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Part IV: Part Development and Analysis Chapter 13. Analysis Tools
12.1 INTRODUCTION
We all have heard the saying life is never perfect, and so it is with
manufacturing. We can never manufacture a perfect form. An example of a
perfect form is a block with 5 3 4 inch dimensions. Instead, variability is
an inherent characteristic of manufacturing. Sources of variability are
abundant and include the skills of the machine operator (machinist), the
accuracy and age of the machine, the ambient conditions, and the condition
and age of the cutting tool. Therefore, producing parts with perfect
dimensions would be impossible and prohibitively expensive. Thus, we
attempt to control manufacturing variability rather than entirely eliminate it.
Tolerances are the key behind the concept of spare (replacement) parts or
interchangeability. Without tolerances, we would not be sure that a spare
part (e.g., a car part) would fit perfectly. We may ask the following question:
When we replace a part, why does the new part sometimes feel a little tighter
or looser than the old one? Also, different copies of the same new product
may feel different; some are tighter than others. This is because the tolerance
we specify on a part dimension generates a normally distributed population
of the part. The mean of the normal distribution is the perfect form (i.e., the
dimension without tolerances on it), for example, the 5 inch dimension of the
block. Thus, depending on where a product copy falls in the distribution
population, we get tighter or looser products when we assemble the parts.
12.2 TYPES
Tolerances are divided into two types: conventional and geometric.
Conventional tolerances are more widely used than geometric tolerances
because they are the first to develop and they are easier to apply and
understand. Conventional tolerances control the part size (dimensions).
Geometric tolerances (GTOL) control the part form (i.e., its shape). Consider
a rectangle. Controlling the width and height is achieved via conventional
tolerances, whereas controlling the angles of the rectangle and the
parallelism of its sides is achieved via geometric tolerances.
Both types of tolerances are used for part inspection after manufacturing.
There exist off-the-shelf inspection gauges that are used to check whether the
parts meet the tolerance requirements, that is, whether their dimensions are
within the specified values (limits). A commonly used inspection gauge is the
Go-NoGo gauge. If the part fails inspection, it is rejected by the inspection
team and becomes scrap. A high percentage of scrap makes the part
manufacturing more expensive and calls for changes to better control the
manufacturing processes. Inspection is an element of the part quality control
(QC) and quality assurance (QA). Other elements include visual inspection
and surface finish (roughness) measurements.
12.3 CONCEPTS
Both conventional and geometric tolerances introduce concepts and
definitions that we must understand to use tolerances correctly in our
designs and to be able to use the tolerance tools offered by CAD/CAM
systems. The concepts are covered in the ASME Y14.5M-1994 publication
titled Dimensioning and Tolerancing; the new revision is ASME Y14.5-
2009. We cover the following concepts here:
2. Shaft and hole: The tolerance concepts are based on a shaft fitting into a
hole. Each has a basic size of ds for the shaft and dh for the hole. Although ds
= dh, each has a different tolerance. Figure 12.2A shows a shaft and a hole.
4. Hole and shaft systems: Both the dimensions of a shaft or a hole are
subject to variability during manufacturing. In order to specify and calculate
tolerances, we need to fix one relative to the other. We may use either as a
reference. If we use the hole as a reference, we have a hole-based system for
specifying and calculating tolerances. A shaft-based system uses the shaft as a
reference. The hole-based system is more widely used in practice over the
shaft-based system because it is believed that manufacturing a hole is more
difficult than manufacturing a shaft. Thus, it is beneficial to fix the hole size
and change the shaft size to achieve the desired tolerance. An example
application that uses the shaft-based system is the textile industry.
11. Datum target: Datum targets define how we define a target. As a datum is
a part plane, how do define a plane? We define a datum via three
noncollinear points, or via a line and a point not lying on it. Datum targets
have physical significance during inspection. The inspection department uses
the targets to design and produce the gauge that is used to inspect the part.
When the part inspector places the part on the inspection gauge, its faces
must make contact with the inspection gauge at the target points and/or lines
to pass inspection; otherwise, it does not pass and becomes scrap.
B. Plus and minus tolerancing: Show the basic size followed by a tolerance
value, as shown in Figure 12.3B. A plus and minus tolerance may be bilateral
or symmetric. This method of tolerancing is practiced most widely because
machinists prefer it. A machinist typically aims to meet the basic size
(dimension) value during machining.
D. In the title block: Specify general tolerances in the title block of the
engineering drawing, as shown in Figure 12.3D.
B. For bilateral tolerancing, you should use the same number of decimal
places, using zeros when necessary, as shown in Figure 12.4B.
A. For unilateral tolerancing, use the same number of zeros for the zero value
as the nonzero tolerance value with the proper sign, as shown in Figure
12.5A.
B. For bilateral tolerancing, you should use the same number of decimal
places in the tolerance values as used in the basic size, using zeros when
necessary, as shown in Figure 12.5B.
D. Keep the zeros in a basic size if you do not specify conventional (size)
tolerance on it as shown in Figure 12.5D.
Note that SolidWorks enforces these rules as shown in Figure 12.5 when
using the IPS (inch, pound, second) Units system. Also, make sure you select
ANSI drafting standard; use this sequence: Tools (SolidWorks menu) >
Options > Document Properties tab > Drafting Standard > ANSI
(from drop-down list) > OK.
5. When you use tolerances on an angle dimension, use the same number of
decimals in the tolerance value as in the basic size, that is, 45.00 0.10, or
45.0 0 30 (which can also be written as 45.0 0.5): Note that a degree
has 60 minutes and a minute has 60 seconds. The symbols of degree, minute,
and second are, respectively, , , and .
7. Use single limit appropriately: You may use MIN or MAX to specify a
tolerance on a dimension where other elements of the design clearly
determine the other unspecified limit. That is, the design intent is clear and
the unspecified limit can be zero or approach infinity and will not result in
design problems. Use a single limit for features such as the depth of a hole,
length of a thread, corner radii, and chamfers. SolidWorks uses this format to
specify a MIN or MAX: 5.000 MIN or 5.000 MAX.
Scheme 2 implies that the taper end diameters, D and d, and its overall
length L are important and should be toleranced. For example, the taper may
be a floating core of a valve that must block the gas or fluid flow from one end
of the valve to the other. The dimensioning and tolerancing of a flat taper
follow similar rules and are shown in Figure 12.6B.
Scheme 3 shows the use of an angle and scheme 4 shows the use of a slope.
Note the use of the slope symbol. SolidWorks does not have the slope symbol
for the conical taper, shown in Figure 12.6A4, but it does have the symbol for
the flat taper shown in Figure 12.6B4.
The taper of the conical taper shown in Figure 12.6A4 is defined by the
following equation:
And the slope of the flat taper shown in Figure 12.6B4 is given by:
Figures 12.6A4 and 12.6B4 show the taper and slope as normalized values of
x:1, where x is the right-hand side of each equation. Observe that the
definitions of the taper and the slope, given by Eqs. (12.1) and (12.2), are a
little different from each other. These definitions are set by the ASME
Y14.5M-1994 standard; the new revision is ASME Y14.5-2009. The tutorials
of this chapter apply the taper concepts discussed here using SolidWorks.
12.6 LIMITS OF DIMENSIONS
The two questions we answer in this section are: Why and how do we
standardize tolerances? And how do we use them to calculate the limits of a
dimension? We need to standardize tolerances to standardize part
manufacturing and inspection. This in turn ensures parts interchangeability,
which guarantees that replacement (spare) parts fit well into products as
intended. Both ANSI and ISO standards have developed two equivalent
systems of standard classes of fits that designers can use. Each fit has
standard tolerances associated with it depending on the basic size that the
designer wants to assign tolerances to. Table 12.1 shows the ANSI fits and
their ISO equivalents. These fits are divided into three classes: clearance,
transition, and interference. Clearance fit occurs when the shaft moves
loosely inside the hole it fits into. Transition fit occurs when the shaft is in
transition from clearance to interference; that is, the shaft is snug fit into the
hole. Interference fit occurs when the shaft is pressed into the hole and
cannot move inside it. There are different grades (levels) within each
tolerance class: very loose, moderate, or tight clearance or interference.
Think of the fits as a sliding scale from very loose clearance to very tight
interference, and anything in between.
Table 12.1 shows that each ANSI fit designation has two ISO symbols. For
example, the ANSI fit designation of RC1 is equivalent to the ISO fit
designation of H5/g4. H5 and g4 designate the hole and shaft, respectively.
All holes use the letter H to indicate that we use a hole-based system,
whereas shafts use different letters. Each letter represents a fit class. The
number next to each letter is the tolerance grade number or the IT grade. Our
example of H5/g4 implies that the hole has a class and IT grade of H and 5,
respectively, and the shaft has g and 4, respectively. The hole IT grade is
always 1 higher than the shaft IT grade because manufacturing the hole is
harder than manufacturing the shaft. There exist ANSI tables (not shown
here) that relate the tolerance IT grades to the different manufacturing
processes. Each process is capable of producing a range of IT grades.
Having answered the first question, we now show how to use the fits in Table
12.1 to calculate the limits on a dimension. These calculations require the
introduction of the concept of allowance a. While the shaft and hole tolerance
zones s and h shown in Figure 12.2B control the dimensions of each of the
shafts and the holes individually, they do not have an effect on how loose or
tight the assembly of the two is; that is, s and h cannot control the type of fit
between the shaft and the hole. The concept of allowance a gives us this
control. We can produce the three classes of fits (clearance, transition, and
interference) by controlling the allowance a. There are variations within each
class. For example, we have loose and tight clearances, tight and shrink-fit
interferences. The allowance a is an abstract algebraic value; it is positive
for clearance and negative for interference.
The three values of the three parameters s, h, and a determine the shaft and
hole limits as well as the type of fit of their assembly. These parameters
provide the designer with full control over the functional requirements of an
assembly. They also ensure that manufacturing meets these requirements.
Figure 12.7 shows the three classes of fit in terms of the three tolerance zones
s, h, and a. As Figure 12.7 shows, we use the basic size d of the shaft or the
hole as a reference (X-axis). We place the tolerance zones as shown for each
fit. The allowance a is defined as the difference between the maximum shaft
and the minimum hole dimensions. This definition is consistent with the
MMC. A transition fit is the changeover fit from clearance to interference, as
shown in Figure 12.7D. Also, notice that the hole tolerance zone h always
butts the basic size reference line, thus ensuring that dhmin is always equal to
the basic size d. This is a result of using the hole-based system. Also, notice
that a transition fit may be a clearance (represented by tolerance zone s below
the basic size line) or interference (represented by tolerance zone s above the
basic size line). Finally, notice that the allowance a may be zero for a
transition fit or not.
We use Figure 12.7 to calculate the dimension limits for both the hole and the
shaft. The following equations are easily derived:
Equations (12.3) (12.6) are applicable to any fit type because the allowance
a is algebraic. We use the tolerance tables listed in Appendix A to calculate
the limits for all types of fits. Follow these steps to calculate the dimension
limits:
1. Select a fit class from Table 12.1 based on the desired fit type between the
shaft and the hole under consideration. This type is determined by the
functional requirements of the shaft/hole assembly.
2. Use the ANSI tolerance tables listed in Appendix A to calculate the limits
on both the shaft and the hole.
Here is how to use the appendix to calculate the hole and shaft limits for a
given basic size d and a given fit:
Step 1: Use the type of fit (clearance, transition, or interference) to select the
appropriate table (Table A.1 for clearance, Table A.2 for transition, or Table
A.3 for interference).
Step 2: Within the selected table, scan the Basic Size column (at the far left
of the table) using the value of the basic size d to locate the row whose range
includes that d value.
Step 3: Go across using the row to locate the Hole and Shaft columns that
correspond to the given fit.
Step 4: Once there, use the four values that intersect the row and are listed
under the two columns as follows:
Substitute the values calculated from Eqs. (12.8) (12.10) into Eqs. (12.4)
(12.6) to calculate the tolerance zones h, s, and a. Keep in mind that a is an
algebraic valuepositive for clearance, negative for interference, and zero for
transition (Figure 12.7). Equation (12.5) should confirm that observation (a =
d - dsmax).
Example 12.1 Calculate the limits and tolerance zones for the following
three fits: clearance of RC3, transition of LT4, and interference of FN2.
Use a basic size of 5.0000 in.
Solution Following the above four steps, Table 12.2 shows the results.
These limits shown in Table 12.2 agree with the SolidWorks results shown in
Figure 12.8.
Find the dimension limits for RC2, LT2, and FN2. Use a basic
size of 6.0000 in.
FIGURE 12.9 Tolerance accumulation
FIGURE 12.12 True position of a hole
The hole center can move along the diagonal whose length is larger than the
specified 2x or 2y. This allows the part to pass inspection when in reality it
should not.
FIGURE 12.13 Sample geometric tolerance
Figure 12.13B shows two tolerances on the hole. One is a size tolerance on the
hole diameter, which is a conventional tolerance. The other is a location
tolerance on the hole center. It reads as follows: There is a tolerance zone
with a diameter of 0.03 mm on the hole center measured with respect to
datums A (Primary) and B (Secondary). In other words, the hole center is
free to move from its true position within a circle whose diameter is 0.03 mm
and which is centered at the true position point. If the hole center is located
outside this circle, the part is rejected during inspection. Why do we use two
datums in Figure 12.13B? It is because the hole location is determined by the
(x, y) coordinates, each requiring a datum.
The size tolerance on the hole indicates that the hole diameter is acceptable
anywhere between circles II and III shown in Figure 12.13C. These two circles
represent the maximum material condition (circle II with a diameter of 24.95
mm) and minimum material condition (circle III with diameter of 25.05
mm). The dashed circle shown in Figure 12.13C represents the basic size of
the hole (25 mm). When we combine the effect of both the size and location
tolerances, we can think of infinite combinations for the resulting hole. All
these holes fall under the bell curve shown in Figure 12.10B. Each part with a
hole is a point under the curve. The correct inspection gauge is capable of
checking for all these infinite combinations and passing only the ones that fit
under the curve.
Points, lines, and areas on datum features are designated on a drawing via
datum target symbols. Figure 12.14 shows different ways to define datum
targets. These targets are created in SolidWorks. Figure 12.14A shows how to
indicate a datum target point. In this case, we specify (define) datum A by the
point located at 40 mm from the left face of the part. When we want to
specify a datum (A) by a line, we specify two points, A1 and A2, on the line, as
shown in Figure 12.14B. Figure 12.14C shows how to specify a datum (C) by
an area. Datum C is the front plane. The area is indicated by a diameter
(10). Figure 12.14C shows the two options to specify the datum: with or
without a shaded area. The area indicates that an area of contact is necessary
to establish a datum. The shape of the target area may be circular or
rectangular. Consult the SolidWorks menu; click Insert > Annotations >
Datum Target.
TABLE 12.4 Tolerance Interpretation
The two most commonly used methods for tolerance analysis are worst case
and statistical. The worst-case method assumes that the dimension of each
component in the assembly is at its worst, that is, maximum or minimum.
This method produces the worst possible assembly limits. In the worst-case
analysis, the assembly tolerance is given by the linear summation of the
component tolerances. For one-dimensional assemblies with N components,
the assembly tolerance is given by:
where T and Ti are, respectively, the assembly tolerance and the component
tolerance. One-dimensional assembly means an assembly in which
toleranced dimensions form a chain in one direction (horizontal, vertical, or
any other direction).
Equations (12.12) and (12.13) assume that the tolerances are symmetric (i.e.,
the negative and the positive limits are equal). If the tolerances are bilateral
(i.e., the limits are not equal), Eqs. (12.12) and (12.13) can be applied to each
limit to give:
and
Equations (12.16) and (12.17) assume that the tolerances are symmetric (i.e.,
the negative and the positive limits are equal). If the tolerances are bilateral
(i.e., the limits are not equal), Eqs. (12.16) and (12.17) can be applied to each
limit to give:
and
Solution The assembly height is 4.00 0.10 in. (3.9, 4.1). Thus, the
assembly tolerance is 0.10 in. Using the worst-case method, Eq. (12.12)
gives:
The tolerance stack-up (0.12 in.) is more than the assembly allowable
tolerance limit of 0.10 in. Thus, the tolerance of the box height must be
tightened.
3. Perform the TolAnalyst study: Click Tools > DimXpert > TolAnalyst
Study.
4. Follow the above four steps needed to perform the tolerance analysis
(study).
The details of each step are shown below. All dimensions are in inches.
Step 1: Create Sketch1 and Boss-Extrude1-Box: File > New > Part > OK >
Front Plane > sketch and dimension rectangle shown > exit sketch > enter
1 for thickness D1 > reverse extrusion direction > > File > Save As > box
> Save.
Note: We use the height as the desired dimension because it controls the
assembly as discussed in Example 12.2.
Step 3: Create assembly: File > New > Assembly > insert four instances of
box > use two coincident mates between edges of instances to assemble and
stack them up as shown in Figure 12.15.
Step 4: Select the assembly dimension to analyze: Tools > Add-ins >
TolAnalyst > OK > Tools > DimXpert > TolAnalyst Study > bottom
face of assembly > top face of assembly > click on screen to place dimension
> .
Step 5: Define the assembly sequence: Next (arrow shown) > select four
components (from assembly tree or graphics pane), in order, from bottom to
top.
Step 6: Set the assembly constraints: Next (arrow shown in Step 5) > box-2
shown above > 1 from the callout (shown above) that pops up to set
constraint between box-2 and box-1 > repeat for box-3 > and box-4 > .
Note: We apply constraints between mating faces of assembly components.
These constraints determine how the dimensions of the assembly
components change relative to the assembly dimension.
Note: Each constraint relates two planes, one from each instance.
Note: Constraints are different from the assembly mates. They control how
the dimensions change in the tolerance stack-up analysis.
Step 7: View and analyze the tolerance analysis results: Next (arrow shown
in Step 5) > view results shown > .
12.15 TUTORIALS
The theme for the tutorials in this chapter is to practice specifying both
conventional and geometric tolerances as well as performing tolerance stack-
up analysis.
FIGURE 12.16 Conventional tolerances
Step 1: Create drawing: File > New > Drawing > OK > OK (accept the
default Standard sheet size) > Browse (locate and select tutorial3.1PlanA
part from Chapter 3) > click in drawing sheet to insert front view > Esc key >
click view just added > Scale section shown > Use custom scale > 1:1 from
dropdown > > click SCALE 1:1 note that shows up underneath view >
Delete key on keyboard > File > Save As > tutorial12.1 > Save.
Step 3: Add tolerance note: Note on Annotation tab > click in sheet to
place note > type text shown in Figure 12.16 in note box > Add Symbol icon
in Text Format section shown on left pane > symbol icon shown >
Plus/Minus icon shown to add symbol to note shown in Figure 12.16 > .
Hands-On for Tutorial 121
GENERAL TOLERANCE
.X .030
.XX .010
.XXX .005
.XXXX .0005
Step 1: Create part: Open > New > Part > OK > Front Plane >
Extruded Boss/Base on Features tab > sketch as shown > exit sketch >
enter 0.75 for thickness D1 > reverse extrusion direction > > File > Save
As > tutorial12.2 > Save.
Step 2: Create drawing: File > New > Drawing > OK > OK (accept the
default Standard sheet size) > Browse (locate and select tutorial12.2 part
from Step1) > click in drawing sheet to insert front and right views > Esc key
> click view just added > Scale section shown > Use custom scale > 1:1
from dropdown > > click SCALE 1:1 note that shows up underneath each
view > Delete key on keyboard > File > Save As > tutorial12.2 > Save.
Step 3: Add dimensions and create basic sizes: Model Items on
Annotation tab > Selected Feature under Source/Destination > click
front view > > horizontal dim 25 shown in Figure 12.17 > Basic from
Tolerance/Precision dropdown shown > repeat for vertical 20 dim > .
Step 5: Add datum features: Datum Feature on Annotation tab > edit
Leader attributes if needed > click once on sheet to place (anchor) feature >
drag mouse and click again to position features > > drag feature and
attach to intended part feature as shown in Figure 12.17 > repeat for other
datums.
The top face of the block must be parallel to its bottom face and
perpendicular to its left face within 0.1 for functional
requirements. Add two geometric tolerances to the top face to
specify these two requirements.
Tutorial 123: Define Datum Targets
We create datum targets to define datums A, B, and C shown in Figure 12.17.
We define datums A and B by two target points each and define datum C by
one target point. Figure 12.18 shows these targets. These targets are used to
build inspection gauges and are used during the part inspection. The
inspector slides the part onto the inspection gauge and pushes the part
against the faces of the gauge and observes the points of contact between the
two. If the part is in complete contact with the gauge at the locations
specified by the target points, the part passes inspection; otherwise, it is a
reject and becomes scrap.
Step 1: Create drawing: File > Open > locate tutorial2.2 file > Open >
delete all dimensions > File > Save As > tutorial12.3 > Save.
Step 3: Add datum targets for datum B: Repeat Step 2, but type B1 and B2
instead of A1 and A2.
Step 4: Add datum target for datum C: Datum Target on Annotation tab
> type C for target name > move mouse close to bottom edge until its color
changes, indicating that you snapped to it > click edge to anchor target there
> click again to place (Figure 12.18) > > Smart Dimension on
Annotation tab > dimension target location as shown in Figure 12.18 > .
Step 1: Create flat taper: File > New > Part > OK > create part shown
using inches units > File > Save As > tutorial12.4A > Save.
Step 2: Tolerance taper per ANSI standard: File > New > Drawing > OK
> OK (accept the default Standard sheet size) > Browse (locate and
select tutorial2.4A part) > add tolerance label shown > .
Step 3: Create conical taper: File > New > Part > OK > create part shown
using mm units > File > Save As > tutorial12.4B > Save.
Step 4: Use scheme 1 to tolerance taper: File > New > Drawing > OK >
OK (accept the default Standard sheet size) > Browse (locate and select
tutorial2.4B part) > add tolerances shown > .
Note: Sketch a vertical line on the view from top to bottom. Dimension the
line as shown. One of the dimensions is driven.
Step 1: Create Sketch1 and Boss-Extrude1-Block: File > New > Part > OK
> Front Plane > Extruded Boss/Base on Features tab > sketch and
dimension as shown > exit sketch > enter 0.5 for thickness D1 > reverse
extrusion direction < File > Save As > block > Save.
Note: We use the block depth as the desired dimension because it controls
the assembly.
Note: DimXpert includes hole diameter in the graphics pane and feature
under Plane2 shown. Delete both of them.
Step 3: Create assembly: File > New > Assembly > insert two instances of
block > use two coincident mates between edges to assemble and stack them
up as shown in Figure 12.20.
Step 4: Select the assembly dimension to analyze: Tools > Add-ins >
TolAnalyst > OK > Tools > DimXpert > TolAnalyst > Study > front
face of assembly > back face of assembly > click on screen to place dimension
> .
Step 5: Define the assembly sequence: Next (arrow shown) > select two
components (from assembly tree or graphics pane), in order, from front to
back.
Step 6: Set the assembly constraints: Next (arrow shown in Step 5) >
block-3 shown above > 1 from the callout (shown above) that pops up to set
constraints between block-2 and block-3 > .
Note: Each constraint relates two planes, one from each part.
Note: Constraints are different from the assembly mates. They control how
the dimensions change in the tolerance stack-up analysis.
Step 7: View and analyze the tolerance analysis results: Next (arrow shown
in Step 5) > view results shown above > .
Step 8: Edit study: DimExpertManager tab > expand Study1 node >
right-click Result > Edit Feature > when done.
Redo the tutorial without deleting the hole feature. Explain the
results. Also, verify the results using Eqs. (12.12) and (12.16).
PROBLEMS
1. List the sources of variability in manufacturing.
3. List the two types of tolerances. What does each type control?
4. Inspection gauges are used to check whether a part is within its tolerance
limits. Perform an in-depth research study on inspection gauges including
their types, their design, and how they are used during part inspection.
9. Which ASME tolerance rule should you use to show dimension limits on a
drawing? Sketch an example showing a shaft and hole dimensioning.
10. The basic size of a dimension and its tolerance are specified as 3.500 in.
and 0.05, respectively. Is this specification correct? Explain your answer.
11. How do you fully define a conical or flat taper? How do you tolerance it?
13. The three parameters (tolerance zones) that determine a fit are s, h, and
a. Sketch the combination of the three for clearance, transition, and
interference fits.
14. Calculate manually the limits and tolerance zones for the following fits:
a. Clearance fit of RC5 for a basic size of 5.0000 in.
15. Figure 12.21 shows a stepped and grooved block sketch with a depth of 2
in. Apply the three dimensioning schemes of Section 12.7 (shown in Figure
12.9) to the sketch. Calculate, manually, the coordinates of point P for each
scheme. Which scheme has the worst tolerance accumulation on the point
location? Calculate the accumulation for each scheme. Note: All missing
dimensions are either 1 in. or 0.5 in.
17. Figure 12.22 shows a toleranced hole. What is the problem with this
tolerancing method? How do you solve it? All dimensions are in mm.
18. What type of geometric tolerance should you use to control the following
variability in a part?
Illustrate your answer by sketching, manually, the tolerance symbol for each
on a block with a rectangular cross section. Also, sketch the interpretation of
each tolerance. Follow the format shown in Table 12.4.
19. Define and sketch, manually, datum targets for the datums you use in
Problem 18.
20. Figure 12.23 shows a four-bar mechanism assembly. Each bar of the
assembly has the tolerance shown. The mechanism is fixed at point A, and its
free end is D and can only slide horizontally. Calculate the tolerance on D
when the mechanism is in the horizontal position. How would you calculate
the tolerance in a nonhorizontal position, for example, when rod AB is at 45
from the horizontal? Use both the worst-case and statistical methods.
FIGURE 12.23 Four-bar mechanism
21. Figure 12.24 shows a hinge assembly. The functional requirement of the
hinge requires a clearance fit, that is, D > A + B + C for any assembly. The
dimensions of the assembly components (parts) are 2.00 0.05, 2.00 0.05,
30.00 0.05, and 35.00 0.10 for A, B, C, and D, respectively. Does the
tolerance specification on a component meet the assembly tolerance
requirement? Use both the worst-case and statistical methods.
FIGURE 12.27 Using multiple datums
28. Use SolidWorks to create the datum targets in Figure 12.28. Assume any
missing dimensions. All dimensions are in mm.
36. Interpret the geometric tolerances of Problem 35. Sketch the tolerance
zone and the feature shape for each case of A through H. Use Table 12.4 style.
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