IE550 - Manufacturing Systems

PART DESIGN SPECIFICATION

Spring 2011

Dr. R. A. Wysk

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Agenda

• Go over engineering specifications

• Functional requirements
• Form, fit and function
– Dimensioning
– Tolerancing
– Engineering drawings
– datum

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Material
s
• Read Chapter 2 and 3 from Computer Aided
manufacturing (3rd Edition)
• Overview of engineering design
• Mechanical design representations
• Engineering drawing
• Geometric dimensioning and tolerancing
• AMSE Y14.5

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THE DESIGN PROCESS

Product Engineering
Design Process Design Process
Off-road bicycle that ... How can this be
accomplished?
1. Conceptualization
2. Synthesis
1. Clarification of the task
3. Analysis
2. Conceptual design
4. Evaluation
3. Embodiment design
5. Representation
4. Detailed design
Functional requirement -> Design

Steps 1 & 2 Select material and properties, begin geometric

modeling (needs creativity, sketch is sufficient)
3 mathematical, engineering analysis
4 simulation, cost, physical model
5 formal drawing or modeling
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DESIGN REPRESENTATION
Design Engineering Manufac-
Representation turing

• Verbal
• Sketch
• Multi-view orthographic drawing (drafting)
• CAD drafting
• CAD 3D & surface model
• Solid model
• Feature based design

Requirement of the representation method

• precisely convey the design concept
• easy to use
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A FREE-HAND
SKETCH
Orthographic Projection

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A FORMAL 3-VIEW DRAWING

0.9444"

4 holes 1/4" dia

around 2" dia , first
hole at 45°


2.000 0.001

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DESIGN DRAFTING
Y

top

Pr o f il e pl a n e
f
b c d e

I I Z
H o riz o n t al I

h i side X
I V
j
III

Fr o n t al pl a n e
front

Third angle projection

Drafting in the third angle

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INTERPRETING A DRAWING

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DESIGN DRAFTING

A
Partial view A

2.0000.001

A -A
A

Cut off view and auxiliary view

Provide more local details

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DIMENSIONING

Requirements
1. Unambiguous
Incomplete
2. Completeness dimensioning

3. No redundancy
0.83 ' 0.98 ' 1.22 '

3.03 '

1.72 '
Redundant dimensioning
0.86 '

0.83 ' 1.22 '

3.03 '

Adequate dimensioning
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TOLERANC
E
Dimensional tolerance - conventional
Geometric tolerance - modern

nominal dimension

1.00 +
- 0.05 means a range 0.95 - 1.05

tolerance

+ 0.10 + 0.00
unilateral 0.95 - 0.00 1.05 - 0.10
bilateral 1.00 +
- 0.05

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TOLERANCE
STACKING
1. Check that the tolerance & dimension specifications are
reasonable - for assembly.
2. Check there is no over or under specification.

"TOLERANCE IS ALWAYS ADDITIVE" why?

0.80 ' ±0.01 1.20 ' ±0.01

1.00 ' ±0.01

What is the expected dimension and tolerances?

d = 0.80 +1.00 + 1.20 = 3.00

t = ± (0.01 + 0.01 + 0.01) = ± 0.03

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TOLERANCE STACKING (ii)

0.80 ' ±0.01 ? 1.20 ' ±0.01

3.00 ' ±0.01

What is the expected dimension and tolerances?

d = 3.00 - 0.80 - 1.20 = 1.00

t = ± (0.01 + 0.01 + 0.01) = ± 0.03

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TOLERANCE STACKING (iii)

x
0.80 ' ±0.01 ? 1.20 ' ±0.01

3.00 ' ±0.01

Maximum x length = 3.01 - 0.79 - 1.19 = 1.03

Minimum x length = 2.99 - 0.81 - 1.21 = 0.97

Therefore x = 1.00 ± 0.03

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TOLERANCE
d,t d,t
GRAPHd,t
A B C D E
d,t

G(N,d,t)
N: a set of reference lines, sequenced nodes
d: a set of dimensions, arcs
t: a set of tolerances, arcs

d : dimension between references i & j

ij
t : tolerance between references i & j
ij

Reference i is in front of reference j in the sequence.

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EXAMPLE TOLERANCE
GRAPH

A B C D E

d,t d,t d,t

A B C D E
d,t

d DE = d DA + d AE = – d AD + d AE
different properties
= – (d AB + d BC + d CD) + d AE between d & t
t DE = t AB + t BC + tCD + t AE

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OVER SPECIFICATION
If one or more cycles can be detected in the graph, we say that the
dimension and tolerance are over specified.

d1 d2
A B C
d1,t1 d2,t2 d3

Redundant dimension
d3,t3
A B C
t1 t2
A B C

t3

Over constraining tolerance

(impossible to satisfy) why?

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UNDER SPECIFICATION
When one or more nodes are disconnected from the graph, the
dimension or tolerance is under specified.

d1 d2
A B C D E
d3

A B C D E

C D is disconnected from the

rest of the graph.

No way to find dBC and dDE

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PROPERLY
TOLERANCED

A B C D E

d,t d,t d,t

A B C D E
d,t

d DE = d DA + d AE = – d AD + d AE
= – (d AB + d BC + d CD) + d AE
t DE = t AB + t BC + tCD + t AE

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TOLERANCE ANALYSIS
For two or three dimensional tolerance analysis:

i. Only dimensional tolerance

Do one dimension at a time.

Decompose into X,Y,Z, three one dimensional problems.

ii. with geometric tolerance

? Don't have a good solution yet. Use simulation?

diamet er & t olerance

A circular tolerance zone, the size is influenced

t rue position by the diameter of the hole. The shape of the
hole is also defined by a geometric tolerance.
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3-D GEOMETRIC TOLERANCE

PROBLEMS

datum surface
datum
surface ±t

Reference
frame
perpendicularity

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TOLERANCE ASSIGNMENT
Tolerance is money

• Specify as large a tolerance as possible as long as functional and

assembly requirements can be satisfied.
(ref. Tuguchi, ElSayed, Hsiang, Quality Engineering in Production
Systems, McGraw Hill, 1989.)

Q u alit y
function Co s t

cost +t

-t d ( n o min al dim e n sio n)

Tolerance value Quality cost

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REASON OF HAVING TOLERANCE

• No manufacturing process is perfect.

• Nominal dimension (the "d" value) can not be

achieved exactly.

• Without tolerance we lose the control and as a

consequence cause functional or assembly
failure.

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EFFECTS OF TOLERANCE (I)

1. Functional constraints

e.g.
flow rate

d±t

Diameter of the tube affects the flow. What is the allowed

flow rate variation (tolerance)?

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EFFECTS OF TOLERANCE (II)

2. Assembly constraints
e.g. peg-in-a-hole dp How to maintain the
clearance?
dh

Compound fitting
The dimension of
each segment
affects others.

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RELATION BETWEEN
PRODUCT &
PROCESS
TOLERANCES
• Machine uses the locators as
the reference. The distances
from the machine coordinate
A system to the locators are
± 0 .0 1 t o le ra nce s known.
Design specifications • The machining tolerance is
measured from the locators.
• In order to achieve the 0.01
Set u p tolerances, the process
lo c at o r s tolerance must be 0.005 or
± 0 .0 0 5 better.
• When multiple setups are used,
± 0 .0 0 5 the setup error need to be
± 0 .0 0 5 taken into consideration.
Process tolerance

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TOLERANCE
A method to allocateCHARTING
process tolerance and verify that the process
sequence and machine selection can satisfy the design tolerance.

st ock
b o un d a ry

± 0 .0 1 ± 0 .0 1

± 0 .0 1
Dim t ol
Not shown are
blue print 1 .0 0 .0 1 process tolerance
1 .0 0 .0 1 assignment and
3 .0 0 .0 1
balance
Op co d e
10
10 lat he
Operation produced tolerances:
sequence 10 lat he
12
process tol of 10 + process tol of 12
20
20 lat he process tol of 20 + process tol 22

20 lat he 22 process tol of 22 + setup tol

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SURFACE FINISH
w avin e s s

roughne s s

roughness widt h

waviness widt h
Usually
simplified:
waviness height
roughness waviness width 63
0.002 - 2
height
( inch) 63 0.010 roughness width cutoff
default is 0.03" (ANSI Y14.36-1978)
0.005 roughness width
Lay (inch)
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PROBLEMS WITH DIMENSIONAL

TOLERANCE ALONE
As designed:

1 .0 0 ±0 .0 0 1

6 .0 0 ±0 .0 0 1

As manufactured:
1 .0 0 1
Will you accept the part 1 .0 0 1
1.0 0 1
at right?

Problem is the control of

straightness.

How to eliminate the

ambiguity?
6 .0 0

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GEOMETRIC TOLERANCES
ANSI Y14.5M-1977 GD&T (ISO 1101, geometric tolerancing;
ISO 5458 positional tolerancing; ISO 5459 datums;
and others), ASME Y14.5 - 1994
FORM ORIENTATION
straightness perpendicularity
Squareness
flatness angularity
Circularity parallelism
roundness
cylindricity
LOCATION
concentricity
RUNOUT
circular runout true position
total runout
symmetry

PROFILE
profile
profile of a line
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DATUM &
FEATURE CONTROL FRAME
Datum: a reference plane, point, line, axis where usually a plane
where you can base your measurement.

A
Symbol:

Even a hole pattern can be used as datum.

Feature: specific component portions of a part and may include one

or more surfaces such as holes, faces, screw threads, profiles, or
slots.

Feature Control Frame:

datum
// 0.005 M A
modifier
symbol tolerance value
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MODIFIERS
M Maximum material condition MMC assembly
Regardless of feature size RFS (implied unless
specified)
L Least material condition LMC less frequently used
P Projected tolerance zone maintain critical
wall thickness or
O Diametrical tolerance zone critical location of
T Tangent plane features.
F Free state

MMC, RFS, LMC

MMC, RFS

RFS
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SOME TERMS
MMC : Maximum Material Condition
Smallest hole or largest peg (more material left on the part)
LMC : Least Material Condition
Largest hole or smallest peg (less material left on the part)

Virtual condition:
Collective effect of all tolerances specified on a feature.

Datum target points:

Specify on the drawing exactly where the datum contact points
should be located. Three for primary datum, two for secondary
datum and one or tertiary datum.

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DATUM REFERENCE
Pr i m a r y
FRAME
Three perfect planes used to
locate the imperfect part.
a. Three point contact on the
primary plane
b. two point contact on the
secondary plane
T
e
ia
y
r
rt

c. one point contact on the tertiary

S e c o n d a ry plane

primary Secondary
C
Tertiary
O 0.001 M A B C
B

A
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STRAIGHTNESS
Tolerance zone between two straightness lines.
0 .0 0 1 Value must be smaller
than the size tolerance.

1.000 ' ±0.002

Me a sur e d err or Š 0 .0 0 1

0 .0 0 1

0 .0 0 1

1.000 ' ±0.002

Design Meaning
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FLATNESS
Tolerance zone defined by two parallel planes.

0 .0 0 1

1.000 ' ±0.002

p a r all e l
p la n e s

0 .0 0 1

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CIRCULARITY
(ROUNDNESS)
a. Circle as a result of the intersection by any plane perpendicular to
a common axis.
b. On a sphere, any plane passes through a common center.

Tolerance zone bounded by two concentric circles.

0 .0 1

1.00 ' ±0.05

0 .0 1 Tole ra nc e zo ne

At any section along the cylinder

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CYLINDRICITY
Tolerance zone bounded by two concentric cylinders
within which the cylinder must lie.

0 .0 1

1.00 ' ±0.05

Rotate in a V

0 .0 1

Rotate between points

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PERPENDICULARIT
Y at a right angle to the datum plane
A surface, median plane, or axis
or axis. A
.0 0 2 T

.0 0 2 A
0 .0 0 2
t olera nc e
zo ne p e rp e ndic ular
1.000 ' ±0.005 t o t he d at u m plane
0.500 ' ±0.005

A
2.000 ' ±0.005

0 .0 0 2 dia met e r t ol
zo ne is p e rpe ndic ular
O 1 .0 0 ± 0 .0 1
t o t he d at u m pla ne
.0 0 2 A
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ANGULARITY
A surface or axis at a specified angle (orther than 90°) from a datum
plane or axis. Can have more than one datum.

0 .0 0 5 A

1 .5 0 0 ± 0 .0 0 5

40°

A
3.500 ' ±0.005

0 .0 0 5 t o le ra nc e z o ne
whic h is e xa c t ly 4 0 °
fro m t he d a t um p lane

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PARALLELISM
The condition of a surface equidistant at all points from a datum plane,
or an axis equidistant along its length to a datum axis.

.0 0 1 A

1.000 " ±0.005

A
2.000 " ±0.005 0 .0 0 1

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PROFILE
A uniform boundary along the true profile within whcih
the elements of the surface must lie.

0 .0 0 5 A B

A 0 .0 0 1

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RUNOU
of one or more features of a partT
A composite tolerance used to control the functional relationship
to a datum axis. Circular runout
controls the circular elements of a surface. As the part rotates
360° about the datum axis, the error must be within the tolerance
limit.

A
1.500 " ±0.005

0 .0 0 5 A
0.361 " ±0.002

Deviat io n on e ach
circular ch e ck ring
is le ss t h an t h e
Dat u m t ole r a n c e .
a xi s

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TOTAL RUNOUT

A
1.500 " ±0.005

0 .0 0 5 A
0.361 " ±0.002

Deviat io n on t h e
t ot al sw e pt wh e n
t h e p art is rot at ing
Dat u m
is le s s t h an t h e
a xi s
t ole r a n c e .

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TRUE POSITION
Tole ra nc e zo ne
0 .0 2 2
Dimensional
tolerance
1 .0 0 ± 0 .0 1

1 .2 0
± 0 .0 1

O .8 0 ± 0 .0 2
Hole center tolerance zone
O 0 .0 1 M A B

True position Tole ra nc e zo ne

0 . 0 1 dia
tolerance

1 .0 0

B
A 1 .2 0
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HOLE TOLERANCE ZONE

Tolerance zone for dimensional toleranced
hole is not a circle. This causes some assembly
problems.

For a hole using true position tolerance

the tolerance zone is a circular zone.

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TOLERANCE VALUE MODIFICATION

O 1 .0 0 ± 0 .0 2
O 0 .0 1 M A B

Produced True Pos tol

1 .0 0
hole size M L S
B 0.97 out of diametric tolerance
1 .2 0
A MMC 0.98 0.01 0.05 0.01
0.99 0.02 0.04 0.01
1.00 0.03 0.03 0.01
The default modifier for 1.01 0.04 0.02 0.01
true position is MMC. LMC
1.02 0.05 0.01 0.01
1.03 out of diametric tolerance
For M the allowable tolerance = specified tolerance + (produced hole
size - MMC hole size)
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MMC HOLE
LMC ho le
MMC ho le

ho le a xis t o le ra nc e zo ne

MMC p e g will fit in t he ho le ,

a xis m us t b e in t he t o le ra nce zo ne

Given the same peg (MMC peg), when the produced hole size
is greater than the MMC hole, the hole axis true position
tolerance zone can be enlarged by the amount of difference
between the produced hole size and the MMC hole size.

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PROJECTED TOLERANCE ZONE

Applied for threaded holes or press fit holes to ensure interchangeability
between parts. The height of the projected tolerance zone is the thickness
of the mating part.

.3 7 5 - 1 6 UNC - 2B
O .0 1 0 M A B C
.2 5 0 p

0 .0 1
Pro je c t e d t o le ra nce
0 .2 5 z o ne

Pro d uc e d p a rt

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SOME
NUMBERS
Krulikowski, A., GD&T Challenges the Fast Draw, MFG ENG, Feb 1994.

GD&T drawings are more expansive to make, however, saves revision

cost.

Drawing revision costs $500 - $2000 on the paper work

How much does it cost to “put a part number” onto a part?

Estimates range from $1,000 -$10,000.

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