Tolerance and surface finishing in machining

prepared by :Mahdi Karim

Lecturer :Assist prof. Dr. Gailan Ismail Hassan
What is tolerance in engineering?
• Engineering tolerance is the permissible variation in measurements
deriving from the base measurement.
• Tolerance is the allowable variation for any given size in order to
achieve a proper function.
 What are different types of tolerance?
• Physical Tolerance
• Limit Tolerance
 Why tolerance is required ?

Variation in the properties of the material.

Improper tool usage(worn tools)
• Inherent inaccuracies of production machines.
• Programming errors(feeds and speed)
• Operator errors for e.g. inaccuracies in settings up of machines
• Employs skill level.
• Environmental conditions
 Wide vs tight?
Wide tolerances result in reduced cost due to:
◦ Fewer defects
◦ Low tool cost
◦ Easy setup
◦ Less skilled and cheaper labor
◦ Lower machine maintenance
◦ Lower inspection cost
Tight tolerances result in
◦ Increased interchangeability
◦ Better fits result in
Better aesthetics of assembled products
Improved functionality, durability and reliability
 What is surface finishing?
➤Surface finishing is the process of altering the surface
on an object (e.g., plating, polishing, anodizing, coating)
for the purpose of enhancing its appearance or
functional properties.

>The outermost boundary of a body adjacent to the air is

called surface.when this surface deformed by a sharp
cutting
edge, the term surface finish describes the boundary.
 The main reasons for Surface finishing are:
• Increased corrosion resistance
• Helping with the adhesion of paint and other coatings
• Elimination of surface defects
• Increased resistance to chemicals
• Improved conductivity and added surface electrical conduction
• Increased strength and resistance to wear while the friction effects are
minimised
• Enhanced aesthetics
What Are the Types of Surface Finishes?
➤ Adding and Altering Processes
Wet painting, anodising, cladding, galvanizing, etc
Wet plating
> Pickling
This is an altering metal finishing.
What Are the Types of Surface Finishes?
➤ Removing and Reshaping Processes
include removing a layer from the surface or
reshaping it. include laser engraving, etching,
blasting, etc.
Grinding
include aluminium, brass, cast iron, mild steels and
stainless steel
> Electropolishing