Unit 14 Location Of Single Holes

TOLERANCING METHODS The location of a single hole is usually indicated by means of rectangular coordinate dimensions, extending from suitable edges or other features of the part to the axis of the hole. Other dimensioning methods, such as polar coordinates, may be used when circumstances warrant. There are two standard methods of tolerancing the location of holes:

Fig 14-1 COMPARISION OF TOLERANCING METHODS Coordinate tolerancing, which refers to tolerances applied directly to the coordinate dimensions, or to applicable tolerances specified in a general tolerance note. (A) Positional tolerancing, regardless of feature size (RFS). (B) Positional tolerancing, maximum material condition basis (MMC). These positional tolerancing methods are part of the system of geometrical tolerancing. Any of these tolerancing methods can be substituted one or the other, although with differing results. It is necessary, however, to first analyze the widely used method of coordinate tolerancing in order to explain and understand the advantages and disadvantages of the positional tolerancing methods. COORDINATE TOLERANCING Coordinate dimensions and tolerances may be applied to the location of a single hole as shown in Fig 14-2. They indicate the location of the hole axis and result in a rectangular or wedgeshaped tolerance zone within which the axis of the hole must lie. If the two coordinate tolerances are equal the tolerance zone formed will be a square. Unequal tolerances result in rectangular tolerance zone. Polar dimensioning, where one of the locating dimensions is a radius, gives a circular ring section tolerance zone. For simplicity, square tolerance zones are used in the analyses of most of the examples in this section.

FIG 14 2 TOLERANCE ZONES FOR COORDINATE TOLERANCES It should be noted that the tolerance zone extends for the full depth of the hole, that is, the whole length of the axis. This is illustrated in Fig 14-3 and explained in more detail in a later work unit. In most of the illustrations, tolerances will be analyzed as they apply at the surface of the part, where the axis is represented by a point.

FIG 14-3 TOLERANCE ZONE EXTENDING THROUGH PART

MAXIMUM PERMISSIBLE ERROR The actual position of the feature axis may be anywhere within the rectangular tolerance zone. For square tolerance zones, the maximum allowable variation from the desired position occurs in a direction of 450 from the direction of the coordinate dimensions.

FIG 14-4 SQUARE TOLERANCE ZONE For rectangular tolerance zones this maximum, tolerance is the square root of the sum of the squares of the individual tolerances, or expressed mathematically (X2 + Y2) For the examples shown in Fig 14-2 the tolerance zones are shown in Fig 14-5, and the maximum tolerance values are: Example 1 (0.22 +0.22 ) = 0.2

Example 2 (0.22 + 0.42 )

= 0.45

For polar co-ordinates the extreme variation is: (A2 + T2 ) where A = R tan a T = tolerance on radius R = mean radius a = angular tolerance

Thus, the extreme variation in the third example is: ((32 * >01745)2 + 0.22) = 0.59 Example 3

NOTE: Mathematically A in the above formula should be 2R tan a/2, instead of R tan a, and T should be T cosa/2 but the difference in results are quite insignificant for the tolerances normally used. Some values of tan A for commonly used angular tolerances are as follows.

A 0 5 0 10 0 15 0 20

Tan a .00145 .00291 .00436 .00582

0 0 0 0

A 25 30 35 40

Tan a .00727 .00873 .01018 .01164

A 0 0 0 1 45 50 55 0

Tan a .01309 .01454 .01600 .01745

FIG 14-5 CHART TOLERANCING

FOR

CALCULATING

MAXIMUM

TOLERANCE

USING

COORDINATE

USE OF CHART A quick and easy method of finding the maximum positional error permitted with coordinate tolerancing, without having to calculate squares and square roots, is by use of chart like that shown in Fig 14-5. In the first example shown in Fig 14-2 the tolerance in both directions is 0.2mm. The extension of the horizontal and vertical lines of 0.2 in the chart intersect at point A, which lies between the radii of 0.275 and 0.30 mm. when interpolated and rounded to two decimal places, this indicates a maximum permissible variation of position of 0.28 mm. In the second example shown in Fig 14-2 the tolerances are 0.2 mm in one direction and 0.4 mm in the other. The extension of the vertical and horizontal lines at 0.20 and 0.40 mm respectively in the chart intersect at point B which lies between the radii of 0.425 and 0.45 mm. when interpolated and round to two decimal places, this indicates a maximum variation of position of 0.45 mm. Fig 14-5 also shows a chart for use with tolerances in inches. MEASURING PRINCIPLE While simple means of measurement such as using a vernier caliper gauge are often employed, precise measurement requires a set up similar to that shown in Fig 14-6. The hole is first fitted with a snug fitting mandrel. The part is supported on a surface plate, with a support directly below and parallel to the axis of the hole to be measured. A further support is used some distance away to maintain the lower face of the part parallel to the surface plate. Dial indicator readings are then made over the mandrel at both sides of the part, and at equal distances from the side of the part. These readings are adjusted to give the distance from the top of the support to the axis of the mandrel. Measurements are then corrected for the length of the hole, using the formula: C = ( R2 - R1 ) a / ( 2a + b ) Where C R1 R2 a b = = = = = correction value low indicator reading high indicator reading distance between the part and the center of the dial indicator part thickness

The corrected readings are then R1 + C and R2 C Both of these values must be within the limits specified on the drawing. This measuring procedure must then be repeated from the vertical edge of the part in order to measure the horizontal dimension on the drawing.

FIG 14-6 MEASURING COORDINATE DIMENSIONS

FIG 14-7 MEASURING COORDINATE DIMENSIONS ALTERNATIVE MEASURING METHOD The method just described assumed that the line element of the side, which rested on the support, was straight and contacted the support along its full length. This is a reasonable assumption if the part is not too thick. For more precise results, if the edge is not perfectly straight, the setup should be inverted and the mandrel supported on suitable blocks on a surface plate, as shown in Fig 14-7. The mandrel must be exactly parallel with the surface plate, and an additional support must be used to align the top surface of the part along its length in a horizontal direction. Indicator measurements are then made on the top side of the part along a line element parallel to the axis, and in the same vertical plane. The procedure is then repeated with the part turned 900 to measure from the vertical edge of the part.

ADVANTAGES OF COORDINATE TOLERANCING The advantages claimed for direct coordinate tolerancing are as follows: It is simple and easily understood, and therefore is a method commonly used. It permits direct measurements to be made with standard instruments and does not require the use of special purpose functional gages, or other calculations. It is often claimed that such tolerances correspond to the control exercised by machine tools, but this is not entirely correct. Some machine tools, such as a jig borer, find the correct position by means of two coordinate movements or adjustments. However, this positioning is usually made to closer than the specified tolerances, and other manufacturing and measurement errors then produce variations in a circular zone surrounding the set position. Remember that instruments used to check the location of features, which have coordinate tolerances, must be so designed that they locate the true center of the hole, regardless of its size. This can be done by means of a fitted mandrel, or for less precise results, a tapered plug.

DISADVANTAGES OF COORDINATE TOLERANCING There are a number of disadvantages to the direct tolerancing method. Among these are It results in a square or rectangular tolerance zone within which the axis must lie. For a square zone this permits a variation in a 45 0 direction of approximately 1.4 times the specified tolerance. This amount of variation may necessitate the specification of tolerances, which are only 70% of those, which are functionally acceptable. It may result in an undesirable accumulation of tolerances when several features are involved, especially when chain dimensioning is used. It is more difficult to assess clearances between mating features and components than when positional tolerancing is used, especially when a group or a pattern of features is involved. It does not correspond to the control exercised by fixed functional GO gages, often desirable in mass production of parts. This becomes particularly important in dealing with a group of holes. With direct coordinate tolerancing the location of each hole has to be measured separately in two directions, whereas with positional tolerancing on an MMC basis one functional gage would check all holes in one operation.