Chapter Eight

Tolerance Charts

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 INTRODUCTION
• A tolerance chart is a graphical method for presenting
the manufacturing dimensions of a workpiece or
assembly at all stages of its manufacturing dimensions
of a workpiece.
• The chart provides an intermediate control system of
checks and balances to insure that processing
dimensions and tolerances will meet those specified on
part prints
• The tolerance charts are useful in sorting dimensional
problems on individual parts, and also useful in
processing assemblies
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 Purpose and Utilization
of Tolerance Charts
1. It permits the process engineer to determine in
advance of tooling whether or not the part can be
made to part print tolerances. A surprising number of
designs are actually dimensionally faulty and can not
be manufactured to print. If this condition can be
discovered in advance, costly scrap can be prevented.
2. It aids in developing proper manufacturing sequence.
3. It provides a means of establishing the proper working
tolerances for each operation in the sequence.

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4. It provides assurance that sufficient stock removal will
always be available for each operation in the sequence and
what that amount is. If sufficient stock is not available
tolerance charts will disclose the same.
5. When accuracy of the machine is known, the tolerance
chart will indicate whether or not it is capable of meeting
part print specifications.
6. It provides an intelligent instrument for negotiating with
product design when manufacturing specifications cannot
be met economically.
7. It offers a convenient and useful check on alternate
methods of dimensioning the part for processing purpose.

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8. It aids the process engineer in determining whether the part
will arrive at its last operation with desired dimensions and
tolerances.
9. It helps to determine the practicability of combined tooling,
such as form tools-or combinations of working and
inspection gauging.
10. It provides a means of reducing dimensional errors which
are likely to occur if complex parts are processed without
the use of tolerance charts.
11. It aids in determining the proper raw material sizes and in
developing the necessary castings and forgings.
12. Together with the process picture sheet, the tolerance
chart provides an invaluable aid in the development of
complete and accurate process routings.
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 Definitions and Symbols
1. A working Dimension is the distance between a
locating surface and the surface being processed.
2. Stock removal is the difference between the
dimension that existed prior to machining and
machining dimension.
3. Resultant dimension is the difference between two
dimensions or a dimension and an intermediate
resultant. It is sometimes called as a balance
dimension. An intermediate resultant occurs when
additional stock removed in later operation will
affect its size.
4. Total tolerance is the total variation from the basic
stock removal dimension which can result from the
operation performed
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Developing Tolerance Chart

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Assumptions
 Rough forging dimension = 2 in
 Nominal finish dimension = 1.920 in
 Difference = 0.080 in to be removed from two
surfaces B and G
 Both B and G surfaces are to be machined,
hardened and ground, therefore let us assume
that 0.010 in is left for grinding for each surface.
 Therefore stock to be removed from each surface
= (0.080/2)-0.010= 0.030 in
 No change in dimensions due to heat treatment
 processes will be assumed in this example.

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Operation 10

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Operation 10: calculations
Forging Dimension = 2.000±0.010 in
Operation 10, W.D. = 1.970±0.002 in
Stock removal = 0.030±0.012 in
Min. of 0.018 in and max. of 0.042 in. can be
removed.
 No final (resulting) dimension is resulted from
this operation.

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Operation 20

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 Operation 20: Calculations
• Three separate surfaces result from this operation. Location
takes place on surface G which was machined in operation
10. Surface A is faced, the center hole is core drilled and
reamed, and the surface C is turned. Here, we concern with
surfaces B and C. Here, as in previous operation, a nominal
0.030 stock will be removed from A. The working tolerance
is ±0.002 as before. Therefore,
• Operation 10, working dimension 1.970±0.002
• Operation 20, working dimension 1.940±0.002
• Stock removal 0.030±0.004

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 Operation 20 continued
• Surface C must be produced as a continuation of
operation 20, using the same locating surface. Because
the position of the surface C with respect to surface G
is affected by the amount which will later be removed
from surface G by grinding, allowance must be made to
insure that the final relationship between these two
surfaces is maintained. Since 0.010 is allowed for stock
removal in grinding, the working dimension will be
1.780±0.002. Therefore,
• Operation 20 (a), working dimension 1.940±0.002
• Operation 20(b), working dimension 1.780±0.002
• Stock removal 0.160±0.004

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Operation 30

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 Operation 30: Calculation
• In the first step performed in operation 20,a nominal
working dimension of 1.940 was established between
surfaces B and G. To determine the nominal working
dimensions for operation 30, two things must be
considered.
1. The nominal dimension between surface G and surface F.
2. The nominal stock removal from surface G by grinding in
the final operation. The nominal working dimension for
this operation is found by subtracting these two
dimensions from the nominal working dimension from
operation 20.
1.940-0.200-0.010=1.730 with working tolerance as ±
0.002.

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 Operation 30 continued
• Because this operation is carried out with a form
tool, two surfaces are created simultaneously.
This automatically fixes the relationship between
surfaces E and F. The form tool dimension which
relates the two surfaces can carry the full part
print tolerance. The resultant dimension between
surfaces F and G can now be calculated as:
Operation 20(a), working dimension 1.940±0.002
Operation 30, working dimension 1.730±0.002
Resultant (intermediate) 0.210±0.004

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Operation 40

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 Operation 40: calculations
Working dimension for this operation must take into
account the allowance for grinding after hardening.
Because the nominal depth of this milling cut is 0.250
and the nominal allowance for grinding is 0.010, the
working dimension fro this operation is will be
0.250+0.010=0.260 with working tolerance ±0.002.

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 Operation 50
The prints requires a finished hardness depth of
0.015±0.010. Actually, this depth can be
controlled within ±0.005. Because 0.010 is to be
removed from each ground surface, the working
case depth is set as 0.025±0.005. Since nothing
has been removed from the workpiece in
carburizing and hardening, no stock removal is
recorded. As indicated previously, there is no
change in workpiece dimension and hence no
change in the resultant occurs.
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Operation 60

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 Operation 60: Calculations
• The working tolerance on grinding can be
achieved as ±0.0005. Because 0.010 has been
allowed for grinding, the working dimension that
must be held in this operation is 1.930±0.0005.
Thus stock removal
• Operation 20, working dimension 1.940±0.002
• Operation 60, working dimension 1.930±0.0005
• Stock removal 0.010±0.0025

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 Operation 60 continued
• With the completion of operation 60, the dimensions from
surface G to , G to C, and F to E are now finalized. Since the
dimension from F to E was established earlier by the form tool
and is not affected by this operation, it can be recorded as a
resultant as shown in figure. Operation 30 was the last to be
performed on surface F before operation 60. The resultant
from G to F can now be recorded.
• Operation 60, working dimension 1.930±0.0005
• Operation 30, working dimension 1.730±0.002
• Resultant 0.200±0.0025
• The resultant dimension between surfaces C and G now
becomes final and can be checked. Its previous dimension was
attained in operation 2(b).
• Operation 20(b), working dimension 1.780±0.002
• Operation 60, Stock removal 0.010±0.0025
• Resultant 1.770±0.0045
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 Operation 60 continued
• The case hardened depth of G must be checked to
make certain the grinding operation did not cause
it to fall below the depth specified.
• The case hardened depth is determined by the
difference between the initial case depth working
dimension and the stock removal in grinding
• Operation 50, working dimension 0.025±0.005
• Operation 60, Stock removal 0.010±0.0025
• Resultant 0.015±0.0075

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Operation 70

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 Operation 70: Calculations
• Aside from balancing final tolerances, operation 70 completes
the machining operations on the workpiece, unless it is found
that additional operations must be performed to correct
tolerance stacking. Stock removal may be calculated as
• Operation 60, working dimension 1.930±0.0005
• Operation 70, working dimension 1.920±0.0005
• Stock removal 0.010±0.001
• Other resulting dimension of B and D
• Operation 40, Working dimension 0.260±0.002
• Operation 70, working dimension 0.010±0.001
• Resultant 0.250±0.003
• Dimension of B (case hardened depth)
• Operation 50, Working dimension 0.025±0.005
• Operation 70, working dimension 0.010±0.001
• Resultant 0.015±0.006

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Balancing of Tolerance Chart
• If the developed tolerance chart is accepted at this
stage, tight and costly processing increases cost of the
product.
• The first step in balancing the tolerance chart is to
examine the final resultant dimensions and compare
them with those specified the part print.
• The resultant whose tolerance compare closest with
the part print tolerance will be the logical place to
start.
• As can be seen in the developed chart, the resultant
dimension between surfaces C and G is 1.770±0.0045,
which compares with the print dimension of
1.770±0.005. This comparison is closer than the others,
balancing will start from here.

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Balancing operation 60
• Operation 60 can now be recalculated as:
• Operation 20(a), working dimension 1.940±0.002
• Operation 60, working dimension 1.930±0.001
• Stock removal 0.010±0.003
• Operation 20(b), working dimension 1.780±0.002
• Operation 60, stock removal 0.010±0.003
• Resultant 1.770±0.005
• The preceding resultant is now identical with the
part print specifications.
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• An intermediate resultant between surfaces F and G
was established as a result of operation 30. The final
resultant was obtained in Operation 60 . Because the
relationship between surfaces E and F was determined
by form tool, an increase can be made in the working
tolerance of operation 30 without affecting other
surfaces. The working dimensions of operation 30 can
be changed to 1.730±0.004. The correct resultant
between surfaces F and G will now be:
• Operation 60, working dimensions 1.930±0.001
• Operation 30, working dimensions 1.730±0.004
• Resultant 0.200±0.005
• The dimension 0.100±0.002 remains unchanged
because it was established from the form tool.
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 Balancing Operation 70
• Operation 70 now can be recalculated as follows:
• Operation 60, Working dimension 1.930±0.001
• Operation 70, working dimension 1.920±0.002
• Stock removal 0.010±0.003
• Operation 40, working dimension 0.260±0.002
• Operation 70, stock removal 0.010±0.003
• Resultant 0.250±0.005
• Operation 50, working dimension 0.025±0.007
• Operation 70, Stock removal 0.010±0.003
• Resultant 0.015±0.010
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Completed Tolerance Chart

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