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Typical Tolerances of Manufacturing Processes, Exams of Engineering

In the past, one of the traditional weaknesses with graduating mechanical design engineers is their inability to select tolerances. Most students were.

Typology: Exams

2021/2022

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EML 2322L MAE Design and Manufacturing Laboratory
Typical Tolerances of Manufacturing Processes
In the past, one of the traditional weaknesses with graduating mechanical
design engineers is their inability to select tolerances. Most students were
reasonably proficient using one or more CAD packages and could produce
drawings which were pretty good (given their limited experience levels).
However, despite knowing how to put a tolerance on a drawing, most
students generally had no idea what the actual numbers should be, or any
sense of what the process for selecting reasonable tolerances might consist of.
Since Geometric Dimensioning and Tolerancing (GD&T) is in widespread
use in industry, the MAE curriculum has changed to include it in EML2023.
Nevertheless, knowing how to properly express a tolerance for cylindricity or
parallelism between two surfaces on a part drawing is not the same thing as
knowing what a reasonable number for that tolerance should be. After taking
EML2322L, the students should be much more proficient in these areas.
To facilitate the students’ understanding of this important area of mechanical
design, we have put together a few slides on some common manufacturing
processes, and what their tolerance producing capability is. After taking
EML2322L, the students should have a tangible understanding of the
tolerances associated with basic manufacturing processes used in this course
(i.e. milling, turning, drilling, reaming, bandsaw cutting, etc.)
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EML 2322L – MAE Design and Manufacturing Laboratory

Typical Tolerances of Manufacturing Processes

In the past, one of the traditional weaknesses with graduating mechanical

design engineers is their inability to select tolerances. Most students were

reasonably proficient using one or more CAD packages and could produce

drawings which were pretty good (given their limited experience levels).

However, despite knowing how to put a tolerance on a drawing, most

students generally had no idea what the actual numbers should be, or any

sense of what the process for selecting reasonable tolerances might consist of.

Since Geometric Dimensioning and Tolerancing (GD&T) is in widespread

use in industry, the MAE curriculum has changed to include it in EML2023.

Nevertheless, knowing how to properly express a tolerance for cylindricity or

parallelism between two surfaces on a part drawing is not the same thing as

knowing what a reasonable number for that tolerance should be. After taking

EML2322L, the students should be much more proficient in these areas.

To facilitate the students’ understanding of this important area of mechanical

design, we have put together a few slides on some common manufacturing

processes, and what their tolerance producing capability is. After taking

EML2322L, the students should have a tangible understanding of the

tolerances associated with basic manufacturing processes used in this course

(i.e. milling, turning, drilling, reaming, bandsaw cutting, etc.)

Process Tolerances

Surface Finish vs. Production Time

FIGURE 15.10. Surface finish produced by various processes. (Source: Wikipedia)

Figure 15.8 shows relative production time as a function of surface finish for common manufacturing processes. Although the curve for each process is slightly different, the general trend shows that the relative production time increases exponentially as a function of achieved surface finish. In other words, doubling the surface finish requirements translates to more than twice the part cost. Therefore we should always be able to justify the surface finish requirement we list on each surface of the parts we design. Saving ten minutes of machining time on one part surface might not seem like a worthwhile achievement, but remember that pennies make dollars, and the savings can be substantial for a properly designed part. Worded differently, failure to specify the roughest surface finishes permissible on each surface can easily increase part cost by an order of magnitude!

Figure 15.10 presents a collection of the most common manufacturing processes and the surface finishes commonly associated with each of them. As explained in the legend, the shaded portions of the bars represent the average application of these processes and means almost any shop should be able to achieve these finishes. The remaining portion of the bar indicates the less frequent application, which means one of two things: (1) highly skilled operators and equipment in excellent condition are required to obtain the surface finishes on the higher precision end of the range or (2) the process can easily achieve the finishes on the lower precision end of the range, but a cheaper alternative likely exists, which could significantly reduce part cost.