Tolerance Charts

Dr. Pulak M. Pandey

http://paniit.iitd.ac.in/~pmpandey
Introduction
‰ A tolerance chart is a graphical method for
presenting the manufacturing dimensions of a
workpiece or assembly at all stages of its
manufacturing dimensions of a workpiece or
assembly at all stages of its manufacturing
‰ The chart provides an intermediate control
system of checks and balances to insure that
processing dimensions and tolerances will
meet those specified on part prints
‰ The tolerance charts are useful in sorting
dimensional problems on individual parts, and
also useful in processing assemblies
Purpose and Utilization of Tolerance
Charts
1. It permits the process engineer to determine in
advance of tooling whether or not the part can
be made to part print tolerances. A surprising
number of designs are actually dimensionally
faulty and can not be manufactured to print. If
this condition can be discovered in advance,
costly scrap can be prevented.
2. It aids in developing proper manufacturing
sequence.
3. It provides a means of establishing the proper
working tolerances for each operation in the
sequence.
4. It provides assurance that sufficient stock
removal will always be available for each
operation in the sequence and what that
amount is. If sufficient stock is not available
tolerance charts will disclose the same.
5. When accuracy of the machine is known, the
tolerance chart will indicate whether or not it is
capable of meeting part print specifications.
6. It provides an intelligent instrument for
negotiating with product design when
manufacturing specifications cannot be met
economically.
7. It offers a convenient and useful check on
alternate methods of dimensioning the part for
processing purpose.
8. It aids the process engineer in determining
whether the part will arrive at its last operation
with desired dimensions and tolerances.
9. It helps to determine the practicability of
combined tooling. Such as form tools-or
combinations of working and inspection
gauging.
10. It provides a means of reducing dimensional
errors which are likely to occur if complex parts
are processed without the use tolerance charts.
11. It aids in determining the proper raw material
sizes and in developing the necessary castings
and forgings.
12. Together with the process picture sheet, the
tolerance chart provides an invaluable aid in
the development of complete and accurate
process routings.
 Definitions and Symbols
‰ A working Dimension is the distance between a
locating surface and the surface being
processed.
‰ Stock removal is the difference between the
dimension that existed prior to machining and
machining dimension.
‰ Resultant dimension is the difference between
two dimensions or a dimension and an
intermediate resultant. It is sometimes called as a
balance dimension. An intermediate resultant
occurs when additional stock removed in later
operation will affect its size.
‰ Total tolerance is the total variation from the
basic stock removal dimension which can result
from the operation performed.
The circled dot denotes a locating
surface or centerline. The arrow
denotes the surface or centerline of the
surface to be machined.

Working dimension when tools are set

in a definite relation ship to one
another. This occurs when combination
tools are used.

This figure represents a resultant

dimension between machined
surfaces, centerlines, or a centerline
and a machined surface.
Rules for adding
and subtracting
tolerances
Example:
Cast steel
drive hub
Conversion of asymmetrical tolerances into symmetrical tolerance
Example of tolerance conversion

Add L

5.000 +−00..007
004 = (5.000 + 0.0015) ± 0.0055

= 5.0015 ± 0.0055
Developing Tolerance Chart
Assumptions
‰ Rough forging dimension = 2 in
‰ Nominal finish dimension = 1.920 in
‰ Difference = 0.080 in to be removed from two
surfaces B and G
‰ Both B and G surfaces are to be machined,
hardened and ground, therefore let us assume
that 0.010 in is left for grinding for each surface.
‰ Therefore stock to be removed from each
surface = (0.080/2)-0.010= 0.030 in
‰ No change in dimensions due to heat treatment
processes will be assumed in this example.
Operation 10
Operation 10: calculations
‰ Forging Dimension = 2.000±0.010 in
Operation 10, W.D. = 1.970±0.002 in
Stock removal = 0.030±0.012 in
‰ Min. of 0.018 in and max. of 0.042 in.
can be removed.
‰ No final (resulting) dimension is resulted
from this operation.
Operation 20
Operation 20: Calculations
‰ Three separate surfaces result from this operation. Location
takes place on surface G which was machined in operation 10.
Surface A is faced, the center hole is core drilled and reamed,
and the surface C is turned. Here, we concern with surfaces B
and C. Here, as in previous operation, a nominal 0.030 stock will
be removed from A. The working tolerance is ±0.002 as before.
Therefore,

‰ Operation 10, working dimension 1.970±0.002

Operation 20, working dimension 1.940±0.002
Stock removal 0.030±0.004
Operation 20 continued
‰ Surface C must be produced as a continuation of
operation 20, using the same locating surface.
Because the position of the surface C with respect to
surface G is affected by the amount which will later
be removed from surface G by grinding, allowance
must be made to insure that the final relationship
between these two surfaces is maintained. Since
0.010 is allowed for stock removal in grinding, the
working dimension will be 1.780±0.002. Therefore,

‰ Operation 20 (a), working dimension 1,940±0.002

Operation 20(b), working dimension 1.780±0.002
Stock removal 0.160±0.004
Operation 30
 Operation 30: Calculations
‰ In the first step performed in operation 20,a nominal
working dimension of 1.940 was established between
surfaces B and G. To determine the nominal working
dimensions for operation 30, two things must be
considered.
1. The nominal dimension between surface G and
surface F.
2. The nominal stock removal from surface G by
grinding in the final operation.
The nominal working dimension for this operation is found
by subtracting these two dimensions from the nominal
working dimension from operation 20.
1.940-0.200-0.010=1.730 with working
tolerance as ± 0.002.
Operation 30 continued
‰ Because this operation is carried out with a
form tool, two surfaces are created
simultaneously. This automatically fixes the
relationship between surfaces E and F. The
form tool dimension which relates the two
surfaces can carry the full part print tolerance.
The resultant dimension between surfaces F
and G can now be calculated as:

‰ Operation 20(a), working dimension 1.940±0.002

Operation 30, working dimension 1.730±0.002
Resultant (intermediate) 0.210±0.004
Operation 40
Operation 40: calculations
‰ Working dimension for this operation
must take into account the allowance for
grinding after hardening. Because the
nominal depth of this milling cut is 0.250
and the nominal allowance for grinding
is 0.010, the working dimension fro this
operation is will be 0.250+0.010=0.260
with working tolerance ±0.002.
Operation 50
‰ The prints requires a finished hardness
depth of 0.015±0.010. Actually, this
depth can be controlled within ±0.005.
Because 0.010 is to be removed from
each ground surface, the working case
depth is set as 0.025±0.005. Since
nothing has been removed from the
workpiece in carburizing and hardening,
no stock removal is recorded. As
indicated previously, there is no change
in workpiece dimension and hence no
change in the resultant occurs.
Operation 60
Operation 60: Calculations
‰ Theworking tolerance on grinding can be
achieved as ±0.0005. Because 0.010 has
been allowed for grinding, the working
dimension that must be held in this
operation is 1.930±0.0005. Thus stock
removal
‰ Operation 20, working dimension 1.940±0.002
Operation 60, working dimension 1.930±0.0005
Stock removal 0.010±0.0025
 Operation 60 continued
‰ With the completion of operation 60, the dimensions from
surface G to , G to C, and F to E are now finalized. Since
the dimension from F to E was established earlier by the
form tool and is not affected by this operation, it can be
recorded as a resultant as shown in figure. Operation 30
was the last to be performed on surface F before
operation 60. The resultant from G to F can now be
recorded.
‰ Operation 60, working dimension 1.930±0.0005
Operation 30, working dimension 1.730±0.002
Resultant 0.200±0.0025
‰ The resultant dimension between surfaces C and G now
becomes final and can be checked. Its previous
dimension was attained in operation 20(b).
‰ Operation 20(b), working dimension 1.780±0.002
Operation 60, Stock removal 0.010±0.0025
Resultant 1.770±0.0045
Operation 60 continued

‰ The case hardened depth of G must be

checked to make certain the grinding
operation did not cause it to fall below the
depth specified. The case hardened
depth is determined by the difference
between the initial case depth working
dimension and the stock removal in
grinding
‰ Operation 50, working dimension 0.025±0.005
‰ Operation 60, Stock removal 0.010±0.0025
‰ Resultant 0.015±0.0075
Operation 70
Operation 70: Calculations
‰ Aside from balancing final tolerances, operation 70
completes the machining operations on the workpiece,
unless it is found that additional operations must be
performed to correct tolerance stacking. Stock removal
may be calculated as
‰ Operation 60, working dimension 1.930±0.0005
‰ Operation 70, working dimension 1.920±0.0005
‰ Stock removal 0.010±0.001
‰ Other resulting dimension of B and D
‰ Operation 40, Working dimension 0.260±0.002
‰ Operation 70, working dimension 0.010±0.001
‰ Resultant 0.250±0.003
‰ Dimension of B (case hardened depth)
‰ Operation 50, Working dimension 0.025±0.005
‰ Operation 70, working dimension 0.010±0.001
‰ Resultant 0.015±0.006
Complete tolerance Chart (unbalance)
 Balancing of Tolerance Chart
‰ If the developed tolerance chart is accepted at
this stage, tight and costly processing increases
cost of the product.
‰ The first step in balancing the tolerance chart is
to examine the final resultant dimensions and
compare them with those specified the part print.
‰ The resultant whose tolerance compare closest
with the part print tolerance will be the logical
place to start.
‰ As can be seen in the developed chart, the
resultant dimension between surfaces C and G is
1.770±0.0045, which compares with the print
dimension of 1.770±0.005. This comparison is
closer than the others, balancing will start from
here.
Balancing operation 60
‰ Operation 60 can now be recalculated
as:
ƒ Operation 20(a), working dimension 1.940±0.002
Operation 60, working dimension 1.930±0.001
Stock removal 0.010±0.003

ƒ Operation 20(b), working dimension 1.780±0.002

Operation 60, stock removal 0.010±0.003
Resultant 1.770±0.005

ƒ The preceding resultant is now identical with the part print

specifications.
‰ An intermediate resultant between surfaces F
and G was established as a result of
operation 30. The final resultant was obtained
in Operation 60. Because the relationship
between surfaces E and F was determined by
form tool, an increase can be made in the
working tolerance of operation 30 without
affecting other surfaces. The working
dimensions of operation 30 can be changed
to 1.730±0.004. The correct resultant
between surfaces F and G will now be:
ƒ Operation 60, working dimensions 1.930±0.001
Operation 30, working dimensions 1.730±0.004
Resultant 0.200±0.005

ƒ The dimension 0.100±0.002 remains unchanged

because it was established from the form tool.
Balancing Operation 70
“ Operation 70 now can be recalculated as
follows:
“ Operation 60, Working dimension 1.930±0.001
“ Operation 70, working dimension 1.920±0.002
“ Stock removal 0.010±0.003

“ Operation 40, working dimension 0.260±0.002

“ Operation 70, stock removal 0.010±0.003
“ Resultant 0.250±0.005

“ Operation 50, working dimension 0.250±0.007

“ Operation 70, Stock removal 0.010±0.003
“ Resultant 0.015±0.010
Completed Tolerance Chart