Manufacturingtolerance standards

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What Is dimensional tolerance

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Tap guides are an integral part in making a usable and straight thread.  When using the lathe or the mill, the tap is already straight and centered.  When manually aligning a tap, be careful, as a 90° tap guide is much more accurate than the human eye.

Calculate the tolerances for shafts and holes, based on DIN ISO 2768.

On the milling machines we have here at LBCC, the feed is independent of the spindle speed.  This is a good arrangement and it permits faster feeds for larger, slowly rotating cutters.

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Tolerancein manufacturingexamples

Feed per tooth, is the amount of material that should be removed by each tooth of the cutter as it revolves and advances into the work.

Engineering Tolerance Chart

This chip thickness or feed per tooth, along with the number of teeth in the cutter, form the basis for determining the rate of feed.

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Drilling machines that have power feeds are designed to advance the drill a given amount for each revolution of the spindle.  If we set the machine to feed at .006” the machine will feed .006” for every revolution of the spindle. This is expressed as (IPR) inches per revolution

Standard drawingtolerances

Why tolerance is importantinengineering

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We live in an imperfect world where pure exactness is impossible. However, even though “almost” is okay in a game of horseshoes, it is dangerous when designing a car engine. To communicate just how precise a part needs to be, designers and manufacturers use tolerances. The ASME Y14.5 standard, which defines the exact rules for communicating tolerance, says that tolerance is “the total amount a specific dimension is permitted to vary.” You should always specify a tolerance for each dimension of your design. Is it okay if the gear varies by a millimeter? Or does it have to be exact down to the micrometer? Some companies have standard tolerances that they apply if no tolerance is given—usually around 3 decimal places, such as ±.001. However, if you do not specify a tolerance, your machining provider has no idea how important or unimportant each dimension is. Choosing the proper tolerances can save you a lot of time, money, and headache. If a dimension is unimportant, asking for a loose (i.e. large range) tolerance will cost less. However, for more important dimensions, parts may not fit together properly unless you ask for a tight (i.e. small range) tolerance. Parts may jam and break from sitting too closely. Or you may have the opposite problem, with parts vibrating and falling off. Specifying the right tolerance will save you the extra cost and waiting that comes from remaking parts. When choosing tolerances, what should you consider? First, think about how everything fits together. For example, a shaft needs to be smaller than the hole it slides into. Your tolerances should reflect that, because your manufacturer may not understand how you plan to assemble your design. Some components need clearance while others need a snug fit. Also consider factors from the part’s intended environment. Does lubrication need to fit around your bearing? Will a brace expand from heating or bend from loading? How fast will the shaft spin? How much vibration can it handle? Tolerances are a trade-off between cost and quality. As a designer, you understand your product best and should make that decision yourself. Don’t leave it up to the manufacturer. When you take the extra time to specify tolerances, it makes a much smoother process of turning your design into a reality. written for HLH by Esther Davis

Once the SFM for a given material and tool is determined, the spindle can be calculated since this value is dependent on cutting speed and tool diameter.

Feeds for end mills used in vertical milling machines range from .001 to .002 in. feed per tooth for very small diameter cutters on steel work material to .010 in. feed per tooth for large cutters in aluminum workpieces.  Since the cutting speed for mild steel is 90, the RPM for a 3/8” high-speed, two flute end mill is

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When drilling and tapping, it is crucial to use oil.  It keeps the bits from squealing, makes the cut smoother, cleans out the chips, and keeps the drill and stock from overheating.

Cutting speed is defined as the speed at the outside edge of the tool as it is cutting.  This is also known as surface speed.  Surface speed, surface footage, and surface area are all directly related.  If two tools of different sizes are turning at the same revolutions per minute (RPM), the larger tool has a greater surface speed.  Surface speed is measured in surface feet per minute (SFM).  All cutting tools work on the surface footage principle.  Cutting speeds depend primarily on the kind of material you are cutting and the kind of cutting tool you are using.  The hardness of the work material has a great deal to do with the recommended cutting speed.  The harder the work material, the slower the cutting speed.  The softer the work material, the faster the recommended cutting speed (See Figure 1).

Manufacturingtolerance chart

The hardness of the cutting tool material will also have a great deal to do with the recommended cutting speed. The harder the drill, the faster the cutting speed.  The softer the drill, the slower the recommended cutting speed (See Figure 2).

Engineering tolerance

As the work advances into the cutter, each tooth of the cutter advances into the work an equal amount producing chips of equal thickness.

Pecking helps ensure that bits don’t overheat and break when using them to drill or tap.  Peck drilling involves drilling partway through a part, then retracting it to remove chips, simultaneously allowing the piece to cool.  Rotating the handle a full turn then back a half turn is common practice.  Whenever the bit or tap is backed out, remove as many chips as possible and add oil to the surface between the drill or tap and the workpiece.

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Manufacturing Processes 4-5 Copyright © by LamNgeun Virasak is licensed under a Creative Commons Attribution 4.0 International License, except where otherwise noted.

The feed (milling machine feed) can be defined as the distance in inches per minute that the work moves into the cutter.

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