CHAPTER 1

MET 3012 METROLOGY

LINEAR & GEOMETRICAL TOLERANCE

TOLERANCING Control of Variability

Goals


Understand the description and control of variability through tolerance. Understand the various classes of fits.

TOLERANCE
The total amount a dimension may vary. It is the difference between the maximum and minimum limits. Way to express: 1. Direct limits or as tolerance limits applied to a dimension 2. Geometric tolerances 3. A general tolerance note in title block 4. Notes referring to specific condition


1. Direct limits and tolerance value

3.53 3.49 A) Direct limits 3.49 0.003

B) Tolerance value

2. Geometric Tolerance System

Geometric dimensioning and tolerancing (GD&T) is a method of defining parts based on how they function, using standard ANSI symbols

3. Tolerance Specification in Title Block

General tolerance note specifies the tolerance for all unspecified tolerance dimensions

4. Notes Referring to Specific Condition



General Tolerances could be in the form of a note similar to the one shown below: ALL DECIMEL DIMENSIONS TO BE HELD TO .002 MEANS THAT A DIMENSION SUCH AS .005 WOULD BE ASSIGNED A TOLERANCE OF 0.002, RESULTING IN UPPER LIMIT OF .502 AND A LOWER LIMIT OF .498

Important Terms single part

.502 Upper Limit (LMC) .498 Lower Limit (MMC)

  

Nominal Size general size, usually expressed in common fraction (1/2 for the slot) Basic Size theoretical size used as starting point (0.500 for the slot) Actual Size measured size of the finished part (0.501 for the slot)

Important Terms single part



Limits maximum and minimum sizes shown by tolerances (.502 and .498 larger value is the upper limit and the smaller value is the lower limit, for the slot) Tolerances total allowable variance in dimensions (upper limit lower limit) object dimension could be as big as the upper limit or as small as the limit or anywhere in between

Important Terms multiple part

 

Allowance the minimum clearance or maximum interference between parts Fit degree of tightness between two parts Clearance fit tolerance of mating parts always leave a space Interference fit tolerance of mating parts always interfere Transition fit sometimes interfere, sometimes clear

Shaft and Hole Fits

Shaft and Hole Fits

Metric Limits and Fit

 

Based on Standard Basic Sizes BS 4500:1990 and ISO 286-1:1988 Note that in the metric system: Nominal size = Basic size Example: If the nominal size is 8 mm, then the basic size is 8 mm.

Metric Tolerance
Nominal size = 8 Minimum clearance = 0.040 Maximum clearance = 0.112 Tolerance band = CLmax CLmin = T1 + T2 = 0.072

0.036 0.036

7.960 7.924 8.036 8.000

Fit systems
1.

2.

Hole basis system Fits are obtained by changing various tolerance class of shaft with single tolerance class of holes Shaft basis system Fits are obtained by changing various tolerance class of holes with single tolerance class of shaft

Basic Hole System or Hole Basis

1.

Definition of the Basic Hole System The minimum size of the hole is equal to the basic size of the fit Example: If the normal size of fit is 20 mm, then the minimum size of the hole in the system will be 20 mm.

Basic Hole System

  

 

Clearance = Hole Shaft Cmax = Hmax Smin Cmin = Hmin Smax Both Cmax and Cmin > 0 Clearance fit Both Cmax and Cmin < 0 Interference fit Cmax > 0 and Cmin < 0 Transition fit System Tolerance = Cmax - Cmin Allowance = Min Clearance = Cmin

Basic Hole System - Example

Calculate Maximum and minimum clearance Clearance = Hole Shaft Cmax = Hmax Smin Cmax = 35.025 35.026 = -0.001 Cmin = 35.000 35.042 = -0.042 What type of fit? Cmax <Cmin < 0 Interference fit


35.042 35.026

35.025 35.000

Basic Hole System - Example

Calculate Maximum and minimum clearance Clearance = Hole Shaft Cmax = Hmax Smin Cmax = 35.062 34.82 = 0.242 Cmin = 35.000 34.82 = 0.08 What type of fit? Cmax >Cmin > 0 Clearance fit


34.92 34.82

35.062 35.000

Basic Hole System

Basic Hole System

Basic Hole System

Tolerance
 

Tolerance is permitted variation of size of a part to allow for variation in manufacturing process Tolerance is indirectly a measure of quality, the smaller the tolerance, the higher the quality; it is also related to the cost of production Ideal interchangeable mating parts would be those without any kind of dimensional variation exact size on blue print or specification

Why impossible to get the exact size in actual practice?



Find the answer..

Type of Tolerance
1.

Standard of tolerance grades Desinated by letter IT (eg. IT7) ISO provides 20 Std tolerance grade IT0 IT18 (IT0 and IT01 not generally in use) When associated with letters, letter IT is ommited (eg. h7) Number representing std grade tolerance

Type of Tolerance
2. Tolerance Zone Desinated by 27 upper case letter for holes (A.ZC) and 27 lower case letter for shaft (azc) Letter indicate fundamental deviation that form tolerance zone

Fundamental Deviation
27 possible fundamental deviations of holes and shaft showed by the tolerance zones. Range of each zone is determined based on practical experience of the manufacturing process involved

Type of Tolerance
3. Tolerance class Fundamental deviation followed by standard tolerance grade form tolerance class Eg. H7 (holes), h7 (shafts)

Type of Tolerance
4. Tolerance size Basic size followed by tolerance class or expilcit deviations Eg. 32H7, 80js15, 100j6

Note
Fitting between mating features is represented by: Common basic size (eg. Diameter) Tolerance class symbol for the hole (eg. H) Tolerance class symbol for the shaft (eg. f) Eg. 52H7/g6 (hole basis system) 52h6/G7 (shaft basis system)

Exercise
Given the fitting of two assemblies as follows: 65h6/P7 145H7/k6

Question
1. 2. 3. 4.

Explain briefly the meaning of each symbol used in the above fitting Calculate Cmax and Cmin for each assy Determine the type of fitting With proper sketch, label the upper & lower limits, allowance, interference and tolerance

Formula of standard tolerance grades

a. Standard tolerance grades IT0 to IT04

Values for std tolerance in grades IT0 and IT01 are given separately in table 5 due to its limited used in practice. No formulae are given for IT2, IT3 and IT4. Value for these grade have been approximately scaled in geometrical progression between the values for IT1 and IT5

Formula of standard tolerance grades

b. Standard tolerance grades IT5 to IT18 Standard tolerance factor i in micrometers is calculated from the following formula: i = 0.453D + 0.001D Where D = geometric mean of basic size range = (D1 x D2)

Standard tolerance grades values

Values of the standard tolerance are calculated in terms of standard tolerance factor, i as shown in table 7 Note: For IT6 upwards, the standard tolerance are multiplied by a factor of 10 at each fifth step. This rule applies to all standard tolerance above IT18

Examples:
Calculate geometrical mean for the basic size range of 3 to 6mm. D = (3 x 6) = 4.243 mm 2. Determine the tolerance grade for IT20 IT20 = IT15 x 10 = 640i x 10 = 6400i Numerical values of various tolerance grades IT are given in Table 1
1.

Fundamental deviation
A. Fundamental deviation for shafts B. Fundamental deviation for holes

Fundamental deviations for js and JS

js and JS are a symmetrical distribution of standard tolerance grade about the zone line

Fundamental deviation
Example: Determine the limit of size for a shaft 40g11 using standard tolerance and deviation information given in table 1 and 2.

Fundamental deviation
Solution: Basic size range = 30 to 50 mm Standard tolerance = 160 m (from table 1, IT11) Fundamental deviation = -9m (from table 2, under g) Upper deviation = fundamental deviation = -9 m Lower deviation = fundamental deviation tolerance = -9 m 160 m = -169 m Limit of shaft size: Maximum = basic size + upper deviation = 40 0.009 = 39.991 mm Minimum = basic size + lower deviation = 40 0.169 = 39.831 mm

Fundamental deviation
Example: Determine the limit of size for a hole 130N4 using standard tolerance and deviation information given in table 1 and 3 fundamental deviation.

Fundamental deviation
Solution: Basic size range = 120 to 180 mm Standard tolerance = 12 m (from table 1) Fundamental deviation = -27 + m (from table 3) Value of = 4 m (from table 3) Upper deviation = fundamental deviation = -27 + 4m = -23m Lower deviation = fundamental deviation tolerance = -23 12 = -35 m Limit of shaft size: Maximum = basic size + upper deviation = 130 0.023 = 129.977 mm Minimum = basic size + lower deviation = 130 0.035 = 129.965 mm

Fundamental deviation
Example: Working from the basic principles, find suitable tolerances: a) 82 mm IT6 b) 440 mm IT12 Compare the calculated values with the rounded values

Fundamental deviation
Solution:
80 mm is in the range 80 120 440 mm is in the range 400 500 From table 7, IT6 =10i and the tolerance increase in accordance with the R5 series (geometric progression) as the IT number increase, hence: IT series 6 7 8 9 10 11 12 13 R5 series 1 1.6 2.5 4 6.4 10 16 25 IT12 tolerances are 16x of IT6 tolerances

Fundamental deviation
82 mm fall in between basic size range 80 and 120 D = (80x120) = 98 i = 0.45(98)1/3 + (0.001 x 98) = 2.173 m IT6 = 10i = 21.73 m (BS4500 gives 22 m) see also Table 1 440 mm fall in between basic size range 400 and 500 D = (400x500) = 447 i = 0.45(447)1/3 + (0.001x447) = 3.888 m IT12 = 16 x IT6 = 160i (see Table 7) = 160 x 3.88 = 622 m (BS4500 gives 630 m) see also Table 1