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Tolerance Charts MM
Tolerance Charts MM
Add L
Developing Tolerance Chart
Assumptions
Rough forging dimension = 2 in
Nominal finish dimension = 1.920 in
Difference = 0.080 in to be removed from two
surfaces B and G
Both B and G surfaces are to be machined,
hardened and ground, therefore let us assume
that 0.010 in is left for grinding for each surface.
Therefore stock to be removed from each
surface = (0.080/2)-0.010= 0.030 in
No change in dimensions due to heat treatment
processes will be assumed in this example.
Operation 10
Operation 10: calculations
Forging Dimension = 2.0000.010 in
Operation 10, W.D. = 1.9700.002 in
Stock removal = 0.0300.012 in
Min. of 0.018 in and max. of 0.042 in.
can be removed.
No final (resulting) dimension is resulted
from this operation.
Operation 20
Operation 20: Calculations
Three separate surfaces result from this operation. Location
takes place on surface G which was machined in operation 10.
Surface A is faced, the center hole is core drilled and reamed,
and the surface C is turned. Here, we concern with surfaces B
and C. Here, as in previous operation, a nominal 0.030 stock will
be removed from A. The working tolerance is 0.002 as before.
Therefore,
Operation 10, working dimension 1.9700.002
Operation 20, working dimension 1.9400.002
Stock removal 0.0300.004
Operation 20 continued
Surface C must be produced as a continuation of
operation 20, using the same locating surface.
Because the position of the surface C with respect to
surface G is affected by the amount which will later
be removed from surface G by grinding, allowance
must be made to insure that the final relationship
between these two surfaces is maintained. Since
0.010 is allowed for stock removal in grinding, the
working dimension will be 1.7800.002. Therefore,
Operation 20 (a), working dimension 1,9400.002
Operation 20(b), working dimension 1.7800.002
Stock removal 0.1600.004
Operation 30
Operation 30: Calculations
In the first step performed in operation 20,a nominal
working dimension of 1.940 was established between
surfaces B and G. To determine the nominal working
dimensions for operation 30, two things must be
considered.
1. The nominal dimension between surface G and
surface F.
2. The nominal stock removal from surface G by
grinding in the final operation.
The nominal working dimension for this operation is found
by subtracting these two dimensions from the nominal
working dimension from operation 20.
1.940-0.200-0.010=1.730 with working
tolerance as 0.002.
Operation 30 continued
Because this operation is carried out with a
form tool, two surfaces are created
simultaneously. This automatically fixes the
relationship between surfaces E and F. The
form tool dimension which relates the two
surfaces can carry the full part print tolerance.
The resultant dimension between surfaces F
and G can now be calculated as:
Operation 20(a), working dimension 1.9400.002
Operation 30, working dimension 1.7300.002
Resultant (intermediate) 0.2100.004
Operation 40
Operation 40: calculations
Working dimension for this operation
must take into account the allowance for
grinding after hardening. Because the
nominal depth of this milling cut is 0.250
and the nominal allowance for grinding
is 0.010, the working dimension fro this
operation is will be 0.250+0.010=0.260
with working tolerance 0.002.
Operation 50
The prints requires a finished hardness
depth of 0.0150.010. Actually, this
depth can be controlled within 0.005.
Because 0.010 is to be removed from
each ground surface, the working case
depth is set as 0.0250.005. Since
nothing has been removed from the
workpiece in carburizing and hardening,
no stock removal is recorded. As
indicated previously, there is no change
in workpiece dimension and hence no
change in the resultant occurs.
Operation 60
Operation 60: Calculations
The working tolerance on grinding can be
achieved as 0.0005. Because 0.010 has
been allowed for grinding, the working
dimension that must be held in this
operation is 1.9300.0005. Thus stock
removal
Operation 20, working dimension 1.9400.002
Operation 60, working dimension 1.9300.0005
Stock removal 0.0100.0025
Operation 60 continued
With the completion of operation 60, the dimensions from
surface G to , G to C, and F to E are now finalized. Since
the dimension from F to E was established earlier by the
form tool and is not affected by this operation, it can be
recorded as a resultant as shown in figure. Operation 30
was the last to be performed on surface F before
operation 60. The resultant from G to F can now be
recorded.
Operation 60, working dimension 1.9300.0005
Operation 30, working dimension 1.7300.002
Resultant 0.2000.0025
The resultant dimension between surfaces C and G now
becomes final and can be checked. Its previous
dimension was attained in operation 20(b).
Operation 20(b), working dimension 1.7800.002
Operation 60, Stock removal 0.0100.0025
Resultant 1.7700.0045
Operation 60 continued
The case hardened depth of G must be
checked to make certain the grinding
operation did not cause it to fall below the
depth specified. The case hardened
depth is determined by the difference
between the initial case depth working
dimension and the stock removal in
grinding
Operation 50, working dimension 0.0250.005
Operation 60, Stock removal 0.0100.0025
Resultant 0.0150.0075
Operation 70
Operation 70: Calculations
Aside from balancing final tolerances, operation 70
completes the machining operations on the workpiece,
unless it is found that additional operations must be
performed to correct tolerance stacking. Stock removal
may be calculated as
Operation 60, working dimension 1.9300.0005
Operation 70, working dimension 1.9200.0005
Stock removal 0.0100.001
Other resulting dimension of B and D
Operation 40, Working dimension 0.2600.002
Operation 70, working dimension 0.0100.001
Resultant 0.2500.003
Dimension of B (case hardened depth)
Operation 50, Working dimension 0.0250.005
Operation 70, working dimension 0.0100.001
Resultant 0.0150.006
Complete tolerance Chart (unbalance)
Balancing of Tolerance Chart
If the developed tolerance chart is accepted at
this stage, tight and costly processing increases
cost of the product.
The first step in balancing the tolerance chart is
to examine the final resultant dimensions and
compare them with those specified the part print.
The resultant whose tolerance compare closest
with the part print tolerance will be the logical
place to start.
As can be seen in the developed chart, the
resultant dimension between surfaces C and G is
1.7700.0045, which compares with the print
dimension of 1.7700.005. This comparison is
closer than the others, balancing will start from
here.
Balancing operation 60
Operation 60 can now be recalculated
as:
Operation 20(a), working dimension 1.9400.002
Operation 60, working dimension 1.9300.001
Stock removal 0.0100.003
Operation 20(b), working dimension 1.7800.002
Operation 60, stock removal 0.0100.003
Resultant 1.7700.005
The preceding resultant is now identical with the part print
specifications.
An intermediate resultant between surfaces F
and G was established as a result of
operation 30. The final resultant was obtained
in Operation 60. Because the relationship
between surfaces E and F was determined by
form tool, an increase can be made in the
working tolerance of operation 30 without
affecting other surfaces. The working
dimensions of operation 30 can be changed
to 1.7300.004. The correct resultant
between surfaces F and G will now be:
Operation 60, working dimensions 1.9300.001
Operation 30, working dimensions 1.7300.004
Resultant 0.2000.005
The dimension 0.1000.002 remains unchanged
because it was established from the form tool.
Balancing Operation 70
Operation 70 now can be recalculated as
follows:
Operation 60, Working dimension 1.9300.001
Operation 70, working dimension 1.9200.002
Stock removal 0.0100.003
Operation 40, working dimension 0.2600.002
Operation 70, stock removal 0.0100.003
Resultant 0.2500.005
Operation 50, working dimension 0.2500.007
Operation 70, Stock removal 0.0100.003
Resultant 0.0150.010
Completed Tolerance Chart