Chapter 4 Tolerancing

Topics Exercises

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Tolerancing: Topics
Summary 4.1) Tolerancing and Interchangeability 4.2) Tolerancing Standards 4.3) Tolerance definitions 4.4) Tolerance Types

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Tolerancing

4.1) Tolerancing for Interchangeability

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Tolerancing / Definition
What are tolerances? Manufacturing processes are not precise. There is always a dimensional error. Tolerance is the leeway allowed on a dimension for accommodating manufacturing errors.

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Tolerancing / Interchangeability
A tolerance is the amount of size variation permitted.
You can choose a tolerance that specifies a large or small variation. 1.005 Size limits = .994 Tolerance = 1.005 - .994 = .011

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Tolerancing / History
The need for GD&T was identified during second world war. Because of the mass production, different parts were manufactured by different vendors. But these parts would not fit together because of dimensional errors. So this laid foundation for the development of a standard for tolerances. This standard is meant to define tolerances and their applications.
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Tolerancing / Interchangeability
Choosing a tolerance for your design.
Specify a tolerance with whatever degree of accuracy that is required for the design to work properly.

Choose a tolerance that is not unnecessarily accurate or excessively inaccurate.

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Tolerancing / Interchangeability
Choosing the correct tolerance for a particular application depends on:
the design intent (end use) of the part cost how it is manufactured experience

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Tolerancing

4.2) Tolerancing Standards

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Tolerancing Standards
Standards are needed for
Defining consistent definitions and rules for tolerances Helps in interchangeability of parts.

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Tolerancing Standards
The two most common standards agencies are;
American National Standards Institute (ANSI) / (ASME Y14.5) International Standards Organization (ISO).

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Tolerancing Definitions

4.3) Tolerance definitions

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Tolerance types and methods

The tolerancing methods presented are:
Limit dimensions Plus or minus tolerances zones

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1. Limit Dimensions
Limits are the maximum and minimum size that a part can obtain and still pass inspection.
For example, the diameter of a shaft might be specified as follows.

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2. Plus or Minus Tolerances

Plus or minus tolerances give a basic size and the variation that can occur around that basic size.

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3. Zones
Zones give the distance between two parallel features, between which the variations are allowed.

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Shaft-Hole Assembly
Used to illustrate concepts and definitions. Both the shaft and the hole are allowed to vary between a maximum and minimum diameter.

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Tolerances Definitions
Limits: The limits are the maximum and minimum size that the part is allowed to be.
Basic Size: The basic size is the size from which the limits are calculated.
It is common for both the hole and the shaft and is usually the closest fraction.

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Skip to next part of the exercise

Exercise 4-2
Fill in the following table.

Shaft Limits .47 - .51 Basic Size .5 or 1/2 Tolerance .04

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Hole .49 - .50

.01

Inch Tolerances Definitions

Maximum Material Condition (MMC): The MMC is the size of the part when it consists of the most material.
Least Material Condition (LMC): The LMC is the size of the part when it consists of the least material.

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Skip to next part of the exercise

Exercise 4-2
Fill in the following table.

Shaft MMC LMC

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Hole

Inch Tolerances Definitions

Maximum Clearance: The maximum amount of space that can exist between the hole and the shaft.
Max clearance = LMChole LMCshaft

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Inch Tolerances Definitions

Minimum Clearance (Allowance): The minimum amount of space that can exist between the hole and the shaft.
Min. Clearance = MMChole MMCshaft

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Exercise 4-2
What does a negative clearance mean?

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Exercise 4-4

Tolerance Types

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Tolerance Types
There are 6 types of tolerances defined in the current standard (ASME Y14.5)

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Size
Size is applicable on features of size. It is a limit dimension. Features of size are those features on which a diameter or thickness can be applied. ex. hole, with a size tolerance of 6 0.3 mm:

Picture from http://gdtseminars.com/2008/02/13/what-is-resultant-condition/

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Form
Form tolerances are used to control the surface characteristics of a feature. Flatness controls the surface variation for a plane. Straightness controls the variation of line elements on a plane or cylindrical surface or axis of a cylinder. Circularity is used to control the variations of a circular element on a cylindrical surface. Cylindricity is used to control both the circular and line elements on a cylindrical surface
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Form

Flatness

Circularity

Straightness
Figures from http://www.roymech.co.uk/Useful_Tables/Drawing/draw_geom_ex.html
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Orientation
Controls the orientation of features with respect to each other 3 types parallelism, perpendicularity, angularity Features are controlled with respect to datums

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Orientation
Parallelism

Perpendicularity

Angularity

Figures from http://denisekitchencad.weebly.com/gdt.html

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Location
Controls the position of features. 3- types - position, concentricity, symmetry Applied to features of size only Need datums

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Location
There

Location

Figures from http://denisekitchencad.weebly.com/gdt.html

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Runout
Controls the surface variation with respect to a datum Applied to cylindrical features or circular elements 2 types- circular and total Circular runout controls one circular element. Total runout controls the entire surface.

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Runout
There
Circular

Total Runout

Figures from http://denisekitchencad.weebly.com/gdt.html

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Profile
Controls size, form, orientation and position. Two types line and surface Line profile controls one element at a time. Surface profile controls the entire surface.

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Profile
There
Line Profile

Surface Profile

Figures from http://denisekitchencad.weebly.com/gdt.html

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