Manufacturing Lecture

Manufacturing Technology I
ME 303
Chap # 5
2007 John Wiley !on"# Inc$ M % &roo'er# Fundamentals of Modern Manufacturing 3(e
)IME*!I+*!# T+,E-.*CE!# .*)
!/-0.CE!
1$ )i2en"ion"# Tolerance"# an3 -elate3
.ttri4ute"
2$ !urface"
3$ Effect of Manufacturing %roce""e"
)i2en"ion" an3 Tolerance"
0actor" that 3eter2ine the perfor2ance of a

2anufacture3 pro3uct# other than 2echanical
an3 phy"ical propertie"# inclu3e 5
)i2en"ion" 6 linear or angular "i7e" of a

co2ponent "pecifie3 on the part 3ra8ing
Tolerance" 6 allo8a4le 'ariation" fro2 the

"pecifie3 part 3i2en"ion" that are per2itte3
in 2anufacturing
)i2en"ion" 9.*!I :1;$5M 1<=2>5
. dimension i" ?a nu2erical 'alue e@pre""e3 in
appropriate unit" of 2ea"ure an3 in3icate3 on a
3ra8ing an3 in other 3ocu2ent" along 8ith line"#
"y24ol"# an3 note" to 3efine the "i7e or
geo2etric characteri"tic# or 4oth# of a part or part
feature?
)i2en"ion" on part 3ra8ing" repre"ent no2inal

or 4a"ic "i7e" of the part an3 it" feature"
The 3i2en"ion in3icate" the part "i7e 3e"ire3 4y

the 3e"igner# if the part coul3 4e 2a3e 8ith no
error" or 'ariation" in the fa4rication proce""
Size and location of a feature are 3eter2ine3 4y a

dimension.
&eo2etric 3i2en"ioning an3 tolerancing (GDT)

"pecifie" engineering 3e"ign reAuire2ent" for
function an3 relation"hip" of part feature"$
Allowance i" the 2ini2u2 clearance "pace inten3e3

4et8een 2ating part" an3 repre"ent" the con3ition
of tighte"t po""i4le fit$
Fig 10-6 In the ideal situation, the process
would make all parts exactly the same size. In
the real world of manufacturing, parts hae
aria!ility in size. "he distri!ution of sizes is
often normal
.fter Material" an3 %roce""e" in Manufacturing# 4y E$
%aul )e&ar2o# J$T$ BlacC# an3 -onal3 .$ Doh"er#
%rentice Eall of In3ia# 2001$ 90ig$ 106>
Tolerance" 9.*!I :1;$5M 1<=2>5
. tolerance i" ?the total a2ount 4y 8hich a
"pecific 3i2en"ion i" per2itte3 to 'ary$ The
tolerance i" the 3ifference 4et8een the
2a@i2u2 an3 2ini2u2 li2it"?
Fariation" occur in any 2anufacturing proce""#

8hich are 2anife"te3 a" 'ariation" in part "i7e
Tolerance" are u"e3 to 3efine the li2it" of the

allo8e3 'ariation
Bilateral Tolerance
Fariation i" per2itte3 in
4oth po"iti'e an3
negati'e 3irection" fro2
the no2inal 3i2en"ion
%o""i4le for a 4ilateral

tolerance to 4e
un4alance3G for
e@a2ple# 2$500 H0$010#
60$005
0igure 5$1 Way" to "pecify
tolerance li2it" for a
no2inal 3i2en"ion of 2$5005
9a> 4ilateral
/nilateral Tolerance
Fariation fro2 the
"pecifie3 3i2en"ion i"
per2itte3 in only one
3irection
Either po"iti'e or
negati'e# 4ut not 4oth
94> unilateral
,i2it )i2en"ion"
%er2i""i4le 'ariation in
a part feature "i7e
con"i"t" of the
2a@i2u2 an3
2ini2u2 3i2en"ion"
allo8e3
9c> li2it 3i2en"ion"
C,.!!E! +0 0IT! 94a"e3 on .*!I>5

Cla""61$ Loose fit:

,arge allo8ance$ .ccuracy i" not e""ential$
Cla""62$ Free fit:

,i4eral allo8ance$ 0or running fit" 8here "pee3"
are a4o'e I00 rp2 an3 pre""ure" are I00 p"i
or a4o'e$
Cla""63$ Medium fit:

Me3iu2 allo8ance$ 0or running fit" 4elo8 I00
rp2 an3 pre""ure" 4elo8 I00 p"i an3 for
"li3ing fit"$
C,.!!E! +0 0IT! 94a"e3 on .*!I>5

Cla""6;$ Snug fit:

Jero allo8ance$ *o 2o'e2ent un3er loa3 i" inten3e3#
an3 no "haCing i" 8ante3$ Thi" i" the tighte"t fit that
can 4e a""e24le3 4y han3$
Cla""65$ Wringing fit:

Jero to negati'e allo8ance$ .""e24lie" are "electi'e
an3 not interchangea4le$
Cla""6I$ Tigt fit:

!light negati'e allo8ance$ .n interference fit for part"
that 2u"t not co2e apart in "er'ice an3 are not to
4e 3i"a""e24le3 only "el3o2$ ,ight pre""ure i"
reAuire3 for a""e24ly$ *ot to 4e u"e3 to 8ith"tan3
other than 'ery light loa3"$
C,.!!E! +0 0IT! 94a"e3 on .*!I>5

Cla""67$ Medium force fit:

.n interference fit reAuiring con"i3era4le pre""ure to
a""e24leG or3inarily a""e24le3 4y heating the
e@ternal 2e24er or cooling the internal 2e24er to
pro'i3e e@pan"ion or "hrinCage$ /"e3 for fa"tening
8heel"# cranC 3i"C"# an3 the liCe to "hafting$ The
tighte"t fit that "houl3 4e u"e3 on ca"t iron e@ternal
2e24er"$
Cla""6=$ !ea"# force and srin$ fits:

Con"i3era4le negati'e allo8ance$ /"e3 for per2anent
"hrinC on "teel 2e24er"$
The I!+ !y"te2 of ,i2it" 0IT!

Thi" "y"te2 i" con"i3era4ly 2ore co2ple@ than the

.*!I$
In thi" "y"te2 each part ha" a %asic size$ Each li2it

of "i7e of a part# high an3 lo8# i" 3efine3 4y it"
3e'iation fro2 the 4a"ic "i7e$
"here are three classes of fits# $1% clearance fits& $'%

transition fits $the assem!ly may hae either clearance or
interference%& and $(% interference fits. )ither a shaft- or
hole-basis system may !e used $fig 10-10%.
*.1.' +ther ,eometric -ttri!utes
Ta4le 5$1 )efinition" of &eo2etric .ttri4ute" of %art"
Angularit#. The e@tent to 8hich a part feature "uch a" a

"urface or a@i" i" at a "pecifie3 angle relati'e to a
reference "urface$ If the angle K <0
o
# then the attri4ute i"
calle3 perpen3icularity or "Auarene""$
&ircularit#. 0or "urface of re'olution "uch a" a cylin3er#

circular hole# or cone# circularity i" the 3egree to 8hich
all point" on the inter"ection of the "urface an3 a plane
perpen3icular to the a@i" of re'olution are eAui3i"tant
fro2 the a@i"$ 0or a "phere# circularity i" the 3egree to
8hich all point" on the inter"ection of the "urface an3 a
plane pa""ing through the center are eAui3i"tant fro2
the center$
&oncentricit#. The 3egree to 8hich any t8o 9or 2ore>
part feature"# "uch a" a cylin3rical "urface an3 a circular
hole ha'e a co22on a@i"$
&#lindricit#. The 3egree to 8hich all point" on a "urface
of re'olution "uch a" a cylin3er are eAui3i"tant fro2 the
a@i" of re'olution$
Flatness. The e@tent to 8hich all point" on a "urface lie
in a "ingle plane$
'arallelism. The 3egree to 8hich all point" on a part
feature# "uch a" a "urface# line# or a@i"# are eAui3i"tant
fro2 a reference plane or line or a@i"$
'er(endicularit#. The 3egree to 8hich all point" on a part
feature# "uch a" a "urface# line# or a@i"# are <0
o
fro2 a
reference plane or line or a@i"$
)oundness. !a2e a" circularity$
S*uareness. !a2e a" perpen3icularity$
Straigtness. The 3egree to 8hich a part
feature "uch a" a line or a@i" i" a "traight line$
Fig 10-1( $a% ,eometric tolerancing sym!ols
.fter Material" an3 %roce""e" in Manufacturing# 4y E$ %aul )e&ar2o# J$T$ BlacC# an3 -onal3
.$ Doh"er# %rentice Eall of In3ia# 2001$ 90ig$ 10613a>
Fig 10-1( $!% feature control sym!ols for part drawings& $c% example
of use of geometric tolerancing# form tolerancing for flatness
.fter Material" an3 %roce""e" in Manufacturing# 4y E$ %aul )e&ar2o# J$T$ BlacC# an3 -onal3 .$ Doh"er#
%rentice Eall of In3ia# 2001$ 90ig$ 106>
0igure 2;$3 !a2ple &)T 3ra8ing 9.fter %hillip 0$ +"t8al3# Jairo Muno7#
Manufacturing %roce""e" an3 !y"te2"# 1<<7# John Wiley !on">
)atu2
. datum i" the theoretically e@act point# plane#

or a@i" that i" the origin fro2 8hich the location
or geo2etric characteri"tic" of feature" of a
co2ponent are e"ta4li"he3$
0igure 2;$; .# %art 3e"ign$ B# %lane "urface"$ C# )# an3 E# )atu2
plane"$ 9.fter %hillip 0$ +"t8al3# Jairo Muno7# Manufacturing %roce""e" an3 !y"te2"# 1<<7# John Wiley
!on">
0i'e type" of geo2etric characteri"tic"5
. form tolerance gi'e" the allo8a4le an3 2a@i2u2

'ariation for an actual "urface or feature fro2 the
"pecifie3 for2 on the 3ra8ing$
. (rofile tolerance gi'e" the 2a@i2u2 'ariation of an

actual "urface or feature fro2 the 3e"ire3 for2 or 3atu2#
a" in3icate3 on the 3ra8ing$
.n orientation "tate" ho8 far an actual "urface or feature

i" per2itte3 to 'ary relati'e to a 3atu2$
)unout i" the per2itte3 'ariation of the actual "urface

fro2 the 3e"ire3 for2 3uring full 3I0L rotation of the part
on a 3atu2 a@i"$
. location tolerance gi'e" the 2a@i2u2 'ariation of an

actual "i7e feature fro2 the perfect location i2plie3 4y
the 3ra8ing$
0igure 2;$I E@tre2e 'ariation" of for2 allo8e3
4y a "i7e tolerance$ .# !haft$ B# Eole$ 9.fter %hillip 0$
+"t8al3# Jairo Muno7# Manufacturing %roce""e" an3 !y"te2"# 1<<7# John Wiley !on">
0igure 2;$7 Tolerancing an angular "urface u"ing a
co24ination of linear an3 angular 3i2en"ion"$ 9.fter %hillip 0$
+"t8al3# Jairo Muno7# Manufacturing %roce""e" an3 !y"te2"# 1<<7# John Wiley !on">
0igure 2;$12 !pecifying flatne""$ 9.fter %hillip 0$ +"t8al3# Jairo
Muno7# Manufacturing %roce""e" an3 !y"te2"# 1<<7# John Wiley !on">
0igure 2;$13
!pecifying cylin3ricity$ 9.fter %hillip 0$ +"t8al3# Jairo Muno7# Manufacturing
%roce""e" an3 !y"te2"# 1<<7# John Wiley !on">
0igure 2;$15
!pecifying paralleli"2 for a plane "urface 9.fter %hillip
0$ +"t8al3# Jairo Muno7# Manufacturing %roce""e" an3 !y"te2"# 1<<7# John Wiley !on">
0igure 2;$1I
!pecifying perpen3icularity for a plane "urface$
9.fter %hillip 0$ +"t8al3# Jairo Muno7# Manufacturing %roce""e" an3 !y"te2"# 1<<7# John Wiley !on">
0igure 2;$17 !pecifying circular runout relati'e
to 3atu2 3ia2eter$ 9.fter %hillip 0$ +"t8al3# Jairo Muno7# Manufacturing %roce""e"
an3 !y"te2"# 1<<7# John Wiley !on">
0igure 2;$1=
!pecifying total runout relati'e to 3atu2 3ia2eter$ 9.fter
%hillip 0$ +"t8al3# Jairo Muno7# Manufacturing %roce""e" an3 !y"te2"# 1<<7# John Wiley !on">
!urface"
+ominal surface 3e"ignerM" inten3e3 "urface
contour of part# 3efine3 4y line" in the
engineering 3ra8ing
The no2inal "urface" appear a"

a4"olutely "traight line"# i3eal circle"#
roun3 hole"# an3 other e3ge" an3
"urface" that are geo2etrically perfect
.ctual "urface" of a part are 3eter2ine3 4y

the 2anufacturing proce""e" u"e3 to 2aCe it
Fariety of proce""e" re"ult in 8i3e

'ariation" in "urface characteri"tic"
Co22ercial an3 technological
I2portance
,. Aestetic reason
-. Surfaces affect safet#
.. Friction and wear
/. 0ffect on Mecanical and '#sical (ro(erties
(e.g. surface flaws can %e (oints of stress
concentration)
1. Affect on assem%l# of (arts (strengt of
adesi"el# %onded 2oints is increased for
sligtl# roug surfaces)
3. Smoot surfaces ma$e %etter electrical
contacts.
!urface Technology
,. Defining te caracteristics of a surface
-. Surfaces te4ture
.. Surfaces 5ntegrit#
/. Te relationsi( %etween manufacturing
(rocess and te caracteristics of te
resulting surface.
CE.-.CTE-I!TIC! +0 !/-0.CE!
0igure 5$2 . 2agnifie3 cro"" "ection of a typical 2etallic part
"urface$
Substrate:
5t is te %ul$ of te (art
as a grain structure tat de(ends on
(re"ious (rocessing of te metal6 e.g.
affect %# cemical com(osition7
te casting (rocess originall# used on te
metal7
an# deformation o(erations
eat treatments (erformed on te casting.
Altered Layer:
8ust %elow te surface is a la#er of metal
wose structure differs from tat of te
su%strate.
it is a manifestation of te actions u(on te
surface during its creation and afterward.
affected %# te a((lication of energ#7 wic
accordingl# alteres its microstructure.
Ma# result from:
wor$ ardening (mecanical energ#)7
eating (termal energ#)7
cemical treatment7 or e"en
electrical energ#.
!/-0.CE TENT/-E
5t consists of te re(etiti"e and9or random
de"iations from te nominal surface of an
o%2ect6
defined %# four features:
rougness7
wa"iness7
la#7 and
flaws
!urface Te@ture
0igure 5$3 !urface$ Te@ture feature"
!urface Te@ture
0igure 5$; %o""i4le lay" of a "urface
!urface -oughne""
.'erage of 'ertical 3e'iation" fro2 no2inal
"urface o'er a "pecifie3 "urface length
0igure 5$5 )e'iation" fro2 no2inal "urface u"e3 in the t8o
3efinition" of "urface roughne""$
!urface -oughne"" EAuation
The a'erage of the 'ertical 3e'iation" fro2 the
no2inal "urface o'er a "pecifie3 "urface
length$
.rith2etic a'erage 9..> 4a"e3 on a4"olute
'alue" of 3e'iation"# i" referre3 to a" a"erage
rougness
8here )
a
K a'erage roughne""G # K 'ertical
3e'iation fro2 no2inal "urface 9a4"olute
'alue>G an3 L
m
K "pecifie3 3i"tance o'er 8hich
the "urface 3e'iation" are 2ea"ure3
.lternati'e !urface -oughne"" EAuation
.ppro@i2ation of pre'iou" eAuation i" perhap"

ea"ier to co2prehen3
8here )
a
ha" the "a2e 2eaning a" a4o'eG #
i
K
'ertical 3e'iation" 9a4"olute 'alue> i3entifie3 4y
"u4"cript iG an3 n K nu24er of 3e'iation"
inclu3e3 in L
m
!urface -oughne"" )eficiencie"
!urface roughne"" "uffer" the "a2e Cin3" of
3eficiencie" of any "ingle 2ea"ure u"e3 to
a""e"" a co2ple@ phy"ical attri4ute$ e$g$
it fail" to account for the lay of the "urface

pattern$
Wa'ine"" can 4e inclu3e3 in )
a
co2putation$
To 3eal 8ith thi" pro4le2 a para2eter calle3

cutoff length i" u"e3$
Cutoff length i" a "a2pling 3i"tance along

the "urface# "horter than the 8a'ine""
8i3th$ 9co22on length u"e3 i" 0$= 22>
!urface -oughne"" !pecification
0igure 5$I !urface te@ture "y24ol" in engineering
3ra8ing"5 9a> the "y24ol# an3 94> "y24ol 8ith
i3entification la4el"$
!urface Integrity
It i" the "tu3y an3 control of 2etallurgical or

other change" in the 2aterial of the "u4"urface
layer 9altere3 layer if "tructure 3iffer" fro2 the
"u4"trate> an3 any change" in it 3ue to
proce""ing that 2ay influence the perfor2ance
of the fini"he3 part$
!urface Change" Cau"e3 4y %roce""ing
!urface change" are cau"e3 4y the application

of 'ariou" for2" of energy 3uring proce""ing
E@a2ple5 Mechanical energy i" the 2o"t

co22on for2 in 2anufacturing
%roce""e" inclu3e forging# e@tru"ion#

an3 2achining
.lthough it" pri2ary function i" to change

geo2etry of 8orC part# 2echanical energy
can al"o cau"e re"i3ual "tre""e"# 8orC
har3ening# an3 cracC" in the "urface layer"
Effect of Manufacturing %roce""e"
Tolerance" an3 2anufacturing proce""e"$
!urface" an3 2anufacturing proce""e"$

Tolerance" an3 Manufacturing %roce""e"
!urface" an3 Manufacturing %roce""e"

Manufacturing Lecture

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Manufacturing Lecture

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Manufacturing Technology I

0actor" that 3eter2ine the perfor2ance of a

)i2en"ion" 6 linear or angular "i7e" of a

Tolerance" 6 allo8a4le 'ariation" fro2 the

)i2en"ion" on part 3ra8ing" repre"ent no2inal

The 3i2en"ion in3icate" the part "i7e 3e"ire3 4y

Size and location of a feature are 3eter2ine3 4y a

&eo2etric 3i2en"ioning an3 tolerancing (GDT)

Allowance i" the 2ini2u2 clearance "pace inten3e3

Fariation" occur in any 2anufacturing proce""#

Tolerance" are u"e3 to 3efine the li2it" of the

%o""i4le for a 4ilateral

Cla""61$ Loose fit:

Cla""62$ Free fit:

Cla""63$ Medium fit:

Cla""6;$ Snug fit:

Cla""65$ Wringing fit:

Cla""6I$ Tigt fit:

Cla""67$ Medium force fit:

Cla""6=$ !ea"# force and srin$ fits:

Thi" "y"te2 i" con"i3era4ly 2ore co2ple@ than the

In thi" "y"te2 each part ha" a %asic size$ Each li2it

"here are three classes of fits# $1% clearance fits& $'%

Angularit#. The e@tent to 8hich a part feature "uch a" a

&ircularit#. 0or "urface of re'olution "uch a" a cylin3er#

. datum i" the theoretically e@act point# plane#

. form tolerance gi'e" the allo8a4le an3 2a@i2u2

. (rofile tolerance gi'e" the 2a@i2u2 'ariation of an

.n orientation "tate" ho8 far an actual "urface or feature

)unout i" the per2itte3 'ariation of the actual "urface

. location tolerance gi'e" the 2a@i2u2 'ariation of an

The no2inal "urface" appear a"

.ctual "urface" of a part are 3eter2ine3 4y

Fariety of proce""e" re"ult in 8i3e

.ppro@i2ation of pre'iou" eAuation i" perhap"

it fail" to account for the lay of the "urface

To 3eal 8ith thi" pro4le2 a para2eter calle3

Cutoff length i" a "a2pling 3i"tance along

It i" the "tu3y an3 control of 2etallurgical or

!urface change" are cau"e3 4y the application

E@a2ple5 Mechanical energy i" the 2o"t

%roce""e" inclu3e forging# e@tru"ion#

.lthough it" pri2ary function i" to change

Tolerance" an3 2anufacturing proce""e"$

!urface" an3 2anufacturing proce""e"$

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