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Limits, Fits and Gauges: Tolerances
Limits, Fits and Gauges: Tolerances
Introduction:
It is well known fact that no two things in the nature can be identical, they may
be found to be closely similar. This is true of production of component parts in
engineering also. We know that every process is a combination of three
elements, man, machine and material. A change in any one of these will
constitute a change in the process. All these elements are subjected to inherent
and characteristic variations.
Generally, in engineering, any component manufactured is
required to fit or to match with some other component.
If a machine is under control, i.e. no assignable causes of
variation exist, and then the resultant frequency distribution
of dimension produced will be roughly in the form of
normal curve, i.e. 99.7% parts will be within 3 limits of
fig 4.1
means setting
The value of depends upon the machine used to produce a component.
If value of has to be used reduced, then precision machines have to be used
produces the component having less variation in dimensions. It is thus important
to note that the cost of production keeps on increasing tremendously for very
precise tolerance as shown in fig 4.1.as the tolerance approaches zero, the task
of achieving it becomes enormous and finally impossible .in general, tolerance
vs. fabrication cost is hyperbolic curve.
Tolerances:
The primary purpose of tolerances is to permit variation in dimensions without
degradation of the performance beyond the limits established by the
specification of the design.
Optimum tolerance:
A good designer must explore information and techniques available as
guidelines in the establishment of realistic and, where possible, optimum
engineering tolerance.
A basic dimension
is the dimension, as worked out by purely design consideration.
If the fit between a shaft and hole is a clearance type, then for complete
interchangeable approach (refer
to fig 4.2) tolerance in shaft
=tolerance in hole =half the
maximum clearance half the
minimum clearance.
fig 4.2
Tolerance accumulation:
The overall tolerance on complete length will be sum of the tolerances on
individual length.
In fig 4.3 g=a+ c+ e and h=b+ d+ f
The affect of an accumulation of tolerances can be minimized by adopting
progressive dimensioning from datum as shown in fig 4.4
fig 4.3
fig 4.4
Compound tolerance:
In fig 4.5, the tolerances on dimension l are dependent on
tolerance on L, h and.the minimum tolerance will be
corresponding to L-b, +a and h+ c.
fig 4.5
Interchangeability:
An interchangeable part is one, which can be substituted for similar part
manufactured to the same drawing.
Process capability of a machine is defined as 3
spread of dimensions of component produced by it.
If a plot is drawn of the actual dimension of the
similar components produced by a machine, it is
found to follow natural law of distribution, i.e.
having mean of the entire component at central value with a
fig 4.6
fig 4.7
fig 4.8
fig 4.9
fig 4.10
limits, but position of the tolerance zone relative to the basic size of the feature
must also be specified.
Basic terms:
Nominal size, basic size, zero line, actual size, limits, tolerance.
Fig 4.11 illustrates the concept of basic size and zero line.
Hole basic system and shaft basic system are defined in fig 4.19(a) and (b) for
clearance fit, transition fit and interference fit.
Example 4.1 calculate the limits of tolerances and allowances for a 25 mm shaft
and hole pair designated H8d9.
The disposition of these tolerances and deviations is shown in fig 4.20
Plain gauges:
Gauges are inspection tools of rigid design, without a scale, which serve to
check the dimension of manufactured parts.
Types of gauges:
The various types of limit plug gauges and limit snap gauges are shown in fig
4.28 below:
Snap gauges:
Fig 4.41
Combined limit gauges: in case of gauging of cylindrical
holes. It is impossible to combine both the 'Go' and 'No Go'
dimensions of plug gauge and thus a single gauge doing
the work of checking both the upper and lower limits.
As shown in fig 4.45
Position gauges:
A simple gauge for checking the location of a recess in relation to a flat surface
is shown in fig 4.46 and another design is shown in fig 4.47.
Taylor's principle
The 'Go' plug gauge (Fig 4.48) is the size of the minimum limit of the hole,
while the 'No Go' plug gauge corresponds to the maximum limit.
The 'Go' snap gauge (Fig 4.49)on the other hand, is of a size corresponding to
the maximum limit of the shaft, while the 'No Go' snap gauge corresponds to
minimum limit.