Languages for engineering communication - 2.

In similar to the laws regulating scientific reporting engineering communication also developed international laws for the technical drawing. These laws form the base for interchangeability

2.1 Interchangeability
Interchangeability allows using all over the world the similar parts of machines which are produced in various countries. There are two possible ways to ensure interchangeability : The first is to produce the part individually and with absolute accuracy. This wave is complex and uneconomic. The second way is to divide the parts, into a number of groups with the typical or standard dimension which is equals to the arithmetical mean for this group. To reduce the number of the standard parts of the machines, all the dimensions in machining design are rounded off to the nearest whole millimeter. These rounded dimensions are known as the nominal size .

2.2 Types of the dimensions

The rounding of the dimensions introduces two types of dimensions: a) the real dimensions, known as the actual size b) rounded dimensions are known as the nominal size . The surfaces also have various types of dimensions. When contacting each to other their dimensions called mating dimensions. All other dimensions are called free dimensions. The mating surfaces usually classified as external or internal and their dimensions are shown in Fig. 1.

Fig. 1 Mating parts: 1- enveloping surface hole() 2enveloped surface (shaft) (.) Internal surfaces of different shapes can be referred to as holes (.) Their mating external surfaces can be referred to as shafts .The typical example is a keyway and its key. 1

2.3 Tolerance .
The international laws for technical drawing are based on system of fits and tolerances . We can say that without the system of fits and tolerances interchangeability of the parts in machinery would be impossible. The tolerances postulates the arithmetical mean diameter for all dimensions within each group of the parts. Each production has its accuracy ( ) which in turn is characterized by limits of sizes reached in production ( . ) Tolerances are based on measuring the actual size of the part. The maximum limit Ab of a hole, or Bb of a shaft is the maximum permissible actual size in production. The minimum limit Am of a hole, or Bm of a shaft is the minimum permissible actual size in production. Tolerance is the difference between maximum and minimum limits and denoted in Fig. 2 by the Greek letter with a sub index:

A = Ab Am hole (( and B = Bb Bm (shaft)( ) Since the tolerances are based on the actual size of the part this is characteristics of the production. The tolerances stipulates the permissible error in manufacturing. The value of tolerance shows if the part can serve as duplicate for original or not. The large tolerance makes easier manufacturing while prevents the part from to be interchangeable. The part is interchangeable if the actual size of the part is between the Limits of sizes.

Fig.2 Tolerance of a dimension

2.4 Deviation
If tolerance is based on actual size, the deviation is based on nominal size . The upper maximum deviation ( ) for a hole is the difference between maximum limits and the nominal size , d of the association Au = Ab d The lower maximum deviation for a hole is the difference between minimum limits and the nominal size d of the association: Al = Am d . The upper maximum deviation for a shaft, is the difference between their maximum limits and the nominal size d of the association: BBu = Bb d . The lower maximum deviation, for a shaft, is the difference between minimum limits and the nominal size d of the association: Bl = Bm d 2

Fig.4 Maximum deviations for a hole

Fig.5 Maximum deviations for a shaft When one of the limits is equal to the nominal size, the maximal deviation is equal to zero. (0). Relation between the deviation and the tolerance is rather simple:

= -
Notifications of the tolerance A common diagram of limits and tolerance zones in Fig. 6 composed of : 1. The line corresponding to the nominal size is called the base line 2. Lines representing the upper elements of holes or shafts and located above the base line correspond to positive deviations (;) 3. Lines representing the upper elements of holes or shafts and located below the base line correspond to negative deviations ()

Fig.6 4. The upper deviation coincides with the upper boundary of the tolerance zone. The lower deviation coincides with the lower boundary of the tolerance zone. Common notations 1. Tolerances (( are expressed in millimeters as the maximum deviations from the nominal size . 2. The upper deviation is arranged above the lower deviation (. ) 3. The figures ( )showing deviations are smaller than these for the nominal size. 4. Deviations equal to zero are omitted. 5. The deviations of the hole are usually located above while the deviations of the shaft are below. 6. The numbers of the parts can be also indicated for clarity.

1 Example

: -

0 2 0.0 + 0 2 0.0 5 0 2 0.0 + 0

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0 2 0.0 + 0 1 0.0

54 4 5

0 4 0.0 + 0 2 0.0 +
40.0

-:

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Conclusions: 1. Tolerance based on actual size and is characteristics of production. 2. Deviation based on nominal size and is regulated by the standard for this part. 3. Tolerance and deviation both affect the interchangeability of the part. In order to check where or not the part is interchangeable, one should measure the actual size. The part is interchangeable if the actual size is within the so-called tolerance zone (between the upper and lower deviations. : . .

Fits 2.5
: The quality of the contact between the parts is specified by the type of the fit, It is difference between the diameters of hole and shaft before association. Clearance ( - )hole is larger than shaft and there is freedom to relative move. Interference ( - ) hole is smaller than shaft and fixed relative to each.

ISO SYSTEM OF FITS AND TOLERANCES A tolerance system ( )may be subdivided: 1) According to the basis, hole ( )or shaft ) ( 2) According to the size of the tolerances, which specify the grades of manufacturing accuracy () 3) According to the size of the clearances or interferences, types of fit(. )

Fig.10 The hole and the shaft base systems In the hole basis system the hole minimum limits Am are constant and not depends on fits when the grade of accuracy and nominal size are fixed. As shown in Fig.10 in order to change the fit ( )one should vary the ()of shaft (.) In the shaft ( )basis system the shaft maximum limits Bb are constant for all fits and to change the fit one should vary the hole limits (.) The hole basis system is more economical since fixed diameter tools reproduce basic size rather well. Hole based + tolerance is marked by large English latter H. A single type of the tolerance for hole is usually of (0 ). This means that lower limit is equal to nominal dimension while upper limit is usually larger then nominal dimension.

Tolerances for shaft are usually marked by small English letters from a to zc. The shafts produced with tolerances from a to g are usually enter the hole with clearance . The shafts produced with tolerance from p to zc, are usually larger then hole and result in . Shaft based system is marked by small English latter h. Upper limit is equal to nominal dimension while lower limit is usually smaller then nominal dimension . Tolerances for holes are usually marked by large English letters from A to ZC (Fig. 13).

Basic notation of the tolerance and fits is composed of: 1.2 ; .(( maximum deviations ( ) or tolerance (3 ;( .fits (4 ;( .grades of accuracy to which the given fit is to be manufactured (.) 8

Small difference exists between the machine drawings and the designers drawings . On the machine drawings ( )indicated directly after the nominal size in millimeters. On the designers drawings ( )indicated by symbols only and thereafter technician convert this notation to millimeters. Examples.

40f7 is a typical example of the designers drawings notation (there are no tolerance numbers). It is the shaft (small f); Its nominal diameter is 40 mm and f7 grade of accuracy ensures the clearance fit (see graph 12) All rest examples are typical for . 30h6 is again shaft (small h), nominal diameter 30mm which is equal to upper maximal diameter. Lowest diameter is 30-0.013 mm and h6 degree of accuracy ensures the clearance fit which is rather close to boundary of clearance ( see fig. 12). 30F7 is the hole (large F) with nominal diameter 30mm, unidirected upper and lower deviations and H7 degree of accuracy of the fit.

Tolerances of shape and position ISO standard stipulates notation of the shape and fits on the drawings.

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Examples

To convert format from designer to machine drawing one should specify the values of tolerances and fits using special tables.

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2. Questions to exam. 1. What is the interchangeability of the parts in machinery and how to reach this requirement? 2. Why all the dimensions used in machining design are rounded off to the nearest whole millimeter. 3. Explain the difference between: a) the actual size and the nominal size ; b) mating dimensions and free dimensions; c) external and internal surfaces. 4. Explain a standard characteristics of the permissible error in manufacturing? 5. When one can say that the part is interchangeable? 6. When the maximal deviation is equal to zero? 7. Explain difference between positive and negative deviations. 8. What kind of association performances is characterized by the fit? 9. Explain difference between the hole and shaft systems. What kind of the system is more effective economically?

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