Tolerance Analysis

Dr. P. M. Pandey
http://paniit.iitd.ac.in/~pmpandey

Causes of Workpiece Variation

The machines which perform operations on the
workpiece may have inherent inaccuracies built
into them.
The tools used on the machines are subject to
dulling, general wear, chipping, breaking, and
differences occurs due to regrinding
The material used is subjected to variations
The involvement of human elements
Any other cause by Chance.

Term used in dimensioning workpiece

dimensions
Nominal Size: It has no specified limits or accuracy
but indicates a close approximation to some standard
size. For eg. a half inch nut will fit into a half inch bolt.
Basic Size: It is the exact theoretical size from which
the limits are established through the applications of
allowances and tolerances.
Allowance: an allowance is an intentional difference
between maximum material limits of mating parts.
Tolerance: A tolerance is the total permissible variation
from the specified basic size of the part.
Limit: Limits are extreme permissible dimension of the
part

Diagram illustrating basic size deviations

and tolerances

Expressing Tolerances

The problem of selective

assembly

Hole or Shaft basis

IS:919-1963 (revised): Recommendations for

Limits and Fits for Engineering
Eighteen standard grades of tolerances with
designations IT01, IT0, IT01-----IT16.
Twenty seven fundamental deviations indicated
by letters. Capital letters are used for hole and
small letter are used for shaft.
The values of these tolerance grades or
fundamental deviations depend on the basic size
of the assembly.
One example of fit may be 60mm H8/f7 Shaft
basis.

Fundamental
deviations

Commonly used fits for holes

Geometrical Tolerancing

Geometric characteristics symbol

Interpretation of Indication of Geometric Tolerances

Straightness

Flatness

Cylindricity

Tolerance Stacks
Cubes are machined to
1.0000.005
If two cubes are stacked
the desired height is
2.0000.005
Design tolerance stack
Process tolerance stack

Effect of tolerance stacking

Control of
product limit
stack by
baseline
dimensioning

Tolerance stack control during processing

A: Machine one surface. Locate on side opposite the one being

machined. Machine dimension 1.0300.002
B: Machine slot. Locate on surface accomplished in operation A.
Machine dimension 0.5300.010
C: Machine opposite surface. Locate same as operation A. Machine
dimension 1.0000.002
Depth of slot cannot be maintained within the the limits

A: Same as in method I.
B: same as in method I except tolerance on slot have been tightened
to 0.006.
C: same as in method I.
Depth of the slot is as specified, however tightening tolerances
will result into higher costs.

A: same as in method I.
B: Machine opposite surface. Locate from surface accomplished
in operation A. Machine dimension 1.0000.002
C: Machine slot. Locate on surface accomplished in either
operation A or B. Machine dimension 0.5000.010
This is the best method as no tolerance tightening is done and
dimensions are achieved within the specifications.

Cost of Arbitrary tolerance selection