MECHANICAL MEASUREMENTS AND METROLOGY

➢ The word metrology has been derived from

the Greek word “metrologia” which means
measure.
➢ Metrology is the science of measurement.
➢ Metrology is concerned with the
establishment, reproduction, conservation
and transfer of units of measurement and
their standards.
What is ➢ The practice of metrology involves precise
measurements requiring the use of
Metrology ? apparatus and equipment to permit the
degree of accuracy required to be obtained.
➢ Metrology, in addition to precise
measurements is also concerned with
industrial inspection and its various
techniques.

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 ACCURACY AND PRECISION

ACCURACY
• It is the agreement of the result of
measurement to the true value of the
measured quantity.
• The difference between the measured value
and the true value is the error of
measurement.
PRECISION
• It is the repeatability of a measuring process
• This concept applies to a set of
measurements.
• In a set of measurements, the individual
results will scatter about the mean value.

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 GENERAL
MEASUREMENT
CONCEPTS

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 ERROR IN
MEASUREMENT
Random Errors
• They are accidental in nature.
• They fluctuate in a way that cannot be
predicted.
• Examples: ambient influences, hysterysis,
variations in the work-piece, etc

Systematic Errors
• They are not usually detected by repetition
of the measurement operations.
• Usually results from faulty calibration of a
local standard or a defect in contact
configuration of an internal measuring
system.

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Systematic or Controllable Errors

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Relationship
between
systematic
and random
errors with
measured
value

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Difference between Systematic and Random Errors

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 ❖ Standard is defined as the fundamental value of
any known physical quantity setup and
established by national and international
organizations of authority which can be
STANDARDS reproduced.
❖ The fundamental units of physical quantities
AND such as length, mass, time, temperature etc.,
form the basis for establishing a measurement
system.
THEIR ROLE ❖ Standards play a vital role for the manufacturers
across the world in achieving consistency,
accuracy, precision and repeatability in
measurements and supporting the system which
enables the manufacturer to make such
measurements.

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 Scientists across the world have always
been in the pursuit of a suitable unit for
length and consistent efforts have been
made to keep the unit of length constant
MATERIAL irrespective of the environmental
conditions.

STANDARD The problem with material standards

used earlier was made of materials which
could change their size with temperature
and other conditions. In order to keep the
fundamental unit unchanged, great care
and attention need to be exercised to
maintain same conditions.

Two standard systems for linear

measurement that have been accepted
and adopted world wide are English and
Metric (yard and metre).

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✓ The Imperial Standard Yard is a bronze bar
having a composition of 82% Cu, 13% tin and
5% Zn.
✓ The bronze bar has a square cross-section of Yard
one inch and has a length of 38 inches. The
bar contains ½ inch diameter X ½ inch deep
holes.
✓ It has a round recess located one inch away
from two ends and extends at both ends up to
central plane of the bar.
✓ A highly polished gold plug having a diameter
of 1/10 of an inch comprising three
transversely engraved lines and two
longitudinal lines which are inserted into
these holes such that the lines lie in the
neutral plane.
✓ The top surface of these plugs lie on the
neutral axis.
✓ Yard is defined as the distance between the
two central transverse lines of the plug
maintained at a temperature of 62°F.

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 ❑ This standard is also known as
METRE International Prototype Metre which
was established in 1875. It is defined
as the distance between the centre
portions of two lines engraved on the
highly polished surface of 102 cm bar
of pure platinum-iridium alloy having
a composition of 90% platinum and
10% iridium maintained at 0°C and
under normal atmospheric pressure
having the cross section of a web.
❑ The bar is supported by two rollers
having at least 1 cm diameter which
are symmetrically located in the same
horizontal plane at a distance of 751
mm from each other such that there is
minimum deflection.
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 1. The material standards are affected by changes in
environmental conditions like temperature,
pressure, humidity and ageing and hence there may
be variations in length.
2. Preservation of these standards is difficult
because they have to be kept under security to
DISADVANTAGES prevent their damage or destruction.
OF MATERIAL 3. The problem with material standards is that their
replicas are not available for use at other places.
STANDARD 4. They cannot be easily reproduced.
5. Comparison and verification of the sizes of gauges
pose considerable difficulty.
6. While changing over to metric/SI system
conversion factor is necessary.

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 HIERARCHICAL
CLASSIFICATION
OF STANDARDS

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SUB-DIVISIONS OF STANDARDS

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 ❖ For precise definition of the unit, there
shall be one and only one material
standard.
❖ The primary standards are preserved
carefully and are kept under standard
atmospheric conditions so that these
PRIMARY standards do not change their values.
❖ This has no direct application to a
STANDARDS measuring problem encountered in
engineering. These are used only for
comparing with secondary standards.
❖ Example: International yard and
International metre as standard unit of
length.

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 ▪ These are derived from primary
standards and very closely resemble the
primary standards with respect to
design, material and length.
▪ Any error existing in these bars is
SECONDARY recorded by comparison with primary
standards after long intervals.
STANDARDS ▪ These are kept at different locations
under great supervision and are used for
comparison with tertiary standards
whenever it is essential.
▪ These safeguard against the loss or
destruction of primary standard.

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 o The primary and secondary standards are the
ultimate controls for standards and are used
only reference purposes and that too at rare
intervals.
TERTIARY o Tertiary standards are reference standards
employed by National Physical Laboratories.

STANDARDS (N.P.L) and are used as first standards for

reference in laboratories and workshops.
o The tertiary standards are replicas of
secondary standards and are usually used as
reference for working standards.

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 LINE AND END
MEASUREMENTS
✓ When the distance between two engraved lines is used to
measure the length, it called line standard or line
measurement. The most common examples are foot and
metre. The rule with divisions marked as lines on it, is widely
used.
✓ When the distance between two flat parallel surfaces is
considered as a measure of length it is known as end standard
or end measurement.
✓ The end faces of the end standards are hardened to reduce
wear and lapped flat and parallel to a very high degree of
accuracy.
✓ The end standards are extensively used for precision
measurement in workshops and laboratories. The most
common examples are measurement using Slip Gauges, End
Bars, Ends of Micrometer anvils, Vernier Calipers etc.

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Characteristics of Line standards

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 CHARACTERISTICS OF END STANDARDS
1. These are highly accurate and are ideal for making close tolerance measurement.

2. They measure only one dimension at a time and consume more time.

3. The measuring faces of end standards are subjected to wear.

4. They possess built in datum because their measuring faces are flat and parallel and be positively located on a
datum surface.
5. Group of blocks/slip gauges are wrung together to build up the required size and faulty wringing leads to
inaccurate results.
6. They are not subjected to parallax errors since the use of end standards depend on feel of the operator.

7. Dimensional tolerance as close as 0.0005 mm can be obtained.

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COMPARISON
OF LINE AND
END
STANDARDS

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 • Slip gauges are rectangular blocks of
SLIP GAUGES high grade steel, hardened and
stabilized by a heat treatment
process to give a high dimensional
stability.
• Steel is the preferred material since it
is economical and has the same
coefficient of thermal expansion as
majority of steel components used in
production.
• Gauge blocks are manufactured from
tungsten carbide, which is an
extremely hard and wear resistant
material and have longer life.
• Slip gauges have 30 mm by 10 mm
cross section.
• Each block has its two opposite
measuring faces ground and lapped
flat and parallel to within very fine
tolerances.

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 SLIP
GAUGES

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 USES OF SLIP
GAUGES
1. Direct precise measurement where
accuracy demands it.
2. Checking the accuracy of a measuring
instruments like vernier calipers,
micrometers.
3. Setting up a comparator to a specific
dimension, enabling a batch of components to
be quickly and accurately checked.
4. For measuring or setting up of angles in
conjunction with sine bar.
5. Any other situation where there is a need to
refer to a standard known length.
6. To check gap between parallel locations
such as gap gauges or between mating parts.

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 ❖ Slip gauges are available in standard sets in
both metric and inch units. In metric units,
sets of 31, 48, 56 and 103 pieces are available.
For instance, the set of 112 pieces consist of:
a) 1 piece of 1.0005 mm
b) 9 pieces ranging from 1.001 to 1.009 mm in
Slip steps of .001
Gauge c) 49 pieces ranging from 1.01 mm to 1.49 mm
in steps of 0.01 mm
Sets d) 49 pieces ranging from 0.5 mm to 24.5 mm
in steps of 0.5 mm
e) 4 pieces ranging from 25 mm to 100 mm in
steps of 25 mm

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 SLIP GAUGE SETS
A set of 56 slip gauges consists of:
a) 1 piece of 1.0005 mm,
b) 9 pieces ranging from 1.001 mm to 1.009 mm in steps of 0.001 mm
c) 9 pieces ranging from 1.01 mm to 1.09 mm in steps of 0.01 mm
d) 9 pieces ranging from 1.0 mm to 1.9 mm in steps of 0.1 mm
e) 25 pieces ranging from 1 mm to 25 mm in steps of 1.0 mm
f) 3 pieces ranging from 25 mm to 75 mm in steps of 25 mm
A set of 45 slip gauges consists of: (Normal Set : M – 45)
a) 9 pieces ranging from 1.001 mm to 1.009 mm in steps of 0.001 mm
b) 9 pieces ranging from 1.01 mm to 1.09 mm in steps of 0.01 mm
c) 9 pieces ranging from 1.0 mm to 1.9 mm in steps of 0.1 mm
d) 9 pieces ranging from 1.0 mm to 9 mm in steps of 1 mm
e) 9 pieces ranging from 10 mm to 90 mm in steps of 10 mm

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SINE BAR

The sine of the angle ‘θ’ formed between the

upper surface of sine bar and the surface
plate (datum) is given by
Sin (θ) = h/L
Where h = the height difference between the
two rollers
L = distance between the centres of rollers
Therefore, h = L X Sin (θ)

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 ✓ Several slip gauges are
temporarily combined together
WRINGING OF SLIP to provide the end standard of
specific length.
GAUGES ✓ While building slip gauges to the
required height, the surfaces of
slip gauges are pressed into
contact by imparting a small
twisting motion while
maintaining the contact
pressure.
✓ The slip gauges are held together
due to molecular adhesion
between a liquid film and the
mating surfaces. This
phenomenon is known as
‘wringing’.
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 BUILDING
SLIP
GAUGES

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BUILDING
SLIP
GAUGES

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BUILDING SLIP GAUGES

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BUILDING SLIP
GAUGES

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 Precautions &
care
1. The surface of gauge must be covered with
natural petroleum jelly or some anticorrosive
to avoid rusting.
2. The gauges should be used under controlled
condition of temperature.
3. Wringing of gauges should be done without
applying undue pressure to avoid damage to
the surface.
4. Never drop slip gauges.
5. Never strike slip gauges with other metallic
objects.
6. Use minimum number of gauges for
building up size combination.

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 • Slip gauges are classified into grades depending
on their guaranteed accuracy.
• The grade defines the type of application for
which a slip gauge is suited, such as inspection,
reference or calibration.
• Accordingly, slip gauges are designated into five
grades, namely, grade 2, grade 1, grade 0, grade 00
CLASSIFICATION and inspection grade.
Grade 2: This is the workshop grade slip gauge.
OF SLIP GAUGES Typical uses include setting up machine tools,
milling cutters, etc on the shop floor
Grade 1: This grade is used for tool room
applications for setting up sine bars, dial
indicators, calibration of vernier and micrometer
instruments and so on.
Grade 0: This is inspection grade slip gauge.
Limited people will have access to this slip gauge
and extreme care is taken to guard against rough
usage

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 Grade 00: This set is kept in the standards room and is
used for inspection / calibration of high precision only.
It is also used to check the accuracy of work shop and
grade 1 slip gauges.
Calibration Grade: This is a special grade, with the
actual sizes of slip gauges stated on a special chart
supplied with the set of slip gauges.
This chart gives the exact dimension of the slip gauge,
Classification unlike the previous grades, which are presumed to have
been manufactured to a set tolerance.
of Slip Gauges They are the best grade slip gauges because even though
slip gauges are manufactured using precision
manufacturing methods, it is difficult to achieve one
hundred percent dimensional accuracy.
For calibration grade slip gauges, sizes are explicitly
specified up to third or fourth decimal place of a
millimetre.

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TRANSFER FROM LINE STANDARD TO END
STANDARD

Line standards are inconvenient for general measurement purposes

and are usually used to calibrate end standards provided that the
length of primary line standard is accurately known.

The end standard must be calibrated from a primary line standard

whose length is accurately known

In order to transfer a line standard to an end standard a composite

line standard is used

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 Transfer from Line Standard to End Standard
The composite line standard whose length is to be
determined is compared with the primary line standard, and
length L is obtained by using the following formula:
• L = L1+ b + c
The four different ways in which the two end blocks can be
arranged using all possible combinations and then
compared with the primary line standard are
• L = L1 + b + c
• L = L1 + b + d
• L = L1 + a + c
• L = L1 + a + d
Summation of these four measurements gives
• 4L = 4L1+ 2a + 2b + 2c + 2d
= 4L1 + 2(a + b) + 2(c + d)

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 Transfer from Line
Standard to End Standard
The combination of blocks (a + b) and (c + d) are
unlikely to be of the same length. The two are therefore
compared; let the difference between them be x
• (c + d) = (a + b) + x
Substituting the value of (c + d),
• 4L = 4L1 + 2(a + b) + 2[(a + b) + x)]
• 4L= 4L1+ 2(a + b) + 2(a + b) + 2x
• 4L = 4L1 + 4(a + b) + 2x
Dividing by 4, we get
• L = L1 + (a + b) + ½x
An end standard of known length can now be obtained
consisting of either L1 + (a + b) or L1 + (c + d), as shown
in Fig. The length of L1 + (a + b) is L1 + (a + b) + ½x less
½x, where (a + b) is shorter of the two end blocks. The
length of L1 + (c + d) is L1 + (a + b) + ½x plus ½x, where
(c + d) is longer of the two end blocks.

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 CALIBRATION OF END
BARS
Let LX and LY be the lengths of the two 500 mm bars. Let e1
be the difference in height between the calibrated metre
bar and the combined lengths of X and Y. Let the difference
between the lengths of X and Y be e2. Let L be the actual
length of the metre bar.
Then the first measurement gives a length of L ± e1 = LX +
LY, depending on whether the combined length of LX and LY
is longer or shorter than L.
The second measurement yields a length of LX ± e2 = LY,
again depending on whether X is longer or shorter than Y.
Then substituting the value of LY from the second
measurement in the first measurement,
we get
• L ± e1 = LX + LX ± e2 = 2LX ± e2
• or
• 2LX = L ± e1 ± e2
Therefore, LX = (L ± e1 ± e2)/2 and LY = LX ± e2

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 TRANSFER FROM LINE STANDARD
TO END STANDARD

Example 1: A calibrated metre end bar which has an actual length of 1000.0005 mm is to
be used in the calibration of two bars X and Y each having a basic length of 500 mm.
When compared with the metre bar the sum of LX and LY is found to be shorter by 0.0003
mm. When X and Y are compared, it is observed that X was 0.0004 mm longer than Y.
Determine the actual length of X and Y.

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 Solution

We have from first principles,

L – e1 = LX + LY
But LX = LY + e2
Therefore, we get, L – e1 = 2LY + e2
or LY = (L – e1 – e2) / 2
Substituting the values for L, e1 and e2, we get,
LY = (1000.0005 – 0.0003 – 0.0004) / 2
LY = 999.9998 /2 mm
i.e, LY = 499.9999 mm
We have LX = LY + e2
LX = 499.9999 + 0.0004 = 500.0003 mm

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Example 2: Three 200 mm gauges to be calibrated are measured on a level
comparator by wringing them together and then comparing with 600 mm
gauge. The 600 mm gauge has an actual length of 600.0025 mm and the three
gauges together have a combined length of 600.0035 mm. When the three
gauges are intercompared it is found that gauge A is 0.0020 mm longer than
gauge B but shorter than gauge C by 0.001 mm. Determine the length of each
gauge.

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 Solution

L = LA+ LB + LC – e1
LA = LB + e2
LC = LA + e3
LC = LB + e2 + e3
Thus,
L = LB + e2 + LB + LB + e2 + e3 – e1
Simplifying,
L = 3LB + 2e2 + e3 – e1
Or, 3LB = L – 2e2 + e3 – e1
LB = (L – 2e2 – e3 + e1) / 3

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Solution

Substituting the values we get,

LB = 600.0025 – 2 x 0.0020 – 0.0010 + 0.001
LB = 599. 9985 / 3
LB = 199.9995 mm.
And
LA = LB + e2
LA = 199.9995 + 0.0020 = 200.0015 mm.
LC = LA+ e3
LC = 200.0015 + 0.0010 = 200.0025 mm

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 TOLERANCE

❑ Tolerance can be defined as the

magnitude of permissible variation
of a dimension or other measured
value or control criterion from the
specified value.
❑ It can also be defined as the total
variation permitted in the size of a
dimension and is the algebraic
difference between the upper and
lower acceptable dimensions.

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Classification
of Tolerances

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Unilateral • The tolerance
distribution is only on
one side of the basic
Tolerance size.
• In other words, the
tolerance limits lie
wholly on one side of
the basic size either
above or below it.
• Unilateral tolerance is
employed in drilling
process wherein the
dimensions of the hole
are most likely to
deviate in one direction
only i.e., the hole is
always of over size
rather than undersize.
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Bilateral
Tolerance
• When the tolerance distribution lies on either side of the basic size, it is known as bilateral
tolerance.
• In other words, the dimension of the part is allowed to vary on both sides of the basic size, but
may not be necessarily equally disposed about it

Tolerances (a) Unilateral (b) Bilateral

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 COMPOUND
TOLERANCE
➢ When the tolerance is determined by the
established tolerances on more than one
dimension.
➢ For example, the tolerance for the
dimension R is determined by the combined
effect of tolerance on the 40 mm dimension,
the tolerance on the 60 degree and the
tolerance on 20 mm dimension.
➢ The tolerance obtained on dimension R is
known as compound tolerance.
➢ Compound tolerance should be avoided as
far as possible in practice.

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Geometric tolerance
❑ Geometric tolerance is defined as the total
amount that the dimension of a
manufactured part can vary. Geometric
tolerance underlines the importance of the
shape of a feature as against its size.
❑ Geometric dimensioning and tolerancing is a
method of defining parts based on how they
function, using standard symbols.

Geometrical tolerance can be classified as

follows:
1) Form tolerance
2) Orientation tolerance
3) Positional tolerance

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 FORM TOLERANCES

✓ Form tolerances are a group of geometric tolerances

applied to individual features.
✓ They limit the amount of error in the shape of a
feature and are independent tolerances.
✓ Form tolerances as such do not require locating
dimensions.
✓ These include straightness, circularity, flatness, and
cylindricity.

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 ORIENTATION TOLERANCES

➢ Orientation tolerances are a type of geometric tolerances used to

limit the direction or orientation of a feature in relation to other
features.
➢ These are related tolerances.
➢ Perpendicularity, parallelism, and angularity fall into this category.

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 POSITIONAL TOLERANCES

❖ Positional tolerances are a group of geometric tolerances that controls the extent of

deviation of the location of a feature from its true position.

❖ This is a three-dimensional geometric tolerance comprising position, symmetry, and

concentricity.

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Accumulation of tolerances

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Progressive
dimensioning

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GEOMETRIC
TOLERANCE

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 PRINCIPLE OF
INTERCHANGEABILITY
• It is essential that the parts are manufactured in bulk to the desired
accuracy and, at the same time, adhere to the limits of accuracy
specified.
• Manufacture of components under such conditions is called
interchangeable manufacture.
• By interchangeable assembly, identical components, manufactured by
different operators, using different machine tools and under different
environmental conditions, can be assembled and replaced without any
further modification during the assembly stage and without affecting
the functioning of the component when assembled.
• For example, consider the assembly of a shaft and a part with a hole.
The two mating parts are produced in bulk, say 1000 each. By
interchangeable assembly any shaft chosen randomly should assemble
with any part with a hole selected at random, providing the desired fit.

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 SELECTIVE ASSEMBLY
APPROACH
• Selective assembly approach is employed wherein the
parts are manufactured to wider tolerances.
• In selectively assembly, the parts fit and function as if
they were precisely manufactured in a precision
laboratory to very close tolerances.
• In selective assembly, the manufactured components are
classified into groups according to their sizes.
• A very pertinent and practical example is the
manufacture and assembly of ball and bearing units as
tolerances desired in such industries are very narrow
and impossible to achieve economically by any
sophisticated machine tools.

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 Fits
Manufactured parts during assembly are required to mate with one another. The
relationship that results between the two mating parts which are to be assembled i.e. a
hole and shaft with respect to the difference in their dimensions before assembly is
termed as a Fit.
Three basic types of fits can be identified depending on the actual limits of hole or
shaft
They are
1. Clearance fit
2. Interference fit
3. Transition fit

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Classification of Fits

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 Clearance Fit

o The largest permissible

diameter of the shaft is smaller
than the diameter of the
smallest hole.
o This type of fit always provides
clearance.
o Small clearances are provided
for a precise fit that can easily be
assembled without the
assistance of tools.
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Interference fit

✓ The minimum permissible

diameter of the shaft exceeds
the maximum allowable
diameter of the hole.
✓ This type of fit always provides
interference.
✓ Interference fit is a form of a
tight fit.

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 TRANSITION FIT
• The diameter of the largest permissible
hole is greater than the diameter of the
smallest shaft and the diameter of the
smallest hole is smaller than the diameter
of the largest shaft.
• In other words, the combination of
maximum diameter of the shaft and
minimum diameter of the hole results in
an interference fit, while that of
minimum diameter of the shaft and
maximum diameter of the hole yields a
clearance fit.

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EXAMPLES
OF
DIFFERENT
TYPES OF
FITS

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 BASIC • In a clearance fit, minimum clearance is the difference between
minimum size of the hole, that is, low limit of the hole (LLH), and
maximum size of the shaft, that is, high limit of the shaft (HLS),
TYPES OF •
before assembly.
In a transition or a clearance fit, maximum clearance is the

FITS arithmetical difference between the maximum size of the hole,

that is, high limit of the hole (HLH), and the minimum size of the
shaft, that is, low limit of the shaft (LLS), before assembly.
• In an interference fit, minimum interference is the arithmetical
difference between maximum size of the hole, that is, HLH, and
minimum size of the shaft, that is, LLS, before assembly.
• In a transition or an interference fit, it is the arithmetical
difference between minimum size of the hole, that is, LLH, and
maximum size of the shaft, that is, HLS, before assembly.
• Thus, in order to find out the type of fit, one needs to determine
HLH − LLS and LLH − HLS. If both the differences are positive, the
fit obtained is a clearance fit, and if negative, it is an interference
fit. If one difference is positive and the other is negative, then it is
a transition fit.
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 ALLOWANCE
➢ An allowance is the intentional difference between the maximum material limits,

that is, LLH and HLS (minimum clearance or maximum interference) of the two

mating parts.

➢ Positive allowance indicates a clearance fit, and an interference fit is indicated by a

negative allowance.

➢ Allowance = low limit of the hole (LLH) − high limit of the shaft (HLS)

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 PROBLEM 1
Problem: In a limit system, the following limits are specified for a hole and shaft assembly:

Determine the (a) tolerance and (b) allowance.

Solution: (a) Determination of tolerance:

• Tolerance on hole = high limit of the hole (HLH) − low limit of the hole (LLH)
= 30.02 − 30.00 = 0.02 mm
• Tolerance on shaft = high limit of the shaft (HLS) − low limit of the shaft (LLS)
= [(30 − 0.02) − (30 − 0.05)] = 0.03 mm
• (b) Determination of allowance:
Allowance = Maximum metal condition of hole − Maximum metal condition of shaft
= low limit of the hole (LLH) − high limit of the shaft (HLS)
= 30.00 − 29.98 = 0.04 mm

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 PROBLEM 2
Problem: Tolerances for a hole and shaft assembly having a nominal size of 50 mm are as follows:

Determine the following: (a) Maximum and minimum clearances (b) Tolerances on shaft and hole (c)
Allowance (d) Maximum metal limit (MMLs) of hole and shaft (e) Type of fit.

Solution: (a) Determination of clearances:

Maximum clearance = HLH − LLS
= 50.02 − (50 − 0.08) = 0.10 mm
Minimum clearance = LLH − HLS
= 50.00 − (50 − 0.005) = 0.05 mm
(b) Determination of tolerance:
Tolerance on hole = HLH − LLH
= 50.02 − 50.00 = 0.02 mm
Tolerance on shaft = HLS − LLS
= [(50 − 0.05) − (50 − 0.08)] = 0.03 mm

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(c) Determination of allowance:

Allowance = Maximum metal condition of hole − Maximum metal condition of shaft

= LLH − HLS

= 50.00 − (50 − 0.05) = 0.05 mm

(d) Determination of Maximum metal limit (MMLs):

MML of hole = Lower limit of hole = 50.00 mm

MML of shaft = Higher limit of shaft = 50.00 − 0.05 = 49.05 mm

(e) Since both maximum and minimum clearances are positive, it can be conclude that the given pair has a clearance fit.

Dr. Sachin B
 Tolerances
grades for
different
applications

Dr. Sachin B
TOLERANCE GRADES

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 Problems on tolerance
Problem 1: Calculate the tolerance for a 40 mm dia shaft which is machined on a lathe. 40 mm
lies in the diameter step 30-50 mm and tolerance value for grade 8 is 25i.

Solution: The standard diameter steps for 40 mm shaft falls in the range of 30 – 50 mm.

Therefore, the value of D = √30 X 50

D = 38.73 mm

The value of fundamental tolerance unit is given by

i = 0.453 (∛38.73) + 0.001(38.73) = 1.57 microns

For hole quality H8 the fundamental tolerance is 25i

25i = 25(1.57) = 39.25 microns = 0.03925 mm

Dr. Sachin B