Chapter 9

MANUFACTURING QUALITY

Dr. Pham Minh Tuan

 Shaft & Hole assembly
 The most common assembly in mechanical engineering field,
available in almost structures, have different performances
depending on requirements.
 Manufacturing technology of shafts and holes are completed.
 Simple circular profile with little parameters, easy to fabricate and
measure.
 Tolerances & Fits
 Basic size: written dimensions in the drawing.
Notices: D (hole’s diameter), d (shaft’s diameter)
 Actual size: measured dimensions of actual parts.
 Limits – Maximum/minimum allowable sizes (Dmax/Dmin, dmax/dmin):
Maximum/minimum dimensions satisfy technical requirements.
 Tolerance: allowable dimensional errors in manufacturing
process, not all dimensions needs tolerances.
Example: φ100+−0,08
0,15 , means:
 Basic size: 100
 Lower and upper deviations (EI/ei and ES/es): –0,15 and +0,08
 Minimum and maximum allowable sizes: 99,85 and 100,08
 Tolerance: 0,08 – (–0,15) or 100,08 – 99,85 = 0,23
 International tolerance grade (IT):
IT = Dmax – Dmin = ES – EI or IT = dmax – dmin = es – ei
 Tolerances & Fits
 Tolerance grades IT (ISO 286-1: 1988):
Tolerances of shaft & hole assembly
 Example
• ϕ35k6: a shaft has basic diameter of 35 mm,
tolerance zone k, tolerance grade 6.
Fundamental deviations
• ϕ50H7: a hole has basic diameter of 50 mm,
tolerance zone H, tolerance grade 7.

Assembly tolerance:
H7
φ40 or φ40H7/k6
k6

An assembly of shaft and hole with basic

diameters of 40 mm, the hole’s tolerance
is H7 and the shaft’s tolerance is k6.
 Hole-basis system (Primary)
 The tolerance zone of hole is always H (lower deviation is 0,
upper deviation is dependent on the tolerance grade).
 The hole is primary because it is difficult to manufacture to
achieve high tolerance and surface roughness, the shaft’s tolerance
is changed to obtained desired fit.
 Shaft-basis system
 The tolerance zone of shaft is always h (upper deviation is 0,
lower deviation is dependent on the tolerance grade).
 Used when assembling a shaft and two holes with different fits.
Types of fits
 Types of fits
1. Clearance fit:
 Shaft’s diameter is smaller than hole’s diameter.
 Normally used for parts having relative motions.
2. Transition fit:
 Diameters of shaft and hole are almost equal.
 Normally used for part having no relative motions and good
concentricity. The parts can be assembled or disassembled easily.
3. Interference fit:
 Shaft’s diameter is bigger than hole’s diameter.
 Used for parts with no need of disassemble and no additional parts
(e.g., key, pin, screw, etc.). The interference between parts is
enough for torque transmission.
SELECTION OF FITS: Fit selection
 Performance of tolerances in drawing
On detailed drawing
On assembly drawing

Hole’s tolerances Shaft’s tolerances

Tolerances of hole and shaft in the assembly
ϕ40H7/k6 together with the assembly
tolerance of key 12J7/h6 (key in hole) and
12K7/h6 (key in shaft).
Geometric and position tolerances

Geometric and
Position Tolerance
 Surface roughness
 Surface roughness is surface texture in term of roughness after
manufacturing.
 Surface roughness can be evaluded by: Ten-point mean roughness
(Rz) and Arithmetical mean roughness (Ra).
 Symbols based on manufacturing processes:

Undefined Cutting processes Deformed processes

 How to use Rz, Ra and notices of specific manufacturing process:

 Surface roughness
 Ten-point mean roughness (Rz): is calculated by measuring the
vertical distance from the highest peak (ypm) to the lowest valley
(yvm) within 5 sampling lengths, then averaging these distances.
1 5 5 
=Rz  ∑ y pmi + ∑ y vmi 
= 5  i 1 =i 1 
 Arithmetical mean roughness (Ra): is calculated by the average
length between the peaks and valleys and the deviation from the
mean line on the entire surface within the sampling length.
1 L 1 n
=Ra =
L ∫0
y x dx ∑
n i =1
yi
 Performance of surface roughness
 Unique surface roughness of entire part:

 Surface roughness of almost surfaces:

 Performance of surface roughness
 Surface roughness of each surface:

 Two different surface roughness in the same surface:

 Performance of surface roughness
 Surface roughness of involute gear tooth’ surface:

 Surface roughness of thread’ surface:

Surface roughness based on
manufacturing process
Standard
roughness values
END OF CHAPTER 9
 (Table 1.2000. 34), and similarly with two sets
of median datum planes mutually at right
angles (Table 1.20, no. 35).
2. a surface which represents the median plane
of a feature is to be symmetrical, within
tolerance, with the median plane of another
feature as datum (Table 1.20 no. 36)
3. two surfaces representing a common median
plane of two similar features are to be
symmetrical, within tolerance (Table 1.20 no.
37)
Runout
A runout tolerance represents the allowable deviation
in position of a surface of revolution as a part is
revolved about a datum axis.
There are two cases of runout: circular runout
(usually referred to as "runout") and total runout.
Runout concerns each circular element or cross-
section and may be applied to cylinders (Table 1.20
no. 38), tapers and end surfaces where such a
surface is at right angles to the axis of revolution.
Total runout is used to provide composite control
of all the cross-sectional surface elements
simultaneously. It also applies in the three cases
stated above for runout (Table 1.20 no. 39).