System of Limits, Fits, Tolerance and Gauging: Definitions, Tolerance, Tolerance analysis (addition & subtraction of tolerances) Interchangeability & Selective assembly. Class & grade of tolerance, Fits, Types of fits, Numerical on limits, fit and tolerance. Hole base system & shaft base system, Taylor's principle, Types of mit gauges, Numerical on limit gauge design.+ No two parts can be produced with identical measurements by any manufacturing process. + In any production process, regardless of how well its designed or how caretully its maintained, a certain amount of variation (natural) will aways exist.Variations arises trom; + Improperly adjusted machines + Operator error + Too! wear + Detective raw materials etc. Such variations are referred as ‘assignable causes’ and can be identified and controlled,+ 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.+ No component can be manufactured precisely to a given dimension; it can only be made to ie between two limits, upper (maximum) and lover (minimum) + Designer has to suggest these tolerance limits to ensure satistactory operation. + The difference between the upper and lower limits is termed permissive tolerance.Shaft has to be manufactured to a diameter of 40 + 0.02 mm. The shaft has a basic size of 40 mm, ‘twill 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.To satisty the ever-increasing demand for accuracy. Parts have to be produced with less dimensional variation. {t 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 compatibiity between mating parts.+ The algebraic dference between the upper and lower acceptable dimensions. + Itis an absolute value + The basic purpose of providing tolerances is fo permit dimensional verations in the manufacture of components, adhering to the performance erterion,s 5 _ SAGAN Us Z/ PFTolerances ‘Manufacturing Cost and Work Tolerance Tolerance is a trade-off between the economical production and the accuracy required for proper functioning of the product Maiifectiring cost ‘Work tolerance Relationship bowlzen werk tolerance and manufacturing costTolerances Classification of Tolerance Unilateral tolerance Bilateral tolerance Compound tolerance Geometric toleranceTolerances Classification of Tolerance 1, Unilateral tolerance + When the tolerance distribution is only on one side of the basic size. Either postive or negative, but not both. Basic size 40mm a 0 Tolorancos (a) Uniatoral(b) BilatoralTolerance ane Unilateral tolerance: Below zero line: Negative‘Tolerance |. Unilateral tolerance: Below zero line: Negative2, Bilateral tolerance ‘When the tolerance distrioution lies on either side of the basic size, + ts nt naessary thal Zao ine il vite erance zone equa n bt sds. + maybe equal ot uresClassitication of Tolerance 3. Compound tolerance R ,4+ Tolerance for the dimension A is determined by the combined effects of 20 201 wer tolerance on 40. mm dimension, on 60%, and ‘on 20 mm dimension 2000Classification of Tolerance 4. Geometric tolerance Geometric dimensioning and tolerancing (GD&T) is a method of detining parts based on how they function, using standard symbols.Classification of Tolerance 4. Geometric tolerance Fea coe fame soho 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 contral frame. Feature control frame comprises three boxes.Classification of Tolerance 4, Geometric tolerance Feature cont Set * First box: On the lett indicates the feature to be controlled, represented symbolically (example: concentriciy). * 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.‘oerance ‘Symbolic representation of geomet tolerances pedtgrmiic Geometric Definion Syme Conds ott daiionl ft fren a ne Enucos contl on extn oon oa feane ton apertectcce ie Contrast tert of ceviation ofa feature [J from a fatlre Contr tw otek dvi ol aftr from a poet jd Cont bw otet dion a ono «a feae om te ue pate baited eames 7 ‘arace fa be role‘Symbolic representation of geometric tolerances Perpencicuaty Exercises contcl onthe anton of deviation of « (three-dimensicra) sutac, ais, cr plano fom a 90" angle Perailism (ree Cons he extent cf deviation of a surface, imensional) ‘axis, oF plane from an orientation parallel to the specfied dum ‘Arguary tee: Exercises contels on the devatin ofa sutace, mensional) axis, or plane fem the angle desrba in the design specications Lt VATolerances + The algetrac dilereice hetween the upice and ower accoptabie dimetsarne, Whig an abeciute vetue. + The basic pumase of providing tderandes is ta peered dimension variation in the manulocture of eomponents, adhering ta fe performance criterionInterchangeability Manufacturing a large number of parts, it is not economical to produce both the mating parts by the same operator. Parts to be manufactured within min. possibie time without compromising on quality. To manutacture identical parts; mass production was the idea, The components are manufactured in one or more batches by different persons on different machines at different locations and are assembled at one place. Manutacture of parts under such condftions is called interchangeable manufactureInterchangeability Interchangeability: Any one component selected at random should assemble with any other arbitrarily chosen mating component. Condition Identical components, manufactured by diferent operators, using different machine tools and under different environmental conditions, can be assembled and replaced without any further modification during the assembly, without affecting the functioning of the component when assembled.Selective Assembly In selective assembly the parts produced are classified into groups according to their size / dimensions by automatic gauging. Bath the mating parts are segregated according to thelr sizes, and matched with the groups of mating parts are assembled. This ensures protection and elimination of defective assemblies. Assay. costs are reduced, as the parts are produced with wider tolerances.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 La MM For Hole Maximum metal mit (MML) = 44.95 mm Least metal limit (LML) = 45.05 mm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FITS 1, Clearance fit Upper limit of shaft is less than the lower limit of the hole. ‘The largest permissible dia. ofthe shaft is smaller than the dia. of the smallest hole. Eg.: Shaft rotating in a bushFITS 2. Interference fit Upper limit of the hole is less than the lower limit of shaft. Misra [ Maxnterference Alin nterfronce + No gap between the faces and intersecting of material will ocour. + Shaft need additional force to fitinto the hole.3. Transition fit Dia of the largest permissible hole is greater than the cia ofthe smallest shat ame Fanene f CILIA} mn + Neither loose no ight ike clearance fit and inerterence ft. + Tobrance zones of the shait and the hole wil be overlapped between the interference and clearance fitsFITS Detailed classification of Fits Fits | ‘ \ Clearance ‘Transition Inerference | i | Side Pash or sug Force or press Easy slide Woinging Driving Running Tight Slack running Shrink Loose runing FreezeFIs, ‘Applications Seager ml gua ne ea hts ate et lt it es “aan ihe pene mn et kad wan dg Loon ples nrg wih etnFITS Applications Description of fit Class of fit Application area Side Ths Easy slide HIT uring are Slock ning Hilt Loeseruming HB hearance fit Sealng ings, baring covers, movable gear in change ear ras, ciches, te, Lat sind, sigals, piston and devas Lubricated boarings (wth lr grease), pumps and sale ctors, gearboxes, sa pays, ee, Gil sels wth metal housings, mul pie shes, etc. Loose pulleys ase earings with ow evliton et.Foe o press Tht ‘ivi FITS Applications ‘Interference ft Hone Crankpin, car wheel aves, bearing bushes in casings, etc, HTis6 lugcr shaft ight larger than the hole Hrs ‘Stepped pulleys onthe dive sft of 9 conayor HTA6, Hu” Bronze crowns on worm wheel hubs, cousins, gear wheels, and assem of piston in In ICengine piston HTB, Hlu7 Insertion of exhaust valve seat inserts in engine cylinder locks and insertion of brass bushes in various assemblesFITS Application of FitsTolerance Grade Tolerance grades indicates the degree of accuracy of manufacture. 1S:18 grades of fundamental tolerances are availabe Designated by the letters IT followed by 2 number. The ISO system provides tolerance grades from T01, !T0, and |T1 to IT16. Tolerance values corresponding to grades ITS ~ T16 are datermined using the standard tolerance unit (in um), which is afunaion of basi size.Tolerance Grade i=0453YD +0.001D microns D = diameter of the part in mm. 0.0010 =Linear factor counteracts the effect of measuring inaccuracies. Value of tolerance unit ‘i’ is obtained for sizes up to 500 mm. Dis the geometric mean of the lower and upper diameters. De (Dy. X DoanTolerance Grade Standard tolerance units Tolerance grade M6 M7 MB TQ THO Arata THB ITH4 TS ITH: ‘Standard tolerance unit() 10 16 25 40 G4 © 100 160 250 400 640 1000Fundamental tolerance sToN-ITs is.117 mrerit maar ITtSIT16 Tolerances grades for applications ‘Applications: Fer preducton of gauges pup gauges, and measuring instruments, Fer fitsin precision engineering epiications such as bal beatngs, qincng fv bring, high-qualty turing. and broaching For general engineering, namely turing, boring, miling,plarring, roling, exusion, ding, and recion ibe drawing Fer sheet metal working press working Fer processes such as casting, stamping, rubber moulng, general cating work, and ame cutingGeneral Terminology ‘Lower deviation Tolerance ' Tolera Upper deviation Lower deviation ‘Upper deviation zero line andGeneral Terminology Basic size: Exact theoretical size arrived at by design. Also called as nominal size. Actual size: Size of a part as found by measurement Zero Line: Straight line corresponding to the basic size. Deviations are measured from this line. Limits of size: Maximum and minimum permissible sizes for a specific dimension. Tolerance: Difference between the maximum and minimum limits of size. Allowan' H-HLSGeneral Terminology Deviation: Algebraic difference between a size and its corresponding basic size. It may be positive, negative, or zero. Upper deviation: Algebraic difference between the maximum limit of size and its corresponding basic size. Designated as 'ES' for a hole and as ‘es' for a shatt. Lower deviation: Algebraic difference between the minimum limit of size and its corresponding basic size. Designated as ‘E!’ for a hole and as ‘ei’ for a shaft.General Terminology + Actual deviation: Algebraic difference between the actual size and its corresponding basic size. + Tolerance Zone: Zone between the maximum and minimum limit size.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, interfetence, and transition fits. (a) Hole basis system (b) Shatt basis systemHole Basis systems + The size of the hole is kept constant and the shatt 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.LEILA, CLL ss rus = @ ® @ (2) Clearance i ()Tanstion (reference mtHole Basis systems es . 4 Ze LLL 3 wherance Zero line @ o © 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.‘Shalt Basis systems ‘The size of the shat is kept constant an the hole size is varied to obtain various types ofits. Fundamental deviation or he upper deviation ofthe shits 2210, ‘System isnot prefered in ncusties, asi requires more numberof stand size too, ke reamor, broaches, and gauges, increases manufactuing and inspection costs‘Shaft Basis systems )charanc ng) anaon (aeons‘Numerical Examples 1. Ina tint syst, te folowing limits are spect fora hole and shaft assembly Hole = 30 mm and shalt= 30 me, Determine the (a) tolerance and () allowance,Solution (2) Deteminaton of tolerance Tolerance oa hole = HLH ~ LLAt =3002- 3000=002mm ‘Tolerance on shaft = HLS ~ LLS (0 002)~ 40-005) = 0.05 () Determination of allowance: “Allowance = Maximum metal combiion of foe ~ Maximo metal contin of shaft SUH HLS‘Tolerance symbols, Used to spect the tolerance anit for mating components, Example: Consider the designation 40 H79 Basic size ofthe shat and hoe = 40 mm. Nature of fttor the hole bass systom is dosignated by H Fundamental deviation othe leis 280. Teerance grado: 17 ‘Tha shalthas a-ype fl the fundamental dovaton has a nogabve value, To werance grade‘Tolerance symbols, Used to spect the tolerance anit for mating components, Example: Consider the designation 40 H79 Basic size ofthe shat and hoe = 40 mm. Nature of fttor the hole bass systom is dosignated by H Fundamental deviation othe leis 280. Teerance grado: 17 ‘Tha shalthas a-ype fl the fundamental dovaton has a nogabve value, To werance grade‘Tolerance symbols, + First eight designations trom A (a) fo H (n) for holes (shafts) are used for oars tk + Designations, JS (js) to 26 (2c for holes (shat), aroused fr intrlrance or transton ts‘Tolerance symbols, Furcamental Deviation: Daviaon either the upper or lower deviation, nearest othe 201. (provides th positon ofthe tleranco 2079). ltmay be postive, negative oF zo Upper dovation: Designated as fora Hole and ase fora sat Lowor dovatin: Designated as I jor a Hole ard as for ashatTolerance Grade BIS: 18 grades of fundamental tolorances re avalabe Dosignated by the lots IT ollowed by a number. ISOWGIS: 1701, Ifo, ane IT w 96, Tolerance valves coresponding to grades ITS ~ (716 are determined using the Stand tolerance unit (in wn)Tolerance Grade 453 +0.001D microns Tolerance unit, =| +0 Jamoter ofthe partin mm + 0.0010 ~ Linear factor counteracts the oft of measuring Iaecuraces. + Value of tolerance units obtained for sizes up 1 500 mm + Os the goomevio mean athe lower and upper diameters.Tolerance Grade De Pm ¥ Onn “The various stops spect for the damter stop are as follows + 123,346, 610, 10-18, 16-90, 30-50, 50-80, 80-120 + 120-180, 189-260, 250-318, 318-40, 400-800 + 500-630, 63-800, ae 800-1000 mmTolerance Grade ‘Standard elorance uns Tolerance grade Me m7 me mo mo mt Me ris mM ms He Standariolranceunt() 0 16 25 40 Bt 100 0 250 400 BAO 1000‘Numerical Examples of olerance and lowance for @ 25 mm shat and hole pk esignated by HE,GAUGES * Gauges perform an essential services in any scheme of quantity production on an interchangeable basis * A gauge (or Limit Gauge) is a tool or instrument to measure or compare a component. * It is employed in the sense of an instrument which having fixed dimension, is used to determine whether the size of some component exceeds or is less than the size of the gauge itselfGAUGES Cont.» « Gauges are used for dimensional control of the component parts , their function being to establish whether or not surface levels lie within the zone specified by the designer. + Gauges must be manufactured & checked with reference to standard of length, which in turn is related to a fundamental length standard. The standard of length is then transferred through the gauge to the component ooGAUGES on.) « The true value of a gauge is measured by its accuracy & service life which, in turn, depends on the workmanship & materials used in its manufacture. Since all gauges are continually subject to abrasive wear while in use, the selection of the proper material is of great importance + High carbon steel & alloy tool steels have been the principal materials for manufacture of such gauges eeAdvantages of gauging:- me Faster checking regarding whether product is within its specified imit or not can be done. Less dependence on operator skill and hence resuk are not getting affected by operator judgment. More than one dimension of product can be checked at a time as well as properties such as roundness, taper etc. as can be checked at atime. Gauges are economical then measuring instruments.Limitations of limit gauges:- a Exact value of product dimension can not be known. Accuracy of gauges is geting affected due to wear and tear with passage of time. Itis useful only for similar product because its difficult to manufacture and maintain large size ‘gauges.Instruments used for gauging:- SSS ‘Snap and ring gauge. Combined gauge. Plug gauge. Radius gauge. Filler gauge. © Screw pitch gauge. © Template and form gauge. » Taper gauge.Classification of limit gauge.Standard gauges + If the gauge is an exact copy of mating part of the component to be checked, it is called standard gauges Limit gauges Widely used for checking the limit of dimensions of part, ie low limit and high limit. They are known as GO -gauge and NO-GO gaugeLimit gauge Used widely in industries For two permissible limits of the dimension of a part Two gauges are required for two limits These are GO and NO GO gauges GO gauge foe MML NO GO for LMLLimit Gauge + Limit gauges are made to the limits of the dimensions of the part to be tested, There are two limit of dimensions, so we need two limit gauge. + ‘Go gauge’ should pass through or over a part while ‘Not Go gauge ‘should not pass through or over the partLimit gauges i ea fl t yes tnt cs4) Limit gauges teLimit Plug Gauge Used for checking holes Check whether hole dimension is wi specitied tolerance G0-plug gauge check the lower limit of Hole NO-GO gauge check the upper limit of HoleNOR ene Types of limit plug gauges Solid type Renewable type — taper inserted type Fastened type — single, double ended Flat type Progressive type Pilot plug gauge Combined dual purpose typeSolid type Double End Cylindrical Plug gaugeFastened type limit plug gauge e%~ aProgressive typeFlat typePilot type plug gaugeSnap and ring gauge. SS The gauge used to check eternal details of the product such as diameter of a shaft, thickness of block etc. it is called snap and ring gauge. Snap gauge is used for cylindrical as well as non-cylindrical workpieces whereas ring gauge is used only for cylindrical work-pieces.. © Go member of snap / ring gauge will have imension equal to higher limit of shaft and not ‘go member will have dimension equal to lower limit ofthe shaft diameterSnap Gauge Used for gauge shaft Used for both cylindrical as well as non cylindrical parts GO snap gauge is the size corresponds to higher limit of shaft NO-GO snap gauge is the size corresponds to lower limit of shaftSnap gauges Double ended progressiveSnap gauge — Double endedSnap gauge AdjustableAdjustable gap gaugesRing gaugeTAPER GAUGE + The most satisfactory method of testing a taper is to use taper gauges. * They are also used to gauge the diameter of the taper at some point. + Taper gauges are made in both the plug and ring styles and, in general, follow the same standard construction as plug and ring gauges.Taper plug gaugeTAPER GAUGEPlug gaugeTHREAD GAUGE Thread gauges are used to check the pitch diameter of the thread, For checking internal threads (nut, bushes, etc.), plug thread gauges are used, while for checking external threads (screws, bolts, etc.), ring thread gauges are used. Single-piece thread gauges serve for measuring small diameters. For large diameters the gauges are made with removable plugs machined with a tang.Threaded Spline (eTHREAD GAUGEae vy LW).RADIUS AND FILLET GAUGE * The function of these gauges is to check the radius of curvature of convex and concave surfaces over a range from 1 to 25 mm. + The gauges are made in sets of thin plates curved to different radius at the ends. * Each set consists of 16 convex and 16 concave blades.RadiusFEELER GAUGE Feeler gauges are used for checking clearances between mating surfaces. They are made in form of a set of steel, precision machined blade 0.03 to 1.0 mm thick and 100 mm long. Each blade has an indication of its thickness. To find the size of the clearance, one or two blades are inserted and tried for a fit between the contacting surfaces until blades of suitable thickness are found.70 FeelerKEY WoRDS ‘Standard Gauges : These are made to the nominal size of the parts to be tested, Limit Gauges : These are ,go" and ,no go" gauges. Plug Gauges : These are used for checking holes of many different shapes and sizes. Ring Gauges : External diameter measuring gauges. ‘Taper Gauges : Taper testing gauges. ‘Snap Gauges : These are used for checking shafts. ‘Thread Gauges : These are used for pitch diameter of the thread. Form Gauges : These are used to check the contour of a profile. Feller Gauges : For checking the clearance between the mating surfaces. Indicating Gaus fo measure the position of the surfaces.