5.

1
INTRODUCTO TOIIRINC(l1RT

dimensions ot Woikmece hieal miethod l epr'senng (1)he 111ufacturm

asseml n
OiSsenbl () the [oleranes held on ihese dinensionS. ( ) lhe
C s e ul c u m y o p a l o n s . ( 1 ) h e mlerinediate and the final
ICSlnt ddin1ensoI. (\) he lorilne
I11anutaclure ulce
sulareJna
nd the
i
sulace lo he prOcessedal all stages of

neprmary pursose ot lolerance chart is to ad 1

Teducng manulacturing cost by
chie ng ihe balanee
CO the toleranees lield on he manufactuTNg dunension AMough most
Iolcrince charts have
bce i usecl tor sluds me the dnensIO1al
poblems on idi1 Icdual parts. the
re cqially uslul in
jprocessi1ng assemblhes n n y casc
5.2 PURPOSE OF TOLER
1NCE CHART
Tho
ri r purpose oleraIee vhart Is reduct0n of manufacturing cost. I
serves many funcions Ismder
DGluraniee ol r t m nfeucture The tolerance chart ells the process engncer whelher or not

the part can be produced o part prnt oleranes. I prev ents the costly serap by inliorming ahou
part production difficully ifan
Mamiutu turing seqnree plemg It ads n developing the proper manufacturing sequence
It can renove process toler:nee stilck if it e\isl thereby ehoosng proper manufacturing scquence.

Meuns of esteublisinnIcnl of pT/pe"r wor'hinng toleTNes It helps in establislimmg the proper

working tolerances for ca:h operati0n.

() Assurun'e f suffici"PI Stok rmoru/s I pron ides assuuranee ihal sufficieni slork remoN al

w ill always he available tor cach operation in the sequcnee. If sulficient slock removal is not

aailable. the 1olerance cl art will disclose he condiion.

I oller some alternale method of dimensioning for economy of

() Product cdesign chng can

manufacture. This is onl poss1ble 1n consultaton Ilh the product designer.

It lhelps find the practicability of conmbned toolng -

(h) Pructic cabilityr of com.ineel ooling o

Such as form lools - or co nbination of workng and in>peclion gaugeCs.

of reducing
1Enminatin o guevnork in cuse of complen parts I proNiedes means

ust
which are ikels to occur if comple paits are processed wilhoul do
0mcnsional errors.

lolcrance charts. In shorl lolerance charts clmnale gucssOrk.

r:iw maleriai sl/Cs
mlle'rial si:es Ii helps in delerminng proper
(n Aid Jor determining rn

e deterniicd
prper castng and fergng iallonances
can
ne
 Pron ess Engnrrng
of
proce's oit112
i d tor cdevelopmenl gether wItl procSs
picluire sheet. the
an naluable and tolerance
hart prov ides
ir
development ot completc And aceuril:
process routing
S pconrol heips n reaucng ne perceniige ol
Serap by properly balançine
the
IolerancCS.

TIGS. WORKIG DIMINSION

S REACE 10
BE MAUINED

LOCATINCi SU'RFACE

5.3 DEFINITIONS AND S¥MBOLS:

The detinilion of various lems. their
sy mbols and certain norms uscd n
preparing
tolerance chart are esplained bel w

(1) Working dimension: (w.d.)

I is the distance betw eei a locating surface and surface beinng processed. The
a
smbol
for the working dimension is stown in fig 5.1. The cirelkd dot denotes the locating surface or

the centrelinc. The arrow heat notes the surtace to be processed or machined.

(2) Stock removal (S.R.

Iis the diffcrence between the dmension tat existed prior to machningand machining
dimension. lts prumary purpose Is o assure that slock s iav:lable tor operation all times. Stock

removal working dmensIOn cef operalion-iw orkng dmenson ol cuTenl operalon.

S.R. .D.pe Wd

In preparation of lolerance chart thc stock removal is idssigned in reverse order i.e.

starting from last 1o first. This reverse sequence is recommended so :hat S. R. is assured even to

the last i.e. finishing operatio 1. (As the finishing operations nced least S.R.) When several

surtace. the practice Is to llen no more stock than the

operations are pertormed on a gINCn

rcquired for the last operation

20 D
200 05

50

48 422684
 a Dislance hetween

'nnesioned Sulace

c) Final Part Print Dimer sion

Represenialion of resultant dimeISIon
FIG.5.2
(.3) Resultant Dmension / Bulance
dimension ( r.d.)
l is a dimension.
uhich may or
may not be given on the
part prnt. I is the distance
belween undimensioned surtaces on the
the
parn print fig 5.2a). It can also be
few known dimensions
(ig 5.26). The final part print dimension
algcbraie sum of
also can be called the resultant
dimension (fig 5.3(c))

Si/e
B:ase S/e

nequ.l Bilat ral Toleranete qual 1lateral Toieranee

FIG 5.3
The resultani lmenion iachie\cd iis dlhoie in Ole OTalion a change due lo sloch

remoal Such dumension which change in further opcratons due to stoch removal is called

intermediates resultant. The resultant dimenson between Iwo surfaces. centerlines or centerlines
and machined surtace is rep csenied hy stmbol as show n in ttiy 5 id
. Rule for addng and subtructing dimension
When addne & s1lHr.acting dmensron. the holeraee e mulaton must he cIdered

The basN Tule ts thal w heiher the basic dunensions l d e l i n subiiicled. then tolcrnces nus!
 adde
This
.
can
illustrale
he ll
be trom t1g s
2an and s
2h In
he tig 5
(a) the dmensIon
sublriactng B tron
ACW lhereas \B Is
oblained by m
hg s
2h) ihe dinunson A)
nddrng AB. Bn & C1) but n beah casCs lhe obtaned by is

toleranee
ohned resullani dimensionvn the
sum of. thc tolerances of the dime ision cosdered lor obtannng this dimenso are

AC1e S0)0) 0.10

BC 20 00 0.05
AB will be 30.00 0.15
Therefore d:
In fig 5.3b
AB 1e 20000 O.05
BC 20.000 0.05
CD i.e. 20.00 0.05
Therefore AB will be 60.0() O.15

5. Working dimensin tolerance:

This is the tolerance on ihe Workng dimensions to be achieved cach
n
operation These
oleranccs are allotted to cach opcralon by the proeess engmeer He issigns these values from

the machining data books. from his knowledge aboul the accuracies that can be achieved w ith the
machines available in his organi/alion For evampie roughmg toler:nee grades ITi1 can he

achieved in rough turning whercas for milling fine tunng. grndng tolerance grade of IT 10.117

& IT5 are achievable respectiv ely. It is the respons1bility of the process engncer that the values
of the tolcranec assigned to the vorking dimension are achiev able on the machines specified to

reduce scrap rework cost.

. Stock removal tolerance or total tolerance -

The stock removal loleinee Is the lotal variaton trom the basie stuck removal

dimension. Which can result from ihe operauon pertomed Though he S.R. is obtained by
taking differciee hetween the eomseculne w . the tolerance onSR s obtaned by add1ng the
lolerances on these dimensions (a per rule tor additon subtractuon of dnensions)

FIG 5.3

Tolerance corersion
For the purpose ol toler:IKe chari,toleranCes on le dinenss are requned lo be equl

Uncjuil hilaleil toleranee or unmlateral toleranee.

bilaleral. lHenee. if al all the part prni sho
biliteral lolerince Dy chanymg basIC SI/e and value of
IISTequired io be connerted mtu equal
cqual bilaleral 1oleranee as under
toleranee old basie si/e djuslnent amount
New basic size for cqual bilateral

Fqual bilateral tolerance

bil.ttet.al tolet.inee
Adjustneni amoul upper toler.anee opual

S0 n4?2684
 Proes Ingin'rg
nequal alaleial toleTanee
ith haI s1/e
0,00 upper toleranee (),O8 and
O T lkrance )04

04
Equal blateral iol:ranee .06

Adjustment amou t O.08 - (0,06

0.02

New basiC size S0,00 (0.02 S0.02

New dimension W7th equl bilaeral tolerance is 50.07 0.06
t ) If S0 In unilatcral tolerance witlh baste sl/e St O0 upper tolerance 0.0 and
lower ioleranee 0,08

0.0 -(),08
Equal bilateral tol :ranee 0.04

Adjustment amouM - 0.0 - 0.04 -0.04

New basIC Sze S0,00 (0.0449.96

New cqual bilateral dinmenson w ith toleranee w ill be 49 96 004
The tolerance can al so be conn erted by using a slandard tolerance conersion chart.

8. Indexing surfaces
For thc purpose of tolerance chart the surtaces considered are always indexed from leti to

These indes numbers in combination help to identify the

right as I. 2. 3 ete. or A. B. C° etc.
relates t dimension between surfacc I
dimension in consideration. For exmple inder no 1 -3
ot tie surlaces mmolied in an operaton such ndex
&3or3 & 1. Fo faciliale he ndenulicauon
dnensions and in
mentioned in nder liable ot toler:ine chart to inndicaic parl prnt
numbers are
dunens0ns.
to tie iarois Workng
front ot cach operalon corresponding
DETELOPIVG THE TOLER:A VCE CH4RT.
5.4 PROCEDURE FOR
tolerance chart are under
sieps
inolvel n makng
The various
dimcnsons. which are to he considered for
the arous

Seleci the \iew of the prt inmol\ing

preparng tolerance chart toleranee chart
cenre ol the page shect
lo be uNCd for devcloping
the lup
D r a w this view
al
vertical lines
as ctc. Irom leti to righi and draw
to e processed
and indey the surfaces

starting from each surtaces. and machinc

No.. oper.iton descriplion
ike operalion
tolerance chart headng
S Layoul the leti of the \ertical
line resulunt
lolerance 011 the
lmension and
used. ndex no. Workng on the right hand side of
tolerance
dmensnon and
lock removal
and loleranee.
dimensiOn

t o l e r n e chart
form lor thi purpose
standardized
ertical lnes or use
 CIt unilletal
anl
uneqaul Iulateral
tulerm
the inde tadle m Clei h e s ot the d n e isoms w uh uler.anees m
of tront
S] Prepare a leniutine the respecivehdey nde numbers
numbers prn prn ded at the lup ottolence chant
ist ot
ope aluons ed
proper sequcnee Dran OS
required for
requred for mnutacturme the part and arange them
manulaetnt n
the
wing. lhe operaiM hori/onual
Ontal Ines mes tor
for each
earh opeial
onei.alion heepng sutticwnn sNcng tot

o Wrile tne opCTaton

deseriptton and machune used
deeript on and the machine used. in chart
Asigin tne operaioN p
nunbern n irsi
colum an l0
column for tirs
j0 or lirst operaton.
as
operaln. 200 for second and so on
Ttor Cacn operalon wrte -0 tor
s
down the inde
processed and the nubers alier findny ul tne sut
locating surface
8] Draw the
horizontal line
coresponding to surface n each nies
locating surtace by a dot and the nut
-urtace o be prucessed by n arrou
[9List dul tne
mtemediate resu lants or
this lune coresnonds to cach
resultant produced in the
working dimensIOn. Tai
manufacturme process. Wnte is nde number and draw he ines
comecting tne surtices
mvalhed Alsu drau ua dors al cnd ot thee mes
from the orking dumensions.
l dilterentate tenm

10 Assign valueS of ihe loleranee on

workmg dmensnns irom slndard proeess udatu and pust
experience.

| I Ass1gn stock remoral dmersion tor last operation firs, the neNI lo last second. and so on
back o the first operation Whn sereal operalons are
pertommed on surtace no more slock
than required should be prov Idad for lust operatom
is

121Caleulate the slock tolerances considermy ilhe uorkmg dmensuN nnolv ed. Though actual
working dimension are not el krown. the assigned olerances on these dmensions are added to
get the S.R. 1olerance. The S.R. toleranee is caleulated serully for each operation ey S.R.
Tolerance for first operation s um of toleranee ol raw materal dimension and olerance on
working dimension of Ist operalion sumilarly tho SR. 1olernee on second operation will be sum
oftolerance on previous w.d. and urrenm nd
)The working toleranee lor the rotary surtace grder is asunmd (0 tor
as
ltcung operton a

005. for lor milling as (0.05. The valucs are lilled at

proper places n t leranee chart
2)The rough dmension on facing n Id1h S00 thusThe 1oal suock nmoval 0
S0.0 2.Omm. Hence stock rem nal per side 0 1.(mm. Oul of this 0. 2mm is keep tor
grinding and 0.8mm for facing on turret lathe. These values are filled au respectine placs m the
SR dmension colunnn from botlum
upu r
he slot dhepth n specilicdis l0 0mm, hut in aier makm this slt 0 mn soes s ill bN

TCnocd in grmdung operallon. Tlenee slock Cmoal lo iO mdes

the oertOn i
se
02m o accouni tor inal grnd ng

$2 422684
 w.d Op( parl prinl elmeson S00
wd Op 4 s00
S.R opeialon
50 5)0 5)2
w d Op 200 wd.40 SR. operalon 50 S0 2
2 504
Smilarly wd. op 1 wd 20 SR 20 )4()8 SI
To cross check abone caleulations he raw maleral dinenson ust be cyqual to w d op
10 S.R.10 i.c.52. which w sume as raw aterial dimensions
menloned n
pin
part
(5) Now the resultant dimensions and tolerance are assigned from bollom upwards. The final
resultant i.c. the resultan un the last
operation iS
nalurally sane as that
of the wd. and tolerance
oflast operation. hence tke sume valuc Is assigned to Resulunt dimension index 1-3 op 50
Similarly the r.d. op 40 p.p. dim index 1-2 1.C. T0.0 iriermediate r.d. op 3) index 1.2
r.d.op 40 S.R. op. 30
10.2 0.2 10.2 mnm
The tolerances are caleulated from top dou nu ards by consiuderin !he w d.d insoled

Tolerance on S.R d. op 30 d . w.d.t.2()wd.t. op 0

0.05 0 5 0.10

Tolerance on Rd.op -400 w d.t. 30 d.I400) ()0 0.06

Tolerance on r.d. 50 w.d.T.op, S)

(6) The tolerance chart is now balanced for tolernce on r.d. op.50 as il most closely

matches wilh the part pri il lolerance.

malches with p.p. tolerance i.e. the by (0.01 so this valuc is
(1) The r.d.t. 50 nost closely
added to all w.d.tolerance all from bouom upw ard

(2) the S. R.T. are recalculated from top dowinwards.

(3) The r.d.t. are lhen changed from top downwards

1.C.n reverC
dimensions starting fron last operaton
(13) ASSign valucs o* the working
for last
Cquence by using the s.f. dimcnsion for that operation. T'he
v:he ol norkng duncision
Wd. ol
The 1aluc vl lis
peration will naturally be cqual to the finished part prin! dinension.
ddung dependny n the S R. or tlal oper:il0m ro
D Onc Wil be caleuliled by subtractmg o
Or To the last operation Iether 1he dine1son I C I s e s o derrasCs
Thus w.d.cuw W.al.e S.R.
 4 (ulelalc the values uf 7ulian: diro"is d iol une.s ng trom hottom upu ard

ltant dmenson and tokrau fo: tuiai s i a sJall. a l n tha a t the

The
toleranecs caleulatuon
imension and
1

ur ner te:lhan dimension the workng

iTns and the tolerances 1 2 f i ct tn ih Tennding oneraton un the a e nder

nunbersare cositered

The values ot the Caliani dimensio t r s altlated 1e niion upuw ards trom pp

iumensions and S R I1 the corre ponfine suner.Alt-s

The final restullani dmeaions are nat i.7sll 1e tha o parn prunt dnensions I he
intermediate resultant is calculacd by adding the R of the neni operalon m wlirh th tinai

resultant is obiained.

15) Balance tolerance chart In b tollow ing the slep gn en below

(a) Select the resulant dimeIIun whoe toleran hnely matches s ith th part print tolerance

change tiii valuc cqutl iu tlhe p it prni olT.JI

(b) Make necessary changes hy nldng this caorTetion iieraee 1alio all toler.ke m
eTÁIng
dimensions of all
(c) Make necessary changes in SR Toleranee workiop dn
nm ard
d) Make changes in rd.t Work top dow nw ards

ip (peration De«riptuo Inde

WripE a tan
and machine uied
Ren.ark
:1
i Chu on f Turn ( ,

& Face 3 lurrct lathe

husn D lu(OD
& aCe .rret athe

Srim rot Sur'at 1

Endr

Grind Ra'an

Surtc irn.in

Fig. 5.4
1OLERCEIRIOR OPOEU