Design For Manufacturing and As fect of Materials and Manufacturing proeses on De 1.EFFECT OF MATERIAL AND MANUFACTURING PROCESSES IN DESIGN 1. Introduction: Design is the process of translating a new idea or a market need into the detailed Information fram which a product can be manufactured. Each of Its stages requires decisions about the materials trom which the product re process for making it. The number of materials lable to the engineer is vast: Between 40000 and 60000. At the ing the design Is fuld and the options are wide all materials must be considered. As the design beromes mare facused and takes shape, te Selection erteria sharpen and the shortist of material, which can satsty them, narrows. “The choice of material cannot be made independently of the choice of process by ‘which. the material to be formed, joined finished, and btherwise treated, Cost enters, both in the choice of materials processed. Good design alone wil not sel a product. Industrial design is one that, i feplected, can ais loss the manufacturer his market Subsequently deciding up ng processes. For Knowledge of the effect of material properties and manufacturing processes Is requied. 1.1. Major Phases of Design: Introductior Engineering design work is usvally performed on three aifferent levels 1 Development of existing products or designs, i.e. Fedesign, by introducing ‘minor meaifieations in size, shape fr materials to improve performance. 2 Adaptation of an existing product or design to operate iin new environment oF to perform a efferent function, new design that has no precedent. ‘This work is more demanding in experience and creatty of the designer. 1.1.1. Major Phases of Design: Engineering design is usually an erative decision making steps where each deck es the framework the next one, There is no single, universolly recognized sequence of ‘eps that leads to 2 workable design a tnese depends on nature of the Problem being solved as well asthe size and structure of the organization, However, a design usually passes through most of the phases. which are basen inthe Fig 1, Identification of the problem and evaluating the need in order to define the objective of the design represent the frst phase of the ‘design in most cases. 2. Functional requirements and ope felated to the required character pected as a result of the active phase | mn, concept formulation, and of manufacturing requirements 5, The evaluation phase involves a comparison of the expacted performance af the design with the performance requirements Established in phase 2.Evaluation of the diferent solution and Selection of the ‘optimum alternative can be performed using Secision making. techniques, modeling techniques, experimental ‘work and for prototypes. 1. Insome cases, I 1s Not possible to arrive at a design that ful Involves the creation of ravings for every part Information that is. necessar ta unambiguously define the part ‘should be recorded [n detailed drawing. The material of the part Should also be selected and specified by reference to standard codes.+ “uO\sop qwouoduoo Uy pasapysu0> 9q pynoys ren SuOWDe4 Z BIL oon ne aunoaeten, sieg weeding Inyssooohs v Stusoyd eta au s} inposd suonanposut :ubised uo semedoid [ee7eW Jo 390M *Z"T ‘suonesyipous UBS 94nN4 94930} UO 3 u9ne 10 OUUMD>e)NUaU Ut Ye PUA ia) pue saubesap aun udoaNaq ds sv90ulOva srevarew pue “Guu ny pun oi fo 2 iy way5 secondary relationships between and material properties, ‘The relationship between design and material properties is complex because the behavior of the material in the finished product 1s quite ferent from that of stock material used in making it This point Is lustrated Inthe following 9.3, Propertis of he > Component 101s that should be considered in anticipating the behavior of the component. This figure shows the dlrect influence of the stock mater production method, and component geometry and extern: Behavior of materats inthe nished component. Ie also shows the Secondary relationships exist between geometry and production method, ‘and between stock materials and component geometry. properties ces on the 1.2.1 Effect of Component Geometry: In most cases, engineering components and machine elements have to incerporate design features, which Introduce changes. it crost-section ‘These changes cause localized stress concentrations, which are higher than those, based upon the nominal cross-section ofthe pat 1.2.2 Stress Concentration Factor: ‘A geometrical or theoretical stress concentration factor K, is usualy used {ovrelate the maximum stress, smax. at the discantiulty to nominal tres, Sw, aecording te the relationship: 5 fect of Materials and Manuf Smax! Sw materials. With more ductile. materials, local yielding in the very small rea of maximum ross causes a. considerabl Th the stress Concentration. So, for auctile materials under st ‘sualy necessary to consider the stress concentration factor. Guidelines for design: especially when designing with the bigh-strength materials and une fotaue loading. i such cares, the Tolowing gaelins should be observed ess concentrations are to be Kept mi 1 ‘Abrupt changes in cross-section should be avoided, if they are nacossay, generous filet radi or stress-elieving Qrooves should be provised ‘nd grooves should be provided with the generous run-out ving grooves of undercuts should be provided at the ‘ends of threads and spines. 3 and external edges should be avoided. far features should be chamered and the bore 6, Weakening features ike the bolt and oil holes, identification marks, land the part numbers should net be located in highly stressed 7, Weakening features should be staggered to avoid the addition of thee stress concentration Factors.“erewelp in sown oz Jo yn6ve| © ut 22:62P TF anoge oy syeus u von>2yep sejn6ue ayy ju OL s} a>MDeNd yensh UL “onel s uossiog = '®" 219UMM (e073 = s22ys ul AjRseI8 Jo smINPOW = 9 214M, “on=0 aroun yp6u9) yun sad “8s J 9j6ue up Aq paunseaus Ayensn st uaueduo> © Jo AypIbu TeUeIsO3 OU. syeus Jo Auprbnt ‘ssouyns 0} swleag Gulubisep ut jenuasso 212 uogaas-sson au ut jeuayeu! 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While crack-lke defect can safely exist in a part of lower- Strength ductile materal, can cause 9 catastrophic fallue the same par is made ofa high-strength, low toughness material High strength is being ner to ave weight or to meet di to be less tolerant of deer Guidelines for design: In. designing with the high-strength, low toughness mater teraction between facture toughness of the Mm: he Crack size, andthe design stress should be considered. In the case of high- Strength, ow-toughness material, 9s the design stress inereases (or as the Sze of the flaw increases) the stress concentration at the edge of the rack, the stress intensity Ky inereases until I reaches Ke and fracture Ki= Ke = Yosina} ‘where F, = fracture stress (controlled by the applied load and shape of the part) 2 = quality control parameter (controlled by the manufacturing method) "Y= dimension! analytically or ume shape factor. (Estimated experiment i” 1.2.6 Designing against Fatigue: In majority of cases the reported fatigue strengths or endurance limits of ‘materials are based on tests of Carefully preparee small samples under Taboratory conditions. Such values cannot be directly used for design purposes because the behavior of the component or structure under fatigue loading does depend not only on the fatigue or endurance hint of the material used in making fe, but also on several other Factors including: >> Size and shape of the component or structure ‘Type af lading and state of stress. Stress concentration > > > Method of Fabrication. “The influence of the above factors on the fatigue behavior of the Component can be accounted for by modifying the endurance imi of the ‘material using a number of factors, Each of these factors is ess than unity land each one fs Intended to account fora single effec. the component: a5 determined by laboratory fatigue test “a= surface finch factor. 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Life under Variable Loading “The stress-rupture fe of a part or a structure, which is subjected to 3 ‘Variable loading, can be roughly estimated If the expected life at each Stress level is known, Under such condltions the lfe fraction rule assumes that rupture occurs when: wie? ‘es Where t1 2,2, are the times spent by the part under stress levels 1,2, 3.. respectively. tia, tra tr. are the rupture lives ofthe part under stress levels 2 respectively. Life under Combined Fatigue And Creep Lea: Similar reasoning con also be applied to predict the life of @ part or 3 Structure when subleced to combined creep and. fatigue’ loading Camulative fatigue damage laws.e.g. Palmgren-Miner Law, canbe B Where nt, n2, nu. are the number of cycles at stress levels 1. 2. 3 respectively Nis N2, NB are the fatigue lives at stress levels 1,2, 3. respectively. 1.3 Effect of Manufacturing Process on Design Introduction Ik is now widely recognized that design. materials selection, and manufacturing are “intimately related activities, which cannot be performed in solation of each other. Creative designs may never develop Ihto marketable products unless they can be manufactured economically tt the required level of performance. In many cases, design modifi fre made to achieve production ecanomy of to suit existing production faciities and environment. Mosfeations of design may also be made in brder to improve quality and performance, im which case the cost of production may increase. 1.3.1 Design Considerations for Cast Components Casting covers a wide range of processes which can be used to shope Simost any metalic and some plastics ina variety of shapes, sizes, fccuracy, and. surface finish, In some cases, casting represents the ovious and only way of manufacturing, as ia the case ef components the afferent types of cast ron or cast alloys. In many other ‘ations, however a decision has to be made whether it as rageous to cast 8 product oF to use anther method of manufacture Insuch eases, the following factors should be considered: 1. Casting is particulary suited for parts which contain internal cavities wecessible, too complex, of t00 large to be easily produced in. 2. 10 advantageous to cast complex parts when required in large ‘numbers, especialy thy are to b¢ made of aluminum or zinc alloys 3. Casting techniques ean be used to one of a Precious metas ae usualy shaped by costing, since there toss of materials. 5, Pars produced by casting have important requirements in some apo properties, which could be on.o1 pue oy “Jeusyeus aup Jo abexuUUs “TeuareU 249 Jou ‘diy 943 4a papoye axe sued apserd paplow uy s9>ue%3 “sued popjow yo A>eunsoy 'sojoy pug o a5e2 ata u pus 2u0 wos} pauioddns aq hyo ue> nq ‘jou nipejnueu e ws) S90 Pouojaud ase sojou yBncsuy'oT Bis Ul se Alessapou 99 Kew S95s0q mol) 40 uon>ouiP pure Bupjou Buunp jeusyew aya jo oy ‘p15 au Uy nao auy pam © squmsip S904 jo orua5018 944 ‘sjeuojew sow aunbas pur opfo Supjow ain pres suon205 Yonp asne>eq s sua “ssauyDNA eM 24 asea:0u"0} vein peo} paidde uy tam 9d0> 01 wed au Jo adeus OM snipe oy sa199 $1 TOABMOH "SpE 198 paypedxe ayy Aue> 03 Su0ns uapyyne shed aia Yen ions. 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For example, a thermosetting plastic ike melamine has mold shrinkage of| . about 017 to 0.9 %, and an after shinkage of 06 to 0.8%. Thus a total part. Larger fons are normally accompanied by larger tolerances. For example, dimensions less than 25m ‘en be held within £50 km. Larger dimensions are usually given tolerances of +10 to 20 y micm. fof tolerances also depends on the direction in relation ta the parting plane ros 2epn beta Ir [r Fig 9 some desiga features of plastic pats. (a) Using rail instead of sharp ry ff AF Fig 10 some design features of plastic parts strengthen areas round holes a Use of bosses to 1.3.3 Design Considerations for Forged Components: Design For fc af Maveriols and Mamie 1g processes represent an important means of producing relatively lex parts for high-performance ay any cases forging ‘loses existing porosity Fefines the grains, and hamogenizes the structure. On the other hand, cast parts are more isotropic than forged parts, which Usually have directional propertes. This directional is due to the fibre Structure, which results from grain flow and elongation of second phases inthe direction of deformation. Forged components are generally stronger land more ductile in the direction of fibres than across the Mbres. Guidelines for Design changes in thickness should be avoided because these could result Taps and cracks in the forged metal as it flows in the di prevent these defects, generous rad Farge changes in thickness. Another simiaity with casting t= that vertical Surfaces of @ forging mast be tapered to permit removal from the le cavity, A draft of § to 10 degrees is usually provided. tis better to locate the parting ine near the midle of the part in order to avoid deep impression In either of the bo halves of the dle and allows easier filing of the cle Cavity. A design would be more economically produced by forging if fsmatch closure require Fig 1 Schematic comparison ofthe grain flow in forged and machined ‘componentso (14 0 e010 pug axp Ounralgns Aq Aisn0281 29se}9 24p Joni0g 5} powjaus saupouy “Baus aif puiod 49N0 05) ‘peg Buus v0} Sunesuaciaoa jo Kem aug ‘porous aie S920) OuIpUoG aA Uaym jeusrew ay Jo Azano>e1 ansejo oun Aq pase st oui 2eq Buds 5 Sulpuog so) Sulubisap uy pasapisue> 24 pyneus You ose) JaAROUY -yeuorew 1¢ ‘Ajensn s) 290us eyo Auge pudg.Teuarew axa 72> 104 5300 ae\N smIpeL log as nul passaudxa st pue feuayeu ayy Jo AyININD uy ey pateta 5 tal “amnge puss sy “urpuag hq apew 99 0} ave el sued uutisep uayr paroprsue> 24 pinove yn sje) Wevoduy YSOW UL ‘w61s9p 40) sounpIND sow oq swesaida! sje0%s uoge> mot jpous eu) Wuowoumbos uiew ays sty wus o70°9 = $€0"0 40 Jaaas Sr yeuayew spaus sua jo 92% ureub au, “Sulmesp Jo/pue "Burpudg "Buueays fq’ poonposd. ave sued Jeaunsaus “syei2ua9 “saqisnput Jewnsv0> ue "yerue “angowome SiR uy Puno} ue sojdwex AueH “sjeuoiew pue “sas "sadeus Jo Alauen opine J0n0D rou! ways los} ape Seg sued [eyoW - 30045 Jo UBISOg S*e"T “suonenias 2ybIens &q p92erd9s 99 Pinous SUNu PUowWeId WT 61s ‘suayuis saye Suuysew fa peenponul axe saumyea, yons Kuessanou !‘papione ru wenn Yo tue RFR er EB j | WW! 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SUL ‘tuuyean Buus pue ‘aun pue airgesada, Sypowis “ainssoud 6uissaid"pasn’ uonesuqn “uapMod Jo. a2 pue ‘dk ‘adeys ed uo spuadap Aa'sovod jo qunowe ou Ayso.0d (01 p urewe> senbuuy2er wid fevouIpen our fq pornpaxd sed sued ABanj|e32W 49pMod 404 SUOReLEpISUD UBISOG °E"T vise 9 soy pe sonny fo psp‘The major part to another {and in such case the strength af ent to cary the ‘expected service loads. In some apy tis aso necessary to prevent leakage. Because’ jints represent. areas. of the assembly. they should bo iocated. in lowestress in dynamically loads structures discontinuities Fegions especial Welding Welding has replaced riveting in many applications including stew! [ructures, boilers, tars, and mocrcar chasse, This fe because riveting fs Strona, whereas a welded jo Welded joints are easier to Inspect and can be made gas and without the caulking which has to be done in riveted Joints. On the nd behave as one piece. This could adversely affect the fracture behavior ofthe structure. For example, 3 ie riveted Structure may not be serous, as the piece luthout detection, However, in the case of @ welded stucture, a crack that Starts ina single plate or weld may progress for a large distance and struct Charpy impact specimen coul show a much tower b temperature than a lorge welded structure made ofthe same material Guidelines for design of weldments AL.Welded structures and joints should be designed to have sufficient co not allow shrinkage of the wela lity to redistribute stress, and are subjected to Aistorions and falure 2. Access match-up. of the joint for welging, welding position and component important elements ofthe design 23. Thin sections are easier to weld than thick ones. 4, Welded section shauld be about the same thickness to avoid excessive Feat distortion 5. Ie s better to locate nelded joints symmetrically around the axis of an assembly in order fo reduce distortion. 6. Whenever possible the meet of several welds should be avotde. a 7. Use weld fixtures and clamps to avoid distortion Adhesive Bonding represent an attractive method of joining and their use is 19M Many applications. Some of main advantages in using S ae 2 allo: 1. Thin sheets and parts of dicsimilar thickness can be easily bonded, 2, Adhesive bonding is the mast gical method of joining polymer: Matrix compasites. 3. Adhesives ar Insulators and can prevent galvanic Ccives better structural integrity and allows thinner gage materials to bevused. “The main limitations of adhesives ae as follows: 1. Bonded joints ate weaker under cleavaye and peel loading than, Under tension or shea. 2.Most adhesives cannot be used at service temperatures above 300 degree C1600 degree F). 3 ‘Solvents ean attack adhesive-bonded joint 4 Some adhesives are attacked by ultraviolet light, water, and ozone, 5. The designer should also be aware of the adhesive's Impact resistance ‘and creep, or cold flow, strength. Design of adhesive joints ‘The strength of the adhesive joint depends on the geometry, the direction ot loading in relation to the achesive materia, surface. preparation, and technique. As the bonded are the strength band double-trap prepared to butt joints. I the geometry constr low for such jolets, a scart fr double “scarf joint should be made, When a lab joint is used to bond thin sections, tensile shear causes in stress Concentration at the end of the is, gives more uniform loading throughout ince adhesive Joints are weaker under peeling forces, Joint design Should avoid this type of loading 1.3.7 Designs Involving Heat Treatment: Heat treatment represents an important step in the sequence of processes that are Usually performed n the manufacture of metallic parts. 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The large hhumber of materials ad the many manufacturing process avaliable to the fengineer, coupled with the complex relaticaships between the ferent Sclection parameters, often make the selection process a difficult task. A Figoraus and through appreach to materials selection is, however. often not followed in industry and much selection Is based on past experience Its often said, “When in doubt make it stout out of the stuff you know Bout.” While ly ignore past experience, the Trequent introduction of new materials and manufacturing process, in addition to the increasing pressure to produce more economic. and competitive Products, make fnecessary for the engineer to be always on the lookout {or possible improvement. The reasons for reviewing the types of material tnd processes used in making an exsting product are: 1. Taking advantage of new materials or processes. 2 Improving service performance, including) longer life and higher retabity 3. Meeting new legal requirements. 4 Accounting for enanged operating conditions. 5, Reducing cost and making the product more competitive. Gradually evolve during the siferent stages of product development ‘These are 1. Analysis of the per 2, Development o alternative solitons to the problem. 5. Evaluation ofthe alfferent solutions 4. Decision onthe optimum solution mance requirements 1.4.1 Analysis of the Material Performance Requirements: Funeti al Requirements: Functional requirements are directly related tothe requlred characteristics of the part of the product. For example, i the aft carries un tensile foad, the yield strength of the material can be directly related to the load-carrying capacity of the product. For the evaluation process of the choracteristics of material propert wear resistance, reliability etc, and simulation service tests are employed. Processability Requirements: ‘The processability of the material i @ measure ofits ablity to be worked Dees For Ma of Mata ard Mo ity and hardenabilty can be relevant to be deformed or hardened by heat treatment respectively. The closeness of the stock form to the required product form can be taken as a measure of processability In some cases. ‘The material properties are closely related to functional requirements cost: Cost is usu: because in many appl tomeet the appiicat ded, the design may have to be changed to allow the use of a less expensive material. The cost ofthe processing often exceeds the cost ofthe stack material Production and processing history Though there are ifficuties in evaluating rel important selection actor in t0 account, Falure analysis techniques are usually used to predict the different ways in which ‘and can Re considered 35.2 systematic approach to Fability evaluation Jit is often an Resistance to Service Conditions: The environment in which the product or part will operate plays an Important vole In determining the material performance requirements, Corrosive environments, as well ae high or low temperatures, can adversely affect the performance of most materiale becomes a selection consideration. For example, the coefficient of thermal expansion of tobe simiar in order to avold therm Felative movements exist between mate Stresses ferent parts, wear 5 valved should be considered. 1.4.2 Cost per Unit Property Method: lecting the optimum fen length () to support a tensile “The cross-sectional area (A) ofthe bar is given by: aatis 0 ‘Where is the working stress of the material, which Is related to ts yleld strenath by an appropriate factor of safety. ‘The cost of the bar's given by: %se 2 ‘Guusiuy “Susso2eud pois) yBtoM yuR sd feuayeU 24y Jo 3609 JIE) =D OU, (oy ten aus Jo nb y‘sIs0q auunjon ‘80s 30) posh st euayeus se poujop 2q voty ue> jouo.ew 24 40} (wy) jun Jed e uo poonpor 2q ue> 3509 uy afayn sase> aun u}{ 2) Xepur a>vewo}ied feparew a4} 0} Jay!pOU se Ajeredas 1 Buvepsu0> fa peztseydwo a9 few 1S09 yo a>uevodtu) 51a J8psue> 0} sonsadosd 40 ssoquNy OBIE} oe o!Oun H OAOMOH “remy ose sia ‘jassod jo saquinu yews a4 owt (us) ye08 4289 20} 5 Jovvonuinu y}909 | Suara iztraueni siseycuy oanejay) |” annisoa | suojsvep 2jss00 Jo seaunn | s1209 otnow 260) e649 avn Buisn sje08 souewoysod jo a>ueyodus! annejau at Jo UONeUISIEG Ts 3141 ‘2}ger aun Uy uMous se yu 949 0 sUusMo9 a4A w Bpew {ue suostediuo» pue "uuunje> peu yo] atA U poy axe s]e98 10 sorvedord 3uq "popnasuo> si 9]ge) e [e068 40 somuedoud ypeo Jo a>ueuodu! ‘nneyes oun aulUsorep OL “uolLenjen® yee 40) vo}spap OU 30 Soke ‘ue 'nounbos ye aoteuo so sapeus ‘ee8 soucwuo}!0d 40 sonuadoid ain Jo voneuique> Inve ye pa.apisuo> ‘te sonuadord on Avo Ye Si ul" auuuoyop sy [oo SneulasKs © se pasn’s! 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Bugsixe Ue Jo} ayMnsgns © 5 eeu 2U0 UDUM “sit d9) AAhuenb ays Avo “sieusew arepipue> wasayIp Guuedwo> UI na= 3 ue sseu yun Jad eusyew 243 J03s03 = 3 2:04Design For Manufacturing and Assembly et of Moerials and Manufacuring processes on Desir = Density ofthe material ‘The weighted properties method can be used afien 3 material is Considered 95 a.substhute for an exsing one, Tis is done by computing the relative figure of merit (RM), which is defined as, it = Mle Me are the ‘figures of marit of the new and existing Tethe Ri fs greater than unity, the new material's more suitable tan te exiting material ‘The steps involved in the weighted properties method can be written in the form of simple computer program to select materials from the data Donk. An Interactive program can also include the digital logic method to help i determining weighting factors 1.4.4 Limits On Properties Method: In the timits on properties method, the performance requirements are divided int three categories: ts on properties method are usualy suitable for optimizing material and process selection when the numberof possible allenatives S| felatively forge. Th sd tor the ‘ifferent properties, can be used for e {data bank. The remaining materials are those whase properties are above. the lower imits, below the upper, and within the limits of target values of mits ig mater AS Inthe case of the weighted properties method, each of the Fequirements of properties is as5.gned a weighted factor. a, which can be determined sing the digital logie method, as discussed earier. A merit parameter, mis then calculated for each material according to the mont} eot Het where 4, and t stand for lower imi, upper limit, and target value properties respectively. hunand n are the numbers of the lower farget value properties respectively. yy, 4 afe the Weighting factors of the lower {and target value propeties respective XoX and X. ae the candidate material lower limit, upper limit, and target value properties respectively. and 2» ‘According fo the equation the lower the value of the merit parameter m, the better the mater {sin the weighted properties method, the cost can be considered in two ways 1. Cost is treated as an upper limit propery and glven the appropriate weight, "Costs included as @ modifier tothe merit parameter as follows: mm = (CxO Where CY and Cx are the specified cost upper limit and candidate material 's case the material with the lowest cast-modified merit parameter, isthe optimum, 1.5. Case Study for Material Selectiot 1.5.1 Materials for springs: Springs come in many shapes as shown in the Fig 28, and have many purposes one thinks of xl springs ea srins, hell springs Shint Springs, torsion bors. Regarless of ther shape. or use, the best ‘hater fos sping of miimurs volume shat wth te greatest ate of ‘97, an for minimum weight iis that wth the greatest valve 540 sonjen endo yam ua umoys st Suanjon un uons219s ous Z°5°T “pBuans syetorew 805 pue ( ‘a sha 9pip 80 98's ‘bunds 00) 10 poy ue KBsav9 3nsei9 oanren 046 an sai eI se sSojpieBar ‘Bulsds Aue 103 jeuoveus aso au, "ABsouD asons SBuUS By Bid ‘og wo ssan0ud Sumrefueyy pu severe formpe Aywessy pac Buamepnacyy 0.) uBis9crNylon 1.6.Problem : le operation sequence for the stub carrier shown in ‘andthe 1. Suggest a sult fig.20 an manutat symbol Design For fc of Metra and Mar260 ENGINEERING METROLOGY (iE TYPICAL EXAMINATION QUESTIONS What doyou understand by sscreitation of ae tobe flowed? Explain in tall the concept of treat laboratories? How it ‘What ar tho essentials of ametrlogy laboratory? plain the procedure for accrediation of eal Discuss the role of 4 Limits, Fits and Gauges i 44. Inkoduetion Itiswell known fact that no two things in the nature can be identical, they may be found to ‘be closely simiar. This is true of production of eomponent parts in engineering alsa, We know that every processis a combination of three elements, viz, tne of these ee ‘on or about the mean value and other values about the mean value and remaining within ‘Thus it can be ssid that due to inevitable inaccuracy of manufacturing method: possible to make any part precisely to given dimension and it can ealy be made to maximum and minimum. The difference can be said that ¢ is impossible to manufacture a part to a specified definite mass produced, Eve accurately enough to prove served by producing any compon definite depending on function can be tolerated, The eos of attempting to produce size without variation would be too high which is uncalled for, thus, snufactured is requiredtofit or match with some ing ofthe two components in match depends hips betwee with each other in a desired way :e.g.ifa shaft is to rotate ina hole, snce between the shaft im tobe maintained for hbrieation. the elearance sto smal of shaft. Ifelearance isto wide, there would be vil ic compression grip them tightly and do net allow any tive movement between them. 261aj asau9 aucasans Sasryua 0 1k 920 Sio139 amos ‘ounypew ox uo soarda0% pa 500 ‘uy 'suryas opi 9yeur oy soyodo Ue sop ayqpssd ‘syed spojiod sonpaid es su0H ei oy) Onur Ing So}esnooeUY quaIOqUT auns anDy SHAjasNaKT soUPPeUU UEKNposd oy ‘1048 sonpostus paunypeu Surg youyew ogy jo sqodoad ayy sosvay Buta fu 81 son2ead yorgoe w14N9 “uoHZeIEA feoOISUOLUEP Jo pur, ure anoupin syzed 40 ie9 pinoss suor Puce fp] z powtoads xe sooUeIOIO) SHAT" “Aqua Arqend ayp wo yoyo ou savy asouy, Aoesnade Jo aauBop vB 220Wp axe suotsueump jeuorouny-tO syuaUoduea Sune Zaypo HAL ay puE pouyPeU 99 OL amet orn ssoup ox” suorsuotp jeuoHouny “suoIsUONN TeUOHOUR)-ON pure [eUOHOUN “sufieap owes atpjoasn poyeodos yo asnimaq sanuent yun posBAsoNY qeIs9 03 SoMpraS puB suORE|MDTED Jo syuNOLN px svat rn soureso|oy ywesoyEp Seu ooy—oyy saleyueapestp stoties aq AEM 91049 UA) AD1829[0) 30 anyes aq appap 0 Syuo ayy £6 woe) st yuaastnbos feuonaty Swiouiamnswous jo wnz3oads oaquo ayy sanz abu Geum SODUE903 Jo JP spoyjout ‘uonesrpsepURys ax way ‘apmney aus sopiaoud tape Suneutwop ax 29, iy azayyy “aRlsap ayy 30 wo ‘uonepeitap nous suojsunnatp yes9 sian 2x9 puatog aotetssopzed oy) Jo syuiod 0) Soou6s9/) jo aeodsnd Azeutad 34, 309205 ss0m) {pI ostuiosduoo sasmnbax sounawes jusuiNbas feuoHoURY Jo UOHeIepIsuOD AIBUMLAd ay pus ssou9j3 Jo aovoyo ay ouanygt ste Ypres “yp spaod ataMyDejN juauodutes jo Kjquiese 3 Burinp squautanaryse ‘ip Jo esnt90q paso? ods 4 wos ao eau 22430 10 UoISUALAIP B ea ajtssTukid jo apraruse ay se pouyp aq we aouvqoy‘payEaipUr Apeouye Sy sooueDIoL Th Hom (nex oxdn yu0% aBne8 pus joor sso ey aN 9oM JOA0> pINoYs Lays ay, syued pays 108q se ans 10 are sonsto}eIEYD AqutOsse OWES 30 9g Fo|LONAed w YEH 05 OEE 2s own Mu aseo.0Ur ysNUH ay 2e|MoNLTM wast oy pastnbos woretaap yeTuoKTEpLN ay 9) 92 ‘saonvo any sala ‘SumT By ‘uoneordde uoass v 0} 240 a tN Sig Jo ales poutsop dye w minx jojs 4 apqssod a9 tN APF }seq KE 219 0 yoee 40} sanqea aouesofon jo au w anvy ysmun YyoUS pu afox Jo aay aTsEG YL “suoqjeot}dde je zaaoo 01 ayenbope oq puv peonpas aq pinoys #1 pue ena Jo oquiNy, ‘sosodind ys0u 10) wueroyyns oq Pinoys wayEKS ayy Sy pazanod saat Jo 98tIEL oy, “sove|d ie ye Suruvou ows ay spueysiapun spogtiare yeu os propueys stuos wo Pi 4 99 ash suorpUOD BuLao[EsYSS|ONNS aq OHS PAE ST n parsnip sstoq sorsuotatpa1eyy 049080) poveUL Stam a19M SiuoUoduD Jo {.nfou stp 8Aep SzE0.94) soueunojad jeuorouny ue ojqissd se yo00 Surmsejrueun no] sv Had 03 sv OF 728 -Ares59000 949 a801490 Tha —— pves701 oo “de soussoim ox SV ‘109 10} dsnopaauan a Jo Sum og + urypEs 99 18 spd g4-66 7 oaunD fora cm 1p Kowonibay; yueysa ay Wang era rape yng JOM akB BULARPA pur vO o2 Sur{ypods 4 paureiqo 2q pyno> ajay pue yoys aang HpqENE Jo uorNpACD postop on, ABOTOWLSN ONILEENIONSlishment of correct engineering or manufac 264 ENGINEERING METROLOGY 1 between acauracy required for proper fue’ produce this accuracy. 42.2. Design Considerations in the Selection of Engineering Tolerances. The estab- ng tolerances isa mat feoncern because mexcessivecost. Tight tolerances result in unnecessary igh rejects, and adversary relationship between design, manvac- os esuiltin assembly problems and poor product performance also be fa ocesses, He must alzo have aclear understanding of in assembly and operation with the ather components, for precision, fear ‘or excessive clearance between assembled parts, from company’ of vender standards which tend to favour fi Oneshould also have good understanding of tolerances resulting from various prodaction processes, ‘The understanding af statistical tool sof great help, Itean be safely assumed thatthe most ing processes produce parts which are normaly distributed, For norm ge arts being in selection of ition of the potential dimensional the assumption f normal Astudy function of machine parts would reve some variations in dime ious parts. Iti, thus, general practice to specify a basic dimension and then indicate hy tolerances as to how mich Lumrts, FITS AND GAUGES 265 joni the basie dimension ean be this part willbe use. ‘ays of expressing Tolerances. ted without affeting the functioning f the assembly lerances arebe: lly specified in wo twabasic mating parts is indicated when the machining of mat 1 parts is called fr, a this greatly assists the. for a hole) knowing fully well yg dimensions Diameter of hole : 25.00 mm, 25.002 mm. Diameter of shalt: 24.999 mm, 24.997 mm ) One limiting size may be specified with its tolerances Diameter of hole: 25,000 + 0.0002 mm, ~ 0.000 mm Diameter of shaft: 24.999 + 0.000, 0.002 mm The nominal size may be specified for both parts, with a notation showing both allowance and tolerance: Diameter of hole: 25,000 + 0.0002, ~ 0.000 mm ameter af shaft: 25.000 ~ 0.0001, 0.008 min Bilateral tolerances may be expressed as = 25,090" 2.002 Diameter of hole = 25.000" 2.002 mm, 25.0907 Diameter of shaft = 25.000~ 000! mm, then these should be changed ‘way between upr 42.5, Specifying tolerances for given asse decided based on func ided using two approach Approach, In complete interchangeability approach, no risk is taken about even a single non-con- forming assembly. If the fit between a shaft and hole is a clearance type, then for complete interchangeable approach (referring to Fig. 4.2 t wll be seen thal tolerance on shaft = tolerance on hole = half the maximum clearanee—half the minimum clearance ‘The statistical approach beses the permissible tolerances onthe normal distribution curve, considering that only 0.3% components would lie beyond = 80 limits. This approach, obviously,“props feuoyeus2yU 0} a1qusaes3 ose 29 Spx pus roo asa gem ay qeatsop UFO sy! 201n0s 2170 {ite wor soredsSuputeygo jo Sos e91 1073 seoyuoqut yo0] $e waowy Buoq Ho Batnaqop 10 0 wom jo suetuaooydos oy, -=2e4d au 3e auop oq uRD STUN [e19205 UY pase} ooee eu pue SaH!9} JoMTO pu JeyEM “soM0d doy saa wos} auoo [ sjuouodwoo Buneu snoEa nse sy yas yeua9e ojur ssz00xd apoyann w jo dn Burg OF Sanbruy Sst ypeosdde peyulao atwowsDe Yat 001 SIqUMOSBE ‘qaisuodsou ozou ou sy aoqesado aes ox Aopos pue SuxBuctp wo rday senbuypoy SutanypeyTUwE Jp vdoouoo auf atsn (Aig BY Poutsap urEIgD oy sywouoduon Sune ayy rsp ‘uve ong ple syn Jo JaquiM [os oF pauyuoD aq o1 pasn woRINpord 591 ynuews 326d sey.uts 205 paymineqne oq UD Yor auo st yed ojquostueyoseUt WY yeaSuUeyPEUT EY 109 pantaop axe yotyn aso ase vous} punodwop "saouvsayo, punodwsog “1 we ‘saonvo Ny suls ‘Sunn 4 posraai 04 wo soe { on 3 wrens ey "Bh WE oes Plnom seubaney Saxgpota yo sees J+Psqnupiavor eed Fy Pe eh eras wo soot s9[0 ojo wan aq Bt] sto}duno9 wo stuns 3uraey days yea days esaaas jo sosuadtnos av UeAs 7245 UEA;E—apOH JO OFS UEaWY = soUDZeOP UOayy ‘nano peuo4 ai ynbayy pear 99 jf 59 Seoumavo ou Jo Aouanbay po ups secspemy 5 passed a dfButpscane prea fou tng u pon void oo boas poroadso uo ‘pqtanuoo Ajnjaze wom ese jo so 0 s}uouodu uot past aq > spoyyour uorzonpoad s LaVHs wo reo ona mma SL & Dunes Wanner Sma 2901 no sours” P 3704 ADOTOLLIN ONIETANIONA ott re Sie Ser th Aha opdamexa og Sani, ypeoudde ssrqeaiaeyp soya oya{duud> 0 pasedutoasoout {0 uy wr wnogs se wnyep » wos Supuotsuoxp oxtsaa80ud Sun dopy “yao [e990 ax UO ssoUBIO|O eth porepaudde oq pins 4, ueuM, FITS AND GAUGES 268 ENGINEERING METROLOGY Desives, meon prc that Desires mean value "note other mating eomponer carrying out any forinterchangeable out classifying manufactured components in subgroup oF wi This typeof nterchanyeabil lealsoas it requires mach ss eapal such machin be select ty ofcha ve prices. This has become poss chine 2g for selective assembly whereby parts manufactured as though they were precise i @ concept which does a old ‘or bad’; good part being used for assémbly and Thine cembenents produced by a machine are classified into several sure ‘This is done both for hole and shaft and then the corresponding groupe eleva pon and | nde et 8nd holes) to be assembled are manufactured to normal toeranges of dire hin the curve af normal distribution, an automatic auge can corneas 'o ten different groups with 0.001 mm limit for selective sent ances of 0,0001 mm are peers IFoo then he ahs belo | eteach subgroup The mane of shalt tobe predic foreach carve fork, ing and ae rtp case canbe whe the proces cgay of th shat producing gmat deret and uh wien eames treet ae breenshaving wort rcs capably broken nto adopts umber svgrounseedaoeed | bareTetharpaa thst toadownn rospetninarrvoe reaped {hentinber fcopnents produced is determined by earlier i case asthe process eapal ‘nach sopregated zone and no bly technique ean be allowed for ater tiv cases also red oe for sdeetve ase i 48 shows anather casein whic the proces capability o hole making machine is mach oe ee ere iH he folerance of part but sha snaking machine can produce cmmporeat ie he eee Se icacage he parte with Hole are segregated into adequate number nf ees y) WesBerp a4 -wojoq ypnur 1 poureyureu st afoy poe YoUS yo SIxw oY MEARENP [BUEN UONUED sy 05 AOHeH9U, wz ‘S300 ONY Sits SLINT ‘se amp 0) 308 smo wins or 231869 Bupuodsa140 pa ‘ug pu squiod sour ‘yetse esp sno pasa. >yEENI 0} ops0 ef “pos "souounauno 9 20g papayput os sy [020ytq 10 fesoye Tan) 644 ey UO ost) age asa ry yng (SEPLERS WeIpU yo NE=IRE) STA 4 papeoKELEDID sy =ISey of Te 1 981000 £10820} pazonoo axe yuoututnbou Futur peu eyuotTEpeny Pe s204e79[o} je|uoUTEpaRY Jo UorEUIGuoD ofgeHTS v Aq pouTErGO 09 Avur souezeo auaxnx9 jo aso oy souara}1oyur auiagxe wosy BuaeA sy oyqesoUIMU ‘a '°0°T'T 9 pono 9g Sow IZA VEZ ‘AXA “a ‘V ka poyuassidas axe suoneuaisop (aos soy 27 oF [y yo soase> wodioo Sune oy wont pur poysaps oq ew ays o sym yey os “euON guy pr sos jo ares oytoads w ns 0 poSureare ssous9(03 Jo aasns Wo ssisu0> woyeKs paar jw Yor pays uaag aney HONS a pu 3 inosyy Sytzoyan aFeanoou9 of pue “nM pue 921g 0 sy “anoge passnasip se 1 anoW pase 9g 09 saouesoyy ypns sqeaa ZaA9MOH |squIOSSE eva - pS ADoTOMSH ONERNION onemS, FITS AND GAUGES 23. 272 ENGINEERING METROLOGY oes ring may be noted ly. Actually itis representative of total tolerance. Itis ion. In schematic reprsentation of tolerances, no regard is | ae om ir ee ait [ re 7 show shafts and holes fully, but only | Fig 412. Limits of sit and tolorance | | | TWEE _nnomnenra, er Poe a oe or mmm pee le bushes which ateinan interference tin their | SSSA 7 sours Sar Se ‘an engine. | LOWER T "DEVIATION ve) ‘Sze Fig 418.Typer ott‘souyew Say0g "worspto pood uy sxe uossden “Baru ‘1309 6 8 L ‘Boy0q om BuspsD g ‘sou Boyd “odes Spend YH ‘seo(gosne TO ‘TO 20) nope pois suoreandde xp 1%+ avooo= 1 por ‘a1000+ aysya= ‘ats ou “ond (—) pur ozs (2 ore 2 ‘ost [ toot | oot [a [ron] wnat | aoa | oar [ona @ rv oiger ‘ ‘are wi gore oxdn pw tras 999 ono 8 uo92 840 sopnyiue 9 coat | eur [ ear | cat | aut 948s oped yove Jo oprayuseu oxpotas jest uanp paxoyunous sor 3x9 Jo a 11 dos sper soap ind 9 jo ezqourrp Jedd pe somo om 0 ue ‘Trav + Gp a¥0=(su0r 7H) #9 ovsnidxo ef suozrur uy 3 ozoyat‘}20}0j oou839[0y prmpLs ox ouLiof i pourseNep a Sones fe}oKmnU om ue seateseoy opuLS so MADLY xe ono om [esomNS Ur ou PUBL BEAT % KAT "TOLL ‘ALT: povwUisep ozv seouesojo jo sopes8 og “woReoyrods st “spoon uo exam om Suxcz0n 44 Pourep are ayy gsegyp pu ‘ozor ay yoys Jo wortaop soddn ose so0g ee ‘00 0q eo Suxpaya8 pw Sayan &q peonposd "GIT EN 012s UoR ARP rom osoGa o "8 Ma EYE EnaENA BuREpONSD 5g saz sszonvo ony suis ‘suinn ory ag sweounsroy(e) wy UOMIEURAL CZ) WY sEHEZID T) soznoy upp sopdysou 30 &2m.95 TWIP} UW eqoHep oF posh Bf IND FRLL—IOHT “04s "89 ‘oxo st woroop saddn ono oye ws oye oto Geen caer ai0 p94 () (onASp Emap) ENP s8K07 (0) mS 9500 1H, ‘(eoupane ouOM GRA sougpaayain ithe ADOTOULBNN ONISENINE oeers at oss - a evaneenwa weraoLoay stitng planing lig, extrusion. ough tuning end boring. Predson tube drawing | oh pron wrk Tube drawing. 18 Pres work Tube rong 14 Stamping. 15 Sand casting lame cating. lerance and allowance for a 25 mm shoftand hole | | | ‘measurements 26 mm les from standard | ‘and symbols for fits In order to sati system provides fr any given basicsize, ‘defining the position of these tolerances Tesh tinea 200-0 | st sono om 24809 eee nage 2e8 a= 82 dapat hee ne ian se Teds tier toma i 28 ham nso dina‘saonvo any suid ‘euinn ‘Suoyo19p jouswepun pe aaoqe waco ase suonetep ‘aq -9ni 21809 axp seraidas pe toy au Stojoures sry jo sau ayp uy aA HoH ur sedn ony uaaanag souatagrpare1qe8e atch | wre oxy UaaaLjoq soUasOATP au, "Pousad ase sUOHyIAaD mde © uy -ouyy oso, soot fq punojoq Seuren rede 300718 ou, oR|g Tey wuzENGINEERING METROLOGY ‘The fundamental deviations for holes to H correepond exactly in value with those for shafts ig. 428 shows the e ? Wi NS to ne \ et Ie devigtions details for var ious shafts and holes a FE zo be . 2 é A N i 7, ane 2 7 : a - 2ST 1 5 Zero corsnotte Fig. 428, Deviations for ehafte and holes {may be noted that fundamental deviations for Jj, Ki, Mim and Nin ‘re different than conventions for others lunrs, FITS ANO GAUGES 281 deviations are functions not ofthe basi size butof the range A group of tolerance (eg, ITB), considered as corresponding ‘Tolerance Zone. In a graphical representation of tolerance, the zone bounded by the two ee zone, It is defined by its magnitude Ge tolerance) Grade ised aystem of imite and fit, group of tolerances are considered as corresponding to the same level of accuracy forall basic sizes. It designed by the is common tothe formulae defining the different grades of tolerances. Shaft. term used by convention to designate all external features fa part neiuding those ‘term used by convention to designate al internal features of apart, inckuding those cslindrical Basie Shaft. A shalt whose upper deviation is zero or where maximum limit of size is equal le. A hole whose ower deviation is zero or whose minimum limit size is equal to basie size, I is H hole in IS: 919 fers tothe lower limit ofa shaft and upper fimit of « ole. Thus it corresponds te the minimum material condition Fit. The relationship existing between two parts, shaft and hole, which ae tobe assembled, with respect to the diference i ther sizes before assembly is called fit that basic size which is common to the two parts ofa fit. ‘Variation of Fit. Tiss the arithmetical sum of the tolerances ofthe two mating parts of is diference between the ses ote hole and shaft, before assembly when Interference. This isthe arithmetical difference between the sizes ofthe hole and shaft before assembly, when the difference is negative. ‘Minimum and Maximum Clearance. in a clearance fit, the maximum clearance is the ie between the minimum size ofthe hale and maximum size ofthe shat 1p maximum clearance is the difference between the im size of the shaft terference fit the minimum interference 1e maximum interference is the arithmetical difference ‘maximum size of the shaft before assembly.saa 9{—0 Jo aBtes o4p Aue sue 3) pu Jo “po Syeys jo soBues oH, Were) ying ates | ‘ru 90g ov wo] 20) yHUS 20} swopiysod tevemrepim.g 20} auTNORE ey O1gNL, Georg wopnop qm ettGe 0p JI + = #2 (yor 9 saonesep Has eye 3a) ZT ~H9= arystones ‘Suyaoroy aug Jo sueoUt 4g, eowes9po prepress ox Jo anqea epnjosqs ays Burn soem _Evexm ag sa ons p ou pronop (9 eee, ‘saonvo owy sui ‘sun ADOTOWSW ONIUEBNIONE204 ENGINEERING METROLOGY Ltrs, Firs AND GAUGES ‘Table 4.3, Most Commonly Used Holes eal a\c| co) | eler|rleo] |u| lus|x uly] |e |s|r|ulv\x)r|z}z4lzalzc rede the shatt limits of the same symbol symbol but of oppsit sign. holes K toZCarenegative and ES, For holes A to ‘ES = BI + [T and for holes K to ZC, EI = BS—IT. "There are certain deviations in some types. | 4 —forhote oftype N and 9, and coaver grades, BS = 0, For hole of JS, ES » El = ‘Table 4.24. Formulaefor Fundamental Deviations for Holes for Sizes upto600 mm. {All deviations exp ths given below (Notes ; Holes A and B are provid W Pandora eke Kana | Upto Grades "acsve Forszeabove | KyMandN | Uptogradee fl Forsasabwe | Puzc | UpwGraieo sam ‘actsan \apead ows sjubsoudos waaay uz ©0511 $20 sf 90 a5¥9 uy ‘30 quopuadapay sy uapelsep Jo onyea ayy ‘gy 30 sf ad soy sade ex porou 9g ueig=s¢ 0 Ut pes » asa 19 L-%=P 2uys 4 pastap ase su suonsjeu Suyao|oy oxy suBEL Ag eouEs9,% ZY Onfea aAnoRgE Sp aoIy0 9, sp aH UT Maa aBTHUINY Se paUTEINIOP 30 1 UoNI49p LOMO} 20 ‘gg 30 29 uoHUAap sadn “>t sore] too [so [1008 mor] re | ow [we | rr | 70 eta evar onan) eu [ear | aa | ear ‘su | par [ear | eas [var sve1g8, + 8ojaq wea axe ura 9gTg 0} 9 wos) 221 2}204 20) 40} aouRAAIPA cnn p smu sopuitsnosnn oy Btpundssin oti paopues oho seen 9, ava =-[T-[e TL 7 ae90 + adr — |. L + 1 avovaat =p. Ps Le o wie + ato - a + a wean = xl F weir ove 5 xl ~ n es ee [9 ure we [er =e ° [ato a eee " wai ef 7 mar o mS 7 nat . 7 [> 0 at ~pe*fel- tLe wag eg | ow nang ng_|"rm" | sa | une | "pme’ | soe, Taeemepalemany oH wm a ‘uru ogT8 oadn puw mat 999 onoqe sa248 405 suoyne}A9G oIOH pire OYE 10} ovMIIO| verges, ssz0nv0 ony suid ‘LINN ny wey 0} poptasd uo om I. 01 FLL sope ous sjoarodans wan ga uo or 81.47 PL ee 8 sons ofsaq any popusoid ate ¢ pa a) syeyg #50 on otseq 20} asax, | ed joe pu quatudenba Aryqxte 4940 04 agony sou, “Syneqreaw Sdn somod yo quapuadoptr pu ajqeod az aso, “uoryranyuyyeuo|sueunp axmisod spun 2504, “sola ay soyexedunoa wo wopaiio [2uorseD00 pue WORE -sooou pry suopey snoouesyx9 s9yyo puY suoR.eHA fyddns soMod yo payp ‘svod ‘quowsnipe jeudyo ayy pue yup o}anp ssoss> wo aay} Sysrquass9 ave SoBe pax ‘are sale ad} soyeseduno 0 uostredumeo uy saiineS poxy yo salewteape Snowe aM, sosined poxto oBeyueapy op oo AU see Bayo 2} ee Ba dg) eo Suppers jee a) xpi poten ap Jo 9) mp rn Buunp stom so Suen ny pe sae Ss jo tou Bu sop pan om aun po sme nn aw Por ne ys 3a deta pu se uo sv not eg se eagle ye 0 aH) “wrpau ‘dousysoy (9) sosodind so 0 BupsHoY @) ang on apo? poutsseppaxe sang ‘syeyspussajoy (papeazyyun urejd Surypoq>.jpasnaxw ses up sya poyoods xp angie ape aze suaed poroodsty at sagan oy se Hgts 20p pas ag suo 9 Sat 3soH a Ho WoISUaLE 662 s30nvo aN Suld ‘suinT) Pawodsur tp Jo onjea jenjoe ayy owoqpur ou op sa¥mep) ‘sued paunpemnueLl Jo sueIsuaKEP m7 AH9ND 09 aasos wpuyas ‘aftos w MMoYRIA “ussop pxBE2 Jo s]o0) uoroadsur azw saneey sone weld Zep “oues09p9 9wax9 7 Hy 05 souozojioyur auasyx9 jo ny Woy Sudues YEYS puPafoy i094 81 J0 s9pess ge sods 616: $1 w porerounus se oues o1e suoREIAap yeys feELAEPUY 40} 9e|NHNI a4, ‘soue29[0) yoyusurepury a SH iuIPpe 49 poureyqo 9q wes sua soo aus, uoTTEINOP reyuourepuny 40 uoneuap atseq ox ‘i JO auo Suruyop ue ‘sity om uses souasaghp eu ‘ausoyop soou ‘QZT Bue Ty somes 943 990g ‘Aijeotromo38 Aayeursoxdae pojuos ose py 04 Yo sanqea au, sannvedso4 qOZO'D + #0 Pat th 2100 + $0 "as00'0 + E70 axe TL Pue QZT "TOL 04 Bexpuodso1409 ssouw.9}n PIMPUEYS OU, ‘616 S120) 8 axe gt 0} g sopeas oy Sumpuodsasi0> seouesofon PrOpUEAS Jo sonyeA 14, (maw 8 q) SUH GF TO’ + GASP-0= 2 10 ate QT} g sope 29 soouRs9[0s prepue}s 0 Sonyes taut Jo SapeiB) ssouesaor Jo sopesd og soptaoad 4] OZ ‘esuortaap oy 4 efo1 24304 2 pepiaoud SoBe yo ad Aue ze zoanjoeynet ot Aq pateyqo sna ayy Ua9.849q SODURIIBND tou sozs story aay ypTHN TLEI—SEBE = SI Hil souEprODLE LI Be ay} asn eur saline szammpeynueU ayy Jo Kovanwde atp Susu Lye ‘Da 18180 pou injsstaiod ou sazeou ses Susey sed en of quoUmzedap 1HAqs 20 nou 9en 0 doysyson ary SupuauIos01 £9 peplone 9q Pt ‘on puP dotasos aig pauteago syne ayp uoasaq douarapT eu sayy “doysyom OMY UH psn asoyy se sof jo sad oures oq soen Jamey om Jo jusunzedap Won}adsur ayy eH fr agndep prone of worms aqqistod 1999 94}, sosMDEFMUEA 8M} Sq woRDDASUY “TPT'F -moqoq want aznpaoosd sade ayy jo Syunzoyuoo aap yo BunIpaWP aK ‘fps you Soop zosetzund ay 1990010) 9p yp Sapa are ‘ty Surmo(iy q poprone ag feu soumpeynaeuL Bayunbar oindstp oy, SoBe szaumojorEut smooqdyuoq urejg 40) 2ompedg Burney spsepueys weIpUL PEF num { 8869 sm { 008607 user [Sates ha! 0008 903,09, anyone atang 307 ww { 21008 sn { 500008 ernst 002 sono 2996 m9 20, ejay Bag sso aTY cs 148 6F= 660006085 GF rw gos =(a00 +600) -08 ‘10 ae 05 OK, 20) SuOISUEUIICL "wu T9T6'6P = 6E00'0- Zeer PHY "unm 26F = $0'0— 08 ore afne8 op, 40} suorsuouN, ‘sine ny oj Se soon spurs B ut peta suORLTTO! ue 99°} ‘Hig Uy ‘uaoys axe satine# dep Jo suofsUSMP snow at, “ado Fur (e) ste ‘s30nvo ONY sald ‘SUINT — sn ype ee pase ee | : | wes] | a sage x sf aca | f ao woe a eS eee “reps sane 05 ON, {Hy 29u8I01) 80m Jo MOTI Hon ov seb 9 tangs mat oF RufpIODY o¥eDg Hey (1 sofia 0) Suss9p3=40.) veotsaeuem pauuoqep 9884 9fOY PE AJeYS Yaoq 40} au02 sGEIe|} ue euOMeNAaP s8Mo| pue soddn ax sry, “Vorb iy wr unos ae YyoHS op 4 suONELABP pu sooUEI9|0)sHONSE ‘wu 16I'0~* ToG0'0~ 90'0~= woryBHAap samory THOM pe aap sed, “a g'0— "am gpg = suas 9g» $< nap [etwouEpuNg, "ym o suoneap pe Ue Fy Ay O05 30 68 2215 215¥8 | Ye ae IB ‘uw 16e0-* 30m . Yj sw st= ary woliensa www sereoe A wats i Saree NOC wowen30 | ww eo: # Heen 225 28 ABOTOMISN ONIURENIONS ve316 ENGINEERING METROLOGY lug gauge made tothe specified “Go! of engagement ofthe hale and shaft. gauged to check thatits maximum diameters not larger than interprets th the Taylor principles followed then the diameter ofthe largest perfact {imaginary eylinder which ean he inscribed within the holeso th er larger than the ‘Ge the minimum diameter at any position onthe shat should not be less than ‘ay be noted that the Taylor principe doesnot take care ofthe error of form, circularity or straightness etc, the tolerances for which should be specified separately. rinciple we require a plug ring gauge having exactly the'G the engagement length ofthe leto pass ver in the workpiesein any consecutive posit he workpiece length, is, the Taylor prinsiplo cannot be strictly and blindly followed. The ywed which basically donot deviate from the principle as such, case the mianufacturing proces assures thatthe errr of straightness the character of it of the assembled workpieces, it is advisable to go for standard ind make the gauge unnecessarily id the special gauge of exactly same working length for one ‘gauge happens to be too heavy, only segmental ylindrical bar could be used provided ‘the manufacturing process ensures thaterrorsofreundness will not have any effet on the character heavy ones itis generally not desirable to use full form ring is purpose the manufacturing process used should take are jected to rapid wear ete. ; these can planes/eylindrical surfaces/spherical surfaces, For gauging very sms ‘workpieces may be deformed to an oval by a two-point mechanical eon of fall form may have to be used. 4.14.4, Allowable Deviation from the Taylor's Principle. tn some applications, dtfcul- ties are experienced in conveniently using gauges if they are strictly based on Taylor's principle. Accordingly some deviations may be permitted device, the‘No Go’ gauge hhaving length equal to ‘units, ITS AND GAUGES a7 For very bg holes, the fll form gauge may be too heavy and inconvenient to use. Therefore, segmental cslindrical bar or spherical gauge may be used if it ean be assumed that the manufac, turing process vould not produce the error or roundness outside the permissible linits to affect the character of fit larly ‘Go gap gauge ean be used in pl for gauging shats) ibject to rapidl wear, these can be replaced by small plane, «faces wienever appropriate. The two-point checking device i also found lesign and manufacturing for gauging very sm igid workpiece may be deformed by 2-point mechanical contact or plug gauges of ul No Go gauges of full eylindrical form can als» be use workpiece, which be out of round due to heat treatment, but would become circular when stch gauges a vith force just sufficient to convert the elastic deformation into circularity 4.14.5. Limit Gauges. The various types oflimit gauges used for gauging internal diameters orholes are wg gauge. The gauging surface is in the form of an externel the eading end ofthe gauge and the al surface is slightly reduced in order to act asa pilot. The method of dle should be such as not to affect the sine and form of the gauge by 4 7. Pll form eyinderial plug ge, Fig. 45, Pull farm dse gauge. form spherical plug or dise gauge. This has gauging surface in the form ofa sphere fom which two equal segments are cut off by planes normal to the axis ofthe handle, (Refer Fig. 458), = ing surface in one of the following two segments are made by lowering down idrieal form in which segments are surface at other places (Refer Fig. 4.59) of (i) Exte formed by removing remaining material (Refer Fig, 4.60, (4) Segmental spherical plug gauge. Its similar to ull orm spherical plug or dise gauge but has to equal segments cu offby planes parallel to theaxis ofthe handle in addition to thesegments cat off by planes normal tothe axis of the handle, (Refer Fig. 461). incal bar gauge with reduoed measuring fa imilar to segmental tal bar gauge but has reduced measuring faces ina plane parallel to the axis of the handle. Fig. 4.62),sede) yeussyuy ayy Jo dap wnat us soqnoue puv auejd 3B ayy wo poe But 40 ym popraoad S14] -4uEYS Pua 2) 40 wrod Sunuasaudas a8me3 op, WHO} Ry BSI SIGE, “UPI “SaBNCD IN}d “TOT 6901 999 wha wy noe ved on os rod eyo 2) ene Hs pw Bd 9 EN, snd Sue Jo uoREIA9p anosqe ayy 3e Ruri Uy doy ouNED “ssnVo Jo ‘sasiNeS asoKp Jo an ay, wap pau 03 padojdiua aq oy ancy sated aus pu Snyd snyy pue jeus7yx9 se om se [eur] yeanaoe jo as0dind tf, 20} sro ay -Koesn998 4847 O} ‘Buzmnyoejreu ut paafoaut ys00 wy Jo asnesoq parapisucojous saline wo ZoUEAO|Te EEA, “nad ayy siaqua aypusds pasodey 249 20 apoy posodey oy suaquo one oxy 495 now Sumou 4 221840} poysoy St soVOMEIP 94, ‘941 + St az o1seq uo ave Bnyd 40} ouEs9}o4, "HIN ZT ‘uu g wor souea 11 pu pus ao4y wod},», oueySIP 1 poyeso| st auE|d aBNes “Bn Bnyd uO 8 904 105 ‘go'y Buy uy ur g 0} 79 wy sozes pue uma z 614 so,oWTETP 8e8 ony wr pany si pus pansoy aq oy aiputds 0 a8ne8 Syd ( swestpinbe anoge anjq woiszad yu ueap axe sour WB aut sod v Jo ssauyve1400 949 BUNSSI aod pou 4g wo ua] 94) FuoTe ote ‘saonvo any suts ‘sulart “Sino Snag, 997 Pk 2ne8 ap soda p9 a Ship : tL od soyoureyp jo aStuonp ayy pu pus sag ye soourerp oy -Pe4 0} st got pasodey wg aeiodr ayy, “sad Fu pow Fnyd zodey Bussn sy parser st sade) ¥ siodey soy so8neg sth sours uyincvom Suneorpur jo sae Rue posn are 20 20 ste Sus 20 Sd oops o wy ayy Uy 30 sae des Buy DDtesosfpootnaopes joy a) UY JoNHD axe BsoH, “soHMeEB 9oUDID;OY, pesn axe somes Suysoys xp ‘sane yum ox snipe pur sods 0} s0ps0 Uy “os potspuryo ryo9 20 ey 94 Hog Av aS FuPZOM ax Surranstoo ssoppins a, “paxpeyp Bulag YS af Jo sIxE ath 03 fetesed Hupeq 19ua8 9 ann8 dog ioe 20g peop euoueg @5'y Bd a8 oq UIE rua TOF a Se=4 ADOTOWLaH ONIBNIONS are.20 evaincenina uerRoLoay irs, ers AND GauGes aan of maximum permissi further 0.01 mamie 4.16.3. Ring Gauge, Plain. This gauge represents an internal taper of asicsze,Irisused for verifying the taper Fig. 4.68. Ring gauge, plain Fig. 469. Ring gauge, tensed FACE OF LARGE END e0GE a Sites Oorauce Papaee | steaigit sayens—* —= StRence a we aauce cov vo Te Tac) Fig 4.72. Teingtapr wt sng eg (lin goes with ight pressure within the two ring marks given 4.164. Ring gauge, Tanged. The gnuge represents a step is provided at the small end of taper which vriles the indicate the minimum dep FASE THE GAUGING SUREACE A caus sunesce, exes too Site | ~ ZIZZO hie f ‘sua woe ex0'0e P6R eine oauce vesr Fig. 473. Testing external taper with rng gaugsCangod).—— — —-———_——-— uo ojezyisouca sow fps am pute Posen “Squmaas0 yno Burst fg ung speusierp on Suspunds sipjourip 0} Buypuodsoss09 200 eoumyep vy ated & 9 2oyou fea SBonvD ony suu4'SUNNT |p onMLaN ounaNONE ae38 ENGINEERING METROLOGY for aeinlcoptnvng apne ctxt ha svat a sng. ro snunderstaning compan yal oye international language roquirng no interpretation et oF Tincerctrtecccseia — ZEE Tolerance tone represents the roe within whieh | the feature i to be contained. This sone may be re, Indicated in a rectangle at the bottom. The nur tolerance. ortant features tobe noted in Fig. 4.81 are: instead feature control symbol put on line AB extended indicates that surface AB should be perpendicular to datum A within 0.02, and the letter B in rectangular box below it indicates that the surface AB is perpendicular to datum B surface, ic esoe EE 115 == al? | 7a== Tron ¢ _ ee Tpee]a Fe Fig. 481 Important fentoron of pmetrieolersnoss. LUMITS, FITS AND @auces [Broad toes Definition ‘Seaihiness Roundaes(Cirealary) | cyinay Profle ine Profleofa sacs Paraiso Crear eeuSpE "S91 0 pp fens soy ‘ur;dunep ood pu stoqnus 25 “soy ‘v9 S204 8 uy ye 29 uo woes {quater zo osm et 2qpIOOH “9 pu gy sump 0} wanes 1.09 IRONS HIYA 218 G10 = OO rumngep ose norpuediod 99 prnoye.g soepNs (par paptngre ou uo foqusssysyuooaaNje Z| moma ean saeramea uo ous pang, sa ne amy joseqpse @ are popuouraoaas sjoquiss 3900 1g soadexp wt poureyda spoqout pur sozmyeaj aoe 8 Jo sUoRTUIP ore OH, | © | Aateauscugy | a szonve ony suts'suINn ADOTOULSH ONEASNIONS330 ENGINEERING METROLOGY ne an the component dimension. From aber ‘dimensions for manufacturing purposesbespitupinta components, the taleranceon this dimension ‘must be shared among its components, For ths reason the advantage tobe obtained by splitting ‘upa functional dimension into com datums, must be weighed against the increased difficulty in produc necessarily reduced tolerances, Compound Tolerances. A compound tolerance is on the component owing ich is determined by the established Fig. 485, the combined effect of the :nce onthe 30.00 mm dimension and the talerance onthe 60° angle give a compound tolerance imension R. Compound tolerances should be avoided as far as posible, Problem 4.5. What do you understand by geometrical tolerances ‘Ans. The tolerances provided in any standard refer only tothe actual size or dimension of feature such as a hole or shaft. In many instances, actual size alone is not of importance but other geometrical dimensions eg roundness and stri lem 4.6. How the following are designated ? tandard tolerance grade (©) Position of tolerance one Upper deviation Lower deviavion Tolerance.lass ()Toleranced size ort. Solution. (a) Standard tolerance grades are designated by the letters IT followed by one of the 20 number +0, 1 t0 18; eg. ITB, Tho letters IT are omitted when the tolerance grade is representing a fundamental deviation i, #18. The position ofthe tolerance zone w.rt zero line is designated by letters to ZC for hole and letters. ato fr sats tion filowed by the number representing the standard example 8 (holes), 8 (shat) tums, FiTs Avo GAUGES 331 (p Toleranced size is designated by the basic size in mm followed by the dasignation ofthe requited tolerance class e.g, 40H8, 8027, 75,3012 (@)A tis designated by the common base ize in mam, followed by tolerance class symbols for hole and sha. #8 For example, 6088/7 or 608 ie, GOH or 60 Problem 4.7 Fig. 486 shows a graphical representation of a shaft and a hole. Provide ullable words for various dimensions marked as A, B,C, D, ee LE Fig. 485 Solution. A —basiesizo — maximum limit of size for shaft ‘minimum limit of size for shaft ‘size tolerance for shat upper deviation of shaft es) lower deviation of shaft i) imit of size of hole bratriir® lower deviation of hole (1) upper deviation of hole 'S) Problem 4.8. Fig. 487 (a) shows deviations for shafts and figure (6) shows the deviations for holes, Mark the fundamental deviation, upper deviation and lower deviation on these. Ron matnoa (e) Shane Holes Fig 48740} poureyureu st 9,092 30 ampesadu PHP 9,081 08ers om ButoK A or squoutoo sou pu antsuadut 1995 Uo9L YF ayer snouea ot, ‘ie de oy jo soeyine Supquom, 2p uo sou ent oxy sonpas ypR PapHoad st nges WI tt OT) HERUN ApEAY AY “payp eangesadurm prose oj wossunda zoo Jo aff00 107 (2) jour TTY PIMOS Bue op 205 road anousnn wig 59910390) 10982 ur suoMauApISUC oH UBES? 9) 210 PHA “STP MUOTAOL, pasos oq wo 330 ues stS0g EUS du are syeys joys tne pyposoLUNBLIOS Lo ‘pasvaioap s 2ues9]0) ‘yy 88 dn soo 0d» o 9800 au ou pet Burdnay zed oqo sumo at Suodond 9g eT Rd oma Jo no 1 ssa00xd 4g ajqusn axe aoqy out} 2. 42> yu Josqueo odd pu samo] pul Joddn puosog 5 6 939 27 opus 205667! z0 a4 oqdorssopgnt = doasg ot ruodap “aoomnAauqeqoad a poe no[9 y osnyes aig asaya Oy 9q a EHD Yor|UO UO STAT ‘op wou “sna-qns o ON of) 51 puw dnax-qns ypeo jo WoREHep prEpUES sto aH ox ‘AL = 290 pounsotep 610 woneop oBesoae oxy uoqy, Hey foro Jo ou fesTUaD Ot | HOI eee ss30nvo aNy suts‘Suin"t ‘dnos3-qne fe jo safezaxe jo afesoae ayy uowy pus “dnox#-qns y>es ys pue uorzodeur anf zroyopouruo fo 2en a pogo apou aq Us SpuPUaqops fuoUA8 OYA (Q) | Aniouod pauajaud jou st uorrods 607 ya (0)"OT'F OLA “4220 9 pio aN og + aprsno puE see" 9qPrHOH SITET 97 = a aprsHNO BIECT (Q) 2512799 99 prom sya oF = era BIE {su yoxuoo eo pen 2100 gop mayan puy soz =u nojanquasp pomou ays v0 07 = urys 1 Prnoye pep 243 Jo yuz09d 70444 (2) "BY WOLD wera ® ® ars3e13 anes ai 0198 092 snot 04 Buspuodsassoo| Tevtoueptng 2c 0 y sop 2 suauajn “US UF aA + PUR LORETAOP ‘0102 0} aso ureRe st wovesap [eyuoUTEpURY ‘FO Y S90 20 01 ys050) xe ¥ 0} 0 eyeYs 20} YORE [enuaEIEpUN “ORIMIOS ADOTOMLAM SATRETINON zeea4 ENGINEERING METROLOGY edize. Theamount deposited ter. ming the worn gauges For gauging aluminium or other materials hi plug gauges having stellte ribs, inserted in the gauging surface are often used, Cast Iron. Ibis often employed for the bodies or frames of large gauges, whose working faces sof tool steel or cemented earbide. The bodies are made of good quality iron, of & from blow holes. The iron is often stabilised before final machining Binvar is much more suitable and has an expansion coefficient of 8x 10% per °C. Elinvar contains 42% nickel Problem 4.14. Write brief notes on the flowing processes used in the manufacture of (©) Lapping. This process does not produce ace UMITS, FITS AND GAUGES 38 ioe is turned over for grinding the opposite face. This process is called spat grinding because ofthe spotted appearance of the ground surface. (€) Lapping Process. The proces of lapping, which is not a Problem 4.15.Writeashortnoteon interchangeable manufacture and the selective assembly’ of machine parts. this type, the following ‘method may be adopted. The tolerances are established which enable the parts tobe manufactured economically and then sorted and assembled according to theit size, This method is known as selective assembly manufacturing,067 ag 09 uazayan HATA ____ a £000°0 = 600'050 sor = ‘tn goo‘ = uu Z6200°0 = L6Z0"0 3050 = ‘wu 2000°0= ur TZ000"0 = 120"0 0 %0T = sm Te000 = 64e0'0.0x0T= Ruane gm names no ru 90 ue 9 atom ygf80)98—* woneHepuouepEng ‘ura ‘TETOO'O x 9g = 198 = LT LLP 204022I04 Pu , «PSS — Jo HOR HNP EHUaUIEpUN HHI YEN OM "uw g920' 9 = 2704 9718 wi ‘au G020°0~ FeT00'O 91 = 9 = kz “wat 90°92 = 10) “4p yo souss9}03 pur wone\sap yreKepLN OH EK 04 ‘aur TETOO'O = SuasoRE gOE'T = gz0'0 + 98z'T = 8e00+ S982 x 9F0 = (suo FEaX TOO ZEEE SFO=? ° au 78 = 08 8IA= 0 "800 near orp Soa) pry uorIIEA aR BuRUREIA}AP Jo poroU sy sMoYS 63°F Aig 2193895 SeorIOUEDD 1 yPIEE aj JUAN Jo WENOUTE om LO 39804 Ht He 2m JUDPKO OWOS OY, 804% [ id Su ur 205 popyaoud 2ou819}04 ae 25 pa000 ‘ups oj wostsoud a sang ysnu vox 9g uoHELIEA UUs Aton B09 paRDEISO oq Ket LF ‘ned "uoIsuoUD Ypexe Ue oj aBne ants paxy v aywUTo9 yduaHye 4 eoKEIOUNGD Us ‘pinoy soeanoow oun “paamy sooap s 8 w 303500 a4 Speeds eset.) 1 UBL eu0 Ao YPOKD PINOY ABNEH JOH LON Z oa ss pemron iva 20 nseuata 28 93m “aio 29109 oy J0 401 eo 20uDm0}9 1900 34, ‘on pun gy fo dys oprunyp ayy 50f us | ind '9'9~= Yor Jf voro}3p son 943 (he ws @ at00°0+ ap 9¥0 = (a0 supoyeufonen yu uaa Buoy ie ‘ss0nv9 any sits‘sLINT ‘umatups ulvsd ayy Bur u0%sIp 40 USs91}2:9803 ‘gnatzonsep ston sn joy 4p seas Pnow ADOTOULAN ONISENIONS38 ENGINEERING METROLOGY “ot od cause May ize SOS 25.0209 lee (rection pee My 020810 “soups cay in size Sian SOS BEE in| genom or bale sedan F (osic=22) paze0mm ox. ae L oa hat CrpSstres, per ce 80 Gauge TF HOT GS My 02570 lrecton oes Mi. se nm rok ey 4503 “NOT 60 cause Fig 490 For hole cor gan (0.0021 60002) wnat Ga gauge = 25.0208" 292 gn gauge = 257 00 Not Go" gauge = 25.0209; 0.0021 as 0002 = 95¢000230 ie = 251002 ig = 25500020 ogy For Shaft ‘The maximum sizeof shaft = 25 -0,02 = 24.98 mm. "The minimum sive of shaft = 250.020.0297 = 24.9503 mm 0003 = 24,957 02 = 24.987 (ooga . 0.0000) = 24-8879. o629 paovene ‘| NOT-GO" gauge = 24.9506 mm Ft for Hof the clearance ft because the minimum sie athe hole is 25 mm while ‘the maximum shaft sizes 24.98 mm, nce» minimum clearence between the mating members = 0.02 mea Problem 4.18, Determine the dimensions and tolerances of shaft and Hye fit Also determine the allowance (ce. minimum clearinee) and mati Solution. For hole Hy and shaft hy the fundamental devi As 30 mm lis in the range of 18 and 80 mm, D = VISIO = *GO" pase an andthevalueot i =045( ¥D) + 0001D=045 (7282) 0.001 x 20.2 mene | ¥0402.865 00291308 mirons Valueot Min sizeof hole =30.000 mand ma. sine fle = $0.0021 mm ‘umiTs. FITS. AND GAUGES Max, sizeof shaft 30.000 mm and value of/P8 for shaft = 25 = 25x 1,808 = 39.7 microns = 0.0083 mm. and min, sizeof shaft = 30,000 -0,0083 = 29.9987 mm. Allowance or minimum clearance = Min, size ofhole - Max. sie = Max. sie f hole Min. si = 80.0000 20.000 = 0 ofshaft = 90,0021 ~ 29.2967 = 0.0054 rum, 2m 4.19, What isthe difference between unilateral and ‘bilateral toleeances ? Why is eramee preferred over bilateral falerance ? and Max. clearance ‘made in only one dieeeton from the ce the variation is beth over and under smension. Examples of two respectively 5° 102, por (gz mm and 60°, mm, Referring to Fig. 49 system of tolerancing, rance or typeof fit eral toleraacing system, for soy ‘oe oxsrance Woue ToLenance ood eo #0 ne soy 000] 20 eooos ALLOWANCE =0.08 00 iu ote 59.99} sags 4 =e T mowanee coo AT saoel p80 2 aed saat ot 008 Soar Shar rouemance s Unilateral nerance hanging the tolerances fr altining same typeof ateral tolerancing system and for a ti ral tlre $e customary. gauges for holes and NO GO gauges for shafts can be standardised, cearas {OEE 4.20.() What are the esential conditions for obtaining i interference ftsand s possible to dill. 25 mm nominal holetoan accuracy of 25* 008 mum using standard ‘machine available. A shat isto be machined to obtain a clearax9 09 “and des OD MyM oqqtssod you sr yom YEN (ouuoqunap pue Suspusg esounyrens 1 OD UHOF Ij JoNpMA “aGnUeF de OH £q you yng anes Su OD 4 payeoyop 9q wes suonsap1aduat soups poses ‘Fargo oy] exon pom fexspU|sD Jos, potas pe 04 P _mqyp 28005 05 ON puny so4y0 49 Opes oq pes ete ond Gey a0 [ry 0 ope wert ‘sabeed oD ONJT aul eye woisuautp au0 suo SEER p Blane f lsviseo says LZ oe BT HA oe woth \ 4 RTA TE rion tf Zyeott0 avon soazs xn ZA be {soy Sunooyo 10] afn03 Snyd pops sgn0p 8750008 snsion alr ads anqssatoud uz Jo soBDquoa oeip pun safojumipo 2) 219 FHM (2) 1 H001 poppy Bupa 40] #08 do8 nsson amo Buys Buen Jo soPoruonpen pO SOBOWUDEPD 2 20 PUA (9) ‘son08 gnu Jo usheop un gdautsd Sasa 9045 (0) Be WGA, “war e9g6cE = $6010 O8T = HEU, ‘wa 216 621 = e@0'0—o8T = wenuEERY ase ons yo sry val ge-= 1-8¢-=uI-sa= Uwopersp somo uilga~=$412-=a+ Sa wwoersep sede, un p=9-cr= tar T= wy = Lw9hty 90~= sa “woREHOp peyMEpIN vu t= aT00'0 + ay 9¥'0=1 = kLI= aounsqorprmperns ‘uu 16 9PT = OBE XAzIN= a days epouerye9'081—00 “ay 0-81 wom2p 10 sq TLL Woy sopnid sun. pasion ny wpag a aioe sey wou ys wan pc 967 8290 0.0) 98)0 9 “an Za0g P= F00~ uv 04 W 0} ajqeonda ‘uu FHOSR'GH AUS pHESR'ED = 999 (99°09 + 96)~=(@'e9 «910+ 96) ~~ 50 Ue 2 woRE}ANP eIUUIEPUNY Jo one be s30nvo any suls‘sumrt sr zop0g = oo 30 9055 0g ‘uu 29900 = SBTON Ox = 96 = ERIN Joan MR ME MF 04 IO saw 9000 98 = 9f0qy0 928 "upg 0 11910429 wonetop reyuauEpUN tu ogtog0 = sumin geset = 2e90'0+ 64't =Z'E9xTO0'0+(<'e9p) g¥O= Tov + (ap) 9¥0= 110m suesOO;0 anIeA tu 69 = OF} OF = 08 Xs = c smeKEEP 0 ana‘ | ‘Joy pu oy Jo wossusunppono0 ay wo ‘uu og &% propuns 2yy Sos vansuoutp Buena roy une Aus PUD INV IEW OLAOAA ‘mst 200 9616 = 99 PINoWs pus ‘war F010" 96169 ~ 86'GP = 9Y04 woo ‘UU 96 6F = 2010 To'98 = ouELapO;U OYA yoHS JO ONE KUHL = 9[04 30 ‘uur 4g'9= —— souaLR]sayU xXeUE OSTy ‘uu $56 = T00~ 65 BF = HL xO YoU JoamE-ayE= ———_afoy oars xy wu 16°9 = aouasoprae ‘uw gg'ey= ye pu tune Toag= -Ueysz. 100- suur 09 o6 7¢0q 8 wosuoup sy pu "wu GOO = PEPE LS'FG= YORE UO SOUELOIOY, ‘uu FeV = 80'0~ 20'9e = souRIwOR Hp ]OK JO Ox OH = OYE JO exe IONOT ‘a g9'0 8 Payjods souesvopa Pw ay AN, "unm 16 PE = TOO 86'FZ = BIMEMEATY ~ofoH JO EIS = yous ez xe \=—— ovea2 ENGINEERING METROLOGY otherhand, NO GO gap gauge can detec errors like barre imperfections whichis not possible with NO GO ring gauge. In f cheek the end of sections andother intended NO GO ring gauge only ean \dvantage of faster operation ns because ofreasons stated is now obvious that GO ring salts, the GO gauge surface and NO GO ga ithe NO GO surface being nearer to le and GO surface on extreme. It has the advantage of faster operation for inspection as it need not be reversed for checking NO GO operation. However, it eannot be used for shallow or blind holes such as rcesees where double ended gauges ae used (@) The GO portion ofa gauge is usually longer than NO GO portion of « gauge. rroblem 4.24. (a) Discuss the different allowances that must be faker indo account in the ‘manufacture ofa gauge Determine the actual dimensions tobe provided fora shaftand hole of 90 mm sce fr Hey ‘ope clearance fit. Size 90 mm falle in diameter steps of 80 and 100 Value of tolerance unit i = 0.45 (¥D) + 0.0010. Value of tolerances for 178 and 19 grades are 251 and 4i. Value of fundamental deviation fore type shaft is - 11D" the GO and NO GO gauges as per the present British system in which the same rion gouges are used Wear allowance—itis provided on GO gauge and not on NO GO gauges as latter have le wear compared to former. It is provided only when work tolerance is more than 0.0875 mm Yeon gauge tolera "or calculation of tolerance D = V80% TOO = 10/80 = 89.5 mm Value of 4 0.45 (¥89.5) + 0.001 x 89.5 microns = 0.45 x 4.46 + 0.0895 microns = 2.0079 0.0895 = 2.0965 microns = 0,0020965 mn. Value of tolerance on hole, correspond ing to grate 78 is 25% = 25 x 0.002006 = 0.0524 mm, Max SIZ 90.0524nm ote Ei AsfundamentaldeviainforHleypetoleis hy wo.e|//7"ocenance Min, size ofhole = 90,000 rm smu SE OF 20.000 and max, size of hole becomes rote uWBauentas 90.0524 mm BENET TS sesso wx size leoe76mm SHAFT = 0.06853 mm, Fig. 499 LuMurs, FITS AND GAUGES 343 Max, sizeof shaft = 90.000 ~ 0.06858 = 89.95147 mem = 89.9915 mm ‘Tolerance for/79 grade is 40: = 40 0,0020065 = 0.08386 mm. Min. sie of shaft = 89.9915 ~ 0.0839 = 89.8476 mm Gauge tolerance for hole = 10% of 0.0524 = 0.00524 mm = 0.0052 mm 0.00829 mm «0.0008 mm ference to Fig. 4.94 No 60 GAUGE f Forhole HLA ss GO gauge 90 one c00ses oRECTION 99° 2951 = 90, oan 9 sau ona «oma NOGO gouge = 9059 0 ‘D.as2e “WEAR ALLOW- 00°57 am wae ts = 90 So Forshatt - aoanis-00008 WEAR ALLon- GO gauge = 89.9315" g008 - 008 ANCE =00008 caggnis 2008 = 88.9315~ 9 9999 IRECTION OF = 9072088 ram caw = Gorm NOGO gauge = 69:47622000? mm nd OE = 907922 om ‘neue Problem 4.25, What do yur under Solution. The gauging force is ‘the component under its own weight the component is quite definitely outside limit and needs reconsideration Similarly, a component should be rejected {gauge assembles freely under its own weight, and not merely because the NOT GO forced to assemble ere such a criterion is used, the entry o the GO gauge thould be facilitated by a chamfer in Fig. 4.99 sos to ensure that cress cornering and jamming ofthe gauge to not prevent free assem“3peq poxpor uowy 5 atin ayy, 28 ay Jo UN oy atF SPIN SH, "THOUT a ‘qu0m ayy uo aru OB 9x04 Tene LoyaurENp wOUDYA © oy punoss syd ap 'sase9 omOs UT ‘yySuoy oxo2 Suypeondde ad wd ‘70430 8u9] ox oy yenbo aq proys fined OD ax yo HO] 9jdund xp 2yepors3]yu9] nruyp 2UH05}0.09 881 OD-LON® ‘uv 09 Jo uoRPuyguios ayeoape sprupue}E Sow |UEISU! 294 “THMPAMES 9 pur juauodiaes ox Jo UD] Try oy yu uy st ined Bd Qo jensn “log stead OD LON IPO AL yunoure ayy a yEyS 2M UU JOpEaID 94S re RYAN SaOYeAN JOANN MO} SHA, A}OROKGTEND Ssnolfy se payers 2q fou soyd und Saoysey ‘sua yexoUad wy scout .20}6Ry, 50 UOK ‘Swournea ae rae uayey ‘pe zopd0y, Aq payee yay axon Sadutsd 94403505 Oy, sve sz0qv0 oN sits ‘SuINTL nq ssoupunos a4 jo amnsvoure Ao anys PIG ONAG G6 Bg PUR POY OMY J spe oy Suoye sou} you ‘on sf oydputad ay, stencouP A) iy 9 9 Bee Gy waa BN | seth com a a ss 249 angen 3H ‘ssougareais ‘inatton Jo 741 Buyeaxpuy soxpARY SUB douapE YoU [HAL HA aT ® AFH, 21g Suton aye a9 (ny jo Se wg ssous ste Jo yoey AL yo ao und oxp oseo w yons uy ‘ssouyyBesyS 7 APH] St |1oK} 3N4 WWHTSTOD St YOU OT 9294 S18 OD ayy Jo ud [Ry ayy ATTIBOOHPE 19 6 7) aun soup 7URysTOD ys £0 pago7 $1901 949 UM agsP KOU I, 0H 10u PINEYS OD-LON STU yoy 19 LON Pub o}o4 249 Jo sum feu unuxpeeU oy 0 HurmsO;UED sor2UrE:p) ‘ud om 97 FespuAD UO w Husa 10g “saHwo8 yay 30 uBISOP "pov ut adionud sucphey, oye (0) "96° WOTAOSKL ‘AooTOULAN ONREANONS be346 ENGINEERING METROLOGY 2. Gauges for circular shafts. For gauging circular shafts ofthe shaft or the length of the engagement ofthe associated component, whichever is shorter. The NOT-GO gage would be in the form of @ gap gauge as shown in Fig. 4.100 ‘To gauge the maximum metal limit of all diameters simultaneously requires a ring gauge equal in diameter to the spd Uheoretically equal in jeableto make aring gauge of Fig. 4.100, Use of NOT.GO gap gauge for ashafe considerations lead to variation from Taylor's principle. The departures of the above nature have been permitted due to accurate madera ‘roduetion machines and equipment available, Peoblom 427 land shin tem ha the dimension 60 #2. The tandad 6 0.45 9D + 0.0001D of geometric man step of 5D to 80 mr. where D = diamets ‘The fundamental deviation for fits given by FD = + (17-7 ~IP-6) forthe relevant range of diameter. The Class of Rt and stateits application. theft and show the actual dimensions. Solution. Nominal diameter of shaft and holes 60 mm. ‘Since 60 mm diameter les inthe diameter steps of 80 and 80 mn, ValueofD = W505 80 = VA000 = 63.2 mm ‘The value of fundamental tlerancefactari = 045 ¥D + 0,001 = 0.45 « VES2 + 0.001 « 68.2 = 0.45 x 3.98 + 0.0632 microns = 1.79 + 0.0832 = 1.85382 microns = 0.00185 mm. Hole is type H-7, and for -Hole, fundamental deviation = 0 ‘Minimum sizeof hole = 60,0000 mm For hole H-7, ie. grade IT7, the value of tolerance = 16i = 16 x 0.00185 = 0.0286 mm 0.0296 = 60,0296 mm ‘Shaftis type m-6 : and value of fundamental deviation for shaft mis given by + UT =1T6) = 16i~ 108 = 6 = 6 0.00185 = 0.0111 mm. Lumits, FITS AND GAUGES ‘Minimum sige of shaft mension + (IT? 1T6)» 60,0000 + 0.0111 = 60.0111 mmm 0. sa se waxsze Or Sade g0-296mn soomne i FR gee 7 sal (ats wie \///Jporasenn ee A Sadi |e 60.000m0 ie wee Fig 4100 It would be obvious from the dispustion of dimensions that itis trans fit is medium eying fit and finds application in medium tight assembly of ms the case of keyed shaft Problem 4.28. Figure 4.102 given belo nension 27 @8 as per IT 919 and determi tolerance factor, Fundamental tolerance factor’ = 0.45 VD + 0.00LD mierons where D is the geo this case is YIB3U since given ot Fig 4.102 dimension 27 mom ies in the diameter steps of 18 and 30 mm D=VI8XI =23.0mm +045 ¥D + 0.0010 = 0.45 99300 + 0,001 «23.0 microns = 1.308 mice ‘Tolerance of IPS grade = 254 = 25 x 0.0013 = 0,0325 mim Fundamental deviation forg = 2.5 xD? =—0.5 «23.0% == 0.5 «2.92 = 7.3 microns =~ 0.0075 =0.0013 mma 26000 00 250006 = gy og worst sa pro eae= YG a ‘uu 2600'0 = sua.Hm 961s = OST L= SuOBHE gOE'T = £200 + $8e't = eea00+ 998% xS¥0=Zee* TOOD+ BEER BVO = (ie ee= og*s1s=@ ‘at000+ aEsKo=* = gprcouesa( yo opesd paw g = y 704s 0 woRewap eivowepung “a 000" 8 sna T-wornIOS too ay Yo>ys (=) = 1epuopp [ets uo sowez9Ioy pue yous Sup o worsuoup iseq ay, '¢ ¥ 900'¢z wisuaxmp amp au “surynpioade yn prrormunoon 2y3apoypus 0) sous.oqey ym 9 yun Busop ay} uo worsuoun yp 27MIN “pjeuyp serous ay uo s0UD.290) 20 3TOPROTID (1) “Bupmoup puouoduoo ay wo pain soqucsayt yo wrong (1) “uw og Pu usu gr wosmsog says soyowsp Jo mou pusood syn 83 au0yR um aouns2}os PLOPUDIS 1£= 9,4] 201049905 J0 901) ut os st worpoufun Burne! 24, a ZOO ru sous opgresraad 0 ung 9 0 a0 uowoqes fo ser 2 yz S200 249 Jo ssauaroNbs my, "wu 9¢0"9 pasaxe you pnoys sou Krouquaoucn ay rn ospusouoo 29 0 Lo BP; wore 2 _gononn et souBenp my) way worries uno) aux oot 247 0 woronpot of anced po ayade sens 9 0) #1 sow eo ayy Jo uonsdrussop ayy, “Ima op-D [eos D samp MOI POI'P AMAT “OFF WOOL egg cor (efo0 unr gee oo gO? ear ga oy poumjearog we> yu 910430 wo}suoUN ca "09 pp = 00-2006 « Joy uoeuaLN opensp jsuemepury oxy aos 2 yey 9} ouNsE| SUIS ‘WI 96FZ0'0 = 9STOO'O * OT = 7 9T St L epeas yo souLIa|OI, yuma ere s30nvo any suld‘suian a gy@0'0-= suo. gy 4g —= SPYXSS~= yg 8EXOS~= soz (7 79~= F YoHS Jo WOR rep ope pe oy yo Jo WOSUOUN PIN, ‘ur ggt00'0= sunt goes t= Leen + Eze = 18000 +86) S¥O= LEX 1000+ LeEp GYO=? wt 96 = usr ps 9g 3 doy xu a op soyusrp sus) HE 0B x OBA= Cd soy (x05 GTO0'0+ Gp 80 =? 1] ov woreuoup 2st pouray9p 09 0) way 81 a4, “WORNIOS ound , g09'9~ = J, wonomag poriumpuny (ur) 191 = 41 902904 J PD “uw os px0 (wong adap oop Jo woot spam oy s1 220 (ouo2!4) q1000 + dp SFO=1 ojo oun pooutopuy won &prgopuyou og 2 ye 27y 4 Jo wouowa ay} us ‘ow2}4 YOY OF, 116: 91-24 so suosuowp a4 yd sore aut tg) A “— heel aaeelt” “soouvoy yo prsuodueo» syne ag uaa? BOT ania Bar WHI vuux 9007, H00"y¢= p uowuounp det yy, ‘ur T90°0= 6F0'0 + OT'0== (6F0'0-)- OT O-= (600'0+ 800'0+ 2010 Po'0)Or'0= soe} 0180, ‘uw gp0'0= (Se00-)- 00°0= ‘un 19 = 001 0€ +09 + oF +12 = 9 ded jo uoysuounp 21eog, eu 700g = ODO“ 12 rg 8 1 woqsuounp 20 ons uu yz, wo SOULE SUR, ‘ww 2096'9@ = spe0'0- Lz66'98= eas Wr oo ‘wm 12656" SL00~00001z = 8 nmap s9070u130 onIANIONA ore350 ENGINEERING METROLOGY ‘The symbols used on the drawing are: R3.50~It stands forthe provision of gradual change between two shafts of 5 and 28.4 mm diameters. A concave surface of radius 8.5 mm is provided as shown in Fig. 4.108 ‘This te an old method of surfaces roughnest and other * 40.280" 4 « 37.100" information like concentrcty error, squareness of the faces with the axisofrotation are not indicated onthe drawing, These will beshown in symbolicform as shown, in Fig. 4.106. [snot enor reset Fig 4106 4.31, Complete the dimensions onthe lock sown aboveas per IS: 919 and explain the block, indamental tolerance factor, i = 0.45 ¥D + 0.0010 (mtcrons) geometric means of diameter saps 10m oe) (ara oa3} [ezaioar| ¢ Fig 107 LUMITS, ATS AND GAUGES 351 Diameter steps for boss are between 30 mim and 60 mm and the diameter steps for hole are between 18 mm and 30 mm. odin this problom are 40 h 8 and 18 HT. Value of D = 10x50 = 38.7 mm and i= 0.45 98.7 + 0,001 x 98.7 0.45 x3.38 + 0.0387 += 1521 + 0.0887 = 1.5597 microns = 0.00156 mm. Fundamental deviation of shaft h =0 land tolerance of grade 8 is = 25: = 25 x 0.00158 = 0.089 mm Value of D for 18 mm is YI8%30 =2321 mm 0.45 1232 + 0001x282 =0.45 2.855 + 0.028 » 1.286 + 0023 = 1.308 microns = 0.001908 mm. tion ofholeH = 0 = 16 x 0.001308 = 0.020928 ~ 0.9209 mim is is 15" 00209 Dimension of 1817 is 18% 22208 mm ‘Meaning of two eymbols is 18% 2° mm 0,000 ‘Meaning ofthe symbols shown on block in Fig 4.107 is uA | 005 | Surface B is parallel to and eror of paral 1A | 002 | Surface C is perpendicular toA and error of perpendicularity is 0.02 mm, ‘The symbol indicates that surface roughness height is 6.8 microns. Problem 4.32. Enumerate the advantages of ied gauge ofthe critical part portion). ) Provide uniform reference standards, vide mast economical inspection, lindrca! plug gauges incteases, their basic design also ‘changes. Discuse some of the common basic designssypoqq ae 94 J0 a 09.8 pauspany jo apeur use) jsouspunéo wo|dyo ed Husa pos uma GLE oF we g-ZT 9248204 (9) ay, ary aa 0° 09 108 09, | l 4 | SBuyreoeyneRs o5e2 0 pos yos yo ape st Apo aes ayy, roquioM HUME ge FoNe pouepsey jo Burysng popzasur ypu posn st dpog Hs ura 2] 0 wt £7 soets 20g (2) "SUY | "ani eno. 10 ealino8 Buss popu fo udop m809 241 fo aoe SenDIC HEY WO|GOA, | aa ov ata | — | | 1 onto qnduay v ancy ‘pe 0} joao oF power sxowyge on papact suojsuouup ur 2qqeyrese oq emu os amp Jo sqUeUa fenplagpu au, — ‘18 asodand pansap oxy 243980} syp01@ aw 30} syuotwantbos sfeRr “SU “sypog a8mn8 1 syuouasenbassofow a) ao.oUnU“OR"F WIOT AON { T y) vive | Sne8 09 Yon se sats sets ane pus Z| 2 sned oxy ay soussoe ss sae ene com ny bmeus S028 CEC, o B 296n06 ux! 09 10" Toy ‘26m06 61g 09 LON ' poyzosur axe soqpuey (reg ayBIeH sonpex Oy pazOg st Gam JO axIUED ABH Joy poprodd st ass Seong rcs oats ore eto ee ir somes nae _ petro pps ses eyepaerintnenenrpenrmmema NE _capngrane aman eaters one ] 26n08 Buy 09) 26006 Brg 09 H_] pre © 5 pus a8 pong te © Pay a ie po suo oda ey pew 9 Ke sory Bu corr aia aver na wus sodas sin oy ur Ssooeseop Jone ane po sswesoTe J80n 0 uopsodp on saoqs FIT BL sUy Neqwaweubren eg tm buns tu pu nid 09 .LON PY 09 zouns2}0)s9y0u 9208 pu zounmerpo 200M Jo wowoderp 2% 04S SEF WAGOI 12} 0}posn ox aBuvy soppy req UHL osNNA UL PHOS 290 21845), ounudood ® yp payransgns aq ue9 alee [a0%g pose st 296.0 Bumpmey 40} Kroydund paSuey yin adie ats pros “an | UCT PUR SEG 89218 Jog) (GOT'F tg s9pPy) “paen st oBTed Hyd ae anna em GT oy IN Gy'9 Wo4} ABI 10 ~~ vene9 — ese ‘S30nvO ONY suid ‘SUNN ABOTOWLSM ONISNIONS ee388 ENGINEERING METROLOGY Problem 4.38. Why great importance is atributed to a high degree of smoothness of the gauging surfaces ofthe gauge blocks ? ‘Ans. — A rough surface creates problem in dependable measurement of the gauge block length by contact instrament, = for interferometric longth measurements, a good reflecting surface is essential — high surface roughness can impede the dependability of dimension transfer. — surface roughness reduces the wringabilty. Problem 4.85. What are the advantages of square gouge blocks over rectangular gauge locks ‘Ans, Square gauge blocks, because of their large surface area, wear longer. — They adhere better to each other when wrung the high stacks, Square gauges with entre the wrung stacks falling a ods as an. added assurance against However these are costly to manufacture as compared to rectangular blocks, Problem 4.39. Match the parts A and B in connection with gouges: Part A ‘measurement in precision manufacturing Hrd cylinders of extreme accuracy used as diameter of screw threads. Agaugeoutsidemessuring surfaces of which fare designed to verify the specified unifor- nity of holes. measuring surfaces of and NO GO gauging sections are combined in a single unit secured to one end of the handle A fixed gauge arranged with inside measur. surfaces for calipering diametors, eness or width ie ofsingleor double zuge the internal contour of whieh eonforms to the frustram of a cane ing diameter, taper and length suitable forthe gauging ofexternal taper dimensions. 9. These consist of conical points or serrated or thhjcaded blades, plates, or eylinders which pat eaiy mend In a spe Part B (@) Measuring wires and rolls (©) Progressive eylindr (@ Spline plug geuge (a) Thread snap gauges (@ Taper ring gauge ( Gauge Blocks © Flat plug gauge 9 Ring gauge © Plain cylindrical plug gauge | luis, FITS AND GauGES pal 0 Wire ype plug gauge A plug gauge comprising a gauging member ‘of straight eylindrical section throughout its length and which is held in a collet-type handle ) Snap gauge (© Plug gauge Dw. fect ‘eondition and the geometric tolerance for that material condition. The process of inspecting «specific parameter, (iv) The process of inspecting a gauge to verify that it meets a spec (W)A device of defined geometric form and size used to assess the compliance ofa featur or pattern of features of a workpiece witha dimensional speifcation and its accompanying faerance. (oi) A fixed —timit gauge used t0 verify offature or then adjusting a gange oro tern of features compiiance with east (measuring sensitivity, accuracy, . for providing desired measurement. (auxiliary sensor and eleetranie counter). ars are usually madoin the form of modified “H, “U" or "X° ines are applied on (op surface, bottom surface, mide surface, ated measuring epreseat a very high level of so (aceuraey, Daring the mens proses npc bar andthe ea be ovasarac pate toads mera ct CO Tecssentilelanenta msn ae eagle tial scales, screw frame). me eee 5 eeeeenenesuosuoU rea opus Suprnsvou soy suouamnsvons axpeseduio so yypsn st Busine ay Ig) “adoso seo wae ayy 2onpou ftyemyae 0 YBnoU asp poyeoo] aq snus soy to oy) Buys aoupns prs ayy "UoHMN|SGE axnoa|jo UE 978229 a, (OG) ‘iy soypvor ofied oywuinaud uy won sod Bune ayy ur suoREHIeA a4 Jo PEND "gun asyuio ap Jo aayea uotsmaud w kg auop st yuounsnipe uv aay pooqg uo suvour q poysrdinoaoe sjuouuos st sine a jo Bur19s 0197 4, (92) ‘soBine 310 Jo worpesodo ‘2yenepeus 20 a8 “eaten joadsnosyonbay ou ats spitos poddesquo 1 ozmys!our pasUapUED ‘6qqun ates ae ayy Jo squowapa Fuuaou ayy ur sessed MOLIEU aM} JO UoHINATSGO (92) ep ‘Anqtssoudoo oxy jo gns30q zo most snes 1 eumnoud aunssaidl yoeq jo ostOdse. 14 (FZ) ‘qqsay you are syuauiasnsvou aspsuss3H30 ‘pts ut suorypuoo Zopun pue suomaunsvout axnNodad 205 poasoyeud aze sane a 20) 98103 umes wo asnaNy ‘rmnbas puv squotunzgeuy Sunevaut ad oqoseduica soso axe med soyeOFpUH SK, (02) -Aovanaoe pu ‘peas jo woreda 20 ‘sxo. yequayod yo soqs0oo ong Fa9psuoo £9 possBsses}Anesna0e 10}E1DUT ep LL 61 -suonsaqts pue S204 und sure s008 fq Sunezado stustuetpou WREST (ey py won pom nog p pepueys w Aunuosardax ypse) syuowoye fenprafpayyBsaAas Surarqun: aupods Jo sprepues pua ofquyreae ayeur oy st sypoqg ae Jo asodand “aay zencuejpas tof qua” a Sy9919 93 use s30nvo ony Sutd‘SuIAT “suoyeuauutp 2409 Jo Buypeas asp aprsoud o3 pasn xe safe o1dons0/%, 6) “yop afeae axe oan oy) uo puw appuyds ayy uo soeHns YEIUOD OH, (x {uounenipe oxoz Sujets jo svat» saptanid a8Ne3 naLos sO WH AS IH, (L) ‘met a usa.Iq ‘quouoseout 20} se Avernaoe aut soy siodiooJoyUIBAWo papracsd ano oe tdaq (9) “tuypeas ayeanaoe pus aonb ayqeus ©} sedrwa sod so;tuBA uo poptaaid st asaups BuRIeO] ¥ (S) ‘qn yo Aveanoow aug, juomomsesut Ul aj ayy Jo Buruonisod sodoad ayy pouitsse snorgya nq suede waoUy yo s9uy| UoRENpEN! aaey SBuNEAH uoRDe: sooumys o saquty piv fb Paypuess gousx9yex vse Papua 11 ‘osno09 osodandl ayy you st woinjoss yy ‘sprepuPys 409 pozenpexd aut Jo 95e9 UIT) “osjej 20 ony axe syuomoyeys SuLMOITO} ONY ISTO 91S ZP'Y WITT “soompi passa feanuen ‘pepeaade f\ye7ep9 "57 ‘2g woaaag sows “9T ‘09 LON “21 0D LON" soous 5 99 SuLNEwaU ‘ads "suonooGop sole “9 foeanooe-g‘aepns aus foxy “zquno9 tu suapojonjogd “p “stansues Suumnsvaur 7 ‘Suorenpesd aty jo Aeamoe poureysns “| “SUy 0) ‘uo syuouraunsvou 20j pousyaud axe sone y 430} spel Geinsoe {(sooejans ude xp uosanjag souwystpyuorsuoump Srepunr ‘uy s} worsuoup Teunuon ayy rpoqq ates wy se) sprepuErs pud 10 (g “ous aie 24804 Fampppen ‘ovo gg@ sa0uBa9f0) some ae ” {OD LONGO) ‘s98aB "9 HD (OD LONIOD) *8nw8 ~~ pore ut paride a go septs jot spots} autuudS 9u02 aotesojy ae oy Butpvadds) saaqe39[0} [2K 5) 09 ys soyourerp 9109 But pe 808 39218) ASOTOMLBN ONIUSBNIONS ose358 ENGINEERING METROLOGY ) The range of size variations which ean be measured with air gauges is functionally ‘open air jets, the magnitude of ranges ofthe order of about 0.975 mm. ‘contact type sensing member in air gauge, the wider range of measerement (of the possible. (5) Aone millimeter tore diameter ote npmeumatic gauge willeonsume rf the order of 0.3 cubic metre/hour. meee an (80) The air of pneumatic gauges mast have minimum of humidity and be feee of oil (True) (38) The most common case of er ‘The back pressure type pneumatic gauges have a relatively quick response in com- Parison to flow type air gauges, back presse ye ir gauges, the responses lower becuse the compres es tothe delayed rasan the orion eight tthe aj ‘wo adjustment usually provided nal peamati ages are Zero aijastment and ation oclration adjustment (42 Zero sting ina pmeumati age is accomplished bya precision valve of he conto ‘purpose of amplification adjustment in pneumatic gauges isto obtain a range of ns which, in terms of the scale graduations arein correspondence withthe size span, lised where the same gauge has tobe measuring ranges, mncan beset with single master gaugeby zeroing ‘The advantagos of velocity differential type air gauges are quick response, operation ge clearance between norzle and object surface (Uhereby reducing the wear of the ‘gauging members) and low air consumption (48) Velocity differential type ar gauges have magnification varying from 500 X to 6000 X. (49) Back pressure type air gauges have magnifications varying. from 5000 X to 40,000 X. (60) For fll calibration of pneumatic auge, wo masters of known sizes eoresponding wo ralue are required. ad lis the characteristies method used in pneu sg with intermedateelements which operateby mechanical contacts also frequ 2) Air gauges per closely spaced on the same (68) The gauging force on the gauge spindle toward the specimen should be sufficient to assure postive contact nyt not bean high hat the eslting la dafarmaton cola a affect the accuracy of gauging, ™ * the simultaneous measurement of several dimensions, even when ums, Ts AND GaUaes 2.True a. True 7True 8 False 12. True 12 Faso 11. True 18. True 22. True 23. True 26. True 27. False 28. True 31. False 32. True 33. True 8. True 31. True 38. True aL true 42, False 48. True 46, Trae 41. Trae 46. True 51. True 52. True 58. True 56. False 51. True, Correct Answers to False Questions 4. True 8. Fatoe 4. False 19. True 24, True 29. True 34, True 239, False 44. True 49, True 54, Paleo 359 5. False 10-Trwe 15. Paleo 20, True 5, Locking serew enables to maintain a fixed jaw opening permitting repetitive readings of several identical parts 6. Depth gauge torque is useful for rapid measurement of depth but the precision of ‘measurement is not as much as between the jaws due to likely deflection and wear-out of torque surface 18. NOT GO gauge assembling indicates thatthe dimension being measured is incorrect and part needa rejection. 39. Reverse is true, 42. It is achieved by a bleed valve 54. For this purpose spherical form tip is preferred. 56. Gauge block eomparator stands are madein generous dimensions, ofheavly ribbed iron ‘asting which is thoroughly stabilise, in order to prove high degree of rigiditysunjsuousp qos} ax 26ut pu sud up pon anf ne a aS 1 Jo"wmpaodasd poos wy “orays YOu wameyE EH HD AO HT U9 Fe i 1 5 pas Aqusese Yousom ue yds 1 souere9p 80} suo PLD umes 2400 vos ut Says aor senor usaf yesareren pus ways oy ING IPH IE ‘wonpmpent Su.seuo a0 yp sya yap A are yuo ous SuRyM > ssahoead ye “ygegesdomyaron 907) puns oy see povoney 9 a 48 Su Fo ya oF pole se of ‘sald 09 On. | ‘urea (2) pus BerooRuauD 3oy wy oy ee _panstsaup 200A oayo PINOYSBBNLI ON ON ¥ paw ty HRyJoOq PINE INES ON A EN ong ot pa pn Ep a0 ON.P 09d Fo On ‘sBned yu, pu sounsop sone aneD, som 0,8 OK ER ‘9¢ Poe go das spoup ayy uy 0 rd 53—= GOH) 5 weap sadn on, asus u @) a 1000 + jy S¥O=\FwIRE)FHeORNIOG AN us md 2H. ay YA o¢ S194 sede sy sdNU ON, PU" 99,322 94 aUHINIOG (Q) ‘woetnpyyoPUsEpUNA (7) ‘oat : ey m9 UHC (2) SNOLLSAND NOLLVNINVXS TVOIGAL ‘ened oj oon spenpyeu oon 63S | 98 ss2pnvo avy suid ‘Suu Aoorouian ONWSaNIONhet ENGINEERING METROLOGY that you understand the meaning rs wll recommended fr permanent azomblios of machine components Give 4 combination fo the type you have receded onthe hlo-ased system on sha-bseed system? nd (jo) Hole basis system of staraor bilateral, iemoro edvantagos? Stato reasons. it gnuging. Can thi prinspl bo sity flowed In practice? Jus of dimensions gags fr checking hlecof'0.+0.02mm diameter ‘A plug gauge for a No.8 Morse ‘Tho taperie60.2:m permet indotail how you would check th angle of taper. [A taper ring gauge has end diamstrsof approximately 60 mm and 45 mm and it length is 55 mm Describe how would you measur te angle ad end dimers Drive any necessary formulae, 1 dscrbo the methed of meaauring a taper plog gauge aed a taper ving gauge using rollers, lip eo ge ie 62 mm long an has larger end ameter of 9.15 mm and inclded angle of 1" Deseribe method t check ts dimensions and driv any formulae needed and estimate the accrary of the results you would obtain, ring gauge has a mean laf 17 mam and an axial length of 82.5 mm. Daseribo haw you would Find the angle ofthe taper. Show all nacssary calculations. ‘hat checks shouldbe madera compete inspection os tape plug gaugo? Describe indetall anethod of checking the angle of apar of such s gauge and incu ell nocassaryealeulations. 5 Comparators 5. Introduction ‘A comparator works on relative measurements, i, to say, it gives only dimensional differences in relation to a basie dimension. So a comparator compares the unknown dimen- sions of a part with some standard or master setting which represents the basic size and dimensional variations from the master setting are amplified and measured. The advantages + of operator in its use, Further ee as comparison is done with @ into great accuracy is possible. The eomparators are generally used for linear measurements, lyin the method used for and (2) Mechanial-optical comparators lectrical and Bleetronic comparators (4) Pneumatic comparators iuid displacement comparatars (6) Projection comparators eck comparators (6) Automatic gauging machines. of Comparsiors Before we discuss the various types of comparators, let us first look into vatious fondamental requirements which every comparator must fulfil These are as follows pairing its measuring accuracy. such that readings are obtained in least possible time }) Provision must be made for maximum compensation for temperature effects. ) The seale must be linear and must have straight line characteristic. \dieator should be constant in it return to zero. ) Instrument, though very sensitive, must withstand a reasonable ill usage without permanent harm. (oii) Instrument must have the maximum vers can be used for-a wide range af operations. (iii) Measuring pressure should be low and constant. 363 w its design must be such that it