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Limit Tolerance Fits PDF
Limit Tolerance Fits PDF
9/28/2011
Terminology
y Nominal size: Size of a part specified in the drawing
y Basic size: Size of a part to which all limits of
Limit,Tolerance&Fits
Limit Tolerance&Fits
BySKMondal
TerminologyContd....
y Limits of sizes: There are two extreme permissible
Minimum
clearance
or
maximum
TerminologyContd....
TerminologyContd....
y Tolerance
The difference between the upper limit and lower
e.g. 25 +0.18
+0.10
limit.
It is the maximum permissible variation in a
dimension.
-0.20
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TerminologyContd....
TerminologyContd....
,250
0.10
e.g. 25 0.04
Basic Size = 25.00 mm
Upper Limit = 25.04 mm
Lower Limit = 24.96 mm
Tolerance = 0.08 mm
TerminologyContd....
Fit
Fits:(assemblyconditionbetweenHole&Shaft)
and
d lower
l
deviations.
d
Transition Fits
Clearance Fits
Hole
Max C
Hole
Max C
Min C
Tolerancezonesnevermeet
Tolerancezonesalways
overlap
Shaft
Max I
Shaft
Theclearancefitsmaybeslidefit,easyslidingfit,running
fit,slackrunningfitandlooserunningfit.
Thetransitionfitsmaybeforcefit,tightfitandpushfit.
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9/28/2011
Interference Fits
Hole
Max I
Shaft
Tolerancezonesnevermeet
butcrosseseachother
ToleranceZone
It is defined graphically
by the magnitude of the
Tolerance Zone tolerance and by its
position in relation to the
zero line.
55
Min I
20
Basic Size
Theinterferencefitsmaybeshrinkfit,heavydrivefitand
lightdrivefit.
5.BasisofFits HoleBasis
BasisofFits ShaftBasis
y Inthissystem,thebasic
diameteroftheholeisconstant
whiletheshaftsizevaries
accordingtothetypeoffit.
I
Legends:
Hole
Shaft
Tolerance
C - Clearance
T - Transition
I - Interference
y Aseriesofdrillsandreamersis
Legends:
Hole
Shaft
Tolerance
IS:LimitsandFits
C - Clearance
T - Transition
I - Interference
requiredforthissystem,
thereforeittendstobecostly.
y Itmay,however,benecessary
touseitwheredifferentfitsare
requiredalongalongshaft.For
d l
l
h f
example,inthecaseofdriving
shaftswhereasingleshaftmay
havetoaccommodatetoa
varietyofaccessoriessuchas
couplings,bearings,collars,
etc.,itispreferabletomaintain
aconstantdiameterforthe
permanentmember,whichis
theshaft,andvarytheboreof
theaccessories.
IS:LimitsandFitsContd...
tolerances
y There are 25 types of fundamental deviations.
y A unilateral hole basis system is recommended but if
whereDisthesizeorgeometricmeandiameterinmm.
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9/28/2011
IES2006Conventional
Find the limit sizes, tolerances and allowances for a
100 mm diameter shaft and hole pair designated by
F8h10. Also specify the type of fit that the above pair
belongs to. Given: 100 mm diameter lies in the
diameter step range of 80
80120
120 mm. The fundamental
deviation for shaft designation f is 5.5 D0.41
The values of standard tolerances for grades of IT 8
and IT 10 are 25i and 64i respectively.
Also, indicate the limits and tolerance on a diagram.
[15Marks]
ToleranceSink
y A design engineer keeps one section of the part blank
LimitGauges
GATE 2003
y Pluggauge:usedtochecktheholes.TheGOpluggaugeis
thesizeofthelowlimitoftheholewhiletheNOTGOplug
gaugecorrespondstothehighlimitofthehole.
y Snap,GaporRinggauge:usedforgaugingtheshaftand
malecomponents.TheGosnapgaugeisofasize
correspondingtothehigh(maximum)limitoftheshaft,
di h hi h(
i
)li i f h h f
whiletheNOTGOgaugecorrespondstothelow
(minimumlimit).
Fig.Pluggauge
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Allocationofmanufacturing
tolerances
y Unilateralsystem:gaugetolerancezoneliesentirely
withintheworktolerancezone.
y worktolerancezonebecomessmallerbythesumof
thegaugetolerance.
thegaugetolerance
y Bilateralsystem:inthissystem,theGOandNOGO
gaugetolerancezonesarebisectedbythehighandlow
limitsoftheworktolerancezone.
Takingexampleasabove:
y Wearallowance:GOgaugeswhichconstantlyrub
againstthesurfaceofthepartsintheinspectionare
subjectedtowearandloosetheirinitialsize.
y Thesizeofgopluggaugeisreducedwhilethatofgo
snapgaugeincreases.
y Toincreaseservicelifeofgaugeswearallowanceis
addedtothegogaugeinthedirectionoppositeto
wear.Wearallowanceisusuallytakenas5%ofthe
worktolerance.
y Wearallowanceisappliedtoanominaldiameter
beforegaugetoleranceisapplied.
y Takingexampleofabove:
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Linearmeasurements
MeasurementofLines&Surfaces
BySKMondal
Applicationsofdialindicatorinclude:
y centering workpices tomachinetoolspindles
y offsettinglathetailstocks
y aligningaviceonamillingmachine
li i i illi
hi
y checkingdimensions
Principleofadialindicator
SlipGaugesorGaugeblocks:
y Used in the manufacturing shops as length standards.
y Not
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Metricslipgaugeset
y Come in sets with different number of pieces in a given
shown in.
in
y To build any given dimension, it is necessary to
Example:
Comparators
y Comparator is another form of linear measuring
MechanicalandOptical
Comparators
MechanicalComparators
y The Mikrokator principle
greatly
magnifies
any
deviation in size so that
even
small
deviations
produce large deflections of
the pointer over the scale.
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OpticalComparators
PneumaticComparators
y Flow type:
y The float height is essentially proportional to the air
the scales
y The
input
pressure
is
regulated
to
allow
magnification adjustment
AngularMeasurement
PneumaticComparators
BevelProtractor
y Is part of the machinist's combination square.
y The flat base of the protractor helps in setting it firmly
Fig.Combinationsquarethatincludesabevelprotractor
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SineBar
y When a reference for a nonsquare angle is required, a
gauge blocks are placed under one end, the sine bar
will tilt to a specific angle.
y Knowing the height differential of the two rollers in
ThreadMeasurements
y Theparametersthatarenormallymeasuredare:
y Threadsarenormallyspecifiedbythemajordiameter.
y Majordiameter
y Thoughtherearealargevarietyofthreadsusedin
engineering,themostcommonthreadencounteredis
themetricVthreadshowninFig.
y Micrometer
y Pitchdiameter
y Screwthreadmicrometer
y Wiremethod
y Pitch
y Screwpitchgauge
y Pitchmeasuringmachine
y Threadform
y Opticalprojector
Surfaces
y No surface is perfectly smooth, but the better the
MeasurementofSurfaces
Measurement of Surfaces
texture
can
be
difficult
to
analyse
quantitatively.
y Two surfaces may be entirely different, yet still provide
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y Surfacegeometrycanbequantifiedafewdifferent
ways.
y Realsurfacesarerarelysoflat,orsmooth,butmost
commonlyacombinationofthetwo.
Lay
Diagram
LayContd..
Symbol Description
Diagram
Symbol
Description
Multidirectional lay: Lay
multidirectional. Surface is
produced by grinding,
lapping, super finishing.
Circular lay:
Approximately
circular
relative to the center.
Surface is produced by
facing.
Radiallay:Approximately
radialrelativetothecenter
ofthenominalsurface.
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RepresentationofSurfaceRoughness
valleys
y Roughness width cutoff a value greater than the
maximum roughness width that is the largest
separation
ti
off surface
f
irregularities
i
l iti included
i l d d in
i the
th
measurements. Typical values are (0.003, 0.010,
0.030, 0.100, 0.300)
y Lay the direction the roughness pattern should
follow
y Stylus travel is perpendicular to the lay specified.
RoughnessGrade
Number
RoughnessSymbol
N12
25
N11
12.5
N10
6.3
N9
3.2
N8
1.6
N7
0.8
N6
0.4
N5
0.2
N4
0.1
N3
0.05
N2
0.025
N1
EvaluationofSurfaceRoughness
1. Centre line average (CLA) or arithmetic mean
DeterminationofMeanLine
y MSystem: After
Roughness
Ra (m)
50
DeterminationofMeanLine
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Arithmetical Average:
y Measured for a specified area and the figures are added
y Theotherparameterthatisusedsometimesistheroot
meansquarevalueofthedeviationinplaceofthe
arithmeticaverage,Thisinexpressionformis
Fig.Surfaceroughnessparameters
MethodsofmeasuringSurfaceRoughness
There are a number of useful techniques for measuring
surface roughness:
ObservationMethods
y Human perception is highly relative.
y To give the human tester a reference for what they are
perceptive to surface
f
roughness
h
should
be
made
against
matched
identical processes.
(discussed later)
StylusEquipment
y uses a stylus that tracks small changes in surface
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Profilometer
y measuring instrument used to measure a surface's
Contactprofilometers
NoncontactProfilometers
y Adiamondstylusismovedverticallyincontactwitha
sampleandthenmovedlaterallyacrossthesamplefor
aspecifieddistanceandspecifiedcontactforce.
y Aprofilometer canmeasuresmallsurfacevariationsin
verticalstylusdisplacementasafunctionofposition.
verticalstylusdisplacementasafunctionofposition
y Theradiusofdiamondstylusrangesfrom20
nanometresto25m.
AdvantagesofopticalProfilometers
OpticalFlats
acquisition electronics.
y Optical profilometers do not touch the surface and
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y Whenthefringesareperfectlystraightandsamefringe
widthfordarkandbrightbandweconcludethatthe
surfaceisperfectlyflat.
y Forconvexsurfacethefringescurvearoundthepoint
F
f th f i
dth i t
ofcontact.
y Forconcavesurfacethefringescurveawayfromthe
pointofcontact.
Talysurf
y It is based upon measuring the generated noise due to
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Clinometer
y An optical device for measuring elevation angles above
horizontal.
y Compass clinometers are fundamentally just magnetic
MiscellaneousofMetrology
BySKMondal
Clinometer
Autocollimator
y An optical instrument for noncontact measurement
of angles.
y Used to align components and measure deflections in
y Visualautocollimatorsareusedforlininguplaserrod
Autocollimator
endsandcheckingthefaceparallelismofoptical
windowsandwedges.
y Electronicanddigitalautocollimatorsareusedas
anglemeasurementstandards,formonitoringangular
movementoverlongperiodsoftimeandforchecking
angularpositionrepeatabilityinmechanicalsystems.
y Servoautocollimatorsarespecializedcompactforms
ofelectronicautocollimatorsthatareusedinhigh
speedservofeedbackloopsforstableplatform
applications.
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LaserScanningMicrometer
y The LSM features a high scanning rate which allows
McLeodgauge
y Used to measure vacuum by application of the
Planimeter
y Adeviceusedformeasuringtheareaofanyplane
surfacebytracingtheboundaryofthearea.
LVDT
y Acronym for Linear Variable Differential Transformer,
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LVDT
ToolMakersMicroscope
An essential part of engineering inspection,
measurement and calibration in metrology labs.
Hence is used to the following:
y Examination of form tools, plate and template
gauges, punches
annular
h and
d dies,
di
l grooved
d and
d
threaded hobs etc.
y Measurement of glass graticules and other surface
marked parts.
y Elements of external thread forms of screw plug
gauges, taps, worms and similar components.
y Shallow bores and recesses.
TelescopicGauges
y Used to measure a bore's size, by transferring the
CoordinateMeasuringMachine
(CMM)
Advantages,
y Aninstrumentthatlocatespointcoordinatesonthree
dimensionalstructuresmainlyusedforqualitycontrol
applications.
y Thehighlysensitivemachinemeasurespartsdownto
Th hi hl
ii
hi
d
thefractionofaninch.
y Specifically,aCMMcontainsmanyhighlysensitiveair
bearingsonwhichthemeasuringarmfloats.
y canautomateinspectionprocess
y lesspronetocarelesserrors
y allowsdirectfeedbackintocomputersystem
Disadvantages,
Disadvantages
y Costly
y fixturing iscritical
y requiresaverygoodtolerancemodel
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TransportEquipment
y Transport equipment is used to move material from
Themajorsubcategoriesoftransportequipmentare:
y Conveyors:usedtomovematerialsoverafixedpath
betweenspecificpoints.
y Cranes:usedtomovematerialsovervariablepaths
withinarestrictedarea.
y Industrialtrucks:usedtomovematerialsover
variablepaths,withnorestrictionsontheareacovered
bythemovement(i.e.,unrestrictedarea).
y Noequipment:Materialcanalsobetransported
manuallyusingnoequipment.
Conveyorsystem
y A common piece of mechanical handling equipment
Typesofconveyors
ChuteConveyor
y Gravityrollerconveyor
y Gravityskatewheel
y Pneumaticconveyor
y Beltdrivenliveroller
conveyor
y Beltconveyor
y Wiremeshconveyors
y Plasticbeltconveyors
y Bucketconveyors
y Flexibleconveyor
y Verticalconveyor
y Spiralconveyor
y Vibratingconveyor
conveyors
y Chainconveyor
y Screwconveyor
y Chaindrivenliveroller
conveyor
y Overheadconveyor
y Dustproofconveyors
y Pharmaceuticalconveyors
y Automotiveconveyors
y Inexpensive
y Usedtolinktwohandlingdevices
y Usedtoprovideaccumulationinshippingareas
y Usedtoconveyitemsbetweenfloors
y
y Difficulttocontrolpositionoftheitems
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Gravityrollerconveyor
Live(Powered)RollerConveyor
y Alternativetowheelconveyor
y Beltorchaindriven
y Forheavydutyapplications
y Forcesensitivetransmissioncanbeusedtodisengage
rollersforaccumulation
y Slopeforgravitymovementdependsonloadweight
y Foraccumulatingloadsandmerging/sorting
g
y Foraccumulatingloads
operations
y Provideslimitedinclinemovementcapabilities
Monorailconveyor
Monorailconveyor
y Unit+Overhead+Accumulate
y Overheadsingletrack(i.e.,monorail)ortrack
networkonwhichoneormorecarriersride
y Carriercanrangefromasimplehooktoahoisttoan
intelligentvehiclelikedevice
y Singlecarrier,singletrackmonorailsimilartobridge
organtrycrane
Bucketconveyor
y Bulk+OnFloor
y Usedtomovebulkmaterialsinaverticalorinclined
path
y Bucketsareattachedtoacable,chain,orbelt
y Bucketsareautomaticallyunloadedattheendofthe
conveyorrun
Beltconveyor
y Unit+OnFloor+NoAccumulate
y Fortransportinglight andmediumweightloads
betweenoperations,departments,levels,and
buildings
y Whenaninclineordeclineisrequired
y Providesconsiderablecontrolovertheorientationand
placementoftheload.
y Nosmoothaccumulation,merging,andsortingonthe
belt
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Beltconveyor
Killedsteel
Definition: Thetermindicatesthatthesteelhas
beencompletelydeoxidisedbytheadditionofanagent
suchassiliconoraluminium,beforecasting,sothat
thereispracticallynoevolutionofgasduring
solidification.
solidification
y Killedsteelsarecharacterisedbyahighdegreeof
chemicalhomogeneityandfreedomfromporosity.
TransferMachines
DyePenetrant Inspection
y Definition: AqualitycontrolandNDEtechnique
y Atransfermachineisanautomatedflowline.
usedforcrackdetectionandotherdiscontinuitieson
thesurfaceinnonmagneticalloys.
y Aftersoakinginmetalpenetrant,thesuspectedpartof
materialtobetestediscleaned,driedandbriefly
t i lt b t t di l
d d i d db i fl
immersedindeveloper.
y Thepenetrant willbleedtothesurfaceindicatingthe
presenceofanimperfection
y Workpiecesareautomaticallytransferredfromstation
tostation,fromonemachinetoanother.
y Operationsareperformedsequentially.
y Ideally,workstationsperformtheoperation(s)
simultaneouslyonseparateworkpieces,withthe
numberofpartsequaltothenumberofstations.Each
timethemachinecycles,apartiscompleted.
ScrewThreadStandardization
y The size listings of metric threads start with " M and
"M 12." This thread has a pitch of 1.75 mm, but the
pitch may be omitted from the callout.
y A fine 12mmOD thread is available. It has a 1.25mm
pitch and must be designated "M 12 x 1.25." An extra
fine 12mmOD thread having a 0.75mm pitch would
receive the designation "M 12 x 0.75.
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Introduction
y Jigs and fixtures are devices that are used for
JigsandFixtures
BySKMondal
Jig
Fixtures
work piece.
work piece.
DesignconsiderationsforJigs
andFixtures
PurposeofusingFixturesandJigs
y Eliminate
marking,
punching,
positioning,
alignments etc.
y Easy, quick and accurate locating, supporting and
clamping the blank.
y Guide
G id the
th cutting
tti tool
t l like
lik drill,
d ill reamer etc.
t
y Increase productivity and maintain product quality.
y Reduce operators labour and skill requirement
y Enhancing technological capacity of the machine
tools
y Reduce overall machining cost and increase
interchangeability.
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321LocatingPrinciple
y A workpiece, just like any free solid body, has six
Fig.Majorelementsofjigandfixtures
purpose.
y So fourth locator is placed in Plane 2 which is
Fig.A
componentwith
t ith
sixlocators
Considering12DOF
Pointstoponder
y You must fix all the 12 degrees of freedom except the three
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DifferentmethodsusedforLocation
y Flat Locator : Used for location of flat machined
workpieces.
y It is superior as it has a capacity to accommodate a
cylindrical workpieces.
yA
suitable
method
to
accommodate
the
the workpiece.
y Used for locating the circular and semicircular type of
workpieces.
workpieces
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DiamondPinLocator
y Diamond pins are often used for radial location .
y One cylindrical locator (Pin A) arrests five degrees of
Ejectors
y Used to remove work from closefitting locators, such
Clamping
StrapClamps
is required.
y Holds the workpiece securely in a jig or fixture against
to the part.
y Heel
H l pin
i is
i the
th fulcrum
f l
about
b t which
hi h the
th lever
l
acts
t while
hil
the clamping force is applied at the stud by tightening
the screw.
y The actual amplification of the applied force depends
upon the distance between the stud and the heel pin
(B), and that between the stud and the part (A).
Page 27 of 29
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ScrewClamps
y A much faster way of applying clamping is to make use
CamClamps
y Provide clamping force because of the contour of the cam
y
y
y
y
surface that comes into contact with the plate used for the
clamping.
Plate is pushed down by the cam against the spring
pressure to hold the part in place.
Cam clamps are quick in operation.
Cam
clamps
are off three
types, eccentric
C
l
h
i cam, flat
fl spiral
i l
cam and cylindrical cam.
The design shown in Fig. is flat spiral and is the most
commonly used clamp.
Fig.Acamclampused
forquickandeasy
clampingapart
Fig.Aswingwasherusedfor
clampingapartwithhole
ToggleClamps
Fig.Apushpull
typetoggle
clamp
Fig.Anexampleofa
fixtureheldbyacam
clamp
Page 28 of 29
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Equalizers
y When the clamping force is to be applied at more than
JigsandFixtures
Q. No
Option
Q. No
Option
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