INTRODUCTION

• No two parts can be produced with identical measurements by

any

manufacturing process.

• In any production process, regardless of how well it is designed or how carefully

it is maintained, a certain amount of variation (natural) will always exist.

 INTRODUCTION

Variations arises from;

• Improperly adjusted machines

• Operator error

• Tool wear

• Defective raw materials etc.

Such variations are referred as ‘assignable causes’ and can be identified

and controlled.
 INTRODUCTION

• It is impossible to produce a part to an exact size or basic size,

some

variations, known as tolerances, need to be allowed.

• The permissible level of tolerance depends on the functional

requirements, which cannot be compromised.

 INTRODUCTION

• No component can be manufactured precisely to a given dimension; it can only

be made to lie between two limits, upper (maximum) and lower (minimum).

• Designer has to suggest these tolerance limits to ensure satisfactory operation.

• The difference between the upper and lower limits is termed

permissive

tolerance.
 INTRODUCTION

Example

Shaft has to be manufactured to a diameter of 40 ± 0.02 mm.

The shaft has a basic size of 40 mm.

It will be acceptable if its diameter lies between the limits of sizes.

Upper limit of 40+0.02 = 40.02 mm

Lower limit of 40-0.02 = 39.98 mm.

Then, permissive tolerance is equal to 40.02 − 39.98 = 0.04 mm.

 Need of Limit, Fits and Tolerances

Mass Production And Specialization

Standardization
Interchangeability
 Tolerance
s

• To satisfy the ever-increasing demand for accuracy.

• Parts have to be produced with less dimensional variation.

• It is essential for the manufacturer to have an in-depth knowledge of

the tolerances to manufacture parts economically, adhere to quality and reliability

• To achieve an increased compatibility between mating parts.

 Tolerance
s

• The algebraic difference between the upper and lower acceptable dimensions.

• It is an absolute value.

• The basic purpose of providing tolerances is to permit dimensional variations in

the manufacture of components, adhering to the performance criterion.

 Tolerances
Classification of Tolerance

1. Unilateral tolerance

2. Bilateral tolerance

3. Compound tolerance

4. Geometric tolerance
 Tolerance
s
Classification of Tolerance
1. Unilateral tolerance

• When the tolerance distribution is only on one side of the basic size.
Either positive or negative, but not both.

Tolerances (a) Unilateral (b) Bilateral

1. Unilateral tolerance: Below zero line: Negative
1. Unilateral tolerance: Above zero line: Positive
2. Bilateral tolerance
When the tolerance distribution lies on either side of the basic size.

• It is not necessary that Zero line will divide the tolerance zone equally on both sides.
• It may be equal or unequal
 Classification of Tolerance

3. Compound tolerance

Tolerance for the dimension R is

determined by the combined effects of

tolerance on 40 mm dimension, on 60o, and

on 20 mm dimension
 Classification of Tolerance
4. Geometric tolerance

Geometric dimensioning and tolerancing (GD&T) is a method of defining

parts based on how they function, using standard symbols.

 Classification of Tolerance
4. Geometric tolerance

• Diameters of the cylinders need be concentric with each other.

• For proper fit between the two cylinders, both the centres to be in line.
• This information is represented in the feature control frame.
• Feature control frame comprises three boxes.
 Classification of Tolerance

4. Geometric tolerance

• First box: On the left indicates the feature to be controlled,

represented symbolically (example: concentricity).
• Centre box: indicates distance between the two cylinders, centres cannot be
apart by more than 0.01 mm (Tolerance).
• Third box: Indicates that the datum is with X.
 MAXIMUM AND MINIMUM METAL CONDITIONS

Consider a shaft having a dimension of 40 ± 0.05 mm and Hole having a dimension of 45 ± 0.05
mm.

For Shaft
Maximum metal limit (MML) = 40.05 mm
Least metal limit (LML) = 39.95 mm

For Hole
Maximum metal limit (MML) = 44.95 mm
Least metal limit (LML) = 45.05 mm
 FITS
The Assembly of Two Mating Parts is called Fit.
 RUNNING FIT: One part assembled into other so as to allow motion eg.
Shaft in bearing
 PUSH FIT : One part is assembled into other with light hand pressure & no
clearance to allow shaft to rotate as in locating plugs.
 DRIVING FIT : One part is assembled into other with hand hammer or
medium pressure. Eg pulley fitted on shaft with a key
 FORCE FIT: One part is assembled into other with great pressure eg. Cart
wheels, railway wheels
 FITS

• The degree of tightness and or looseness between the two mating parts.

Three basic types of fits can be identified, depending on the actual limits of the
hole or shaft.

1. Clearance fit

2. Interference fit

3. Transition fit
 FITS

1. Clearance fit Upper limit of shaft is less than the lower limit of the hole.

The largest permissible dia. of the shaft is smaller than the dia. of the smallest hole.
E.g.: Shaft rotating in a bush
 FITS
2. Interference fit Upper limit of the hole is less than the lower limit of shaft.

• No gap between the faces and intersecting of material will

occur.
• Shaft need additional force to fit into the hole.
 3. Transition fit
Dia. of the largest permissible hole is greater than the dia. of the smallest
shaft.

• Neither loose nor tight like clearance fit and interference fit.
• Tolerance zones of the shaft and the hole will be overlapped between the interference and
clearance fits.
 FITS
Detailed classification of Fits
Interchangeability:
Interchangeability occurs when one part in an assembly can be substituted for a similar
part which has been made to the same drawing. Interchangeability is possible only when
certain standards are strictly followed.
Universal interchangeability means the parts to be assembled are from two different
manufacturing sources.
Local interchangeability means all the parts to be assembled are made in the same
manufacturing unit.
Selective Assembly:
In selective assembly, the parts are graded according to the size and only matched grades
of mating parts are assembled. This technique is most suitable where close fit of two
components assembled is required.
Selective assembly provides complete protection against non-conforming assemblies and
reduces machining costs as close tolerances can be maintained.
Suppose some parts (shafts & holes) are manufactured to a tolerance of 0.01 mm, then
an automatic gauge can separate them into ten different groups of 0.001 mm limit
for selective assembly of the individual parts. Thus high quality and low cost can be
achieved.
Selective assembly is used in aircraft, automobile industries where tolerances are very
narrow and not possible to manufacture at reasonable costs.
 Hole Basis and Shaft Basis Systems

• To obtain the desired class of fits, either the size of the hole or the size of the
shaft must vary.

Two types of systems are used to represent three basic types of fits, clearance,

interference, and transition fits.

(a) Hole basis system

(b) Shaft basis system.

 Hole Basis systems

• The size of the hole is kept constant and the shaft size is varied to
give

various types of fits.

• Lower deviation of the hole is zero, i.e. the lower limit of the hole is same as

the basic size.

• Two limits of the shaft and the higher dimension of the hole are varied

to obtain the desired type of fit.

 Hole Basis systems

(a) Clearance fit (b) Transition fit (c) Interference fit

 Hole Basis systems

This system is widely adopted in industries, easier to manufacture shafts

of

varying sizes to the required tolerances.

Standard-size plug gauges are used to check hole sizes accurately.

 Shaft Basis systems

• The size of the shaft is kept constant and the hole size is varied to
obtain

various types of fits.

• Fundamental deviation or the upper deviation of the shaft is zero.

• System is not preferred in industries, as it requires more number of standard-

size tools, like reamers, broaches, and gauges, increases manufacturing and

inspection costs.
 Shaft Basis systems

(a) Clearance fit (b) Transition fit (c) Interference fit

 No-Go gauge
Go-gauge
 Difference between angle gauge and slip gauge
Angle gauge Slip gauge

Angle gauges are made of hardened steel, Slip gauge is a height standard used with
which is lapped and polished to a high sine bar. Slip gauges are available in three
degree of accuracy and flatness. basic shapes: rectangular, square with a
central hole, and square without a central
hole.
The gauges are about 75 mm long and 15 The slip gauges are held together due to
mm wide, and the two surfaces molecular adhesion between a liquid film
that generate the angles are accurate up to and the mating surfaces. This phenomenon
±2" is known as ‘wringing’.
 How angle is measured using clinometer

A Clinometer is a special case of application of spirit level,

in which it is mounted on a rotary member carried on
housing. A semicircular scale is used to measure the angle
of inclination of the rotary member carrying the spirit level
relative to its base. Clinometer is mainly used to measure
the included angle between two adjacent faces of the
workpiece.
The Clinometer is first placed on one face of the workpiece
and the rotary member is adjusted till the bubble is exactly
at the center of the spirit level. The included angle is then
the difference between the two readings.
i.e. from fig, g=180-(+).
Clinometers are used for checking face & relief angles on
large cutting tools & milling cutter inserts. Also they are
used for setting jig boring machine tables & angular work
TWO WIRE METHOD
Thread gauge micrometer
- It is used for accurate measurement of pitch diameter of screw threads. The micrometer has a pointed
spindle and a double V-anvil, both correctly shaped to contact the screw thread of the work being gauged.
- It directly reads in terms of pitch diameter as the zero reading of the micrometer corresponds to the closed
position of anvil and spindle when both are in perfect match with each other.
Measurement of Minor Diameter (Floating Carriage Micrometer):
- Floating carriage micrometer is used to measure the minor diameter. It is suitable for almost all kinds of
threads.

- The V-piece is available in various sizes having suitable radii at the edge. The standard is kept between the
micrometer anvils with the help of V- pieces as shown in Figure. The indicator anvil is used to maintain the
same constant pressure at the time of measurement.

- The diameter of standard cylinder is known to us and the reading is taken for the Vpieces in position as r 1.
Now without changing the position of indicator anvil, the standard cylinder is replaced by screw. The reading
is now taken for the screw thread in position as r1. If d is the minor diameter of a screw thread then the value
of d can be calculated as,

Minor dia. d = (diameter of standard cylinder) ±

(difference between the readings)
d = d1 ± (r2 – r1)