زنجيره تلرانسي
زنجيره تلرانسي
زنجيره تلرانسي
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1 INTRODUCTION........................................................................................................3
1.1 MACHINING ANALYSE ....................................................................................................3 1.2 ECONOMIC TOLERANCES.............................................................................................3
2 DIMENSIONS.............................................................................................................4
2.1 CONDITION DIMENSIONS..............................................................................................4 2.2 MACHINING DIMENSION WD MD TD............................................................................4 2.3 MINIMUM STOCK REMOVAL SR................................................................................14 2.4 MINIMUM RAW DIMENSION RD..................................................................................14
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1 INTRODUCTION
1.1 MACHINING ANALYSE machining a part is deliver at the good dimensions asked by the study department drawing at the minimum price. And for this the technician of the method department define the different steps of the process from the raw to the finish part. They must make a choice among the process and the means of the factory.
Machining a part is very expensive, so the technician of the method department must try to: avoid machining which dont add functional value to the part (rough, semi finish, temporary start point, ..) Calculate the raw part dimensions according to the minimum stock removal of each operation. Machining the part directly with the final drawing dimensions. Choose the machining means capable to carry out the asked tolerances. 1.2 ECONOMIC TOLERANCES All machine setting at a precise dimension dont make the parts at the tolerance of the setting but at nearly dimensions depending of different parameters ( tool life, repeatability of the machine, ..) Each machine have a range into witch it machining the best , this is its economic tolerance. Machining with more closed tolerance cost more. (reject, reworking, more setting, .) Example for economic tolerances. milling turning drilling broaching grinding boring Rough 0.5 0.5 and length 0.3 0.1 0.2 0.3 Semi finish 0.2 0.2 and length 0.2 0.03 0.05 0.1 finish 0.05 0.05 and length 0.1 0.01 0.01 0.03
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2 DIMENSIONS
2.1 CONDITION DIMENSIONS This is the dimension of the final drawing and this is the dimension to respect 2.2 MACHINING DIMENSION WD MD TD
Each operation of machining need a setting of the tool, either from stopper on machine, either between two tools or from machining fixture. To be capable of setting machine, the technician of the method department have to put these dimensions on the process sheets. 3 types of machining dimensions : Working dimension ( moving of the tool) Machine dimension ( distance between two holes,.) Tool dimension ( diameter, step, .) Example
Tool dimension
Tool dimension
Working dimension
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Tool dimension
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Working dimension
Working dimension
Tool dimension
Working dimension
Tool dimension
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Working dimension
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TD
TD
TD
TD
WD WD
WD
WD
TD TD
TD
TD
WD
TD
TD
WD
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WD
WD
TD WD TD WD Sol 2 WD Sol 1 WD
TD Sol 1 TD Sol 2
TD
WD
TD WD TD WD Sol 1 Sol 2 WD WD
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WD
MD
WD
WD
WD WD
WD MD
TD
TD
TD
TD
TD
TD
WD
WD
WD
WD
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2.3
MINIMUM STOCK REMOVAL SR For make a good working with a tool it is necessary to have a minimum thickness , under this minimum thickness , the tool dont cut, the material is crushed and the dimension isnt realized. The name of this thickness is the minimum stock removal. Example for minimum stock removal rough Semi finish Finishing with tool Grinding Super finish 0.5 0.2 0.1 0.05 0
2.4
The minimum raw dimension is the dimension necessary to make a good part. With this dimension the raw department put his tolerance to define the raw drawing.
Example
MSR for rough MSR for semi finish Finish tolerance Semi Finish tolerance
MINIMUM RAW
Rough tolerance
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generally for positioning a part you need 6 points in space you have 6 possible moving : 3 translatory motion and 3 rotations.
3.2.1
PRISMATIC PART
2 points
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1 point
Long V
4 points
Concentric Chuck
5 points
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Center
3 points
5 points
Important remarks THE STARTING POINTS IN THE MACHINE FIXTURE MUST BE SMALLEST AS POSSIBLE THE STARTING POINTS IN THE CONTROL MEAN MUST BE THE SAME THAN THE FIXTURE IN THE MACHINE. (DIMENSIONS, POSITIONNING AND FORM)
3.3
CLAMPING
TO AVOID THE BUCKLING OF THE PART , THE CLAMPING POINTS MUST BE DIRECTLY OPPOSED TO THE STARTING POINTS.
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3.4
SYMBOLS
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At the first step of the machining its necessary to use raw surfaces. The used raw surfaces must generally stay on the finish part and generally they have a dimension to a machining surface on the study department drawing. For the following machining we use for starting point the surfaces machining at the previous operations. Example Study department drawing
600.1 200.1 152 380.2 200.05
OP10
OP20
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5 CHART OF TOLERANCES
5.1 PRINCIPE OF THE CHART OF TOLERANCES Its not still possible to carry out the positioning of the part to machining directly the dimensions of the final drawing. In this case the surface for the starting points arent the surfaces of the final drawing dimensions. So its necessary to make some calculations. THIS CALCULATIONS IS CALLED CHART OF TOLERANCES Principles of calculations. Every time that the machining of a surface need for the tool setting a different dimension than the final drawing dimension , there are a chart of tolerance. The final drawing dimension witch not used in machining is nevertheless the dimension that its imperatively to carry out. The final drawing dimension is called condition dimension and generally drawing with a positive arrow whith a double line like this.
The machining dimensions necessary to obtain the condition dimension are the links of the chart of tolerances. This chart of tolerances answer at two equations : TOL CD > OR = TOL WD Tolerance of the condition dimension = sum of the tolerances of the Working dimensions to make the condition dimension.
WD = CD
Sum of the chain vector for working dimensions = vector of the condition dimension (this is true only when you used the average dimensions) The methods of the chart of tolerance consist in : - Find the condition dimension ( all the final drawing dimension and all the minimum stock removal) - Find the chain with the links of the chart of the tolerances ( one chain per condition dimension) - Calculate the tolerances of the machining dimensions. Calculate the machining dimensions (rough, semi finish and finish) and the raw dimensions.
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5.2 5.2.1
Final drawing
20
+0.1 0
20
0 -0.2
For the chart of tolerances its necessary to use the average dimensions
CD 1 20.05 0.05
CD 2 19.9 0.1
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Machining of the part This part is machining in turning machine Starting points Concentric chuck 1 stop S 5 points 1 point S
1-3
Machining dimensions
WD 1 WD 2
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Working dimension WD 1
WD1 = 20.050.05
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Working dimensions to make CD2 its necessary to use 2 working dimensions. We know WD1 = 20.05 WD 2 WD 1
CD2 = WD2 WD1 We know : WD1 = 20.05 CD2 = 19.9 19.9 = WD2 20.05 WD2 = 19.9 + 20.05 = 39.95
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WD 2 WD 1
- + - +
+ +
CD 2 mini
We can see here that the variation of CD2 depend of the variation of WD1 and of WD2 TOL CD2 = TOL WD1 + TOL WD2 We know : TOL CD2 = 0.1 TOL WD1 = 0.05 0.1 = 0.05 + TOL WD2 TOL WD2 = 0.1 - 0.05 = 0.05
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Other solution We know : WD1 20.05 0.05 WD1 mini = 20 WD1 maxi = 20.1 CD2 19.9 0.1 CD2 mini = 19.8 CD2 maxi = 20 CD 2 maxi WD 2 maxi
WD 1 mini
+ +
CD2 maxi = WD2 maxi WD1 mini 20 = WD2 maxi 20 WD2 maxi = 20 + 20 = 40
WD 2 mini WD 1 maxi
+ +
CD 2 mini
CD2 mini = WD2 mini WD1 maxi 19.8= WD2 mini 20.1 WD2 mini = 19.8 +20.1 = 39.9 WD2 = 39.950.05 26/65
Name
Condition dimensions
mini 20 19.8 ? ?
maxi 20.1 20 ? ?
CD 1 CD 2
Working dimensions
WD 1 WD 2
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WD = CD
+
Name
Condition dimensions
Dim 20.05 19.9 20.05 39.95 20.05 20.05 19.9 20.05 39.95
mini 20 19.8 ? ? 20
CD 1 CD 2
Working dimensions
WD = CD WD1 = CD1 WD1 = 20.05 WD = CD -WD1+WD2 = CD1 -20.05 + WD2 = 19.9 WD2 = 19.9 + 20.05 WD2 = 39.95
CD2
0.1
19.8
20
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+
Name
Condition dimensions
Dim 20.05 19.9 20.05 39.95 20.05 20.05 19.9 20.05 39.95
CD 1 CD 2
Working dimensions
CD2
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+
Name
Condition dimensions
Dim 20.05 19.9 20.05 39.95 20.05 20.05 19.9 20.05 39.95
0.05
CD 1 CD 2
Working dimensions
CD2
0.1
19.8
20
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Final drawing
400.2 100.1 200.2
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OP20
WD2
OP30
WD3
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Dimension to respect
CD1 = 40 0.2
Working dimension
WD1
CD1 maxi = WD1 maxi = 40.2 CD1 mini = WD1 mini = 39.8
(WD1 = 400.2)
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Dimension to respect
CD2 = 100.1
Op10
Op30
10 = 40 WD3 WD3 = 40 10 = 30 Variation of CD2 -The variation of CD2 depend of the variation of WD1 and WD3 - Tol WD1 + Tol WD3 = Tol CD2 -We know Tol WD1 = 0.4 (0.2) and Tol CD2 = 0.2 (0.1) 0.4 + Tol WD3 = 0.2 -Tol WD3 = 0.2 0.4 = -0.2 < 0 its not possible to have a negative tolerance. 2 solutions to respect the tolerance of CD2 : -Take for tolerance of WD1 and WD3 0.05 ( Tol CD2 = Tol WD1 + Tol WD3 0.2 = 0.1 + 0.1) - Change the process for machining CD2
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For the example we use the first solution WD1 = 400.05 +WD1
-WD3
-WD3
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+ WD1
-WD3
-WD3
+
WD1 mini WD3 mini
WD1 maxi WD3 mini WD1 mini WD3 maxi WD1 maxi WD3 mini
CD2 mini = WD1 mini WD3 maxi 9.9 = 39.95 WD3 maxi WD3 maxi = 39.95-9.9 = 30.05
CD2 maxi= WD1 maxi WD3 mini 10.1 = 40.05 WD3 mini WD3 mini = 40.05-10.1 = 29.95 36/65
Dimension to respect
CD3 = 200.2
Op10 Op20
Op30
CD3 = WD3 + WD2 WD1 We know WD1 = 40, WD3 = 30 and CD3 = 20
20 = 30 + WD2 40 WD2 = 40 +20 30 = 30 Variation of CD2 -The variation of CD3 depend of the variation of WD1,WD2 and WD3 - Tol WD1 + Tol WD2 +Tol WD3 = Tol CD2 -We know Tol WD1 = 0.1 (0.0.5) Tol WD3 = 0.1 (0.05) and Tol CD3 = 0.4 (0.2) 0.1 + Tol WD2 + 0.1 = 0.4 -Tol WD2 = 0.4 0.1 0.1 = 0.2 WD2 = 300.1
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-WD1
+WD2
+WD3
+WD3
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-WD1
+WD2
+WD3
+WD3
+
- WD1 mini + WD3 mini
WD2 mini
CD3 mini CD3 maxi CD3 mini = - WD1 maxi + WD3 mini +WD2 mini 19.8 = -40.05+ 29.95+ WD2 mini WD2 mini = 19.8 - 29.95 + 40.05 = 29.9
WD2 maxi
CD3 maxi= - WD1 mini + WD3 maxi + WD2 maxi 20.2 = -39.95+ 30.05 + WD2 maxi WD2 maxi = 20.2 - 30.05 + 39.95 = 30.1
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Name
Condition dimensions
Dim 40 10 20 ? ? ?
CD 1 CD 2 CD 3
Working dimensions
WD 1 WD 2 WD 3
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WD = CD
+
Name
Condition dimensions
Dim 40 10 20 ? ? ? 40 40 10 40 30 20 30 40 30
CD 1 CD 2 CD 3
Working dimensions
CD1 CD2
CD3
0.2
19.8
20.2
WD = CD WD1 = CD1 WD1 = 40 WD = CD WD1-WD3 = CD2 40 - WD3 = 10 WD3 = 40 - 10 WD3 = 30 WD = CD WD3-WD1+WD2 = CD3 30-40+WD2 = 20 WD2 = 4030+20 WD2 = 30
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+
Name
Condition dimensions
Dim 40 10 20 40 30 30 40 40 10 40 30 20 30 40 30
CD 1 CD 2 CD 3
Working dimensions
CD3
0.2
19.8
20.2
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+
Name
Condition dimensions
Dim 40 10 20 40 30 30 40 40 10 40 30 20 30 40 30
0.2
0.1
CD 1 CD 2 CD 3
Working dimensions
With this table we can see that the sum of the working dimension tolerance are no good to carry out the tolerance of the condition dimensions
CD3
0.2
19.8
20.2
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+
Name
Condition dimensions
Dim 40 10 20 40 30 30 40 40 10 40 30 20 30 40 30
0.05
0.1
CD 1 CD 2 CD 3
Working dimensions
We see here that the tolerance of WD1 and WD3 are so closed. this is due to the changing of starting point at the op 30. Now we try another process
CD3
0.2
19.8
20.2
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CD2 = 100.1
OP20
WD2
OP30
WD3
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Name
Condition dimensions
Dim
Tol
mini
maxi
Working dimensions
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WD = CD
+
Name
Condition dimensions
Dim 40 10 20 ? ? ?
CD 1 CD 2 CD 3
Working dimensions
WD 1 WD 2 WD 3 CD1
CD2
CD3
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+
Name
Condition dimensions
Dim 40 10 20 40 30 10 40 40 10 10 20 10 30
CD 1 CD 2 CD 3
Working dimensions
WD = CD WD1 = CD1 WD1 = 40 WD = CD WD3 = CD2 WD3 = 10 WD = CD -WD3 + WD2= CD3 WD2 = CD3 + WD3 WD2 = 20 + 10 = 30
+
Name
Condition dimensions
Dim 40 10 20 40 30 30 40 40 10 10 20 10 30
0.2
0.1
CD 1 CD 2 CD 3
Working dimensions
WD = CD WD1 = CD1 WD1 = 40 WD = CD WD3 = CD2 WD3 = 10 WD = CD -WD3 + WD2= CD3 WD2 = CD3 + WD3 WD2 = 20 + 10 = 30
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5.2.2.3 Conclusion First process 0.05 0.1 0.05 Second process 0.2 0.1 0.1 1>2 X4 0 X2
We can see in this example that is very important to try to keep the same start points in all the process.
5.2.3
The same part but with CD3 = 20 0.05 For this we decide to change the process in 4 operations.
Final drawing
CD2 = 100.1
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OP20
WD2
SR1
OP30
WD3
SR2
OP30
WD4 TD1
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Building of the chart of tolerance Recap of the dimensions We take for the minimum stock removal of SR1 and SR2 : 0,1 mm
Name
Condition dimensions
Dim
Tol
mini
maxi
Stock removal
Working dimensions
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+
Name
Condition dimensions
Dim 40 10 20
CD 1 CD 2 CD 3
Stock removal
SR1 SR2
Working dimensions
WD 1 WD 2 WD 3 WD 4 TD 1 CD1
? ? ? ? ?
? ? ? ? ?
? ? ? ? ?
? ? ? ? ?
CD2
CD3
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+
Name
Condition dimensions
Di m
40 10 20
Tol
0.2 0.1 0.05
mini maxi
39.8 9.9 19.95 0.1 0.1 40.2 10.1 20.05
0.1
0.1
CD 1 CD 2 CD 3
Stock removal
SR1 SR2
Working dimensions
WD 1 WD 2 WD 3 WD 4 TD 1
40 ? ? 10 20
? 0.1 0.1 ? ?
? ? ? ? ?
? ? ? ? ?
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+
Name
Condition dimensions
Dim 40 10 20
0.2
0.1
0.1
0.1
CD 1 CD 2 CD 3
Stock removal
SR1 SR2
Working dimensions
WD 1 WD 2 WD 3 WD 4 TD 1 CD1 CD1 WD1 CD2 CD2 WD4 CD3 CD3 TD1 SR1 SR1
40 ? ? 10 20 40 40 10 10
20 20
0.05 0.05
20.05 20.05
SR2
SR2
0.1
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Name
Condition dimensions
Dim 40 10 20
0.2
0.1
0.1
0.1
CD 1 CD 2 CD 3
Stock removal
SR1 SR2
Working dimensions
WD 1 WD 2 WD 3 WD 4 TD 1 CD1 CD1 WD1 CD2 CD2 WD4 CD3 CD3 TD1 SR1 SR1 TD1 WD4 WD2 SR2 SR2 WD3 WD4
40 ? ? 10 20 40 40 10 10
20 20
0.05 0.05
19.95 19.95
20.05 20.05
0.1
0.1
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Name
Condition dimensions
Dim 40 10 20
0.2
0.1
0.1
0.1
CD 1 CD 2 CD 3
Stock removal
SR1 SR2
Working dimensions
40 10 20 40 40 10 10 20 20
0.2 0.1 0.1 0.1 0.05 0.2 0.2 0.1 0.1 0.05 0.05
40.2 10.1 20.05 40.2 40.2 10.1 10.1 20.05 20.05 0.1= -20.05-10.1+WD2 mini WD2 mini = 20.05+10.1+0.1 WD2 mini = 30.25
0.1 = - WD3 maxi + 9.9 WD3 maxi = 9.9 0.1 WD3 maxi = 9.8
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5.2.4
RD 3 RD 2 SR 2
SR 3
SR 4
SR 5
SR 1
SR 6
RD 1
Final drawing
CD2 = 100.1
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OP20
WD2
WD3
OP30
WD4
OP40
WD5
OP50
TD1
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Name CD SR CD 1 CD 2 CD 3 SR1 SR2 SR3 SR4 SR5 SR6 RD1 RD2 RD3 WD1 WD2 WD3 WD4 WD5 TD1 40 10 20
Dim
mini 39.8 9.9 19.95 0.2 0.2 0.1 0.1 0.2 0.2
0.5
0.1
RD WD
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CD SR
RD WD
Name CD 1 CD 2 CD 3 SR1 SR2 SR3 SR4 SR5 SR6 RD1 RD2 RD3 WD1 WD2 WD3 WD4 WD5 TD1 CD1 WD2 CD2 WD5 CD3 TD1 SR1 WD1 WD2 SR2 RD2 WD1 WD2 WD4 SR3 WD4 WD5 SR4 TD1 WD5 WD3 SR5 WD3 WD2 WD1 RD3 SR6 WD1 RD1
Dim 40 10 20
mini 39.8 9.9 19.95 0.2 0.2 0.1 0.1 0.2 0.2 41.7 30.15 40.4 39.8 30.25 9.6 9.9 19.95 39.8 39.8 9.9 9.9 19.95 19.95 0.2 40.4 0.2
0.5
0.2
0.1
0.1
0.1
9.6 40.9 40 30.35 9.7 10 20 40 40 10 10 20 20 0.5 0.2 0.1 0.1 0.1 .05 0.2 0.2 0.1 0.1 0.05 0.05 41.4 40.2 30.45 9.8 10.1 20.05 40.2 40.2 10.1 10.1 20.05 20.05 0.2 = +wd1 mini 40.2 wd1 mini = 40.2+0.2 = 40.4 40.2 9.6 40.4 40.2 9.6 0.1 9.8 9.9 0.1 20.05 10.1 30.25 0.2 30.45 39.8 41.4 30.15 0.2 41.4 41.6 0.2 = -41.4 +rd1 mini rd1 mini = 0.2+41.4 = 41.6 0.1 =- wd4 maxi + 9.9 wd4 maxi = 9.9-0.1= 9.8 0.1 = - 20.05 10.1 + wd3 mini wd3 mini = 0.1+20.05+10.1 wd3 mini = 30.25 0.2 = -30.45+41.4-40.9+rd3 mini rd3 mini = 0.2+30.45-41.4+40.9 rd3 mini = 30.15 0.2 = -rd2 maxi +40.4-40.2+9.6 rd2 maxi = -.2+40.4-40.2+9.6 rd2 maxi = 9.6
SR2
SR3
SR4
SR5
SR6
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OP20
400.2
30.350.1
OP30
9.70.1
OP40
100.1
OP50
200.05
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41.6 mini
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5.3
statistical calculate
we know, in the work dimensions calculate, that the tolerance of the condition dimension is equal to the sum of the tolerances of the dimension of the chain. TOL CD > OR =
TOL WD
This calculate is true if we consider that all the dimensions of the chain are at the limit (minimaxi). In reality the probability that all the dimensions of a chain are at the limit is very small. And this reality is all the more true that the number of dimensions is big. We can consider , with a limited risk , to increase the tolerance of the working dimension by a statistical calculate when we have some problems.
TOL CD
> OR =
(TOL WD)
Be careful , generally we dont use this method when we have less than 3 working dimensions. Example :
TOL CD
> OR =
TOL WD
not possible
(TOL WD)
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