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