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Welding International
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To cite this article: E Richter (1987) Dimensional tolerances of welded products, Welding International, 1:1, 58-61, DOI:
10.1080/09507118709449026
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The principal aims of production engineering are to Dimensional tolerances are determined by
obtain high productivity with low costs while ensuring experiment if no previous model exists and if calculation
product quality. The individual stages of development is not possible.
from manual production to automated mass production T h e four methods of calculation described in TGL
can be considerably affected by each respective stage of 19115 (maximum-minimum method, theoretical
development.' Tolerance specifications and tests based probability method, compensation method and method
on scientific experiment are important to ensure and of group inter~hangeability)~form the basis for
improve the quality of products and production calculating dimensional and tolerance chains. Because of
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Rail vehicles B
Motor vehicles B; C
Crane construction B; C
DAR construction B; C
Steel construction B; C
Machine construction B; C; D
Shipbuilding C; D
1
A" -
Transverse distortion Ab as a function of the weld
quantities in [2] are minimised.
T h e tolerances of the individual parts and the
assembly can be considerably influenced through
seam cross section A,; free distortion
suitable choice of the method of manufacture. Using
AN
AN= 1.7.. . 7.5AZw,Ab up 0.03.- 4- 0.22;
S
holding jigs is another way of reducing tolerances. The
theoretical pre-conditions for this were discussed in
AN ref.8 taking into account the joint width and the
AbMAcc 0.03- 4- 0.03.
S
distortion. Functional relationships between individual
and equipment tolerances are explained using graphs.
Item S, bspr
The amount of distortion, i.e. shrinkage after welding, is
mm mm
determined by the welding method, weld cross section
1 10 0 and restraint of the welded parts (Fig.1). T h e size of the
2 10 4
3 12 4 weld cross section A, can on the one hand be seen from
the joint shape and the parts of the joint which
determine the measurements e.g. the joint width bsp,
the dimensions may vary involves extra costs in the
angle of opening a, height of weld c.
welding operation the accuracy classes must be selected
Alternatively, the weld cross section is determined
with care. In many cases the mean accuracy classes B
from influencing quantities specific to the particular
and C suffice?.5
process such as: welding current I,, welding voltage Us,
T h e advantage of the tolerances specified in Table 1
welding rate v,, electrode diameter d,. The effect these
over those specified in TGL 28973 is that these have
have on the cross section A, can be represented in a
been tried out in practice over many years with
general form by equation [4]:
particular consideration being given to the special
requirements of fusion welding. The dimensional . ..[4]
variations occurring on welded constructions are in fact
not only determined by the dimensional variations of the In addition there are the effects of the shielding
individual component parts but are also dependent on a gases (pure shielding gas o r mixed gas), welding flux,
number of influencing factors from the manufacturing weld pool formation erc which must be considered
process: the most important of which are listed in Table separately.
2. The measuring uncertainty is determined by the
According to this, the sum tolerance T, is: method of measurement and apparatus chosen and
should not exceed 20% of the dimensional tolerance.
T, = JTET2 + Tz2 + Tv2 + M Z . ..[2] CALCULATING WITH DIMENSIONAL
TOLERANCES
which agrees well with results obtained in practice. When calculating with dimensional tolerances, one
for dimension
2 Guide dimension and dimensional chain for container component
example: Sheet thickness, s = 20mm; joint gap, 6, = 4
f lmm; shrinkage Ab = 1 k 0.6. part
L 7000 k 8 16 7008 6992
starts with the graph of the dimensional chain. Following A 198 k0.5 1 19S.5 197.5
this the starting equation is drawn up and solved B k 1.5 3 1647.5 1644.5
according to the final term. In accordance with the 2nd
principal theorem of the tolerance condition T, = G, -
2, 1646
4
1
k1 2
k0.6 1.2
5
1.6
3
0.4
K, the final term tolerance To and other sought
quantities are determined. The control calculation is T, = Ti = 30;T, = JCTf = 8 < TFu = 16
then done with the 1st principal theorem of the
tolerance condition:
The resulting starting equation for the dimensional
m chain is:
Ts = 1 Ti
i = l
2A + 4B + 5b,, - 5Ab - L = 0 .. .[6]
To explain this procedure a container (Fig.2) is
chosen as an example; it comprises two bases (A and F)
ifA = F a n d B = C = D =i= E.
and .four shell rings (B, C, D and E). The dimensional
chain can then be identified as a closed continuous line The solution after the final measurement M, = L
consisting of the construction dimensions A to F, the gives:
joint gaps b,, and the transverse deformation (shrinkage)
Ab. M, = 2A + 4B + 5b,, - 5Ab .. .[7]
To simplify things it is assumed that the nominal
dimensions and dimensional tolerances are the same for
the two container bases. The same should also apply for The final term tolerance To = G, - K, is found
the four shell rings, the joint gaps and the transverse from
deformations.
T h e construction dimensions KM, are calculated G, = 2GA + 4G" + 5G,,, - 5K,, .. . [Sa]
from the difference between the guide measurement
RM, and the share of the joint gap b,,, therefore
K, = 2KA + 4K" + 5K,,, - 5G,, ...[Sb]
KMA = K M = R M -!h
F " 3
:. . [5a]
and for the values in Table 3a gives the final dimensional
and tolerance To = 56mm, i.e. it was assumed that all
positive maximum dimensions and all negative minimum
KM,, = . . . = KM, = RM,, - b,, .. .[5b] dimensions occur in the welding process, in order to
determine G, and conversely K,,; a situation which is
The nominal dimensions (construction dimensions), very improbable. If a quadratic error propagation T, =
tolerances, maximum and minimum dimensions for the which better reflects the real operating conditions is
example chosen are listed in Table 3. assumed, the value drops to T, = 17.75. This value is
60 WELDING INTERNATIONAL 1987 No.1
variations cannot as yet be calculated. The effects of
these influencing factors must still be determined
experimentally for the time being.
SUMMARY
The effects of many influencing factors on dimensional
variations in welded construction can largely be
determined by calculation using the described method
and can therefore be used for manufacturing
preparation. The interrelationships between parts
preparation, assembly, welding and distortion were
considered in a composite manner and the multifarious
special test results relating to accuracy in thermal
separation and to welding deformation were included as
an organic whole in the overall presentation of welding
TE, - tolerance of individual part production.
The systematically calculated tolerance
3 Relationship between equipment and individual part specifications ensure an assembly with little need for
tolerance according to Taober.
adaptations and continuous welding production. It was
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