LECTURE 2 Production Engineering Dr Karl Haapala January

LECTURE 2 Production Engineering Dr. Karl Haapala January 8, 2015 MFGE 336 Winter 2015 Karl R. Haapala, Ph. D. School of Mechanical, Industrial, and Manufacturing Engineering

Review from last time… • Manufacturing engineers interpret the intent of the designer to produce a product – Primarily based on part print analysis • The engineering function depends upon – Product and process technologies employed – Stage of the design-manufacturing life cycle – Production environment • Communication between design and manufacturing requires a common language MFGE 336 Winter 2015 Karl R. Haapala, Ph. D. School of Mechanical, Industrial, and Manufacturing Engineering

What is the Language? • Geometric Dimensioning and Tolerancing – Communicates _________ to manufacturing – Parts need to have desired • • Form Fit Function Interchangeability – • Why bother to “speak” GD&T? – – http: //campaign. asme. org/gdt/about. cfm MFGE 336 Winter 2015 Karl R. Haapala, Ph. D. School of Mechanical, Industrial, and Manufacturing Engineering

Geometric Dimensioning and Tolerancing • Companies need engineers that can read and understand drawings! • GD&T standard -– Replaces ASME Y 14. 5 – 1994 – “Considered the authoritative guideline” – “Establishes uniform practices for stating and interpreting GD&T” http: //campaign. asme. org/gdt/about. cfm MFGE 336 Winter 2015 Karl R. Haapala, Ph. D. School of Mechanical, Industrial, and Manufacturing Engineering

Dimensions • Value that uses the appropriate units to indicate the following for a feature: – – – MFGE 336 Winter 2015 Karl R. Haapala, Ph. D. School of Mechanical, Industrial, and Manufacturing Engineering

Dimensions • Each dimension has a tolerance except – Reference dimensions – _____ and _____ dimensions – • Basic dimensions – Considered theoretically perfect – Basis for variations established by _____ – MFGE 336 Winter 2015 Karl R. Haapala, Ph. D. School of Mechanical, Industrial, and Manufacturing Engineering

Plus-Minus Dimensioning • Calculate the upper and lower limits from the specified dimension and plus-minus tolerance MFGE 336 Winter 2015 Karl R. Haapala, Ph. D. School of Mechanical, Industrial, and Manufacturing Engineering

Tolerances • The total amount a dimension can vary • Indicated – In a general note – In the drawing title block – As applied to the dimension • Calculate the tolerance MFGE 336 Winter 2015 Karl R. Haapala, Ph. D. School of Mechanical, Industrial, and Manufacturing Engineering

Problems with Conventional Tolerancing The Drawing Shows: 10. 5 ± 0. 25 ∅1. 0 ± 0. 1 Which part is OK? a) 1. 0 10. 5 b) 10. 5 1. 0 1. 1 c) 1. 0 10. 5 1. 0 MFGE 336 Winter 2015 Karl R. Haapala, Ph. D. School of Mechanical, Industrial, and Manufacturing Engineering

Which part is OK? Examples of _____________ MFGE 336 Winter 2015 Karl R. Haapala, Ph. D. School of Mechanical, Industrial, and Manufacturing Engineering

Extreme Form Variation • Established by ________ • Specified by ____ in ASME Y 14. 5 – “Size limits control surface form. ” MFGE 336 Winter 2015 Karl R. Haapala, Ph. D. School of Mechanical, Industrial, and Manufacturing Engineering

Dimensioning and Tolerancing • Conventional tolerancing – Doesn’t use geometric tolerancing – • Geometric tolerancing – – – MFGE 336 Winter 2015 Karl R. Haapala, Ph. D. School of Mechanical, Industrial, and Manufacturing Engineering

Types of GD&T Symbols • • • Dimensioning symbols Geometric characteristic symbols Feature control frame Material condition symbols Datum feature and datum target symbols MFGE 336 Winter 2015 Karl R. Haapala, Ph. D. School of Mechanical, Industrial, and Manufacturing Engineering

Geometric Characteristic Symbols • Provide specific controls related to: – Form of an object – Outlines of features (profile) – Location of features – Orientation of features – Relationship of features to an axis (runout) MFGE 336 Winter 2015 Karl R. Haapala, Ph. D. School of Mechanical, Industrial, and Manufacturing Engineering

Material Condition Modifiers • Used to specify when geometric tolerances must be held on ___________. – One cylindrical or spherical surface, or a set of two parallel plane surfaces, each feature being associated with a size dimension. • S M L I MFGE 336 Winter 2015 Karl R. Haapala, Ph. D. School of Mechanical, Industrial, and Manufacturing Engineering

Part Print Analysis Exercise Page 435 (Madsen) a) List the names of five dimensioning symbols, excluding geometric dimensioning and tolerancing symbols, found on this print. b) List the names of at least eight geometric dimensioning and tolerancing symbols found on this print. MFGE 336 Winter 2015 Karl R. Haapala, Ph. D. School of Mechanical, Industrial, and Manufacturing Engineering

Feature Control Frame (FCF) • For individual features, FCF specifies – –

Feature Control Frame (FCF) • The FCF is a box with several compartments 0. 13 M A BM C

Part Print Analysis Exercise Page 435 (Madsen) c) Give a complete identification for each of the items found in the feature control frame associated with the ∅4. 500 dimension. Identify these items from left to right. d) Why is there no material condition symbol in the feature control frame described in the last question? MFGE 336 Winter 2015 Karl R. Haapala, Ph. D. School of Mechanical, Industrial, and Manufacturing Engineering

Material Condition • ____________ (RFS) Condition – A geometric tolerance applies at any increment of size of the actual mating envelope of the feature of size (GT applies for any size part produced) – Implied for all geometric tolerances unless otherwise specified (symbol under ASME Y 14. 5 -1994; redundant and not used under ASME Y 14. 5 -2009) S MFGE 336 Winter 2015 Karl R. Haapala, Ph. D. School of Mechanical, Industrial, and Manufacturing Engineering

Material Condition M • ______ Material Condition (MMC) – Condition when a feature of size contains the maximum amount of material within stated limits – For example • Largest shaft • Smallest hole MFGE 336 Winter 2015 Karl R. Haapala, Ph. D. School of Mechanical, Industrial, and Manufacturing Engineering

Material Condition M • What is the MMC… Shaft – For the shaft? – For the hole? ∅10. 5 ± 0. 25 Hole ∅10. 5 ± 0. 25 MFGE 336 Winter 2015 Karl R. Haapala, Ph. D. School of Mechanical, Industrial, and Manufacturing Engineering

Material Condition L • _______ Material Condition (LMC) – Condition when a feature of size contains the least amount of material within stated limits – For example • Smallest shaft • Largest hole MFGE 336 Winter 2015 Karl R. Haapala, Ph. D. School of Mechanical, Industrial, and Manufacturing Engineering

Material Condition L • What is the LMC… Shaft – For the shaft? – For the hole? ∅10. 5 ± 0. 25 Hole ∅ 10. 5 ± 0. 25 MFGE 336 Winter 2015 Karl R. Haapala, Ph. D. School of Mechanical, Industrial, and Manufacturing Engineering

ASME Y 14. 5 Rule #1 • “Size limits control surface form. ” – Features have perfect form at MMC – Exceptions • • When still in purchased condition stock size When subject to free state variation in unrestrained condition When “AVG. ” (average) follows the dimension When using some geometric tolerances that eliminate the envelope of MMC at perfect form • When noted with independency symbol: (in ASME Y 14. 5 – 2009) I • MFGE 336 Winter 2015 Karl R. Haapala, Ph. D. School of Mechanical, Industrial, and Manufacturing Engineering

Part Print Analysis Exercise Page 435 (Madsen) a) Are the dimensions in inches or millimeters? b) Refer to the ∅4. 4997 -4. 4994 dimension: – What is the tolerance? – What is the MMC? – What is the LMC? MFGE 336 Winter 2015 Karl R. Haapala, Ph. D. School of Mechanical, Industrial, and Manufacturing Engineering

Standard ANSI/ISO Fits • Clearance fits: • Transition fits: • Interference fits: • • MFGE 336 Winter 2015 Karl R. Haapala, Ph. D. School of Mechanical, Industrial, and Manufacturing Engineering

Allowance Calculation • Allowance Formula: MMC HOLE –MMC SHAFT ALLOWANCE Allowance: The intentional difference between the maximum material limits of mating parts (tightest fit) MFGE 336 Winter 2015 Karl R. Haapala, Ph. D. School of Mechanical, Industrial, and Manufacturing Engineering

Clearance Calculation • Clearance Formula: LMC HOLE –LMC SHAFT CLEARANCE Clearance: The intentional difference between the least material limits of mating parts (loosest fit) MFGE 336 Winter 2015 Karl R. Haapala, Ph. D. School of Mechanical, Industrial, and Manufacturing Engineering

Interference Fit (or Force Fit) • Allowance Formula: MMC HOLE –MMC SHAFT ALLOWANCE • Clearance Formula: LMC HOLE –LMC SHAFT CLEARANCE MFGE 336 Winter 2015 Karl R. Haapala, Ph. D. School of Mechanical, Industrial, and Manufacturing Engineering

Announcements • Homework 1 – Due Thursday, January 15 • Quiz #2 – Right now! MFGE 336 Winter 2015 Karl R. Haapala, Ph. D. School of Mechanical, Industrial, and Manufacturing Engineering