ree 376 A Textbook of Production Engineering 9.6, SELECTIVE ASSEMBLY ‘The discussion so far has been in connection with full interchangeability or random assembly in which any component assembles with any other component. Often special cases of accuracy and uniformity arise which might not be saisfied by certain of the fits given under 2 fully imerchangeable system. For example ia part tits low limit is assembled withthe mating part at high limit, the fit so obtained may not fully satisfy the functional requirements of the assembly. Also machine capabilities are sometimes not compatible with the requirements of interchangeable assembly. Complete interchangeabilty inthe above two eases can be obtained at some exira cost in inspection and materials handling by using the selective assembly method In this system, the parts are graded according according to size and only matched grades of ‘mating parts are assembied. This method is especialy useful where close fits of t¥o component assemblies are required. It resuts in complete protection ageinst defective assemblies and reduces machining costs since the tolerances can be increased. ‘Taking the case of mating of pistons in motor car cylinder bores. Let the bore size be 63.5, sm and the best skirt clearance for a certain type of piston is 0.13 mm on the diameter. Let the tolerance on bore and on piston skirt each be 0.04 mm. Dimension of bore diameter is 63.5 +002 aos Dimension of piston skirt is 63.37 +002 -omsmm Now minimum clearance smallest bore ~ largest piston = 0.09 mm, ‘Maximum clearance = largest bore-smallest piston 0.17 mm By grading and marking the bores and the pistons as shown below, they may be selectively assembled to give the conditions req) Cylinder bore 6348 63.50 63.52 Piston 6335 6337 6339 Another application of manufacturing. by selective assembly is that of ball bearings. The variation in sizes of the inner race, balls and outer race that make the difference between a snug and loose bearing are very small, of the order of 2.5 thou of a mm. To reduce their cost, these components are manufactured more liniently and graded into groups. The bearings are assembled from comparable groups. Only the inside and outside diameters of each bearing need be finished to interchangeable dimensions. An incidental advantage of this system is that the manufacturer is able to arrange bearings suitable for various purposes by combining components from different groups. By that means, three desirable classes are drived : a free running and loose bearing, a snug but free bearing, and a preloaded bearing for close constraint of a shaft or spindle. 9.7. SOLVED EXAMPLES Example 1. Find the values of allowance, hole tolerance and shaft tolerance for the {following dimensions of mated parts according 19 basic hole system. Hole: 37.50 mm —— Shaft : 37.47 mm 37.52 mm 37.45 mm Solution. a Hole tolerance ~ High limit ~ Low limitLimits, Tolerances and Fits 7.52 ~ 37.50 mm = 0.02, mm. Shaft tolerance = High limit ~ Low fimit, = 37.47 37.45 = 0.02. mm Allowance = Maximum metal condition of Hole = Maximum metal condition of shaft = Low limit of hole ~ High limit of shaft 37.50 37.47 = 0.03 mm ' Example 2. 4 75 mm shalt rotates na bearing. The tolerance for both shaft and bearing {0.075 mm and the required allowance is 0.10 mm. Determine the dimensions of the shaft, and the bearing bore with the basic hole standard. Solution, Refer to Fig. 9.15 It is clear with the basic hole standard that, Low limit of hole = 75 mm High limit of hole = Low limit + tolerance 75°+°0.075 = 75.075 mm High limit of shaft = Low limit of hole ~ allowance = 750.10 = 74.90 mm Low limit of shaft'= High limit ~ tolerance = 74.90 — 0.075 ~ 74.825 mm ops mony | s Ww Git) oto ig 918 Example 3. 4 medium force fit on a 75 mm shaft requires a hole tolerance and shaft tolerance each equal to 0.225 mm and an average interference of 0.0375 mm. Determine the ‘proper hole and shaft dimensions withthe basic hole standard. Soutlon. Refer Fig, 9.16, - com s “FI Hole : Fig. 916.A Textbook of Production Engineering a8 It is clear with the basic hole standard that, Low limit of hole = 75 mm I High int oF ole ~ 75295 + 00375 = 152825 mm High int of shan = 752625 0.225 = 734873 mm Example 4. Calcite the fundamental deviation and tolerances and hence the limits of size {for the shaft and hole for the following fit 60 mm H18-f7. The diameter steps are 50 mm and 30 mm Solution. (2) Now the tolerance unit is given as, 45 YD + 0.001 D, microns D= J50%80 =6325 mm 1 = 045 x ¥6525 +0001 x 6325 1.850 microns = 0.001856 mm. 251 = 0.0464. mm = 02046 mm (rationalized) For shaft 7, tolerance = 16/ =,0,0297 mm = 0030 mm (rationalized) (®) We know that for hole ‘H’, fundamental deviation is zero, The fundamental deviation for shaft (Table 9.1) is, where Now for hole H8, the tolerance 5.5 = 5.5 (63.25) = ~ 30.113 microns = + 0.030 mm (absolute) (©) Limits of Size Hole : Low limit = Basic size = 60 mm High limit = Low limit + tolerance = 60.046 mm ‘Shaft : High limit = Basic size - fundarhental deviation since the shaft ‘/ lies below the zero | T i : 4 Fig. 9.17. High limit = 60 ~ 0.030 = $9.97 mm Low limit = High limit - toleranceLimits, Tolerances and Fits 379 9.97 — 0.03 = $9.94 mm The fit is shown in Fig. 9.17. It is a clearance fit with 0,03 t0 0.106 mm clearance. Example . in a limit system, the following limits are specified to give a clearance fit between a shaft and a hole -0mns shaft 30 —f9g md +0020 hhote 30 * ON mang * Determine : (a) Basic size (b) shaft and hole tolerances (c) the shaft and hole limits (d) the ‘maximure and minimum clearance. Solution. @ Basie Size = 30 mm © Shaft tolerance = 0.018 ~ 0.005 = 0.013 mm Hole tolerance = 0.020 mm © High limit of shaft = 30 ~ 0,005 = 29.995 mm. Low limit of shaft = 30 ~ 0.018 ~ 29.982 mm High limic of hole Low limit of hole @ Maximum clearance = High limit of hole ~ low limit of shaft 30.020 — 29.982 1.038 mm Minimum clearance ~ Low limit of hole ~ High limit of shaft 0,000 - 29.995 .005 mm Example 6.4 hole and shaft have a basic size of 25 mm, and are to have a clearance ft vith maximum clearance of 0.02 rim and a minimum clearance of 0.01 mm. The hole tolerance isto be 13 tes the shaft tolerance. Determine limits for both hole and shaft (a) using a hole basis system (8) using a shaft bass system Solution. Referring to Fig. 9.18. $ f ATF mn 002 te Hole ‘Shatt Fig. 9.18 If is the shaft tolerance and y is the hole tolerance, then y+ 001+ x= 0.02 LSx +001 +x = 0.02380 A Textbook of Production Engineering = 0.004 mm and y = 0.006 mm. (a) Hole basis system. The lower deviation is zero, Low limit of hole = 25 mm (Basie size) High limit of hole = 25 + tolerance = 25.006 mm Upper (High) limit of shaft = low limit of hole ~ minimum clearance 25 - 0.01 = 24.99 mm Low limit of shaft = 24.99 - 0.004 = 24.986 mm (b) Shaft basis system, The upper devi High limit of shaft ~ Basic size = 25 mm Low limit of shaft = 25 ~ 0,004 = 24.996 mm Low limit of hole = 25 + 0.01 - 25.01 mm High limit of hole ~ 25.01 + 0,006 = 25.016 mm Example 7. A fit is designated as 100 G-/e, Find the dimensions of the hole and the shafi The diameter steps are © 80 mm and 120 mm. Solution. Geometric mean diameter, D = 0120 4) OE shat Tolerance grade, 1 ~ 045(D)'+0.001 D, microns 0.45 (98) +0.001 98, = 2,079 + 0.098 = 2.177 microns jon is zero. Now, for hole G,, tolerance = 161 = 34.832 microns 0,035 mm (rationalized) For shaft ¢,, tolerance ~ 251 = $4.425 microns 0.054 mm (rationalized) We can get these values of tolerances directly from Table : Appendix IE. Now F.D. for hole G = + 2.5 D/%, microns (T 9.2) 25 98)" = 0.012 mm (rationalized) F.D. for shaft @ = — 11D", microns (79.2) = = 11 (98), microns 0.072 mm (rationalized) Dimension See F 9.13. (Hole LL, of Hole ~ Basie Size ~ F.D. 100 + 0.012 mm ~ 100.012 mm HL, of Hole ~ LL. + Tolerance 100,012 + 0.035 ~ 100.087 m or 1007812 mm (i) Shane UL. oF HL. Shaft = Basic Size ~ FD. 100 ~ 0.072 = 99.928 mm HL, ~ Tolerance = 99.928 - 0.084 ‘ LiL, of Shaftmits, Tolorancos and Fite 2 = 9874 mm or 100-39 mm ymple 8. A [00 mm diameter journal and bearing assembly has a clearance fit, with the follwing specifications Tolerance on bearing = 0.005 mm Tolerance on Journal = 0.004 mm Allowance = 0.002 mm Determine the sizes of the bearing anid the journal on (i) Hote Basis System (ii) Shaft Basis System. Take Unilateral System of tolerances. Solution, (a) Hole-Bi is System : Refer Fig, 9.13, Lower limit of Bearing Highest limit of Bearing Basis Size = 100 mm LL. of Bearing + Tolerance = 100 + 0.005 ~ 100.005 mm Refer to Fig. 9.2, Lower limit of be 100 =0.002 99.998 mm Higher limit ~ Tolerance = 99.998 0.004 = 99,994 mm Higher limit of Journal ~ allowance Lower limit of Journal (6) Shaft-Basis System : Refer Fig. 9.13 Upper limit of Journal = Basic Size = 100 mm Lower limit of Journal. ~ Upper limit Tolerance = 100. 0.004 = 99.996 mm Refer to Fig. 92, Lower limit of Bearing = Upper limit of Journal + allowance = 100 +0.002 = 100,002 mm - Upper limit of Bearing = Lower limit + tolerance = 100,002 + 0.005 = 100.007 mm, Example 9. fn an assembly of two mating parts of 100 mm basic sce, she ft is Interference land the interference varies from 0.05 mm to 0.12 mm. The tolerance on the two mating parts is equal. Determine the sices of the two mating paris on (a) Hole Basis System (b) Shafi Basis Spotem Solution, (@) Hole Basis System : Refer Fig. 9.13, Lower limit of hole = Basic size = 100 mm Now Refer to Fig. 9.5 (a), sna, Mum interference willbe when he Roles ats lower Limi andthe shai a its upper iit,382 AA Textbook of Production Engineering Upper limit of shaft = Lower limit of hole + Maximum interference 100 + 0.12 = 100.12 mm Now it is clear that, Maximum interference ~ Minimum interference = Upper limit of shaft ~ Lower limit of hole — (Lower limit of shaft ~ Upper limit of hole) = (Upper limit of shaft ~ Lower limit of shaft) + (Upper limit of hole ~ Lower limit of hole ~ Tolerance on shaft + Tolerance on hole <2 27 = 0.12 - 005 = 0.07 mm Tolerance on shaft = Tolerance on hole = 0.035 mm Higher limit of hole = Lower limit + Tolerance = 100.035 mm Upper limit ~ Tolerance Lower limit of shaft = 100.12 - 0.035 ~ 100.085 mm. O) Upper limit — Tolerance 100 ~ 0.035 = 99.965 mm Upper limit of shaft - Maximum interference = 100 - 0.12 = 99.88 mm. Upper limit of hole ~ Lower limit + Tolerance = 99.88 + 0.035 = 99.915 mm, Example 10. For a number of interchangeable mating parts (holes and shafts) the average allowance is 0.04 mm and the allowance must not exceed * 0.012 mm from the average value. The basic size is 100 mm. Tolerance on hole = 2 x tolerance on the shaft. Determine the sizes of holes and Shafts using Hole basis system and Unilateral system of tolerances, Solution, Refer to Fig. 9.2 ‘Maximum allowance ~ Minimum allowance = Tolerance on shaft + Tolerance on hole Lower limit of hole ! (0.04 + 0.012)~(@.04-0.012)= -T+2T 37 = 0.024, T= 0.008 mm 2 Tolerance on shaft = 0.008 mm or Tolerance on Hole ~ 0.016 mm Lower limit of Hole ~ Basic Size ~ 100 mm Upper limit of Hole = Lower limit + tolerance 100 + 0.016 = 100.016 mm Lower limit of hole ~ Upper limit of shaft Upper limit of shaft = 100 ~ 0.028 = 99.972 mm.Limits, Tolerances and Fits 383 Lower limit of shaft. = Upper limit ~ Tolerance 99.972 ~ 0.008 = 99.964 mm: PROBLEMS 13. Define “Interchangeability” and discuss its importance Define tolerance Why is it impossible to obtain an exact dimension? ‘What is meant by the term “fit”. Explain the various types of fits. Define = allowance, clearance and interference. What is 2ero line? Define : Upper deviation, Lower deviation and Fundamental deviation ‘Explain unilateral System and bilateral system of tolerances. What is meant by “Basic Hole and “Basic Shaft"? Explain and compare “Hole basis system” and “Shaft basis system” of fits ‘A hole and mating shut are to have @ nominal assembly size of 38 mm. The assembly isto have ‘@ maximum total clearance of 0.15 mm and a minimum total clearance of 0.08 mm. Determine the specifications of the parts (a) for 100% interchangeabiity and. (b) for statistical average interchangeability. How will you write the ft = Shaft “m* of grade $ and hole “H" of grade 11 and the basic size is 40 mm? Give the designation for (0, 30 mm H-hote to the tolerance grade IT. Gi) 30 mm Fshaf tothe tolerance grade 177. (it) the above ft. Caleulate the fundamental deviation and tolerances and hence obtain the limits of size for hole and shaft in the fit: 25 mm H-d,. The diameter steps are 18 mm and 30 mm, The fundamental deviation for ‘d° shaft is given as ~ 16 D"™. The tolerance unit is, 45 YD + 0.001 D ‘The tolerance grade for number & quality is 25i and for number 9 quality is 40 AA gear ring of 85 mm diameter bore is fitted on to & hub resulting in a Hj, fit. Calculate the tolerances and hence the limits of size forthe hub and the gear bore. Specify the type of fit, The diameter steps are 80 mm and 100 mm. The fundamental deviation for shaft is 0.009 mn, Calculate the fundamental deviations and tolerances and hence the limits of size for shaft and hole pair designated as 60 mm H/m,. The tolerance unit is given as i= 0.45 YD + 0.001 D microns. The diameter steps are $0 mm and 80 mm. The fundamental deviation. for m shaft is = + (1T7 ~ 176). For quality 7, the multiplier is 16 and that for quality 6 itis 10 Calculate the tolerances, limits and allowances for a 25 mm shaft and hole pair designated as Hd, The diameter steps are 24 mm and 30 mm. The multiplier for quality 8 i 25. The FD for “a shaft is ~ 160% microns. Name the type of fit Determine the types of fits produced by the following mating of holes and shafl. (a) 30 mm Hyf, (®) 30mm HY, (©) $0 mm Pyih,cms 384 [A Textbook of Production Engineering 19. Ait is designated as 60mm Hh, Determine the minimim clearance and maximum clearance of the fit 20, A turned shaft is to rotate in a reamed hole, The selected fit is Hc, Determine the actual Jimensions of the hole and the shall. The basic size is 60 mm, The diameter steps are SO mm ‘and 80 mm. The fundamental deviation for the shaft is, ~ (95 + 0.8 D) microns. Por quality 7, the multiplier is 16 21. An idler gear is to rotate over a 30 mm shaft. The chosen fit is He, Determine the actual dimensions of the shaft and the bore of the iler. The diameter steps are 30 and 40 mm. The fundamental deviation for the hole HY is zero and that for the shaft ¢ is = (95 + 0.8 D) microns. ‘The multiplier for quality 7 is 16 and that for quality 8 is 25. 22. Define and compare : Random assembly, statistical assembly and selective assembly. 23, Give some common applications of selective assembly. 24, What are the main aims of any Limit System? 25. Two shafls A and B have their diameters specified 2s 100-+0.1 mm and 0.1+0.0001 mm, respectively. Which of the following statements is/are true? (GATE 1992) (@) Tolerance in the dimension is greater in shaft A. (8) The relative error in the dimension is greater in shat A. (©) Tolerance in the dimension is greater in shall B. (@) The relative error in the dimension is greater in shaft B. (Ans: a) 05 +0 26, A shat (diameter aft (ameter 20798 +020 and a hole (diameter 20°)” mm) when assembled would ‘mm ) and a hole (diameter 20 1 mm) led yield (@) Transition Fit (4) Interference F it (c) clearance fit (d) None (GATE 1993) (Ans. = ¢) 27, The fit on a hole-shaft system is specified as H, ~ 5, The type of fit is () Clearance ft (running fit (sliding 6) (©) push fit (transition ft) (a) force fit (interference fit) (GATE 1996) Ans. : 4) 28, In the specification of dimensions and fits {@) allowance is equal to bilateral tolerance. (8) alowance is equal to unilateral tolerance (© allowance is independent of tolerance (@ allowance is equal to the difference between maximum and minimum dimension specified by the tolerance (GATE 1998) [Ans. : ¢] 29. “A journal and beating assembly has the following sizes : - 0.001 0.002" +0.001 0.002" Determine : Tolerance on Joural, Tolerance on Bearing, Minimum clearance, Maximum clearance and type of fit. (Ans : 0.001 mm, 0.003 mm, -0.001 mm, 0.003 mm, Transition ft) Joumal : $0 Bearing : 50Limits, Tolerances and Fits 385 30, In an assembly of journal and bearing, the basis size is $$ mm. The lower deviation, and upper deviation for bearing is O micron and 4 microns respectively. the corresponding values for Journal are ~ 3 and -7 microns. Determine the sizes of journal and bearing and the type of ft HAL, = 54.997 mm HL. =58.004 mm LL 58.993 mm | Beating T= SS 008 mm clearance fi. 31. Explain the difference between tolerance and allowance. 32. Why do manuftcturing processes produce parts with such a wide range of tolerances? 33. The journal and bearing assembly has abasic size of 200 mm. For the bearing = ED, (Here, LD.) =0 micron, and Tolerance = 46 micron. For the journal the values are ~ $20 and 115 microns respectively. Find the dimensions of journal and bearing, assuming unilateral system of tolerances. Also, determining the allowance and type of fic. Which systems of fit has been adopted? (Ans. Hole: 200, 200.46 mm; Journal: 199.180, 199.065 mm, Clearance fit, Hole ~ basis system) 34. The following are the sizes of a shaft and a hole ~ 0.000 (Ans : = Journal Sha = 307 NON ttm + 0.000 Hole: 30 730% um Determine the type of ft obtained when these are assembled Sol. Maximum size ofthe shaft ~ 30 mm Minimum size of the shaft = 300.013 =29.987 mm. Maximum size of the hole = 30+ 0.013 men = 30,013 mm Minimum size ofthehole = 30mm “Maximum clearance = Maximum size ofthe hole ~ Minimum sizeof the shaft '= 30,013 ~ 28.987 = 0.026 mm ‘Minimum clearance = Minimum size of Hole ~ Maximum sizeof sh =30-30=0mm Since both the maximum and minimum clearances are greater than or equal to zero, the fit will be "Clearance Fit" 38. The following are the sizes ofthe shat and the hole = +0,000 = 0.026 shaft S000 *9}91)) im; Hote: 50.000 — 9'9¢¢ mm Determine the fit obsained Sel. 50mm, = 50-0011 = 49.989 mm 50-0.026= 49.974 mm 500.065 = 49.935 mm Maximum size ofthe hole Minimum size ofthe hole Maximum Clearance ‘= Maximum size of hole - Minimum size ofthe shaft = 49,974 49.989 =~ 0.015 mm Minimum Clearance Minimum size of hole - Maximum size ofthe shaft = $9,935 - 50,000 =~ 0.065 mm ‘Since both the maximum and minimum clearances are negative; the ft obtained willbe “interference hea ‘ 36. Determine the ype of fit j +0.05 2 | Hole size: 20 7998 mm; Shaft: 20 Sol, Maximum size ofthe hole - 20.05 mm & Minimum size ofthe hole = 19.95 mm ; Maximum size ofthe shaft = 20,05 mm 8 Minimum sizeof the shaft = 19.95 mm Since the Maximum Clearance is postive andthe Minimum Clearance is negative, theft obtained will be the “Transition fi.Gauges and Gauge Design 407 (ii) Combined Bore / Face Gauge : The position and parallelism of a bore in relation to a datum face ean be checked by means of a combined bore/face gauge, Fig. 10.38. The pin which Jocates in the bore is in effect, 'Go" plug gauge, and the steps ground on the other pin are the °Go' and "Not Go’ limits for the datum face to hole axis dimension, The length of the plug gauge rnceds to be sufficient to enable the length of the “Go! step on the pin to check for parallelism. The tolerance on the hole must be less than the tolerance on the dimension to the face for the gauge to operate satisfactorily, Fig, 10.38, A combined boreiface gauge 10,11, SOLVED EXAMPLES Example 1. 4 25 mm H&--f7 ft is 10 be checked. The limits of size for H8 hole are ~ High limit 25.033 mm. tow timit 25.000 mm. The limits of size for f7 shafts are : High limit 24.980 ‘mm, low limit 24.959 mm. Taking gauge maker's tolerance 10 be 10% of the work tolerance, design plug gauge and gap gauge to check the fit Solution. Tolerance for hole = Hil. ~ LiL. = 25.033 — 25.000 = 0.033 mm Gauge makers tolerance for plug gauge = 0.1 x 0,033 mm. = 0.0033 mm. = 0.003 mm (rationalised) Gauge makers tolerance for gap gauge = 0.0021 mm = 0.002 mm (rationalised) ‘As the work tolerances are less than 0.09 mm, wear allowance may not be provided. (0 Plug Gauge Basic size of ‘Go’ plug gauge = LL. of the hole (MMC) = 25.000 mm In unilateral system, + 0.003, Dimensions of “Go" plug gauge = 25.00 mm = 0.000 That is, ; High limit of *Go" plug gauge ~ 25.000 + 0.003 Z = 25.003 mm Low limit of Go" plug gauge = 25.000 mm Now, Basic size of ‘Not Go" plug gauge ~ 25.033 mm + 0.000 Dimensions of ‘Not Go' plug gauge = 25.033 mm ~ 0,003 (Fig. 10.40 shows @ sketch of combined ‘Go and ‘Not Go’ plug gauge.)408 A Textbook of Production Engineering Fig. 10.40. Plug Gauge (combined type) (i) Gap Gauge Go" side = H.L. of shaft (MMC) = 24.980 mm. + 0.000 Dimensions of “Go' gap gauge ~ 24.980 mm = 0.002 t ‘Not Go? side = LL. of shaft = 24.959 mm + 0,002 Dimensions of ‘Not Go’ gap gauge = 24.959 mm 0.000 (Fig. 10.41 shows a sketch of combined “Go” and ‘Not Go” gap gauge) a a i 3 Z 3 Fig. 10.41. Gap Gauge (combined type). Example 2. Shafts of 75 + 0.02 mm diameter are to be checked by the help of a Go, Not Go snap gauges. Design the gauge, sketch it and show ts Go size and Not go size dimensions Assume normal wear allowance and gauge maker's tolerance. Solution, High limit of shaft = 75.02 mm Low limit of shaft = 74.98 mm Work tolerance ~ 75.02 ~ 74.98 = 0.04 mm Gauge makers tolerance (10%) = 0.004 mm. ‘Wear tolerance = 0.002 mm é “Go side’ of snap gauge = HLL. of shaft, (MMC) = 75.02 mm i “Not Go" side of snap gauge = 74.98 mm Wear allowance is to be applied first to ‘Go" side, before gauge maker's tolerance is applied. (Refer to Fig. 108), “Go! side of snap gauge after considering the wear allowance = 75.02 — 0,002 = 75.018 mm Dimensions of snap gauge are given asGauges and Gauge Design 409 Unilateral System + 0,000 + 0,004 °Go' 75.018 mm “Not Go’ 74.98 mm — 0.004 = 0.000 Bilateral System + 0,002 + 0.002 go" 75.018 mm SNot Go’ 74.98 mm = 0,002 ~ 0.002 Example 3. Find the ‘Go’ and ‘Not Go' gauge dimensions of a plug gauge using Bilateral and Unilateral Systems and including wear allowance for gauging 75 + 0.03 mm diameter holes. Solution, High limit of hole = 75.05 mm Low limit of hole = 74.95 mm work tolerance = 75.05 - 74.95 = 0.1 mm Gauge maker's tolerance = 0.01 mm Wear allowance ~ 0.005 mm ‘Go" side of plug gauge = L-L. of hole (MM.C) = 74.95 mim “Go' side of plug gatige after the application of wear allowance = 74.95 + 0.005 (Fig. 10.8) = 75.955 fn Dimension of plug gauge are given as = Unilateral System + 0.010 + 0.000 *Go" 74.955 mm. "Not Go’ 75.05 mm = 0.000 = 0.010 Bitateral System + 0.005 + 0,005 “Go! 74.955 mm ‘Not go’ 75.05 mm. ~ 0.005 0.005 Example 4. The rectangular hole shown in Fig. 10.42 is 10 be checked. The limits of size for the width of hole are - + 004 60 mm 40.05 = 0.00 iE _-0.00 The limits of size for the breadth of hole are : ir” +005 80 mm - 0.00 Design the suitable gauges based on Taylor's principle. Solution. According to Taylor’ principle, there will bbe one ‘Go Gauge’ of full form and of length equal to the length of the hole. There will be two ‘Not Go Gauges;’ of pin form to check the width and breadth of the hole, 10.420 A Textbook of Production Engineering High limit of width of hole = 60.04 mm Low limit of width of hole = 60.00 mm High limit of breadth of hole = 80.05 mm Low limit of breadth of hole ~ 80.00 mm Tolerance on width of hole = 0.04 mm Tolerance on breadth of hole 0.05 mm Gauge markers tolerance (10%) For breadth of hole 1.005 mm For width of hole = 0,004 mm Go Gauge (0 60 mm dimension Go gauge will correspond to low limit of width of hole (MMC), ie., 60 mm. Basic size of ‘Go Gauge’ for 60 mm dimension = 60.09 mm Using unilateral system, the limits of size for ‘Go Gauge’ for 60 mm dimension are + 0.008 60.00 mm = 0.000 (i) 80 mm dimension Basie size of ‘Go Gauge’ for 80 mm dimension = 80.00 mm Limits of size of ‘Go Gauge’ for 80 mm dimension are + 0.005 80.00 mm (unilateral system) = 0.000 ‘The ‘Go Gauge’ is shown in Fig. 10.43. | iy _| QW 0,006, “000 ———) a | m "9.000 Fig. 10.43.Gauges and Gauge Design an Not Go Gauges (Refer Fig. 10.7) ‘The ‘Not Go Gauges’ will correspond 1o the minimum metal condition of hole ie. high limits of dimensions. *. Basic size of *Not Go Gauge’ for 60 mm dimension 60.04 mm Basic size of ‘Not Go Gauge’ for 80 mm dimension = 80.05 mm Limits of size of “Not Go Gauge’ for 60 mm dimension are + 0.004 60.04 mm = 0.000 mits of size of ‘No Go Gauge’ for 80 mm dimension are : + 0.008 80.05 mm = 0.000 ‘The two pin gauges are shown in Fig. 10.44, ODS “9000 20.05 mm ig, 10.44 PROBLEMS 1, What is 2 gauge? 2. How does a gauge differ from a measuring instrument? 3. How the plain gauges are classified? 4. What is the difference between standard gauge (non-limit gauge) and a limit gauge? 5, Differentiate between : Workshop gnuge, inspection gauge and master gauge ‘6. What is gauge maker's tolerance? How is it applied in the design of gauges? 7. Give the advantages and disadvantages of unilateral and bilateral system of gauging ‘8. What is wear allowance? How is it applied in the design of gauges? 9. ‘State and explain Taylor's principle of limit gauging, 10, Discuss the various materials used for gauge manufacture. 1, What are the advantages of limit gouges? 12, What are the limitations of limit gauges? 13, How the pauges should be cared for before and after use? 4 14, What is MMC? 15, Determine the specification for the ‘go’ and ‘not go’ ends of a set of manufacturing and inspection plug gauges to be used in checking a hole with + 0.075 diameter specification of 25 mm = 0,000‘ + az 16. v. 18. 9. Note. a. 22. = A Textbook of Production Engineering pein sens NE mes a ee EE) CHE Mey dimensions. Allow for wear and gauge maker's tolerance. ‘lint gage i ogre wo check he ie 50. 1952 nm (50H), The dap of hole a 200 mm, Design the gauge and sketch it with dimensions, Discuss briefly various aspects for deciding the tolerance on limit gauges. ‘A hole and shaft system has the following dimensions 60 mm HBie8 “The standard tolerance is given by 1 = 045 (Dy! + 0.001 D Where D = Diameter of geometric mean of steps. mm 1= standard tolerance, micron ‘The multiplier for grade & is 28. The fundamental deviation for shaft ¢ for D> 40, is given by = (95 +08 D) ‘The diameter range lies between $0 to 80 mm. Sketch the fit and show on it the actual dimensions of hole and shaft. Name the class of fit. Also, design the suitable gauges to check te hole and the shaft. (AMIE 1974 $) [Ans. Hole : LiL, = 60.000 mm, HL, = 60.046 mm Shaft: H.L. = 59854 mm, LL. = 59.808 mm, Clearance fit Plug Gouge, Osi : 60:4 998 mm Not Go side: 0046 +9899 mm Snap Gouge, Go side 59856 + 8909 wit +0.000 Not Go side : 59808 +209? nm Unilateral system has been used. Wear allowance has been neglected: work tolerance being less than 0.09 mm, ‘The minimum size of a hole is 25.00 mm. Its maximum size is 25.002 mm, When matching shaft of this hole is measured, the fundamental deviation is found to be — 0.02 mm. Shaft tolerance is 0.003 mm. Design gauges for hole and shafl. Take the usual values of gauge makers tolerance and wear allowance. Design ‘GO" and “NO GO’ ends of a plug gauge to measure a hole of size 28.000 * 0.014 mm adopting (a) Unilateral system (6) Bilateral system, ‘bore of 3789 mm dia 45 mm long is abe checked. Design rew-and dimension a plug sr fer tn, bcd nT paso panei {A squme peg having limits of 25.00 mm-and 2437 tn isto be checked. Design a emuse (gauges) for checking this, based on Taylor's principle of gauge design. Discuss the principle of Taylor's forthe design of gauges for checking (0) of an oval hole with a cylindrical ‘Not Go" gauge (@) of rectangular hole (©) circular holes (@) circular shan. (©) Non-circular holes and shafts noGauges and Gauge Design 413 25, 26. 2. 28, 2, 30. 3 32, 34, 35. 36. 3% Sketch and discuss various pes of Plug gauges Sketch and diseuss various types of soap gauges Discuss the procedure of manufacturing Limit plug gauges Discuss the procedure of manufacturing Limit sap gauges. What role do gauges play in the mass preduction sytem? Where ae pug gnoges used? Whore are Snap gauges used? Sketch and giscuss the use of folowing gauges (@) Length gauges (6) width or Gap gauge (6 Receiver gauge (Fash pin gauge, What ae serew gauges? How are they used 1 contol the complex dimensions of threads? Sketch and discuss the se of (0) Phag serew gauges (2) Ring srew gauges (6) Thad caliper enuges. xlan the meaning ofthe expression 30 mm HB-f7 Derive the formula to give the depth of the step “A” ofthe taper plug gauge in terms of max. and min, dameters ofthe lage end. Caleuiate ‘A’ given @= 1°-S8, Max. dia, = 23.42 mm, min. fia = 23.40 mm {Ans: = (D2 tan 872; 0.588 mm) Write on materials resisting wear for gauges Sol. The various muteras for gauges have been discussed under An 10.3(). Special wear resisting materials for applications whore the plug will ose ts size very rapaly due 1 abrasive wear (for example, a small diameter screw plug gauge used on a cas ion component), can be = (@) HSS. (Better wear resistance than Cte. (6) Mara Chromium pling on hardened sel (See Ar. 10.3(9), which i fly ground w sie. (©) WC, sintered met-powder mouliings ground with diamond git abrasive, though very expensive, have w proatly improved wear fe. 3. Write the- disadvantages of limit Gauging, Sol. Two limitations of limit Gauges have been discussed in An. 10.8. The other drawbacks (a) Suitable for Mass production of components only: Their cos may not be recovered from 4 small quantity of work. (6) The use of limit gauging is restricted to certain gauge sizes and types because of practical considerations such as weight, flexcure and manufacturing complexity. (©) As with any components, the limit gauges can not be manufactured entirely without err. Also, they lose their accuracy due to wear during use. (a) Particular sourees of error in the component are less easily revealed. Refinements in machine tool control and better instrumentation (mainly, due to elecwonics) have allowed the dimensional control to be easily integrated with the machining process. Thus mspection can be limited to "first off checks and subsequently by sampling methods for imporant ‘dimensions. However, limit gauging is stil the cheapest and most convenient method of ‘checking plain bores, both intemal and extemal serew threads, spines and serrations.