5.51141058
2.621038824

0.81093022

4.95179479

0
0.810930216 0.81093022
1.481604541 1.185623666 2.66722821

1
1

1.011600912 0.405465108 1.41706602

2.621038824 2.890371758 5.51141058

2.33075597

1
1

0.810930216 0.81093022

Table 6 - CNC Automated Machine Selection Software

The functions of this automated machine-tool picking software are:

Pick the best machine among the available machines based on the information
axiom
Ability to activate and de-activate the machines in case of non-availability or if
the machine is not apt for the purpose.

The final list of machines according to the information axiom, given by the program for
the surface group selected are:

Description

Finalized Machines

Length cut

High precision Lathe

Diameters

High Precision Lathe

Shaft Hole

High Precision Lathe

Undercutting

Horizontal Milling Machine

Teeth

Cylindrical Grinding Machine

Table 7 - Final list of machines selected
35

III.1.8. Statistical Process Control

The given data for input gear is:

Sample
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

1
102.00
101.91
101.89
101.10
101.08
101.94
102.09
102.01
102.00
101.92
101.91
102.01
101.98
102.02
102.00

Observation
2
3
101.97
102.10
101.94
102.10
102.02
101.97
101.09
101.05
101.92
101.12
101.98
102.06
102.00
102.00
102.04
101.99
101.96
101.97
101.94
102.09
101.99
102.05
102.00
102.06
101.99
102.06
102.00
102.05
102.05
102.01

4
102.08
101.96
101.99
101.95
101.05
102.08
102.03
101.95
102.03
102.00
102.10
101.97
102.03
101.95
101.97

Range
0.13
0.19
0.13
0.90
0.87
0.14
0.09
0.09
0.07
0.17
0.19
0.09
0.08
0.10
0.08
0.22
R bar

X Bar
102.04
101.98
101.97
101.30
101.29
102.02
102.03
102.00
101.99
101.99
102.01
102.01
102.02
102.01
102.01
101.91
X Bar
Bar

Table 8- Statistical data for Input Gear

36

The X-Charts and the R Charts are:

X-Chart:
1.00
0.90
0.80
0.70
0.60

Range

0.50

UCLR

0.40

LCLR

0.30

Expon. (Range)

0.20
0.10
0.00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Figure 9 - X-Chart for giving Input Gear data

R Chart:
102.20
102.00
101.80
101.60

Series1

101.40

Expon. (Series1)

101.20
101.00
100.80
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Figure 10 - R-Chart for giving Input Gear data

37

Cpk = 0.008464
Cp=0.009353
Std Dev = 0.280579311
Obviously there are spikes in the charts. So, there are samples that need to be eliminated.

Figure 11 - Scenario after first correction

38

Figure 12 - Scenario after second correction

39

Figure 13 - Scenario after modify designer specification for Input Gear

Therefore the process is under one sigma level.

40

III.2 Drilling Jig Part 2

III.2.1. Analysis
III.2.1.1 DFA Analysis
III.2.1.1.1 B&D method
1

Part
ID No.

Number of
time the
operation is
carried out
consecutively

Two-digit
manual
handling
code

Manual
handling
time per
part

Two-digit
manual
insertion
code

Manual
insertion
time per
part

Operation
Time, in
seconds
(2)*[(4)+(6)]

Operatio
n cost, in
cents
0.4*(7)

Figures for
estimation
of
theorical
minimum
parts

1
2
5
3
4
6

1
2
2
1
2
2

20
30
10
20
10
00

00
00
38
00
00
58

1,5
1,5
6
1,5
1,5
10

3,3
6,9
15
3,3
6
22,26
56,76
TM

1,32
2,76
6
1,32
2,4
8,904
22,704
CM

1,8
1,95
1,5
1,8
1,5
1,13

1
0
0
1
0
0
2
NM

Name of
Assembly

Base
End Bracket
Screw
Center Plate
Bolt
Nut
Design
Efficiency

360
360
360
360
360
180

180
360
0
180
0
0

0,106

Table 9 - DFA B&D Method for Drill Jig

41

III.2.1.1.2 Lucas method

Component
Number

TOTAL

Component
Description

Number
of parts

Functional
Assembly

Fitting Assembly

Feeding
Assembly

1 Base

1 A

1.5

1.5

2 End Bracket

2 B

1.1

5 Screw

2 B

1.1

3 Center Plate

1 A

1.0

1.0

4 Bolt

2 B

1.1

2.4

6 Nut

2 B

1.0

2.0

10

2.4
2.0

2.0

2.0

6.8
18.3

Table 10 - DFA Lucas Method for Drill Jig

42

Checking the essential and total quantity of parts, it is possible to obtain the efficiency of
the design:
Ed = 2 / 10 *100% = 20%
Evaluating the result obtained, the first indicator that it is important a redesign appears,
since the efficiency is too low and far from the objective value.
For the feeding analysis, the only piece that it is necessary to carry with two hands is the
base, and for that reason, it is assigned a 1.5 value. Also considering the symmetry and the end to
end part of each piece, it is required to sum 0.1 in some of the pieces. As it was mentioned in the
previous chapter, the expected index for each part is 1.5; some of the pieces have values of 1,
which is very low. Also, the feeding ratio was obtained:
Feeding Ratio = 6.8 / 2 = 3.4
For the fitting analysis, the base requires a non- assembly process, to give a preorientation to the part. When analyzing the next part, the end bracket, the first question that it is
required is related with the orientation of the piece and the probability of assembly the part in the
wrong way. The answer for the question must be yes, since the piece is symmetric and the holes
have different sizes and, for that reason, it is required a redesign since these point. However, it
was completed the analysis, continuing with the screws which requires an insertion process and a
non-assembly process (screwing process). Same analysis was done for the rest of the parts,
obtaining their indexes.
The expected value for each index is 1.5, and some of the indexes obtained are too far
from the target, for example the value for each bracket is 2.7, which is almost double of the
expected index. Same situation is occurring with the fitting ratio, where the ideal value is 2.5 and
the result obtained is the following:
Fitting Ratio = 18.3 / 2 = 9.1
Also, considering the disassembly required, the efficiency of the process will decrease,
since it is required to remove the bolts and nuts, and obviously, this will move away more the
result from the ideal ratios.
After this evaluation, the best option is to redesign the piece in order to obtain better
efficiency that can meet the target.

43

III.2.1.2 Redesign

Figure 14 - Center Plate

Figure 15 - Base
44

Figure 16 Bolt

For the redesign, it was considered three pieces, the base, which includes a hold with
groove for the bolt; the center plate, which it wasnt change and the bolt which is used to
maintain the position of the center plate.

45

III.2.1.2.1 DFA with B&D method

Part
ID
No.

Number of
time the
operation is
carried out
consecutively

Two-digit
manual
handling
code

Manual
handling
time per
part

Two-digit
manual
insertion
code

Manual
insertion
time per
part

Operation
Time, in
seconds
(2)*[(4)+(6)]

Operation
cost, in
cents
0.4*(7)

Figures for
estimation
of theorical
minimum
parts

Name of
Assembly

30

1,95

00

1,5

3,45

1,38

1 Base

360

360

20

1,8

00

1,5

3,3

1,32

1 Center Plate

360

180

10

1,5

92

6,5

2,6

0 Bolt

360

13,25

5,3

TM

CM

NM

Design
Efficiency

0,453

Table 11 - DFA B&D Method for Redesign

It can be observed that the efficiency obtained with the new design increased around 35% compared with the original design.

46

III.2.1.2.2 DFA with Lucas method

Fitting Assembly
Component
Number

Component
Description

Number of
parts

Functional
Assembly

Feeding
Analysis

1 Base

1.5

1.5

2 Center Plate

1.0

3 Bolt

1.0

TOTAL

1.0

3.5
4.5

Ed = 2 / 3 * 100% = 66.7 %
The efficiency of the design obtained from the functional analysis meet the target expected with this new design. Also, the
ratios of feeding and fitting are very close to the ideal values, as it is shown next:
Feeding Ratio = 3.5 / 2 = 1.75
Fitting Ratio = 4.5 / 2 = 2.25

47

III.2.2. Modular System Characteristics based in physical attributes

Function Modules:

Basic function: the basic function is given by the base, which helps to position the
rest of the pieces and works as a backstop when drilling.

Auxiliary function: the screws and the end brackets have an auxiliary function, to
help maintaining the central plate in his position in an indirect way.

Adaptive function: the central plate can be change to adapt and adjust the size of
the hole for the drilling.

Special function: the nuts and the bolts have a special function, since they help to
maintain the central plate in its position in a direct way.

Production Modules:

The piece gives to the user safety when drilling a piece

Easy to manipulate for the user

Allows changing the size of the hole that it is going to be drilled.

48

SLS Matrix

Components
Phisics
Component
1
Base

End Brackets

Screws

Central Plate

Bolts

Screws

Arragment
Component2 In Line
End Brackets
Screws
Central Plate
Bolts
Nuts
Base
Screws
Central Plate
Bolts
Nuts
Base
End Brackets
Central Plate
Bolts
Nuts
Base
End Brackets
Screws
Bolts
Nuts
Base
End Brackets
Screws
Central Plate
Nuts
Base
End Brackets
Screws
Central Plate
Bolts

Proximity

Parallel
1
1
1
0
0
1
1
1
0
0
1
1
1
0
0
1
1
1
0
0
0
0
0
0
1
0
0
0
0
1

In contact
0
0
0
1
1
0
0
0
1
1
0
0
0
1
1
0
0
0
1
1
1
0
0
0
0
1
1
1
1
0

Separated
1
1
1
0
0
1
1
1
1
1
1
1
0
0
0
1
1
0
1
1
0
1
0
1
1
0
1
0
1
1

0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
0
0
1
0
0
1
0
1
0
0
1
0
1
0
0

49

Chapter IV. Conclusions

The report gave a brief idea in how to make a rapid prototyping of pieces, an analysis of
assembly efficiency and times, tolerances, positional control, structures of D-chains and D-trees,
positional control, modular system, analysis of calculation of dimensions, etc. All those
procedures mentioned, that were developed during the work, are vital guidelines that all
companies must follow in order to design a prototype. The manufacture of a prototype is costly,
which makes more important all the analysis and calculation, which must be done very carefully,
since the failure of the prototype designed must not fail.

All the material covered can help to covered can help to future engineers to understand
the basics of computer aid manufacturing, and the way to design a prototype considered its
physical attributes, functions, assembly order and other key points for where the analysis start.

50

Chapter V. Appendix

51

52

COMPONENT 0 X-120 SPEED SENSOR ASSEMBLY

Assumption 1: Highest diameter of sensor is equal to 18

mm.
Assumption 2: The lower diameter of sensor is equal to
12 mm.
Assumption 3: The ring retainer is 1 mm from the top of
the sensor.
Note 1: Sizes were randomly assigned.

18.00 mm

+0.00
-0.50

1.00 mm

18.00 mm

+0.50
-0.00

+0.50

12.00 mm -0.00

+0.00

12.00 mm -0.50
1.00 mm

9.00 mm

+0.125
-0.00

+0.05
-0.05

+0.00

20.00 mm -0.50

16.00 mm
30.00 mm

+0.50
-0.00

+0.50
-0.00

18.00 mm

+0.125
-0.00

+0.00
-0.50

+0.00

18.00 mm -0.05

16.00 mm

+0.00
-0.50

Ring Retainer
1.00 mm

+0.05
-0.05

1.00 mm

+0.05
-0.05

X-122
O Ring

53

COMPONENT 1 - X-108 ASSY-INPUT GEAR

Note 2: It is required to calculate the tolerances.

X-109/

X-104 (LC10)
Diameter of Shaft = 0.9843 in
0.9850 in
25.02 mm

+0.0008
-0.0000
+0.02
-0.00

0.9843 in
25.00 mm

+0.0000
-0.0008
+0.00
-0.02

ds(max)= d a = 0.9843 in
Since a =0.0007, d = 0.9850 in
dh(min) =d = dh(min) = 0.9850 in
dh(max) = d+h = dh(max) = 0.9858 in
ds(max) = d a= 0.9843 in

Range
0.71
1.19

a
7.0
23.0

h
+8.0
0

L
-7.0
-15.0

For clearance fit, the allowance is

the lower value, the hole tolerance
is the non-zero value and for the
shaft, is used the next formula:
s=|Lmin + a|=|-0.0015+0.0007|=
0.0008 in

ds(min)= d-a-s = ds(min)=0.9835 in

54

COMPONENT 2 - X-103 COVER ASSEMBLY

Note 3: It is required to calculate the tolerances.

0.9853 in +0.0012
-0.0000
25.03 mm +0.03
-0.00

0.9843 in
25.00 mm

X-105 / X-104 (LC11)

Diameter of Shaft = 0.9843 in

+0.0000
-0.0012
+0 00
-0.03

Range
0.711.19

a
10
34

h
+12
0

L
-10
-22

ds(max)= d a = 0.9843 in
Since a =0.001, d = 0.9853 in
dh(min) =d = dh(min) = 0.9853 in
dh(max) = d+h = 0.9833 + 0.0012 = dh(max) = 0.9865 in
ds(max) = d a= 0.9843 in

For clearance fit, the allowance is

the lower value, the hole tolerance
is the non-zero value and for the
shaft, is used the next formula:
s=|Lmin + a|=|-0.0022+0.0010|=
0.0012 in

ds(min)= d-a-s = ds(min)= 0.9831 in

55

0.9850 in
25.02 mm

+0.0012
-0.0000
+0.03
-0.00

0.9843
25.00 mm

X-109/

X-104 (LC11)
Diameter of Shaft = 0.9843in
ds(max)= d a = 0.9843 in
Since a =0.0010, d = 0.9853 in
dh(min) =d = dh(min) = 0.9853 in
dh(max) = d+h = 0.9853 + 0.0012 = dh(max) = 0.9865 in

+0.0000
-0.0012
+0.00
-0.03

Range
0.711.19

a
10
34

h
+12.0
0

L
-10
-22

For clearance fit, the allowance is the

lower value, the hole tolerance is the
non-zero value and for the shaft, is
used the next formula:
s=|Lmin +
0.0012in

a|=|-0.0022+0.0010|=

+0.004

4.7224in -0.000

ds(max) = d a= 0.9843 in

+0.10
113.95 mm
-0.00

ds(min)= d-a-s = ds(min)= 0.9831 in

3.45 mm

119.95 mm +0.10
-0.00

+0.15
-0.15

56

12 mm

+0.05
-0.05

1.872 in
47.55 mm

X-105

/ X-102 (LC4)
d = 1.872 in
dh(min) = 1.872 in
dh(max) = d+h = dh(max) = 1.876 in
ds(max) = d a= 1.872 in
ds(min)= d-a-s = 1.8695 mm

+0.000
-0.0025
+0.00
-0.06

+0.004
-0.000
mm +0.10
-0.00

1.872 in
47.55

Range
1.19
1.97

a
0
6.5

h
+4.0
0

L
0
-2.5

For
clearance
fit,
the
allowance is the lower value,
the hole tolerance is the nonzero value and for the shaft, is
used the next formula:
s=|Lmin + a|=|-.0025+.000|=
0.0025 in

57

COMPONENT 3 - X-101 HOUSING ASSEMBLY

0.9850 in
25.02 mm

+0.0008
-0.0000
+0.02
-0.00

58

5.4 mm

+0.35
-0.35

Assumption

4: The Plug cup has the same

dimensions as the bushing.

Assumption 5: The hole of housing for plug cup

and bushing is same as the Input Gear hole for
bushings.

tickness:

2.00 mm
0.9853 in

+0.0012
-0.0000

25.03 mm +0.03
-0.00

54.80 mm +0.03
-0.00

X-112/ X-108 (LC11)

Diameter of Shaft = 0.9843 in
ds(max)= d a = 0.9843 in
Since a =0.001, d = 0.9853 in
dh(min) =d = dh(min) = 0.9853 in
dh(max) = d+h = 0.9833 + 0.0012 = dh(max) = 0.9865 in
ds(max) = d a= 0.9843 in

0.9843 in
25.00 mm

Range
0.711.19

+0.0000
-0.0012
+0.00
-0.03

10
34

+0.05

-0.05

30.92 mm

h
+12
0

L
-10
-22

13 mm

+0.00
-0.03

+0.05
-0.05

For clearance fit, the allowance is

the lower value, the hole tolerance
is the non-zero value and for the
shaft, is used the next formula:
s=|Lmin + a|=|-0.0022+0.0010|=
0.0012 in

30.80 mm +0.06
-0.00

ds(min)= d-a-s = ds(min)= 0.9831 in

59

27.00 mm

+0.00
-0.05

23.00 mm +0.50
-0.00

3.0 mm +0.50
-0.00

6.655 mm

+0.005
-0.005

60

9.9825 mm +0.0325
-0.0325

21.0 mm +0.10
3.75 mm

+0.25
-0.25

-0.10

27.035 mm +0.025
-0.025

47.00 mm +0.04
-0.04

60.31 mm +0.05
-0.05

2.75 mm +0.25
-0.25

18.91 mm +0.01
-0.01
26.60 mm +0.05
-0.05

60

12.00 mm

Assumption

6: Both shafts have the same

length.
Assumption 7: Ring retainer X-129 has the same
thickness as the rings retainers X-117.

+0.00
-0.04

156.2 mm +0.00
-0.20

+0.12

1.5 mm -0.00

65.1 mm +0.20
-0.00

Important:

the shat is going to move 10

mm.

61

COMPONENT 4 - X-126 SHIFT FORK ASSEMBLY

Nota

4: Diameter of shift fork is equal to biggest

diameter of collar shift.

tickness: 9.5 mm

73.94 mm

+0.50

-.000

+0.00
-0.44

12

X-112/ X-108 (FN2)

Range
0.40
0.56

a
0.5
1.6

h
+0.7
0

L
+1.6
+0.2

d a = 0.4724
dh(min) =d = dh(min) = 0.4708 in
+0.0007

0.4708 in -0.0000
11.96 mm +0.02
-0.00

0.4724 in
12.00 mm

+0.0000
-0.0014
+0.00
-0.04

ds(max)= d a = 0.4724 in
dh(max) = d+h = dh(max) = 0.4715 in
ds(min)= d-a-s = ds(min)= 0.4710 in

For interference fit, the allowance

is the higher value, the hole
tolerance is the non-zero value and
for the shaft, is used the next
formula:
s=|Lmin + a|=|0.0002 0.0016|=
0.0014 in

62

Assumption 8: Diameter of hole in collar shift is

0.5 bigger than the diameter of hub and has a
tolerance of +0.5.
Assumption 9: Diameter of pin dimensions are
calculated based on the worst case scenario.

6.30 mm +0.01
-0.01
12.50 mm +0.50
-0.00
18.95 mm +0.00
-0.08
61.11 mm +0.25
-0.25

73.72 mm +0.22
-0.22

6.305 mm +0.015
-0.015

X-112/

X-108 (FN2)
18.91 mm +0.04
-0.04

0.2476 in

Diameter of Shaft = 0.2476 in

ds(max)= d a = 0.2476 in

+0.0000
-0.0004

Since a =0.0014, d = 0.2462 in

6.29 mm +0.00
-0.01
15.75 mm +0.50
-0.00

dh(min) =d = dh(min) = 0.2462 in

6.25 mm
0.2462 in

+0.02
-0.00
+0.0006
-0.0000

ds(max)= d a = 0.2476 in
dh(max) = d+h = dh(max) = 0.2468 in

Range
0.240.40

a
0.4
1.4

h
+0.6
0

L
+1.4
+1.0

For interference fit, the allowance

is the higher value, the hole
tolerance is the non-zero value and
for the shaft, is used the next
formula:
s=|Lmin + a|=|0.001 0.0014|=
0.0004 in

ds(min)= d-a-s = ds(min)= 0.2472 in

63

ASSEMBLY:

Note

5: The holes for all the pieces are equal to

the hole calculated for the shift fork.

+0.24

3.0 mm -0.00

0.4236 in

+0.0007
-0.0000

11.96 mm +0.02
-0.00

+0.12

1.5 mm -0.00

64

Assumption

10: The ring retainer X-121 has

same dimensions as X-117.

1.0611 in
26.95 mm

1.063 in

+0.0008
-0.0000
+0.02
-0.00

X-115

/ X-104 (FN2)

27.00 mm

Range
0.951.19

0.6
1.9

+0.0000
-0.0005
+0.00
-0.01

h
+0.8
0

L
+1.9
+1.4

Diameter of Shaft = 1.063 in

ds(max)= d a = d = 1.0611 in
dh(min) =d = dh(min) = 1.0611 in
dh(max) = d+h = 1.0611 + 0.0008 = dh(max) = 1.0619 in
ds(min)= d-a-s = ds(min)= 1.0625 in

1.2173 in

s=|Lmin +
0.0005 in

+0.005
-0.000
+0.13
23.72 mm -0.00

0.934 in

30.92 mm
For interference fit, the allowance
is the higher value, the hole
tolerance is the non-zero value and
for the shaft, is used the next
formula:

+0.0000
-0.0012
+0.00
-0.03

1.56 mm

+0.06
-0.06

a|=|0.0014-0.0019|=

65

1.2184 in
30.95 mm

1.2174 in

+0.0012
-0.0000
+0.03
-0.00

X-116 / X-117 (LC11)

Diameter of Shaft = 1.2174 in
ds(max)= d a = 1.2174 in
Since a =0.001, d = 1.2184 in
dh(min) =d = dh(min) = 1.2184 in
dh(max) = d+h = 1.2164 + 0.0012 = dh(max) = 1.2196 in

30.92 mm

Range
0.711.19

a
10
34

h
+12
0

+0.0000
-0.0012
+0.00
-0.03

L
-10
-22

For clearance fit, the allowance is

the lower value, the hole tolerance
is the non-zero value and for the
shaft, is used the next formula:
s=|Lmin + a|=|-0.0022+0.0010|=
0.0012 in

ds(max) = d a= 1.2174 in
ds(min)= d-a-s = ds(min)= 1.2162 in

66

Assumption 11: The bigger diameter of the

washer- thrust is equal to the diameter of the
hole for the shaft seal in the cover.
1.56 mm

47.60 mm

+0.06
-0.06

0.9853 in

+0.05
-0.05

+0.0012
-0.0000

25.03 mm +0.03
-0.00

7.25 mm

0.9843 in
25.00 mm

+0.0000
-0.0012
+0.00
-0.03

+0.25
-0.25

X-116

/ X-104 (LC11)
Diameter of Shaft = 0.9843 in

Range
0.711.19

a
10
34

h
+12
0

L
-10
-22

ds(max)= d a = 0.9843 in
Since a =0.001, d = 0.9853 in
dh(min) =d = dh(min) = 0.9853 in
dh(max) = d+h = 0.9833 + 0.0012 = dh(max) = 0.9865 in
ds(max) = d a= 0.9843 in

For clearance fit, the allowance is

the lower value, the hole tolerance
is the non-zero value and for the
shaft, is used the next formula:
s=|Lmin + a|=|-0.0022+0.0010|=
0.0012 in

ds(min)= d-a-s = ds(min)= 0.9831 in

67

Assumption

12: The biggest diameter of the

output gear is equal to the biggest diameter of

the input gear.

33.4 mm

Assumption

13: The diameter of the output gear

for the spacer is equal to the cover diameter for
the shaft seal.

+0.50
-0.00

15.4 mm

+0.50
18.00 mm
-0.00

0.9843 in
25.00 mm

+0.00
102.0 mm
-0.20

0.9843 in
25.00 mm

Diameter of Shaft = 0.9843 in

ds(max)= d a = 0.9843
Since a = 0.00, d = 0.9843 in
dh(min) =d = 0.9843 in
dh(max) = d+h = 0.9843 + 0.0035 = dh(max) = 0.9878 in

23.00 mm

4.00 mm

+0.0035
-0.0000
+0.09
-0.00

X-118 / X-104 (LC4)

2.5 mm

+0.000
-0.002
+0.00
-0.05

Range
0.711.19

0
5.5

+0.50
-0.00

h
+3.5
0

+0.00
-0.50

47.65 mm

+0.00
-0.10

L
0
-2.0

For clearance fit, the allowance is

the lower value, the hole tolerance
is the non-zero value and for the
shaft, is used the next formula:
s=|Lmin +
0.002 cm

+0.50
-0.00

+0.00
-0.04

60.69 mm

4.00 mm
Width of the groove:

2.00 mm

+0.00
-0.18

70.19 mm

+0.50
-0.00
+0.00
-0.50

a|=|-0.002+0.00|=

ds(max) = d a= 0.9843 in
ds(min)= d-a-s = ds(min)=0.9823 in

68

+0.00
-0.24

4.08 mm

47.55 mm

+0.00
-0.04

+0.10
-0.00

0.9843 in
25.00 mm

+0.0035
-0.0000
+0.00
-0.05

X-119

/ X-104 (LC4)
Diameter of Shaft = 0.9843 in
ds(max)= d a = 0.9843
Since a = 0.00, d = 0.9843 in
dh(min) =d = 0.9843 in
dh(max) = d+h = 0.9843 + 0.0035 = dh(max) = 0.9878 in
ds(max) = d a= 0.9843 in

0.9843 in
25.00 mm

+0.000
-0.002
+0.00
-0.05

Range
0.711.19

0
5.5

h
+3.5
0

L
0
-2.0

For clearance fit, the allowance is the

lower value, the hole tolerance is the
non-zero value and for the shaft, is
used the next formula:
s=|Lmin + a|=|-0.002+0.00|= 0.002
cm

ds(min)= d-a-s = ds(min)=0.9823 in

69

1.2173 in

+0.0000
-0.0012

+0.005
-0.000
+0.13
23.72 mm -0.00

0.934 in

30.92 mm

+0.00
-0.03

0.945 in

+0.000

-0.004
24.00 mm +0.00
-0.10

+0.0047

1.62 mm

0.0591 in -0.0000
1.56 mm

+0.00
-0.12

+0.06
-0.06

X-117

/ X-104 (FN1)
Diameter of Shaft = 0.945 in

Range
0.710.95

a
0.2
1.1

h
+0.5
0

L
+1.1
+0.7

ds(max)= d a = 0.945 in
Since a = -0.011, d = 0.934 in
dh(min) =d = 0.934 in
dh(max) = d+h = 0.934 + 0.005 = dh(max) = 0.939 in
ds(max) = d a = 0.945 mm

For interference fit, the allowance is

the highest value, the hole tolerance
is the non-zero value and for the
shaft, is used the next formula:
s=|Lmin + a|=|0.007-0.011|= 0.004 in

ds(min)= d-a-s = ds(min)=0.941 mm

70
X-124

X-100