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ENM202

ANADOLU UNIVERSITY
Industrial Engineering Department

Lecture 3 – Dimensions, Tolerances and Surfaces


Spring 2007

Saleh AMAITIK
Manufacturing Processes
Affected Areas

Tolerance & Surfaces

Product Design Quality Control

Manufacturing

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Manufacturing Processes
Dimensions, Tolerances and Surfaces

In addition to mechanical and physical properties, other


factors that determine the performance of a
manufactured product 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.

Surfaces - surface finishes obtained by manufacturing process that


produce the shape

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Dimensions

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.

The dimension indicates the part size desired by the


designer, if the part could be made with no errors or
variations in the manufacturing process

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Tolerances

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

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Why is tolerancing necessary?

It is impossible to manufacture a part to an exact size


or geometry

Assemblies: Parts will often not fit together if their


dimensions do not fall within a certain range of values

Tolerances are needed to control the dimensions of any


two mating parts so that any two parts may be
interchangeable.

Tolerances on parts contribute to the expense of a part,


The smaller the tolerance the more expensive the part

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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.

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How Is Tolerance Specified?
Tolerances can be expressed in Several ways:
General Tolerances
A note may be placed on the drawing which specifies the tolerance
for all dimensions except where individually specified

ALL DECIMAL DIMENSIONS TO BE HELD TO ±0.020

Specific Tolerances
The tolerance for a single dimension may be specified with the
dimension based on one of the following methods
• Limits
• Unilateral tolerance
• Bilateral tolerance

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Specific Tolerances

Limit Dimensions
Permissible variation in a part feature size, consisting of the
maximum and minimum dimensions allowed

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Specific Tolerances

Unilateral Tolerance
Variation from the specified dimension is permitted in only one direction,
either positive or negative, but not both.

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Specific Tolerances
Bilateral Tolerance
Variation is permitted in both positive and negative directions from
the nominal dimension.

It is possible for a bilateral tolerance to be unbalanced; for example,


2.500 +0.010, -0.005

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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.

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Dimensional Tolerances (Size)
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.

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Manufacturing Processes
Geometrical Tolerances (Form)

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Geometrical Tolerances (Form)

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Geometrical Tolerances (Form)

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Geometrical Tolerances (Form)

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Geometrical Tolerances (Location)

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Geometrical Tolerances (Location)

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Geometrical Tolerances (Orientation)

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Geometrical Tolerances (Orientation)

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Geometrical Tolerances (Orientation)

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Geometrical Tolerances (Orientation)

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Geometrical Tolerances (Orientation)

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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 .
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ISO Tolerance Band "T "micrometres = (m-6) based on ISO 286  IT Grades 1 to 14  

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Fits between Mating Parts
Fit is the general term used to signify the range of
Looseness and Tightness
of mating parts

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Important Terms

Nominal size: a dimension used to describe the general size.

Basic size: the theoretical size used as a starting point for the
application of tolerances.

Actual size: the measured size of the finished part after machining.

Limits: the maximum and minimum sizes shown by the toleranced


dimension

Allowances: the minimum clearance or maximum interference


between parts, or the tightest fit between two mating parts.

Tolerance (Tolerance zone): the total allowable variation in a


dimension; the difference between the upper and lower limits

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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

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Fits Types
The most common types of fit found in industry

Clearance Fit occurs when two toleranced mating


parts will always leave a space or clearance when
assembled.

Interference Fit occurs when two toleranced mating


parts will always interfere when assembled.

Transition Fit occurs when two toleranced mating


parts are sometimes an interference fit and
sometimes a clearance fit when assembled.

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Clearance and Interference fits between two Shafts and a Hole

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Transition fit between a Shaft and a Hole

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Fit Type Determination
If feature A of one part is to be inserted into or mated with feature B
of another part, the type of fit can be determined by the following:

The Loosest Fit is the


difference between the
smallest feature A and the
largest feature B.

The Tightest Fit is the


difference between the
largest feature A and the
smallest feature B.

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ISO Tolerances for Holes (ISO 286-2)

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ISO Tolerances for Shafts (ISO 286-2)

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Recommended Fits

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Tolerances and Manufacturing Processes

Some manufacturing processes are more accurate than


others

Examples:
– Most machining processes are quite accurate,
capable of tolerances = 0.05 mm or better

– Sand castings are generally inaccurate, and tolerances


of 10 to 20 times those used for machined parts must
be specified

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Manufacturing Processes associated with ISO IT Tolerance Grade

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Metric Symbols of Fits

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Creating a Clearance Fit using The Basic Hole System
Given the following fit Φ40 – H11/c11
From table for hole diameter = 40 and H11 we find
Upper deviation = +160 μm & Lower deviation = 0
From table for shaft diameter = 40 and c11 we find
Upper deviation = -120 μm & Lower deviation = -280 μm
Calculations of dimension limits for hole and shaft
- Maximum hole diameter = 40 + 0.16 = 40.16 mm
- Minimum hole diameter = 40 + 0 = 40 mm
- Maximum shaft diameter = 40 +(-120) = 39.88 mm
- Minimum shaft diameter = 40 + (-280) = 39.72 mm

Maximum clearance = Maximum hole diameter – Minimum shaft diameter


= 40.16 – 39.72 = 0.44 mm
Minimum clearance = Minimum hole diameter – Maximum shaft diameter
= 40 – 39.88 = 0.12 mm

Allowances = minimum clearance = 0.12 mm = 120 μm


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Creating an Interference Fit using The Basic Hole System
Given the following fit Φ40 – H7/s6
From table for hole diameter = 40 and H7 we find
Upper deviation = +25 μm & Lower deviation = 0
From table for shaft diameter = 40 and s6 we find
Upper deviation = +59 μm & Lower deviation = +43 μm

Calculations of dimension limits for hole and shaft


- Maximum hole diameter = 40 + 0.025 = 40.025 mm
- Minimum hole diameter = 40 + 0 = 40 mm
- Maximum shaft diameter = 40 + 0.059 = 40.059 mm
- Minimum shaft diameter = 40 + 0.043 = 40.043 mm

Maximum interference = Maximum shaft diameter – Minimum hole


diameter
= 40.059 – 40 = 0.059 mm
Minimum interference = Minimum shaft diameter – Maximum hole diameter
= 40.043– 40.025 = 0.018 mm
Allowances = maximum interference = 0.059 mm = 59 μm
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Surfaces
Nominal surface - intended surface contour of
part, defined by lines in the engineering drawing

– The nominal surfaces appear as absolutely straight


lines, ideal circles, round holes, and other edges and
surfaces that are geometrically perfect

Actual surfaces of a part are determined by the


manufacturing processes used to make it

– The variety of manufacturing processes result in wide


variations in surface characteristics

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Why Surfaces are important

• Aesthetic reasons.

• Surfaces affect safety.

• Friction and wear depend on surface characteristics.

• Surfaces affect mechanical and physical properties.

• Assembly of parts is affected by their surfaces.

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Surface Technology

Concerned with:
– Defining the characteristics of a surface
– Surface texture
– Surface integrity
– Relationship between manufacturing
processes and characteristics of
resulting surface

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A magnified cross‑section of a typical metallic part surface

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Surface Texture
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
It also possesses a pattern and/or direction resulting
from the mechanical process that produced it

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Surface Integrity
Concerned with the definition, specification, and control of the
surface layers of a material (most commonly metals) in
manufacturing and subsequent performance in service.

Manufacturing processes involve energy which alters the part


surface.

The altered layer may result from work hardening (mechanical


energy), or heating (thermal energy), chemical treatment, or even
electrical energy

Surface integrity includes surface texture as well as the altered


layer beneath

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Four elements of surface texture
1. Roughness - small, finely‑spaced deviations from nominal surface
determined by material characteristics and process that formed the
surface
2. Waviness - deviations of much larger spacing; they occur due to
work deflection, vibration, heat treatment, and similar factors
– Roughness is superimposed on waviness

3. Lay - predominant direction or


pattern of the surface texture

4. Flaws - irregularities that occur on the


surface
– Includes cracks, scratches, inclusions,
and similar defects in the surface.

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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

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Surface Roughness
Average of vertical deviations from nominal surface over a specified
surface length

Surface roughness can be approximately calculated using the following equation


n y
i
Ra  
where i 1 n
Ra = average roughness;
yi = vertical deviations (absolute value) identified by subscript i; and
n = number of deviations included in Lm

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Surface Integrity

• Surface texture alone does not completely describe a


surface
• There may be metallurgical changes in the altered
layer beneath the surface that can have a significant
effect on a material's mechanical properties
• Surface integrity is the study and control of this
subsurface layer and the changes in it that occur
during processing which may influence the
performance of the finished part or product

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Surface and Manufacturing Processes

• Some processes are inherently capable of


producing better surfaces than others
– In general, processing cost increases with
improvement in surface finish because
additional operations and more time are
usually required to obtain increasingly better
surfaces
– Processes noted for providing superior
finishes include honing, polishing, and
superfinishing

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Surface Roughness Produced by common Manufacturing Processes

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Surface Roughness and Production Cost

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Surface Roughness and Production Time

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Metrology
Science of physical measurement applied to variables
such as dimensions, surface finish, and mechanical and
physical properties.
Measurements require Precision and Accuracy.
Precision is the degree which the instrument gives
repeated measurements of the same standard.
Accuracy is the degree of agreement of the measured
dimension with its true magnitude.

Sensitivity is the smallest difference in dimensions


that the instrument can detect or distinguish.
Stability – The instrument’s capability to maintain its
calibration over a period of time
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