INTRODUCTION-

Factors that determine the performance of a manufactured

product, other than mechanical and physical properties, include
 Dimensions - linear or angular sizes of a component
specified on the part drawing
 Tolerances - allowable variations from the specified part
dimensions that are permitted in manufacturing.
•A dimension is "a numerical value expressed in appropriate
units of measure and indicated on a drawing and in other
documents along with lines, symbols, and notes to define the
size or geometric characteristic, or both, of a part or part
feature"
Dimensions on part drawings represent nominal or basic sizes
of the part and its features.
A tolerance is "the total amount by which a specific
dimension is permitted to vary. The tolerance is the
difference between the maximum and minimum limits"
Variations occur in any manufacturing process, which
are manifested as variations in part size
Tolerances are used to define the limits of the allowed
variation.

Dimensioning can be divided into three categories:

general dimensioning,
geometric dimensioning, and
surface texture.
 TYPES OF TOLERANCES

A Dimensional tolerance is the total amount a specific

dimension is permitted to vary, which is the difference
between maximum and minimum permitted limits of size.

A Geometric tolerance is the maximum or minimum variation

from true geometric form or position that may be permitted in
manufacture.

Geometric tolerance should be employed only for those

requirements of a part critical to its functioning or
interchangeability.
Bilateral Tolerance
Variation is permitted in both
positive and negative directions
from the nominal dimension
 Possible for a bilateral Fig: Ways to specify
tolerance limits for a
tolerance to be unbalanced; for nominal dimension of 2.500
example, 2.500 +0.010, -0.005

Unilateral Tolerance
Variation from the specified dimension
is permitted in only one direction
 Either positive or negative, but not
both Fig: Ways to specify
tolerance limits for a
nominal dimension of 2.500
 TOLERANCE-

Dimensional tolerance - conventional

Geometric tolerance - modern
nominal dimension 1.00
tolerance 0.05
means a range 0.95 - 1.05

unilateral + 0.10 1.05 + 0.00

0.95 - 0.00 - 0.10
bilateral 1.00 0.05
REASON OF HAVING TOLERANCE

 The raw material may be defect.

 No manufacturing process is perfect.
 Nominal dimension (the "d" value) can not be achieved
exactly.
 Without tolerance we lose the control and as a
consequence cause functional or assembly failure.
 The work piece may be too slender to take the load.
Tolerances and Manufacturing
Processes
Some manufacturing processes are inherently more accurate
than others
Examples:
 Most machining processes are quite accurate, capable of
tolerances = ±0.05 mm (± 0.002 in.) or better
 Sand castings are generally inaccurate, and tolerances of
10 to 20 times those used for machined parts must be
specified
DIMENSIONAL TOLERANCES (SIZE)
Angular size dimension tolerance

It specifies the allowable variation on the

size or gap formed by two angular
elements of the shape.
Curved dimension tolerance
It is a tolerance on a dimension for a
curved feature element measured along the
entire path of the curve

Diameter dimension tolerance

It is the allowable variation of the size of

a hole in a feature.
 Radial Dimension Tolerance
It is the allowable variation for the radial
distance from the center of a feature circular
curve to a point on the curve.
Location Dimension Tolerance

It is the allowable variation in locating one

feature of a point with respect to another.

Angular Dimension Tolerance

It defines the allowable variation in the angle
between two elements of a feature.
Tolerance Grades

The tolerance of size is normally defined as the difference between th upper

and lower dimensions.

ISO 286 implements 20 grades of accuracy to satisfy the requirements of

different industries.

Production of gauges and instruments.

IT01,   IT0,   IT1,   IT2,   IT3,   IT4,  IT5,  IT6.

Precision and general Industry.

IT 5,   IT6,   IT7,  IT8,  I9,  IT10,  IT11,  IT12.

Semi finished products

IT11,   IT14,   IT15,   IT16.

Structural Engineering
IT16,   IT17,  IT18 .
 Tolerancing Holes and Shafts
Preferred fits: A specified system of fits for
holes and shafts for SI units

- Hole basis
•The minimum hole size
equals the basic hole size
• Uses the symbol “H” in the
tolerance specification
- Shaft basis
•The maximum shaft size
equals the basic shaft size
•Uses the symbol “h” in the
tolerance specification
Ex.-20H7f8
40H8f6
Geometrical Tolerances (Form)
Geometrical Tolerances (Orientation)
Geometrical Tolerances (Orientation)
 GEOMETRIC CHARACTERISTIC CONTROLS
14 characteristics that may be controlled
TYPE OF TYPE OF CHARACTERISTIC SYMBOL
FEATURE TOLERANCE
FLATNESS
INDIVIDUAL (No STRAIGHTNESS
Datum FORM
Reference) CIRCULARITY
CYLINDRICITY
INDIVIDUAL or LINE PROFILE
RELATED PROFILE
SURFACE PROFILE
FEATURES
PERPENDICULARITY
ORIENTATION ANGULARITY
PARALLELISM
RELATED
FEATURES CIRCULAR RUNOUT
RUNOUT
(Datum TOTAL RUNOUT
Reference
Required) CONCENTRICITY
LOCATION POSITION
SYMMETRY
 FIT-
When two parts are to be assembled, the relation
resulting from their sixes before assembly is
called FIT.

TYPES OF FIT:-
1.Clearance fit
2. Transition fit
3. Interferance fit
Clearance and Interference fits between two Shafts
and a Hole

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
 Surface Texture

• Repetitive or random deviations from the nominal surface which form the
pattern of the surface
The topography and geometric features of the surface
When highly magnified, the surface is anything but
straight and smooth. It has roughness, waviness, and
Flaws
Surface Roughness and
Surface Finish

Surface roughness - a measurable characteristic based on

roughness deviations
Surface finish - a more subjective term denoting smoothness
and general quality of a surface
 In popular usage, surface finish is often used as a
synonym for surface roughness
 Both terms are within the scope of surface texture
Surface Roughness
Average of vertical deviations from nominal surface over a
specified surface length

Figure - Deviations from nominal surface used in the two definitions of

surface roughness.
Surface Roughness Specification

Fig: Surface texture symbols in engineering drawings: (a)

the symbol and (b) symbol with identification labels.
Elements of surface texture
 CONCLUSION
It is impossible to make a perfect component so when we design a part we
specify the acceptable range of features that make-up the part.
Traditionally, the tolerance allocation is done based on the hypothesis that the
assembly process deals with infinitely rigid bodies. The resultant tolerance of
individual components obtained based on this hypothesis will be on the tighter
side, thereby increasing the manufacturing cost.
In reality all the components of the assembly are deformable bodies and they
undergo deformation due to inertia effects. Through finite element simulation,
the
values of deformation due to inertia effects like gravity, angular velocity and
temperature effect have been determined in the design and process planning
stage itself. Due to this, the tolerance requirements of the given assembly are
relaxed to certain extent for critical components, resulting in reduced
manufacturing cost and high product reliability.
With this approach, the component tolerance values found are the most robust
to variation during the product’s application.
These benefits make it possible to create a high-quality and cost-effective
tolerance design.