Activity 2.1.1 Tolerate This!

Additional Practice Answer Key

PLTW Engineering

Activity 2.1.1 Tolerate This! Additional Practice

1. Study the drawings below to identify specified tolerances.
a. Highlight each dimension that has a tolerance associated with it.
b. Label each tolerance dimension with one of the following tolerance types:
limit dimensions, unilateral tolerance, or bilateral tolerance.
c. Label each identified tolerance with a separate letter, A through Z.
d. In the table, record the letter of each tolerance identified, the tolerance
format, a short phase that describes the dimensional variation allowed for
that dimension, the tolerance (a number representing the total allowed
dimensional variation), and an explanation of why that dimension requires
a tolerance.

Part Name: _Adjustable Rocker Arm__________________________

Letter Tolerance Written Explanation Tolerance Why?
Type
A LIMIT Dimension x is 0.531 in. 0.005 in. To accommodate dimensional
DIMENSIONS ≤ x ≤ 0.536 in. variations and/or fit of shaft that
fits in hole
B LIMIT Dimension x is 0.750 in. 0.005 in. To accommodate dimensional
DIMENSIONS ≤ x ≤ 0.755 in. variations and/or the fit of shaft
that fits in hole
C LIMIT Dimension x is 0.590 in. 0.005 in. To accommodate dimensional
DIMENSIONS ≤ x ≤ 0.595 in. variations and/or fit of shaft that
fits in hole

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Part Name: __Base Plate_________________________

Letter Tolerance Written Explanation Tolerance Why?
Type
D UNITALERAL Diameter may be up to 0.003 in. To accommodate a tighter fit and
TOLERANCE 0.003 in. larger than more precise alignment between
0.50 in. but not smaller the anchor bolts and the base
plate than would be provided by
the general tolerances. Note that
in many cases the tolerances on
the size and location of the
anchor bolt holes is generous to
allow for misalignment of the
anchor bolts when placed in
concrete.
E BILATERAL Dimension may be as 0.004 in. To accommodate a specific fit
TOLERANCE much as 0.002 in. larger between the cylindrical object
or smaller than 0.25 in. that fits in the hole and the base
diameter plate that would not be
accommodated with the general
tolerances.
F LIMIT Dimension x is 2.000 in. 0.003 in. To limit the location of the center
DIMENSIONS ≤ x ≤ 2.003 in. hole (and the inserted cylindrical
object).
G LIMIT Dimension x is 3.000 in. 0.003 in. To limit the location of the center
DIMENSIONS ≤ x ≤ 3.003 in. hole (and the inserted cylindrical
object).

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Part Name: __Drill Block_________________________

Letter Tolerance Written Explanation Tolerance Why?
Type
H BILATERAL Depth of the counter 0.006 in. To force a tighter tolerance (than
TOLERANCE bore may be as much as the general tolerance) to limit
0.003 in. larger or the depth of the bolt head from
smaller than specified the surface.
depth of 0.250 in.
I LIMIT Surface diameter, d, of 0.005 in. To force a tighter tolerance (than
DIMENSIONS the countersink hole can the general tolerance) to provide
vary such that 0.753 in. a more precise fit of the screw
≤ d ≤ 0.748 in. head in the hole.
J UNITALERAL Diameter of the thru 0.004 in. Potentially to accommodate a
TOLERANCE hole may be up to 0.004 specific fit for the object inserted
in. larger than 0.500 in. into the hole.
but not smaller.
K BILATERAL Location dimension may 0.10 in. To loosen the tolerance (from
TOLERANCE be as much as 0.05 in. the general tolerance) on the
larger or smaller than location of the bolt or screw to
1.50 in. diameter. reduce manufacturing cost
where a tighter tolerance is not
needed.

2. Consider the adjustable rocker arm represented in the drawing above. An axle is
to pass through the smallest hole. The manufacturer is considering buying bar
stock for the axle that is manufactured according to the following drawing using
the same general tolerances as those specified on the Rocker Arm Drawing.
Answer the following questions and SHOW YOUR WORK.

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a. What is the tolerance (the acceptable amount of dimensional variation) for

the diameter of the rod? 0.005 inches
b. What is the tolerance for the rod length? Based on the general tolerances,
a bilateral tolerance of ± .03 applies. So, the tolerance will be 0.06 inches.
c. Is the fit between the rod and the hole a clearance fit, interference fit, or
transition fit? Explain your answer.
Rod diameter: Upper limit = 0.530; Lower limit = 0.525
Hole diameter: Upper limit = 0.536; Lower limit = 0.531
Clearance fit because there will always be a clearance between the axle
and the opening.
d. What is the allowance between the rod and the smallest hole?
Allowance = MMC internal feature (ID of hole) – MMC external feature
(OD of rod)
= 0.531 – 0.530 = 0.001 inches
e. If the design of the assembled machine requires that the rod is sized such
that the actual clearance between the rod and the hole is never greater
than 0.005 inches, will the current rod design meet the requirement?
Explain. No. If the hole diameter is the upper limit of 0.536 in, and the rod
diameter is the lower limit of 0.525 in., the actual clearance would be
(0.536 – 0.525) equal to 0.011 in. which is greater than the allowed 0.005
in.
f. The machine specification requires that the rod is no longer than 3.025
inches and no shorter than 2.955 in.
 Let L represent the actual length of the rod. Write the length
constraint as a compound inequality. 2.955 in. ≤ L ≤ 3.025
 Will the stock rods always meet the length constraint? Explain.
Rod length Upper Limit = 3.00 + 0.03 (general tolerance) = 3.03 in.,
which is greater than the maximum specified length of 3.025 in.
g. If the stock rods do not always meet the machine specifications for rod
length, how can the manufacturer alter the rod part drawing such that the
rod length will always conform to the specifications? The manufacturer
can include a specific tolerance on the length measurement (such as
including a bilateral tolerance of 3.00 ±.02). Another option to ensure that
the rod length meets the requirement is to change the specified length to
2.99 in. Using the general tolerances, this would result in an upper limit of
(2.99 + 0.03) = 3.02 in. (within specifications) and a lower limit of (2.99 –
0.03) = 2.96 in. (also within specifications).

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3. Design a rod that will have an interference fit so that the allowance (the
maximum interference) is 0.010 with the center hole in the Rocker Arm and the
tolerance on the rod diameter is .002. Sketch a section view of your rod design
below. Be sure to specify the tolerance in the diameter dimension of your design.
Allowance = MMC internal feature (min. diam. of hole) – MMC external feature
(max OD of rod)
–0.010 in. = 0.750 in. – MMC external feature
0.760 in. = MMC external feature
Therefore, the maximum rod diameter is 0.760 in.
Tolerance = Upper Limit – Lower Limit
0.002 = 0.760 – Lower Limit
Lower Limit = 0.758
This is an interference fit, since the smallest axle diameter is 0.758 in., which is
larger than the largest hole diameter of 0.755.

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