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Professor of Mechanical Engineering.

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Queen’s University, Kingston, ON, Canada K7L 3N6
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[email protected]

Lecture 3
Topic: Geometry of Manufactured Parts
Textbook reference: pp 1085 - 1109

Queen’s University, Mechanical Engineering

© J. Jeswiet

MANUFACTURING ENGINEERING
MECH 213
Good morning everyone.

1
 What does one first notice about a part?

„ Shape

„ Texture

„ Material

SHAPE
9 determined by
function,
function what we want the part to do,
do
esthetics,
esthetics how we want the part to look,
ergonomics,
ergonomics, is it comfortable?
9 complexity limits the choice of manufacturing processes
9 so, design simple shapes, unless the product is marketed
only on shape.

2
The next thing one observes about a shape is
DIMENSIONS
DIMENSIONAL UNITS
Système Internationale
– METER (m) ← primary unit of length
– MilliMETER (mm) 10-3 m ← used on drawings
– MicroMETER (μm) 10-6 m ← micron
– NanoMETER (nm) 10-9 m
United States Customary System
–INCH (in) ← primary unit of length, used on drawings
–“THOU” 10-3 in [or 0.001 inches]
–MicroINCH (μin) 10-6 in
Remember that 0.001 inches = 0.0254 mm
On average the width of one human hair is? ……
The average potato chip is how thick? …….
…….

TOLERANCES are closely associated with

DIMENSIONS

A part will have two or more dimensions

For instance a shaft has two dimensions

There will always be a tolerance

associated with a dimension

3
What kind of tolerances can be achieved with manufacturing processes?

what dimensional accuracies can one expect in nano-sized parts?

Dimensional Tolerances
Definition: The variation in a given dimension
that can be tolerated; either on a part or its position

Some history:
Rudimentary part tolerancing was used around 1900.
Position tolerancing is a British invention which started in
the Royal Torpedo Factory in Scotland in the 1930’s.
British efforts led to British Standard BS-308 [1953].

Tolerances are needed to control the dimensions of any two

mating parts so that any two parts may be interchangeable

4
 Two Rules of Tolerance Limits
Limits should be set close enough to allow
functioning of the assembled parts.
Limits should be set as wide as functionally
possible to avert unnecessary expense;
the “closer” the tolerance the greater the expense.
International Tolerance Standards are found in
ISO 406: Technical drawings – Tolerancing of linear and
angular dimensions.
ISO 129 – Dimensioning – General principles, definitions,
methods of execution and special indications.
ISO 3098-
3098-1, Technical drawings – lettering – Part 1: Currently
used characters.

An example of tolerances
shaft using INCHES

1.248
Shaft limit dimensions
1.247

both have a
0.001 inch
tolerance
1.251
Hole limit dimensions
hole 1.250

5
 In metric the foregoing is:

31.70
Shaft limit dimensions
31.67
both have a
0.03 mm
tolerance
31.78
Hole limit dimensions
31.75

Some definitions
ƒ Nominal size:
size the designation usually identifying a dimension;
for instance 1¼ inches or 1.25 inches in the foregoing example
or 31.75 mm in the metric system
ƒ Basic dimension:
dimension the number to which all dimensions are applied 1.250
ƒ Actual size:
size measured size of the finished part; after manufacturing
tolerance
ƒ Tolerance:
Tolerance the amount by which a dimension may vary 0.001 inch
ƒ Limits:
Limits the maximum and minimum sizes of the tolerance
ƒ Allowance:
Allowance the minimum clearance space (or maximum interference)
0.002
for example
[1.250 – 1.248]
1.248
Shaft limit dimensions
1.247
1.251
Hole limit dimensions
1.250

6
 FITS BETWEEN MATING PARTS:
Fit is the general term used to signify the
range of looseness or tightness
of mating parts
See ANSI Y 14.5M – 1982 (R1988)

tight fit

loose fit

Types of Fit
Clearance Fit: Parts will always be able to rotate or
slide past one another.
Interference Fit: Parts will fit tightly together, and
can even be fitted to develop a specified pressure.
Transition Fit: Limits are such that the resulting fit
could be an interference or a clearance fit.

7
 Part tolerances use one of two systems:

Basic Hole system or Basic Shaft system

preferable

Basic Hole System:

System The minimum sized hole is the smallest allowable
dimension; it is the reference for other dimensions

Basic Shaft System:

System the maximum shaft size is used as the
reference to which all dimensions are related; it is the largest
allowable dimension

Basic Hole fit Basic Shaft fit

Note: we will use the

Basic Hole system

0.502 0.498 0.505 0.500

0.500 0.495 0.502 0.499

Based on the minimum sized hole Based upon maximum shaft size
which is 0.500 inches in this case which is 0.500 in this case

A Design allowance of 0.002”;

gives a maximum shaft size of 0.500” – 0.002” = 0.498”

8
 Specifying Tolerances
General Tolerances:
‰ if tolerances are not given, then a general tolerance is assumed
‰ every dimension on a drawing should have a tolerance

‰ +/- 0.005” is a usual tolerance assumed by all shops

‰ the actual general tolerance must be placed somewhere on a part dwg
in a printed note
‰ ie: if a general tolerance of +/- 0.001 inches is placed on a part
‰ the note will read as DECIMAL DIMENSIONS TO BE HELD TO +/- 0.001
and
‰ if a dimension of 3.250 is given,
‰ then the machinist works between the limits 3.249 and 3.251

Note: a tolerance of 0.001” is considered fairly “tight” and will cost a

lot more to produce.
There has to be a very good reason for specifying this tolerance

Several methods have been approved for expressing tolerances;

see ANSI [Y14.5M – 1982 (R1988)]*

1. LIMIT DIMENSIONING, is the preferred method

1.750 high value 31.78

1.735 low value 31.75

2. PLUS/MINUS DIMENSIONING METRIC

1.878 +0.000 high value

inches
–0.002 low value

+0.00 high value mm METRIC

47.70 low value
–0.05

* ANSI: American National Standards Institute

9
 Unilateral tolerance: allows variations in only
one direction from the basic size

1.878 +0.002 The tolerance is 0.002

–0.000 all in one direction

Basic size

Bilateral tolerance: allows variations in

both directions from the basic size

1.878 +0.002
–0.001

or if equal on both sides

1.878 +/- 0.002

ANSI* uses letter symbols to identify fits:

ƒ RC: Running or sliding clearance fits
ƒ LC: Location clearance fits
ƒ LT: Translation clearance or interference fits
ƒ LN: Location interference fits
ƒ FN: force or shrink fits

The ANSI tables are designed for the BASIC HOLE SYSTEM
* reference: ANSI B4.1 – 1967 (R1987) preferred limits and fits for cylindrical parts

10
 An example of ANSI
RC fits
Remember
RC: Running or sliding
clearance fits
H5, g4; H6, g5; etc…
etc…

enlarging his section

Example
Parts in machine shop:
fit RC7

RC: running or sliding

clearance fits

Shaft: d8
Hole: H9
1.000” diameter hole

11
 Part of ANSI table

Hole: H9
Shaft: d8

1” diam. bore
class RC7
Interpretation

RC7: medium running fit; for higher speeds

From the foregoing table

Note: hole tolerances are
clearance
Limits of

given with an UPPER case

Hole Shaft and shaft tolerances are
H9 d8 given with a lower case

2.5 +2.0 -2.5

5.7 -0 -3.7

12
 From the foregoing table
Basic Hole fit Basic hole size = 1.000”

clearance
Limits of
Hole Shaft
H9 d8
2.5 +2.0 -2.5

1.002 0.9975
5.7 -0 -3.7
1.000 0.9963
1.000 + 0.002
1.000 - 0.000
Hole tolerance = 0.002”
Shaft tolerance = 0.0012”

Minimum clearance (gap) = 1.000 – 0.9975 = 0.0025”

Maximum clearance: 1.002 – 0.9963 = 0.0057”

In most cases the fit used for a particular application can be found
in sources such as SKF
SKF: a bearing company

The following two slides give examples

13
Example from SKF handbook

14
 Accumulation of Tolerances

The manner in which tolerances are added can

have an impact upon the final accuracy of a part
for instance:
3.000
3.000 2.995
2.995 2.000
1.995
1.000 1.000 1.000
1.000
0.995 0.995 0.995
0.995

There is a 0.005” variation in Base line dimensioning

each case gives better accuracy
If the maximum value occurs in
each case then the final variation
in dimension could be 0.015”

But usually the required tolerance will be 0.005” for all dimensions, as shown

Thank
Thank you
you for
for your
your attention
attention

15
 APPENDIX

ANSI Standard Fits can be

represented graphically:
Also see ISO 286 – 1, page 229

In thousands of an inch: 0.001”

Recall:
ƒ RC: Running or sliding clearance fits
ƒ LC: Location clearance fits
ƒ LT: Translation clearance or interference fits
ƒ LN: Location interference fits
ƒ FN: force or shrink fits

16
 ANSI system for acceptable methods of giving tolerances
using metric measures
[ANSI Y14.5M – 1982 (R1988)]

These have been set up by ANSI to correspond directly to ISO standards

The ISO system uses an International Tolerance (IT) grade

that varies varies according to the Basic Size and provides
a uniform level of accuracy within a grade.

For this example assume a 50 mm diameter Hole/Shaft with

a close running fit

This is written as 50H8

This is the IT grade

Hole diameter
Basic tolerance is on the Hole

Increasing “tightness”

17
Now consider the 50 mm Hole/Shaft system, with an H8 fit

ANSI table for Basic Hole system; for metric system

a closer view shows

18
Basic Hole system [METRIC] 50H8/f7

50.039
HOLE DIMENSIONS
Max hole size
0.039
50.000 tolerance

Min hole size

SHAFT DIMENSIONS
49.975 0.025 Minimum
Max shaft clearance

49.950 0.025
tolerance
Min shaft
0.089 Maximum
clearance

Tolerances may be given in one of several acceptable forms:

50H8 is the preferred form

50.039
or 50H8
50.000

or 50.039(50H8)
50.000

In all cases, the information you enter into a computer or

write down on paper must be correct and must be clear
to other engineers.

19
Different machining processes can produce different tolerances,
tolerances
as shown in the following table:

20