TOLERANCE ANLAYSIS

INTRODUCTION: Any two parts produced, can never be exactly alike even under most closely controlled conditions. Variation from work piece to work piece, will always be found as long as an Inspector can measure their differences. Interchangeability of parts is the basic requirement of modern production methods, which means that individual parts can be produced at many locations and brought together for assembly without bench fitting or rework. The responsibility to select an economic tolerance for the product is shouldered by the product designer. The process engineer selects the correct process, establishes the necessary controls, to meet the design specifications economically. If relative tolerances are well specified on the drawing, many of the common causes of excessive cost and waste manufacturing efforts can be curtailed. A current economic picture of selecting proper tolerance can only be understood, when full knowledge of the process and its capabilities are known.

ADDITION OF TOLERANCES

Fig.1 Consider A and B as two linear dimensions which are to be added, each having bilateral tolerance of a1, a2 and b1, b2 respectively as shown in Fig 1. The sum of the two dimensions A and B is equal to C and the effect on the tolerance of C is to be analysed.

The value of C is maximum and minimum when the dimensions A and B are also maximum and minimum respectively. Cmax Cmin Cmax Cmin = = A max + B max A min + B min. (A + a2) + (B + b2) (A a1) + (B b1) ------- ( 1 ) ------- ( 2 )

= ( C + c2 )= = ( C - c1 )=

Subtracting C min ( 2 ) from C max ( 1 ) We get If ( a1 + c2 + a2 ) = T a c1 = (a1+a2) + (b1 + b2)

( b1 + b2 ) = T b ( c1 + c2 ) = T c

The new form of the tolerances will be T c = Ta + Tb SUBTRACTION OF TOLERANCES

Fig 2 Considering the dimension B being subtracted from A where a 1, a2 and b1, b2 are bilateral tolerance of the respective dimensions as shown in fig 2. The dimension C is the resultant of subtraction of (A-B) and the effect of the tolerances on C is to be analysed. Dimension C is maximum when A is maximum and B is minimum, Dimension C is minimum when A is minimum and B is maximum. Thus C max = A max B min C min = A min B max; 2

A max A min Therefore

= =

A + a2 ; B min = B b1 A a1 ; B max = B + b2

C max = ( C + c 2 ) = ( A + a2) ( B b1 ) ----------- ( 3 ) C min Subtracting If = ( C c1 ) = ( A a1) ( B + b2 ) ---------- ( 4 )

C min ( 4 ) from C max ( 3 ) (c 2 + c 1 ) = ( a2 + a1 ) + ( b2 + b1) ( a2 + a1 ) = Ta ( b2 + b 1 ) = T b ( c2 + c1 ) = Tc

The T c = Ta + Tb Here again the tolerance on the dimension C is equal to the sum of the tolerances on the dimensions A and B. So, the sum of the tolerances on the both sides of the equation is equal in addition and as well as in subtraction. In the following cases, the value of X and tolerances x1, x2 are un-known. Case-1 x2 a2 z2 x1 a1 z1 X A = Z x2 a2 x1 a1 X A Therefore Example: x2 a1 x1 a2 x2 - a1 x1 - a2 = (X A) = z2 = z1 = 10
0.2

z2 z1 = Z

x2 x1 0.1 X 5

x2 ( 0.1 ) = + 0.2 x2 + 0.1 = + 0.2 x2 = + 0.2 0.1 = + 0.1 x1 ( + 0.1 ) = 0.2 x1 0.1 = 0.2 x1 = 0.1 x2 x1 X Case-2 = 10
0.2

+ 5

0.1

= 15

0.1

a2 x2 z2 a1 x1 z1 A X = Z a2 x1 z2 a1 x2 z1 (A - X) = Z The tolerance of the equation can be equated. 3

a2 - x1 = z2 x1 = a2 - z2 a1 - x2 = z1 x2 = a1 - z1 Therefore X Example: 15 x2 x1

= -

(Ax2 x1 X

a1 - z1 a2 - z2 Z)
0.2

0.1

= 10

x2 - 0.1- (-0.2) x1 + 0.1- (+ 0.2) X = ( 15 - 10 ) x2 x1 X

0.1

= 5

Fig 3 What should be the dimension X of the component shown in Fig 3 if it is to be made on a capstan lathe. Also analyze the effect of tolerance if the reference is changed. Considering MM as reference a2 a1 A
+ 0.0 - 0.1

x2 x1 X x2 x1 8

= B

b2 b1

30

= 22

0.1

( 30 8 ) 0.0 x1 x1

+0.0 -0.1

- x1 - x2

0.1 = 22

= + 0.1 = 0.1 4

 0.1 - x2 x2 x2 x1 X

= 0.1 = 0.0
+ 0. 0 0.1

The value of Considering LL as reference

= 8

a2 b2 a1 b1 A B 30
+ 0.0 - 0.1

= X
0.1

x2 x1

22

= 8

x2 x1

x2 = + 0.0 ( 0.1) = + 0.1 x1 = 0.1 ( +0.1) = 0.2 x2 x1 X =

+ 0.1 - 0.2

MULTIPLICATION BY A CONSTANT NUMBER Any dimension with tolerances, if multiplied by a positive constant number, the tolerance of the result also increases proportionately. Also when divided by a constant number, the tolerance of the result, similarly decreases proportionately When A is multiplied by a constant K , it becomes (A ) * Example of multiplication:
+ 0.1 + 0.3

a2 a1

a1

a2

a2 * K a1 * K

= (A*K)
(+0.1) 3 (+0.3) 3

* (3)

= (4 * 3)
+0.3 +0.9

= 12 DIVISION BY A CONSTANT NUMBER

a2 a2 / K a1 / K

When A is divided by a constant K , it becomes

a1

a2 a1

(A) Example of division:

= (A K)
0.3/3 0.9/3

+0.3 +0.9

( 12 )

3 = ( 12 / 3 )
+0.1 +0.3

= 4

Fig 4 Example 1 : In the above Figure 4, shaft is placed between plates 1 & 2.For the dimensions given in the Fig , taking LL as reference , find out the variation of dimension x.
x2 x1
+0.0 -0.2 +0.1 -0.0 +0.0 -0.2 +0.0 -0.1

x2 x1

= 50 5 38 5 = 2 = + 0.0 ( 0.0 ) ( 0.2 ) ( 0.1 ) = + 0.3 = 0.2 ( + 0.1 ) 0.0 - 0.0 = 0.3

x2 x1

Verification:

x2 +0.3 x1 -0.3 0.3 X = 2 = 2 Ta + Tb + Tc + Td = T x Ta + Tb + Tc + Td = 0.2 + 0.1 + 0.2 + 0.1 = 0.6 T x = 0.3+0.3 = 0.6 0.6 = 0.6 Since LHS = RHS, the result is correct.

Example 2 :
+0.040

150 - 20 + 95 - 15 + 65 + 15 = 290 x2=(0.040)-(0.073)+(0.013)-(0.001)+(0.000)+(-0.006) = + 0.119 x1=(0.000)-(-0.040)+(-0.009)-(0.012)+(-0.019)+(-0.017) = 0.017

x1 x2 +0.119 -0.017

-0.040 +0.013 +0.012 +0.000 -0.006 -0.073 -0.009 +0.001 -0.019 -0.017

x2 x1

Verification:

X = 290 Ta+ Tb+ Tc + Td + Te + Tf = Tx Ta+ Tb+ Tc + Td + Te + Tf = 0.040+ [(0.040)(0.073)] + [0.013(0.009)] + [(+0.0120(+0.001)] + (0.019)+ [(0.006)( 0.017)] = 0.136 T x = [0.119(0.017)] = 0.136 6

0.136 = 0.136 Since LHS = RHS , the result is correct. Example 3 : 240
+0.046 + 0.030 + 0.011 +0.021 +0.008 +0.030 +0.011 x2 x1

+75

20

60

= X

X = (240 + 75 20 60) = 235 x2 = + 0.046 + 0.030 ( + 0.008 ) ( + 0.011 ) = + 0.057 x1 = + 0.000 + 0.011 ( + 0.021 ) ( + 0.030 ) = 0.040
x1
X2

235 Verification:

235

-0.040

+0.057

Ta + Tb + T c + Td = Tx. Ta + Tb+ T c+ Td = 0.046 + ( 0.030 0.011 ) + ( 0.021 0.008 ) + ( 0.030 0.011 ) = 0.097 Tx = 0.097 0.097 = 0.097 Since LHS = RHS, the result is correct. Example 4 :
+0.012 +0.009 -0.007 -0.004 +0.013 +0.008 -0.009 -0.003 x2 x1

+0.063

65 -20 +450 -120 +12 = 387 x2 = + 0.012 ( 0.004 ) + 0.063(0.009) + 0.008 = + 0.096 x1 = 0.007 ( + 0.009 ) + ( + 0.000 ) ( + 0.013) + (0.003) = 0.032 387

x2 x1

+0.0 96 -0.032

= 387

Verification:

Ta+Tb+Tc+Td+Te = Tx Ta+Tb+Tc+Td+Te =0.012(0.007)+ 0.009 (0.004)+0.063+0.013 (0.009)+0.008(0.003) = 0.128 Tx = 0.096 (0.032) = 0.128 0.128 = 0.128 Since LHS = RHS, the result is correct.

Fig 5 The Fig 5 is of a gear box, it is required to have the axial clearance between bearing and the shaft, as 1.25 0.25 mm (D), what is the variation of, value of X, if the values of A, B, C and E are known. Considering LL as reference, the value of X must lie as the difference between the sum of the dimension of B, C, D, and E to A. Thus the equation is :
x2 x1

X = B + C + D + E
x2 x1 -.05
+0.0

b1

b2

c1

c2

d2

d1

e1

e2

- A

a1

a2

-0.10

+0.00

-0.25 x2 x1

+0.25

+0.00

-0.05 x2 x1

+0.25

-0.25

X= X
x2 x1

+ 140 + 1.25

+ 5

- 100

= ( 151.25 100 ) = ( 51.25 )

x2 = + 0.0 + 0.00 + 0.25 + 0.00 ( 0.25 ) = + 0.5 x1 = 0.05 0.1 0.25 0.05 ( + 0.25 ) = 0.7 (51.25) = 51.25
x1 x2
+0.5 -0.7

Verification:

Tb+Tc+Td+Te+Ta = Tx Tb+Tc+Td+Te+Ta = +0.05 + 0.1 + 0.25 +0.25 + 0.05 +0.25 + 0.25 =1.2 Tx = 1.2 1.2 =1.2 Since the LHS = RHS, the result is correct.

Fig 6 In Fig 6, the dimension P1, P3 advances one side and may be considered as positive where as the dimension P2 and N advances in an opposite direction to the former is considered as negative. Chain dimensioning is a group of dimensions, which are determined by the links of the chain and are interconnected in definite succession also have a close loop characteristic.
+ 0.05
- 0.03

- 0.13
- 0.20

In Fig 7, the dimension A = 100 . 0 , and the variation for the dimension C.

B = 60 calculate the nominal size

Fig 7 Nominal size C = Nominal size A Nominal size B C = 100 60 = 40

c2 c1 a2 a1 b2 b1

C = A

c2 c1

+ 0.05 0.03

0.13 0.20

40 = 100 60 c2 = + 0.05 ( 0.20 ) = + 0.25 c1 = 0.03 ( 0.13 ) = + 0.1

c1 c2 +0.25 + 0.1

C = 40 Tc = Ta +Tb Ta + Tb = + 0.05 ( 0.03 ) + ( 0.13 ) ( 0.2 ) = 0.15 Tc = 0.15 0.15 = 0.15 Since, LHS = RHS , the result is correct. However it must be noted that the tolerance should not be given on a concluding dimension like C as the cumulative tolerances of B and C may exceed the tolerance given on the dimension A.

Fig.8 A hole 16H6 has to be drilled and reamed as shown in Fig 8. The dimension is 79 0.1 from one side of the component. In a box jig plate the tolerance for the dimension from one end, is to be calculated. Here the component is butting against a rest pin which can be maintained within close tolerances as it needs surface grinding. The resultant dimension here is 79 0.1. From the Fig, the nominal dimension of the hole from A A reference is, 20 + 12 + 79 = 111. On the jig plate, the same dimension can be maintained within a close tolerance of 111 0.05. The jig plate thickness can be very easily maintained to a dimension of 20 - 0.05. Now the tolerance of 12 is to be calculated in such a way that the resultant dimension should be 79 0.1. 10

- 0.05 X1 79 = 111 20 12 Max. limit : + 0.1 = + 0.05 ( 0.05 ) x1 x1 = 0 Minimum limit : 0.1 = - 0.05 ( + 0 ) x2 x2 = 0.05 + 0.05 +0.00 + 0.00 - 0.05 The tolerance for the dimension 12 is 12 or 12.05 Verification: Td = Ta + Tb + Tc
0.1 0.05
0.01 0.05

+0.00

X2

+ 0.0

0.05

+ 0.05 - 0.00

79 = 111 - 20 12 Td = 0.2 Ta + Tb + Tc = (0.05)-(-0.05)+0.0-(-0.05)+(0.05)-(-0.0) = 0.2 0.2 = 0.2 Since LHS = RHS, the result is correct.

Fig 9 A hole of 16H7 [Fig 9 (a)] is to be made with reference to another predrilled and reamed hole 10H7 which lies on a perpendicular plane as shown in the Fig 9, A box jig is a most suitable solution and the dimension of the hole 10H7 with reference to one side of the box jig is given as 245 0.05 as shown in Fig 9.b. The tolerance for the dimension 97 must be found to position the drill jig bush to drill and ream dia 16H7 hole. x2 x1 Dimension should be 148 0.1 = 245 0.05 97 x2 x1 148 0.1 + 97 = 245 0.05 +0.1 ( x1 ) = + 0.05 x1 = + 0.05 0.1 ( x2 ) = 0.05 x2 = 0.05 The tolerances for the dimension 97 should be 0.05 11

Verification:

245 0.05 - 97 0.05 = 148 0.1 Ta +Tb = 0.1+ 0.1 = 0.2 Tc = 0.2 0.2 = 0.2 Since , LHS = RHS the result is correct.

The tolerance 0.05 can be maintained in a tool room.

Fig 10 The component shown in Fig.10 is dimensioned by two methods, out of which the more practical one is to be analyzed. On the component drawing in case 1 the dimensions, 50 0.1; 100 0.2 , and the overall dimensions 180 0.05 are toleranced and in case 2 , dimensions 100 0.2 , 130 0.05and 30 0.05are toleranced . In case 1 considering LL as the reference
X2

X = 180 0.05 50 0.1 100 0.2 x2 = + 0.05 - ( - 0.1 ) - ( - 0.2 ) = + 0.35 x1 = - 0.05 - ( + 0.1 ) - ( + 0.2 ) = - 0.35
x2

x1

X = 30 0.35 In case 2 considering AA as reference

X2

X1

Xx1 = 130 0.05 - 100 0. 2 x2 = + 0.05 - ( - 0.2 ) = + 0.25 x1 =

X2

- 0.05 - ( + 0.2 )

- 0.25

Xx1 = 30 0. 25 In neither of the two cases the tolerances of 30 0.05 is achievable. Thus in practice, taking the datum as AA, the given tolerances is easily achievable in jig boring.

12

Fig 11 In the above Fig 11, the designer reflects the dimension C from the functional reference LL . +0.08 - 0.14 It is impracticable to measure the depth ( 20 ) of the hole having diameter D1 from the functional reference LL , hence an auxiliary reference must be chosen to facilitate the measurement of the depth of the hole D1. The best auxiliary reference selected in this case is MM , which is also reference for manufacturing. In view of this new reference the dimensions of A, B, C and their tolerances are evaluated as follows. Nominal dimension of A = Nominal dimension B+ Nominal dimension C A = B+C A = 20 +10 =30 Total Tolerance of C = Total tolerance of A-Total tolerance of B The equation will be A - B = C
a2 a1 b2 b1 c2 c1
+ 0.08 0.0 5

A - B
a2 a1

- 0.14

30 10 = 20 a2 ( 0.05 ) = + 0.08 a2 = 0.08 - 0.05 = + 0.03 a1 ( + 0.05 ) = 0.14 a1 = 0.09

a2 a1 +0.03 -0.09

A = 30
+0.03

The depth of hole is = 30 -0.09. It is however difficult to calculate the resulting dimensions if the component or the assembly has number of dimensions. In such cases compensating elements or spacers or adjusting shims are to be employed.

13

Tolerancing Dimensions between centers

There are three methods of dimensioning between centers of holes, which are as follows: 1. Series or chain dimensioning 2. Parallel dimensioning of each hole with respect to the datum. 3. Series and parallel a combination of the above two methods. The methods mentioned are shown in Fig12.

Fig 12

Tolerance on Dimensions between centers of two holes

`

14

Fig 13.1

Fig 13.2 On two plates two holes are made at a distance of M apart, with a tolerance of m and if the plates are to be assembled with the aid of screws they should assemble freely , or the tolerance should be of critical magnitude critical value to achieve 100% interchangeability. Case1: When sizes of the holes and shafts are identical. Ifd is the diameter of the shafts and D is the diameter of holes in two plates, a set up for the worst case of interchangeability is shown in Fig no. 13.1. 1-1 = Axis of holes in the plate1 2-2 = Axis of the holes in the plate 2 CC = Axis of the shafts mating the holes. M = The distance between the centers of holes m = The tolerance on M on the respective holes ( D-d ) = Clearance between hole and shaft = L Considering a datum line of no clearance from the figure, the following chain of dimension can be placed keeping in view the signs, an equation for the expression of tolerance is as 0 = D/2 - ( M+ m ) + D/2- d+ D/2 + ( M-m ) + D/2 -d 0 = 2D - 2m - 2d 2m = 2 ( D-d ) 2m = 2L or m = L, as this is a critical value, m can be less than L but not more, as 100% interchangeability is to be achieved. Therefore m = L ------------------------- ( 1 ) CONCLUSION: If 100% interchangeability is to be achieved in the above case, the tolerance on dimension between the two holes cannot be more than twice the diametrical clearance between the holes and shafts. It could be less or equal to the clearance. 15

Case II: The size of the holes and shafts vary: Fig 14

Fig 14 Let D1 be the diameter of the holes in plates 1 and 2, for the mating shaft d1. Let D2 be the diameter of the holes in plates 1 and 2 for the mating shaft d2 . A worst case set-up for 100% interchangeability is shown in the Fig. 1-1 = Axis of holes in the plate 1 2-2 = Axis of holes in the plate 2 c1 -c1 = Axis of the shaft of diameter d1 c2 -c2 = Axis of the shaft of diameter d2 M = The distance between the centers of holes m = The tolerance on M. ( D1- d1 ) , ( D2 - d2 ). =The clearance between the holes and Shafts. Starting from a point of no clearance, a set of chain dimensions can be placed as follows, keeping in view the directional sign and equating it to zero. 0 = D2/2 - ( M+ m )+ D1/2 - d1 + D1/2 + ( M - m ) + D2/2 - d2 0 = - 2m + ( D1 + D2 ) - ( d1 + d2 ) 2m = ( D1 - d1 ) + ( D2 - d2 ) 2m = ( L1 + L2 ). Since ( D1 - d1 ) = L1 and ( D2 - d2) = L2 m = ( L1 + L2 ) 2 --------------------------- ( 2 ) CONCLUSION: The critical tolerance m on the centers of two holes in the above case should be equal to half the sum of clearances in both holes and could be less for 100% interchangeability between the two plates. The principle involved in framing the equation is that the relative displacement of a point is zero, when it travels between two fixed points and returns by the same path. Starting from a point of no clearance, a set of chain 16

dimensions can be framed as above, keeping in view the directional sign and equating it to zero.

Tolerance on Dimensions between centers of three Holes

Series Dimensioning.

Fig 15 If D is the diameter of holes in the plates 1 and 2 and d the diameter of mating shafts, Fig 15 shows the holes displaced according to the tolerance for the worst case. 1-1 = Axis of the holes in plate 1 2-2 = Axis of the holes in plate 2 c-c = Axis of the shafts M = Dimension between holes m = The tolerance of the dimensions. 0 = D/2 + ( M- m ) + ( M m ) + D/2 d + D/2 - ( M+ m )- ( M + m ) +D/2 - d 0 = 2D - 2d - 4m 4 m = 2 ( D d ) = 2 L. Since ( D - d ) = L m = L/2 Similarly For 4 holes dimensioned in series m=L/3 For 5 holes dimensioned in series m=L/4 If n holes are in series m= L/n-1------------------------- ( 3 ) For n holes dimensioned in series tolerance between the holes should be equal to or less than L/n-1 for 100% interchangeability. Fig 16

17

Fig 16 CONCLUSION: As the number of holes increases in case of series dimensioning, the tolerance, between the holes decreases. Hence the cost of production increases and it is difficult to make. If same tolerances are given to the large dimensions as that of small dimensions, it will be in many instances impracticable.

Parallel Dimensioning

Fig 17 18

If D is the diameter of holes in the plates 1 and 2 and d is the diameter of the shafts mating with, Fig 17 shows the holes displaced according to the tolerances for the worst case. 1-1 = Axis of holes in plate 1 2-2 = Axis of holes in plate 2 c-c = Axis of the shafts M1 = The distance of the second hole from the first M2 = The distance of the third hole from the first m = The tolerance of M1 dimension m = The tolerance of M2 dimension Considering a datum line of no clearance from the figure the following chain of dimensions can be laid down taking care of the signs of the dimensions, the expression for the tolerances is, as follows. -d+D/2+(M1-m)+D/2-d+D/2-(M1+m)+(M2+m)-D/2+d-D/2-(M2-m)-D/2+d= 0 2 m 2 m = 0 m = m ----------------------------------- ( 4 )

Fig 18 19

CONCLUSION: As the number of holes increases the tolerance remains the same L/2 The tolerance between the first hole and second hole is equal to tolerance between the first hole and third hole. We also conclude that, if the tolerance is equal, it has no bearing on the number of holes .The same tolerance for small dimension remains unaltered even for larger dimensions, but difficulties may occur to achieve the tolerances on larger dimension

Comparison between series & parallel Dimensioning:

By comparing the series and parallel dimensioning we understand that if the number of holes exceeds 3, parallel dimensioning is only recommended. By series dimensioning, tolerance decreases which is difficult to achieve and expensive.

Tolerance on Dimensions of holes in plates I and II from their common edge for interchangeability:

Fig 19 Case1: Fastener having clearance in both the plates (Fig 19). Two plates are to be assembled by a fastener of diad, passing through the holes of dia D. The locations of holes are with reference to the common edge 0.The distance of the holes from the common edge is M m , where m is the tolerance. The hatched square in the Fig 19 indicates the largest area in which the hole centers can lie for complete interchangeability. Let us consider a position in which the center of the hole in plate 1 is at a distance of ( M + m ) and the center of the hole in plate 2 is ( M m ) on both axis. In the plan view a line joining the common edge and the centers makes an angle of 45 degrees and the figure shows the respective distance from the common edge. Applying the principles as before, 0 = (D/2)-2 (M+m) +2(M-m) + (D/2)-d 0 = (D-d) - 2 2m, Therefore 2*2m = (D d) (Dd)=L 20

2m = ( D d ) 2 = 0.7 * L

Case II: Fastener having clearance in plate 1 and press fit in plate 2.

Fig 20 For the position as shown in Fig 20. 0 = (D/2)-2(M+m)+2(M-m)-(d/2) (D-d)/2 = 2*2m ; ( D d ) = L 0.35 L = 2m.

Tolerances of dimensions in two plates from common surface for interchangeability

There are two plates and the position of the two holes in these plates is determined by the distance between the datum surface. How much should be the tolerance of these distances, if we want to have 100% interchangeability so that it can assemble without any difficulty.

21

Case I:

Fig 21 Fastener having clearance in both plates . Holes of dia D in plates 1and 2 are at a distance of ( M + m ) and ( M m ) respectively and is assembled by a fastener of dia d . Applying the principle 0 = ( D/2 ) ( M m ) + ( M + m ) + ( D/2 ) d Dd = 2m D d = L, L = 2m 0.5 L = m for complete interchangeability m 0.5 L Case II: Fastener having clearance in one plate and press fit in other plate Fig 21

Fig 22 0=D/2-(M+m)+(Mm) (d/2) (Dd)/2=2m (Dd) = L L/2 =2m m = 0.25 L For complete interchangeability m 0.25 L 22

Calculation of tolerance for distance between holes on Drill Jigs

Fig 23 Two holes are to be drilled and reamed at a distance W0 within the limits T0 , by using a jig plate with slip bushes as shown in Fig 23 Let W1 T1 be the distance between the liner bushes in jig plate. L1, L2 = Clearance (around) between the slip bush and liner bush for the first and second holes respectively. e1, e2 = eccentricity of inside diameter of slip bush with respect to its outside diameter for the two bushes respectively. So that W0 = f (w1, L1, L2, e1, e2.). CONDITION 1: When the distance between liner bushes in the jig plate is at maximum distance (W1+T1) and slip bushes at far off position. O1, O2 are centers of the slip bushes which are eccentric with respect to their outside diameter of slip bushes by e1 and e2. OO1 = L1 + e1 OO2 = L2 + e2. 23

They are in extreme positions as shown in the figure. This distance between holes on the component W 1 + T1 + OO1 + OO2 The sum of these distance should be less than the maximum distance given on the component. ( W1 + T1 + L1 + e1 + e2 ) W0 + T0. CONDITION 2: When the distance between liner bushes in jig plate is at minimum distance (W1-T1) and when slip bushes are also at minimum distance: O1, O2 are the centers of the slip bushes, which are eccentric with respect to outside by e1 and e2 respectively. OO1 = L1 + e1 OO2 = L2 + e2 The distance between the holes obtained on the component ( W1 + T1 ) = ( W1 - T1 ) - OO1 - OO2 = ( W1 - T1 ) - ( L1 + e1 ) - ( L2 + e2 ) = ( W1 - T1 - L1 - L2 - e1 - e2 ) The sum of these distances should be more than the minimum distance ( Wo - To ) given on the component ( W1 - T1 ) - L1 - L2 - e1 - e2 ( W o - To ) Note: The clearance between the drill and the slip bushes has its effect on the distance between the holes on the component. The drill size is minimum , bushes and the drill are at far off position. O1, O2 are the positions of the centres of the slip bush when the clearance between the drill and the slip bush are considered. With the effect of clearance between the drill and the slip bushes, the maximum extreme dimension obtained is as = W1 + T1 + L1 + L2 + e1 + e2 + OO1 + OO2 = W1 + T1 + L1 + L2 + e1 + e2 + ( d b + Tb ) - ( d - Td ) The sum of these distances should be less than or equal to Wo + To.

24

Fig 24

Fig 25 CASE II: When drill size is minimum the bushes position is also at minimum distance , the drill is at minimum distance. OO1 = OO2 = ( d b - Tb ) - ( d - Td ) 2 Actual distance between holes on component = W1 - T1 - L1 - L2 e1 - e2 - OO1 - OO2 = W1 - T1 - L1 - L2 - e1 - e2 - ( d b + Tb ) + ( d - Td ) This should be more than the minimum distance ( W0 - T0 ) given on component. W1 - T1 - L1 - L2 - e1 - e2 - ( d b + Tb ) - ( d - Td ) > W0 - T0 Final conditions are W1 + T1 + L1 + L2 + e1 + e2 + ( d b +Tb ) - ( d - Td ) ( W0 + T0 ) W1 - T1 - L1 - L2 - e1 e2 - ( d b + Tb ) + ( d - Td ) > ( W0 - T0 ) As per Indian standard the tolerance on drill is = h 9 The tolerance of the hole in slip bush is = F 7 The clearance between the liner bush and the slip bush is = F 7 / h 6 25

26