Chart of tolerances For machining

Patrick CABAUD PSA/DPTA/DPMO/IDMT/IDPP april 2004

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1 INTRODUCTION........................................................................................................3
1.1 MACHINING ANALYSE ....................................................................................................3 1.2 ECONOMIC TOLERANCES.............................................................................................3

2 DIMENSIONS.............................................................................................................4
2.1 CONDITION DIMENSIONS..............................................................................................4 2.2 MACHINING DIMENSION WD MD TD............................................................................4 2.3 MINIMUM STOCK REMOVAL SR................................................................................14 2.4 MINIMUM RAW DIMENSION RD..................................................................................14

3 STARTING POINT AND CLAMPING.......................................................................15

3.1 GENERALITY................................................................................................................15 3.2 STARTING POINT .........................................................................................................15 3.3 CLAMPING ....................................................................................................................17 3.4 SYMBOLS.......................................................................................................................18

4 GENERAL REMARKS FOR THE MACHINING.......................................................19 5 CHART OF TOLERANCES......................................................................................20

5.1 PRINCIPE OF THE CHART OF TOLERANCES...........................................................20 5.2 EXAMPLES....................................................................................................................21 5.3 STATISTICAL CALCULATE...........................................................................................65

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1 INTRODUCTION
1.1 MACHINING ANALYSE machining a part is deliver at the good dimensions asked by the study department drawing at the minimum price. And for this the technician of the method department define the different steps of the process from the raw to the finish part. They must make a choice among the process and the means of the factory.

Machining a part is very expensive, so the technician of the method department must try to: avoid machining which dont add functional value to the part (rough, semi finish, temporary start point, ..) Calculate the raw part dimensions according to the minimum stock removal of each operation. Machining the part directly with the final drawing dimensions. Choose the machining means capable to carry out the asked tolerances. 1.2 ECONOMIC TOLERANCES All machine setting at a precise dimension dont make the parts at the tolerance of the setting but at nearly dimensions depending of different parameters ( tool life, repeatability of the machine, ..) Each machine have a range into witch it machining the best , this is its economic tolerance. Machining with more closed tolerance cost more. (reject, reworking, more setting, .) Example for economic tolerances. milling turning drilling broaching grinding boring Rough 0.5 0.5 and length 0.3 0.1 0.2 0.3 Semi finish 0.2 0.2 and length 0.2 0.03 0.05 0.1 finish 0.05 0.05 and length 0.1 0.01 0.01 0.03

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2 DIMENSIONS
2.1 CONDITION DIMENSIONS This is the dimension of the final drawing and this is the dimension to respect 2.2 MACHINING DIMENSION WD MD TD

Each operation of machining need a setting of the tool, either from stopper on machine, either between two tools or from machining fixture. To be capable of setting machine, the technician of the method department have to put these dimensions on the process sheets. 3 types of machining dimensions : Working dimension ( moving of the tool) Machine dimension ( distance between two holes,.) Tool dimension ( diameter, step, .) Example

Tool dimension

Working dimension Machine dimension

Tool dimension

Working dimension

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Working dimension Working dimension Working dimension

Working dimension Tool dimension

Tool dimension

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Working dimension

Tool dimension Working dimension Tool dimension Working dimension

Working dimension

Working dimension Tool dimension Tool dimension Working dimension

Tool dimension

Working dimension

Tool dimension

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Working dimension

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TD

TD

TD

TD

WD WD

WD

WD

TD TD

TD

TD

WD

TD

TD

WD

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WD

WD

TD WD TD WD Sol 2 WD Sol 1 WD

TD Sol 1 TD Sol 2

TD

WD

TD WD TD WD Sol 1 Sol 2 WD WD

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12/65

WD

MD

WD

WD

WD WD

WD MD

TD

TD

TD

TD

TD

TD

WD

WD

WD

WD

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2.3

MINIMUM STOCK REMOVAL SR For make a good working with a tool it is necessary to have a minimum thickness , under this minimum thickness , the tool dont cut, the material is crushed and the dimension isnt realized. The name of this thickness is the minimum stock removal. Example for minimum stock removal rough Semi finish Finishing with tool Grinding Super finish 0.5 0.2 0.1 0.05 0

2.4

MINIMUM RAW DIMENSION RD

The minimum raw dimension is the dimension necessary to make a good part. With this dimension the raw department put his tolerance to define the raw drawing.

Example

MSR for rough MSR for semi finish Finish tolerance Semi Finish tolerance

MSR for finish

MINIMUM RAW

Rough tolerance

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3 STARTING POINT AND CLAMPING

3.1
GENERALITY - The positioning and the clamping of the part during the machining are the principal conditions to make a good part an also in mass production for insure a good repeatability . - The starting points in the control mean must be the same than the fixture in the machine. (dimensions, positioning and form) 3.2 STARTING POINT

generally for positioning a part you need 6 points in space you have 6 possible moving : 3 translatory motion and 3 rotations.

3.2.1

PRISMATIC PART

3 points define a plane :

you delete 1 tranlatory motion and 2 rotations.

2 points

you delete 1 tranlatory motion and 1 rotation.

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1 point

you delete 1 translatory motion

3.2.2 Cylindrical parts

Short V 2 points delete 2 translatory motions

Long V

4 points

delete 2 translatory motions and 2 rotations

Concentric Chuck

5 points

delete 2 translatory motions and 3 rotations

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Center

3 points

delete 3 translatory motions

Center and counter center

5 points

delete 3 translatory motions and 2 rotations

Important remarks THE STARTING POINTS IN THE MACHINE FIXTURE MUST BE SMALLEST AS POSSIBLE THE STARTING POINTS IN THE CONTROL MEAN MUST BE THE SAME THAN THE FIXTURE IN THE MACHINE. (DIMENSIONS, POSITIONNING AND FORM)

3.3

CLAMPING

TO AVOID THE BUCKLING OF THE PART , THE CLAMPING POINTS MUST BE DIRECTLY OPPOSED TO THE STARTING POINTS.

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3.4

SYMBOLS

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4 GENERAL REMARKS FOR THE MACHINING

At the first step of the machining its necessary to use raw surfaces. The used raw surfaces must generally stay on the finish part and generally they have a dimension to a machining surface on the study department drawing. For the following machining we use for starting point the surfaces machining at the previous operations. Example Study department drawing
600.1 200.1 152 380.2 200.05

OP10

OP20

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5 CHART OF TOLERANCES
5.1 PRINCIPE OF THE CHART OF TOLERANCES Its not still possible to carry out the positioning of the part to machining directly the dimensions of the final drawing. In this case the surface for the starting points arent the surfaces of the final drawing dimensions. So its necessary to make some calculations. THIS CALCULATIONS IS CALLED CHART OF TOLERANCES Principles of calculations. Every time that the machining of a surface need for the tool setting a different dimension than the final drawing dimension , there are a chart of tolerance. The final drawing dimension witch not used in machining is nevertheless the dimension that its imperatively to carry out. The final drawing dimension is called condition dimension and generally drawing with a positive arrow whith a double line like this.

The machining dimensions necessary to obtain the condition dimension are the links of the chart of tolerances. This chart of tolerances answer at two equations : TOL CD > OR = TOL WD Tolerance of the condition dimension = sum of the tolerances of the Working dimensions to make the condition dimension.

WD = CD
Sum of the chain vector for working dimensions = vector of the condition dimension (this is true only when you used the average dimensions) The methods of the chart of tolerance consist in : - Find the condition dimension ( all the final drawing dimension and all the minimum stock removal) - Find the chain with the links of the chart of the tolerances ( one chain per condition dimension) - Calculate the tolerances of the machining dimensions. Calculate the machining dimensions (rough, semi finish and finish) and the raw dimensions.

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5.2 5.2.1

EXAMPLES EXAMPLE 1 :AXLE WITH 2 DIAMETERS

Final drawing

20

+0.1 0

20

0 -0.2

For the chart of tolerances its necessary to use the average dimensions

CD 1 20.05 0.05

CD 2 19.9 0.1

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Machining of the part This part is machining in turning machine Starting points Concentric chuck 1 stop S 5 points 1 point S

1-3

2-4 1-2 3-4

Machining dimensions

WD 1 WD 2

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Principle of the chart of tolerances Dimension to respect 20.050.05 CD 1

Working dimension WD 1

Dimensions machining CD 1 maxi = WD1 maxi = 20.1 CD 1 mini = WD1 mini = 20

WD1 = 20.050.05

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Dimension to respect CD 2 19.90.1

Working dimensions to make CD2 its necessary to use 2 working dimensions. We know WD1 = 20.05 WD 2 WD 1

CD2 = WD2 WD1 We know : WD1 = 20.05 CD2 = 19.9 19.9 = WD2 20.05 WD2 = 19.9 + 20.05 = 39.95

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WD 2 WD 1

- + - +

Variation of CD2 CD 2 maxi

+ +

CD 2 mini

We can see here that the variation of CD2 depend of the variation of WD1 and of WD2 TOL CD2 = TOL WD1 + TOL WD2 We know : TOL CD2 = 0.1 TOL WD1 = 0.05 0.1 = 0.05 + TOL WD2 TOL WD2 = 0.1 - 0.05 = 0.05

WD2 = 39.95 0.05

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Other solution We know : WD1 20.05 0.05 WD1 mini = 20 WD1 maxi = 20.1 CD2 19.9 0.1 CD2 mini = 19.8 CD2 maxi = 20 CD 2 maxi WD 2 maxi

WD 1 mini

+ +

CD2 maxi = WD2 maxi WD1 mini 20 = WD2 maxi 20 WD2 maxi = 20 + 20 = 40

WD 2 mini WD 1 maxi

+ +

CD 2 mini

CD2 mini = WD2 mini WD1 maxi 19.8= WD2 mini 20.1 WD2 mini = 19.8 +20.1 = 39.9 WD2 = 39.950.05 26/65

Building of the chart of tolerance Recap of the dimensions

Name
Condition dimensions

Dim 20.05 19.9 ? ?

Tol 0.05 0.1 ? ?

mini 20 19.8 ? ?

maxi 20.1 20 ? ?

CD 1 CD 2
Working dimensions

WD 1 WD 2

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Calculation of the value of the working dimension

WD = CD

+
Name
Condition dimensions

Dim 20.05 19.9 20.05 39.95 20.05 20.05 19.9 20.05 39.95

Tol 0.05 0.1 ? ? 0.05

mini 20 19.8 ? ? 20

maxi 20.1 20 ? ? 20.1

CD 1 CD 2
Working dimensions

WD 1 WD 2 CD1 CD1 WD1 CD 2 WD1 WD2

WD = CD WD1 = CD1 WD1 = 20.05 WD = CD -WD1+WD2 = CD1 -20.05 + WD2 = 19.9 WD2 = 19.9 + 20.05 WD2 = 39.95

CD2

0.1

19.8

20

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Calculation of the tolerance of the working dimension Tol CD > or = Tol WD

+
Name
Condition dimensions

Dim 20.05 19.9 20.05 39.95 20.05 20.05 19.9 20.05 39.95

Tol 0.05 0.1 ? ? 0.05 0.05 0.1 0.05 0.05

mini 20 19.8 ? ? 20 20 19.8 20 39.9

maxi 20.1 20 ? ? 20.1 20.1 20 20.1 40

CD 1 CD 2
Working dimensions

WD 1 WD 2 CD1 CD1 WD1 CD 2 WD1 WD2

CD2

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Tol CD > or = Tol WD

+
Name
Condition dimensions

Dim 20.05 19.9 20.05 39.95 20.05 20.05 19.9 20.05 39.95

Tol 0.05 0.1 0.05 0.05 0.05

mini 20 19.8 20 39.9 20

maxi 20.1 20 20.1 40 20.1

0.05

0.05 0.05 0.1

CD 1 CD 2
Working dimensions

WD 1 WD 2 CD1 CD1 WD1 CD 2 WD1 WD2

CD2

0.1

19.8

20

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5.2.2 Example 2 :Prismatic part 5.2.2.1 1st process

Final drawing
400.2 100.1 200.2

CD1 CD2 CD3

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Machining process OP10

WD1

OP20
WD2

OP30
WD3

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Dimension to respect
CD1 = 40 0.2

Working dimension
WD1

CD1 maxi = WD1 maxi = 40.2 CD1 mini = WD1 mini = 39.8

(WD1 = 400.2)

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Dimension to respect
CD2 = 100.1

Working dimension To make CD2 its necessary to use 2 working dimensions

+WD1 -WD3

Op10

Op30

CD2 = WD1 WD3 We know WD1 = 40 and CD2 = 10

10 = 40 WD3 WD3 = 40 10 = 30 Variation of CD2 -The variation of CD2 depend of the variation of WD1 and WD3 - Tol WD1 + Tol WD3 = Tol CD2 -We know Tol WD1 = 0.4 (0.2) and Tol CD2 = 0.2 (0.1) 0.4 + Tol WD3 = 0.2 -Tol WD3 = 0.2 0.4 = -0.2 < 0 its not possible to have a negative tolerance. 2 solutions to respect the tolerance of CD2 : -Take for tolerance of WD1 and WD3 0.05 ( Tol CD2 = Tol WD1 + Tol WD3 0.2 = 0.1 + 0.1) - Change the process for machining CD2

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For the example we use the first solution WD1 = 400.05 +WD1

-WD3

-WD3

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+ WD1

-WD3

-WD3

+
WD1 mini WD3 mini

WD1 maxi WD3 maxi

WD1 mini WD3 maxi

WD1 maxi WD3 mini WD1 mini WD3 maxi WD1 maxi WD3 mini

CD2 mini CD2 maxi

CD2 mini = WD1 mini WD3 maxi 9.9 = 39.95 WD3 maxi WD3 maxi = 39.95-9.9 = 30.05

CD2 maxi= WD1 maxi WD3 mini 10.1 = 40.05 WD3 mini WD3 mini = 40.05-10.1 = 29.95 36/65

Dimension to respect
CD3 = 200.2

Working dimension To make CD3 its necessary to use 3 working dimensions

-WD1 +WD2 +WD3

Op10 Op20

Op30

CD3 = WD3 + WD2 WD1 We know WD1 = 40, WD3 = 30 and CD3 = 20

20 = 30 + WD2 40 WD2 = 40 +20 30 = 30 Variation of CD2 -The variation of CD3 depend of the variation of WD1,WD2 and WD3 - Tol WD1 + Tol WD2 +Tol WD3 = Tol CD2 -We know Tol WD1 = 0.1 (0.0.5) Tol WD3 = 0.1 (0.05) and Tol CD3 = 0.4 (0.2) 0.1 + Tol WD2 + 0.1 = 0.4 -Tol WD2 = 0.4 0.1 0.1 = 0.2 WD2 = 300.1

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-WD1

+WD2

+WD3

+WD3

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-WD1

+WD2

+WD3

+WD3

+
- WD1 mini + WD3 mini

- WD1 maxi + WD3 maxi

- WD1 mini + WD3 maxi

- WD1 maxi + WD3 mini

WD2 mini

CD3 mini CD3 maxi CD3 mini = - WD1 maxi + WD3 mini +WD2 mini 19.8 = -40.05+ 29.95+ WD2 mini WD2 mini = 19.8 - 29.95 + 40.05 = 29.9

WD2 maxi

- WD1 maxi + WD3 mini + WD2 mini

- WD1 mini + WD3 maxi + WD2 maxi

CD3 maxi= - WD1 mini + WD3 maxi + WD2 maxi 20.2 = -39.95+ 30.05 + WD2 maxi WD2 maxi = 20.2 - 30.05 + 39.95 = 30.1

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Building of the chart of tolerance Recap of the dimensions

Name
Condition dimensions

Dim 40 10 20 ? ? ?

Tol 0.2 0.1 0.2 ? ? ?

mini 39.8 9.9 19.8 ? ? ?

maxi 40.2 10.1 20.2 ? ? ?

CD 1 CD 2 CD 3
Working dimensions

WD 1 WD 2 WD 3

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Calculation of the value of the working dimension

WD = CD

+
Name
Condition dimensions

Dim 40 10 20 ? ? ? 40 40 10 40 30 20 30 40 30

Tol 0.2 0.1 0.2 ? ? ? 0.2 0.1

mini 39.8 9.9 19.8 ? ? ? 39.8 9.9

maxi 40.2 10.1 20.2 ? ? ? 40.2 10.1

CD 1 CD 2 CD 3
Working dimensions

CD1 CD2

WD 1 WD 2 WD 3 CD1 WD1 CD 2 WD1 WD3 CD 3 WD 3 WD 1 WD 2

CD3

0.2

19.8

20.2

WD = CD WD1 = CD1 WD1 = 40 WD = CD WD1-WD3 = CD2 40 - WD3 = 10 WD3 = 40 - 10 WD3 = 30 WD = CD WD3-WD1+WD2 = CD3 30-40+WD2 = 20 WD2 = 4030+20 WD2 = 30
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Calculation of the tolerance of the working dimension Tol CD > or = Tol WD

+
Name
Condition dimensions

Dim 40 10 20 40 30 30 40 40 10 40 30 20 30 40 30

Tol 0.2 0.1 0.2 ? ? ? 0.2 0.1

mini 39.8 9.9 19.8 ? ? ? 39.8 9.9

maxi 40.2 10.1 20.2 ? ? ? 40.2 10.1

CD 1 CD 2 CD 3
Working dimensions

WD 1 WD 2 WD 3 CD1 CD2 CD1 WD1 CD 2 WD1 WD3 CD 3 WD 3 WD 1 WD 2

CD3

0.2

19.8

20.2

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Tol CD > or = Tol WD

+
Name
Condition dimensions

Dim 40 10 20 40 30 30 40 40 10 40 30 20 30 40 30

Tol 0.2 0.1 0.2 ? ? ? 0.2 0.1

mini 39.8 9.9 19.8 ? ? ? 39.8 9.9

maxi 40.2 10.1 20.2 ? ? ? 40.2 10.1

0.2

0.1

0.1 0.2 0.3 0.4

CD 1 CD 2 CD 3
Working dimensions

WD 1 WD 2 WD 3 CD1 CD2 CD1 WD1 CD 2 WD1 WD3 CD 3 WD 3 WD 1 WD 2

With this table we can see that the sum of the working dimension tolerance are no good to carry out the tolerance of the condition dimensions

CD3

0.2

19.8

20.2

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Calculation of the tolerance of the working dimension Tol CD > or = Tol WD

+
Name
Condition dimensions

Dim 40 10 20 40 30 30 40 40 10 40 30 20 30 40 30

Tol 0.2 0.1 0.2 0.05 0.1 0.05 0.2 0.1

mini 39.8 9.9 19.8 39.9 5 29.9 29.9 5 39.8 9.9

maxi 40.2 10.1 20.2 40.05 30.1 30.05 40.2 10.1

0.05

0.1

0.05 0.05 0.1 0.2

CD 1 CD 2 CD 3
Working dimensions

WD 1 WD 2 WD 3 CD1 CD2 CD1 WD1 CD 2 WD1 WD3 CD 3 WD 3 WD 1 WD 2

We see here that the tolerance of WD1 and WD3 are so closed. this is due to the changing of starting point at the op 30. Now we try another process

CD3

0.2

19.8

20.2

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5.2.2.2 2nd process Final drawing

CD1 =400.2 CD3 = 200.2

CD2 = 100.1

Machining process OP10

WD1

OP20
WD2

OP30
WD3

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Building of the chart of tolerance Recap of the dimensions

Name
Condition dimensions

Dim

Tol

mini

maxi

Working dimensions

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Calculation of the value of the working dimension

WD = CD

+
Name
Condition dimensions

Dim 40 10 20 ? ? ?

Tol 0.2 0.1 0.2 ? ? ?

mini 39.8 9.9 19.8 ? ? ?

maxi 40.2 10.1 20.2 ? ? ?

CD 1 CD 2 CD 3
Working dimensions

WD 1 WD 2 WD 3 CD1

CD2

CD3

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Calculation of the tolerance of the working dimension Tol CD > or = Tol WD

+
Name
Condition dimensions

Dim 40 10 20 40 30 10 40 40 10 10 20 10 30

Tol 0.2 0.1 0.2

mini 39.8 9.9 19.8

maxi 40.2 10.1 20.2

CD 1 CD 2 CD 3
Working dimensions

WD 1 WD 2 WD 3 CD1 CD2 CD3 CD1 WD1 CD 2 WD 3 CD 3 WD 3 WD 2

0.2 0.1 0.2

39.8 9.9 19.8

40.2 10.1 20.2

WD = CD WD1 = CD1 WD1 = 40 WD = CD WD3 = CD2 WD3 = 10 WD = CD -WD3 + WD2= CD3 WD2 = CD3 + WD3 WD2 = 20 + 10 = 30

Calculation of the tolerance of the working dimension 48/65

Tol CD > or = Tol WD

+
Name
Condition dimensions

Dim 40 10 20 40 30 30 40 40 10 10 20 10 30

Tol 0.2 0.1 0.2 ? ? ? 0.2 0.1 0.2

mini 39.8 9.9 19.8 ? ? ? 39.8 9.9 19.8

maxi 40.2 10.1 20.2 ? ? ? 40.2 10.1 20.2

0.2

0.1

0.1 0.2 0.1 0.2

CD 1 CD 2 CD 3
Working dimensions

WD 1 WD 2 WD 3 CD1 CD2 CD3 CD1 WD1 CD 2 WD 3 CD 3 WD 3 WD 2

WD = CD WD1 = CD1 WD1 = 40 WD = CD WD3 = CD2 WD3 = 10 WD = CD -WD3 + WD2= CD3 WD2 = CD3 + WD3 WD2 = 20 + 10 = 30

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5.2.2.3 Conclusion First process 0.05 0.1 0.05 Second process 0.2 0.1 0.1 1>2 X4 0 X2

Op10 Tol WD1 Op 20 Tol WD2 Op 30 Tol WD3

We can see in this example that is very important to try to keep the same start points in all the process.

5.2.3

Example 3 :Prismatic part with minimum stock removal

The same part but with CD3 = 20 0.05 For this we decide to change the process in 4 operations.

Final drawing

CD1 =400.2 CD3 = 200.05

CD2 = 100.1

Machining process OP10

WD1

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OP20
WD2

SR1

OP30
WD3

SR2

OP30
WD4 TD1

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Building of the chart of tolerance Recap of the dimensions We take for the minimum stock removal of SR1 and SR2 : 0,1 mm

Name
Condition dimensions

Dim

Tol

mini

maxi

Stock removal

Working dimensions

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Calculation of the value of the working dimension

+
Name
Condition dimensions

Dim 40 10 20

Tol 0.2 0.1 0.05

mini 39.8 9.9 19.9 5 0.1 0.1

maxi 40.2 10.1 20.05

CD 1 CD 2 CD 3
Stock removal

SR1 SR2
Working dimensions

WD 1 WD 2 WD 3 WD 4 TD 1 CD1

? ? ? ? ?

? ? ? ? ?

? ? ? ? ?

? ? ? ? ?

CD2

CD3

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+
Name
Condition dimensions

Di m
40 10 20

Tol
0.2 0.1 0.05

mini maxi
39.8 9.9 19.95 0.1 0.1 40.2 10.1 20.05

0.1

0.1

CD 1 CD 2 CD 3
Stock removal

SR1 SR2
Working dimensions

WD 1 WD 2 WD 3 WD 4 TD 1

40 ? ? 10 20

? 0.1 0.1 ? ?

? ? ? ? ?

? ? ? ? ?

CD1 CD1 WD1 CD2 CD2 WD4 CD3 CD3 TD1 20 20 10 10 40 40

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+
Name
Condition dimensions

Dim 40 10 20

Tol 0.2 0.1 0.05

mini 39.8 9.9 19.95 0.1 0.1

maxi 40.2 10.1 20.05

0.2

0.1

0.1

0.1

0.05 0.2 0.1 0.05

CD 1 CD 2 CD 3
Stock removal

SR1 SR2
Working dimensions

WD 1 WD 2 WD 3 WD 4 TD 1 CD1 CD1 WD1 CD2 CD2 WD4 CD3 CD3 TD1 SR1 SR1

40 ? ? 10 20 40 40 10 10

0.2 0.1 0.1 0.1 0.05 0.2 0.2 0.1 0.1

39.8 ? ? 9.9 19.95 39.8 39.8 9.9 9.9

40.2 ? ? 10.1 20.05 40.2 40.2 10.1 10.1

20 20

0.05 0.05

19.95 19.95 0.1

20.05 20.05

SR2

SR2

0.1

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Name
Condition dimensions

Dim 40 10 20

Tol 0.2 0.1 0.05

mini 39.8 9.9 19.95 0.1 0.1

maxi 40.2 10.1 20.05

0.2

0.1

0.1

0.1

0.05 0.2 0.1 0.05

CD 1 CD 2 CD 3
Stock removal

SR1 SR2
Working dimensions

WD 1 WD 2 WD 3 WD 4 TD 1 CD1 CD1 WD1 CD2 CD2 WD4 CD3 CD3 TD1 SR1 SR1 TD1 WD4 WD2 SR2 SR2 WD3 WD4

40 ? ? 10 20 40 40 10 10

0.2 0.1 0.1 0.1 0.05 0.2 0.2 0.1 0.1

39.8 ? ? 9.9 19.95 39.8 39.8 9.9 9.9

40.2 ? ? 10.1 20.05 40.2 40.2 10.1 10.1

20 20

0.05 0.05

19.95 19.95

20.05 20.05

0.1

0.1

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Name
Condition dimensions

Dim 40 10 20

Tol 0.2 0.1 0.05

mini 39.8 9.9 19.95 0.1 0.1

maxi 40.2 10.1 20.05

0.2

0.1

0.1

0.1

0.05 0.2 0.1 0.05

CD 1 CD 2 CD 3
Stock removal

SR1 SR2
Working dimensions

CD1 CD2 CD3 SR1

WD 1 WD 2 WD 3 WD 4 TD 1 CD1 WD1 CD2 WD4 CD3 TD1

40 10 20 40 40 10 10 20 20

0.2 0.1 0.1 0.1 0.05 0.2 0.2 0.1 0.1 0.05 0.05

39.8 9.9 19.95 39.8 39.8 9.9 9.9 19.95 19.95

40.2 10.1 20.05 40.2 40.2 10.1 10.1 20.05 20.05 0.1= -20.05-10.1+WD2 mini WD2 mini = 20.05+10.1+0.1 WD2 mini = 30.25

SR1 TD1 WD4 WD2 SR2 SR2 WD3 WD4

0.1 20 10 30.3 5 0.05 0.1 0.1 20.05 10.1 30.25

0.1 9.7 10 0.1 0.1 9.8 9.9

0.1 = - WD3 maxi + 9.9 WD3 maxi = 9.9 0.1 WD3 maxi = 9.8

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5.2.4

Example 4 :Prismatic part with minimum raw dimension

RD 3 RD 2 SR 2

SR 3

SR 4

SR 5

SR 1

SR 6

RD 1

Final drawing

CD1 =400.2 CD3 = 200.05

CD2 = 100.1

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Machining process OP10

WD1

OP20

WD2

WD3

OP30

WD4

OP40

WD5

OP50

TD1

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Name CD SR CD 1 CD 2 CD 3 SR1 SR2 SR3 SR4 SR5 SR6 RD1 RD2 RD3 WD1 WD2 WD3 WD4 WD5 TD1 40 10 20

Dim

Tol 0.2 0.1 0.05

mini 39.8 9.9 19.95 0.2 0.2 0.1 0.1 0.2 0.2

maxi 40.2 10.1 20.05

0.5

0.1

0.1 0.2 0.1 0.05

RD WD

0.5 0.1 0.1

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61/65

CD SR

RD WD

CD1 CD2 CD3 SR1

Name CD 1 CD 2 CD 3 SR1 SR2 SR3 SR4 SR5 SR6 RD1 RD2 RD3 WD1 WD2 WD3 WD4 WD5 TD1 CD1 WD2 CD2 WD5 CD3 TD1 SR1 WD1 WD2 SR2 RD2 WD1 WD2 WD4 SR3 WD4 WD5 SR4 TD1 WD5 WD3 SR5 WD3 WD2 WD1 RD3 SR6 WD1 RD1

Dim 40 10 20

Tol 0.2 0.1 0.05

mini 39.8 9.9 19.95 0.2 0.2 0.1 0.1 0.2 0.2 41.7 30.15 40.4 39.8 30.25 9.6 9.9 19.95 39.8 39.8 9.9 9.9 19.95 19.95 0.2 40.4 0.2

maxi 40.2 10.1 20.05

0.5

0.2

0.1

0.1

0.1

0.05 0.2 0.1 0.05

9.6 40.9 40 30.35 9.7 10 20 40 40 10 10 20 20 0.5 0.2 0.1 0.1 0.1 .05 0.2 0.2 0.1 0.1 0.05 0.05 41.4 40.2 30.45 9.8 10.1 20.05 40.2 40.2 10.1 10.1 20.05 20.05 0.2 = +wd1 mini 40.2 wd1 mini = 40.2+0.2 = 40.4 40.2 9.6 40.4 40.2 9.6 0.1 9.8 9.9 0.1 20.05 10.1 30.25 0.2 30.45 39.8 41.4 30.15 0.2 41.4 41.6 0.2 = -41.4 +rd1 mini rd1 mini = 0.2+41.4 = 41.6 0.1 =- wd4 maxi + 9.9 wd4 maxi = 9.9-0.1= 9.8 0.1 = - 20.05 10.1 + wd3 mini wd3 mini = 0.1+20.05+10.1 wd3 mini = 30.25 0.2 = -30.45+41.4-40.9+rd3 mini rd3 mini = 0.2+30.45-41.4+40.9 rd3 mini = 30.15 0.2 = -rd2 maxi +40.4-40.2+9.6 rd2 maxi = -.2+40.4-40.2+9.6 rd2 maxi = 9.6

SR2

SR3

SR4

SR5

SR6

62/65

Machining process OP10

40.90.5

OP20

400.2

30.350.1

OP30

9.70.1

OP40

100.1

OP50

200.05

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Raw dimensions 30.15 mini 9.6 maxi

41.6 mini

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5.3

statistical calculate

we know, in the work dimensions calculate, that the tolerance of the condition dimension is equal to the sum of the tolerances of the dimension of the chain. TOL CD > OR =

TOL WD

This calculate is true if we consider that all the dimensions of the chain are at the limit (minimaxi). In reality the probability that all the dimensions of a chain are at the limit is very small. And this reality is all the more true that the number of dimensions is big. We can consider , with a limited risk , to increase the tolerance of the working dimension by a statistical calculate when we have some problems.

TOL CD

> OR =

(TOL WD)

Be careful , generally we dont use this method when we have less than 3 working dimensions. Example :

0.2 0.1 0.1 0.1

TOL CD

> OR =

TOL WD
not possible

0.2 > 0.1 + 0.1 + 0.1

TOL CD > OR = 0.2 >

(TOL WD)

0.1 + 0.1 + 0.1 = 0.1732

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