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MECH 691T Engineering Metrology and Measurement Systems: Instructor: N R Sivakumar
MECH 691T Engineering Metrology and Measurement Systems: Instructor: N R Sivakumar
Lecture 3
Instructor: N R Sivakumar
Outline
Tolerancing and interchangeability
Tolerance representation
Tolerance stackup
Maximizes quality
99% Quality Means
20,000 lost pieces of mail per hour
Geometric Tolerance
Form
Profile
Location
Orientation
Runout
Tolerance vs. Mfg Process
Basic Size - of a dimension is the theoretical size from which the limits
for that dimension are derived by the application of the allowance and
tolerance.
Design Size - refers to the size from which the limits of size are derived
by the application of tolerances.
Limits of Size - are the maximum and minimum sizes permissible for a
specific dimension.
Maximum Material Size - The maximum material size is the limit of size of a
feature that results in the part containing the maximum amount of material.
Thus it is the maximum limit of size for a shaft or an external feature, or the
minimum limit of size for a hole or internal feature.
Limits and tolerances
Terminology
Representing Linear Tolerance
General tolerance
Note: all decimals .02
Limit dimensions
The fit between two mating parts is the relationship between them with
respect to the amount of clearance or interference present when they
are assembled. There are three basic types of fits: clearance,
interference, and transition.
Running and Sliding Fits - A special type of clearance fit. These are
intended to provide a similar running performance, with suitable lubrication
allowance, throughout the range of sizes.
Locational clearance fits - are intended for parts that are normally
stationary but that can be freely assembled or disassembled.
Nominal size - 2
1.994 2.000
Hole tolerance - .004
1.991 2.004
Shaft tolerance - .003
Allowance - .006
SHAFT
HOLE
Fits and Allowances
Basic Hole System
In the basic hole system, which is recommended for general use, the basic
size will be the design size for the hole, and the tolerance will be plus. The
design size for the shaft will be the basic size minus the minimum clearance,
or plus the maximum interference (Refer Handout)
+.0020 +.0000
Hole 1.0000 Shaft .9975
-.0000 -.0012
Waviness - Waviness is usually the most widely spaced of the surface texture
components and normally is wider than the roughness-width cutoff.
Linear Tolerance
Size
Geometric Tolerance
Form
Profile
Location
Orientation
Runout
Reason for GD & T
Geometric tolerancing
Rationale
The tolerances and limits of size that are seen so far do not specifically
control other variations form, orientation, and position to some extent
To meet functional requirement, geometric tolerances need to be added
to control limits of size, but also to ensure that limits of form orientation
and position are maintained
Manufacturing
axis.
The tolerance zone here is the space between the 2 cylinders separated by
specified tolerances and coaxial with the datum axis
Total runout is more costly to verify than circular runout and hence seldom used
Tolerance Buildup
During assembly, small variations in the part dimensions can multiply until the
final assembled result is unacceptable from the original design.
Though each part variation is small by themselves; however, with each added
part, the errors can compound to a defected final part.
Size tolerances is fairly straightforward. However, when added with form,
location and/or orientation variances, then it becomes more difficult to predict
dimensional fit.
Tolerance Stack-up
Worst-Case analysis
Root Sum of Squares
Taguchi tolerance design
Worst-Case Methodology
This is not a statistical procedure but is used often for tolerance
analysis and allocation
E (-)
A (-)
B (-)
C (-)
D (+)
Calculating Stackups
Part Name Dim Tol (+ve) Tol (-ve) Direction
Cylinder1 A 54 +0.2 -0.2 -ve
Cylinder2 B 54 +0.2 -0.2 -ve
Holder C 20 +0.2 -0.2 -ve
Holder D 150 +0.2 -0.2 +ve
Worst Case 2 1 -1
E (-)
A (-)
B (-)
C (-)
D (+)
Statistical Principles
Statistical Principles
Statistical Principles
6 translates to 2 parts
per billion