DEPARTMENT OF MECHANICAL ENGINEERING

09MD06/09ML06 - Design for Manufacture and Assembly

M.E (Engineering Design, Lean Manufacturing)

Assignment : Cumulative effect of Tolerances

PROBLEMS 07-Oct-2010

1. Three parts are to be placed in an end-to-end assembly. The tolerances are 0.23 mm, 0.305 mm
and 0.90 mm. Form an estimate for the variations in the lengths of the assemblies by averaging the
results of the arithmetic and normal laws. (i.e., the worst case approach and RSS approach)

2. Two parts have normally distributed errors centered on their natural tolerances of 0.23 mm and 0.30
mm. In an end-to-end assembly, find the proportion of assemblies whose length is 0.25 mm less than
the mean of the assembly. Draw the normal curve for the assembly and mark completely.

3. A shaft diameter is specified A0.09 mm and the corresponding hole diameter is B0.11 mm. The
mean dimensions B-A differ by 0.13 mm. If the errors are normally distributed and centered on the
tolerances, find the expected proportion of interferences on assembly. Sketch the assembly curve and
dimension completely.

4. A shaft diameter is specified 50.80.076 mm. The hole diameter is B0.10mm. If the permissible
interferences on assembly are to be limited to 1%, find the value of B. Assume error distributions are
like 1 symmetrically truncated normal curve with t = 0.88.

5. For the fit 40H8e8,

a. Estimate the clearance by (i) WC method (ii) RSS method
b. % of assemblies with clearance 0.005 for RSS approach
c. Practical application of RSS method.

6. Same as problem 5 having,

a. Hole Cp = 0.67 ; Shaft Cp = 1.00
b. Hole Cp = 0.33 ; Shaft Cp = 0.67

Reference book: M.F.Spotts Dimensioning and Tolerancing for Quantity Production , 1983, Prentice-
Hall, Inc., USA

Faculty Team: Dr.P.V.M, Dr.R.R, Mr.V.VA

 DEPARTMENT OF MECHANICAL ENGINEERING

09MD06/09ML06 - Design for Manufacture and Assembly

M.E (Engineering Design, Lean Manufacturing)

Assignment : Selective Assembly

PROBLEMS 12-Oct-2010

1. The fit requirement between a piston and cylinder is 0.0150.009 mm. The bore basic size is 80.
Assume that the cylinder bore honed (IT7) and the piston outside diameter is high quality lapped (IT3).
Also assume ts=gs; hole basis system being followed. It is proposed to achieve the above fit by following
selective assembly procedure. Specify the size ranges and the tolerance range for different mating
groups that would satisfy the requirement of fit. Show the size zones of piston and cylinder neatly, side
by side.

2. The selective assembly chart for the crown wheel bore and expandise collet assembly to be used in
spiral bevel gear cutting is as follows:
Group Matching expandise outside
Crown wheel bore size (mm)
No. diameter (mm)

01 140.000 to 140.014 139.988 to 139.998

02 140.014 to 140.028 140.002 to 140.012

03 140.028 to 140.042 140.016 to 140.026

04 140.042 to 140.056 140.030 to 140.040

Based on the above data, suggest appropriate secondary production process for the crown wheel bore
and expandise outside diameter. Also determine the fit requirement between the mating parts to
ensure proper clamping under gear cutting conditions. Compute the expected percentage of gears lie in
each group.

3. A bearing OD is to be fitted on to the housing. The nominal size of the OD is 100mm. Hole basis
system is followed. The fit requirement is 0.020 0.007. The bearing OD and housing bore are finished
by grinding process to the tolerance of IT7. Assuming model 1, decide the number of groups required
and also estimate the percentage of components which will fall into each one of the groups. Justify the
need for selective assembly.

Faculty Team: Dr.P.V.M, Dr.R.R, Mr.V.VA