Activity 7.

3 Tolerances Part 2

E
F

1. Consider the adjustable rocker arm represented in the drawing above. An axle is to pass through the
smallest hole (labeled “D”). The manufacturer is considering buying bar stock for the axle that is
manufactured according to the drawing below using the same general tolerances as those specified on
the Rocker Arm Drawing. Answer the following questions and SHOW YOUR WORK.

ROD LENGTH ROD DIAMETER

a. What is the tolerance (upper limit – lower limit) for the diameter of the rod?

b. What is the tolerance for the rod length? (Hint: Use the General Tolerance table in the
drawing.)

© 2012 Project Lead The Way, Inc.

IED Activity 7.3 Tolerances – Page 1
 c. Is the fit between the rod and the hole (“D”) a clearance fit, interference fit, or transition fit?
Explain your answer.

d. What is the allowance (smallest hole – largest rod diameter) between the rod and the hole
(“D”)?

e. If the design of the assembled machine requires that the rod is sized such that the actual
clearance between the rod and the hole is never greater than 0.005 inches, will the current rod
design meet the requirement? Explain.

f. The machine specification requires that the rod is no longer than 3.025 inches and no shorter
than 2.955 in.
 Let L represent the actual length of the rod. Write the length constraint as a compound
inequality. (compound inequality: lower limit ≤ L ≤ upper limit)

 Will the stock rods always meet the length constraint? Explain.

g. If the stock rods do not always meet the machine specifications for rod length, how can the
manufacturer alter the rod part drawing such that the rod length will always conform to the
specifications?

2. Design a rod that will have an interference fit so that the allowance (the maximum interference) is
0.010 with the center hole in the Rocker Arm (labled “F”) and the tolerance on the rod diameter is .002.
Sketch a section view of your rod design below. Be sure to specify the tolerance in the diameter
dimension of your design.

© 2012 Project Lead The Way, Inc.

IED Activity 7.3 Tolerances – Page 2
Conclusion
1. Why do engineers place tolerances on dimensions?

3. What are the three types of tolerances that appear on dimensioned drawings?

4. What is the difference between a general and a specific tolerance, and how can you tell the
difference on a drawing?

© 2012 Project Lead The Way, Inc.

IED Activity 7.3 Tolerances – Page 3