5.
DIMENSIONS,
TOLERANCES AND SURFACE
5.1 Dimension, Tolerances and Related Attributes
5.2 Surfaces
5.3 Effect of Manufacturing Processes
Introduction
Dimensions the sizes and geometric
features of a component specified on
the part drawing.
How well the parts of a product fits
together.
Tolerance Allowable variation in
dimension.
Surface affects product performance,
esthetic and wear
5.1 Dimensions, Tolerance
and Related Attributes
Dimension a numerical value expressed
in appropriate units of measure and
indicated on a drawing along with lines,
symbols and notes to define the
size/geometric characteristics of a part
Variations in the part size comes from
manufacturing processes
Tolerance the limit of the allowed
variation
Tolerance
Bilateral Tolerance
Unilateral Tolerance
Limit dimension
Other Geometric Attributes
Angularity
Circularity
Concentricity
Cylindricity
Flatness
Parallelism
Perpendicularity
Roundness
Squareness
Straightness
5.2 Surface
Nominal Surface - intended surface contour of
part
Actual surface - determined by the
manufacturing processes
Wide variations in surface characteristics
Important reasons to consider surface
Esthetic reason
Safety
Friction and wear
Affects the mechanical integrity of a material
Ability to assemble
Better contact
Surface Technology
Relationship between processes and
surface characteristics
Defining the Characteristics of a surface
Surface texture
Altered layer result of some processes
Oxide film
Substrate grain structure
Surface Texture
Repetitive deviation from the nominal
surface.
Roughness - the small, finely spaced
deviations from the nominal surface
Waviness the deviation of much larger
space that come about from deflection,
vibration, heat treatment and etc.
Lay the predominate pattern of the
surface texture
Flaws irregularity such as cracks,
scratch, inclusions and etc.
Surface texture features
Possible lays of a surface
Lay - predominant direction
or pattern of the
surface texture
Surface Roughness & Finish
Surface roughness - a measurable characteristic
based on roughness deviations
Surface finish a subjective term
Arithmetic Average (AA)
Ra =
0L m
Lm
dx
Approximation
Ra =
Ra = arithmetic mean value of roughness
y= the vertical deviation from nominal surface
Lm=the specified distance
i =1
yi
n
Root-mean-square (RMS) the square root of
the mean of the squared deviation over the
measured length
RMS > AA usually.
Surface Roughness
A problem with the Ra computation is that waviness
may get included
A parameter called the cutoff length is used
Cutoff length is a sampling distance along the surface.
A sampling distance shorter than the waviness width
eliminates waviness deviations.
Surface Roughness
Deficiency
Remedy
Too simplified
Waviness is not included
Use Cutoff length (a sampling distance along
the surface)
Symbols
Surface Integrity
Metallurgical changes in the altered layer
beneath the surface can significantly
affect a material's mechanical properties.
Surface integrity is the study and control
of this subsurface layer and the changes
in it that occur during processing
Absorption
Alloy depletion
Cracks
Craters
Heat-affected Zone
Inclusion
5.3 Effect of Mfg Processes
Typical tolerance
Sand Casting
Cast Iron
Steel
Aluminum
1.3mm
1.5mm
0.5mm
Die Casting
.12mm
Plastic Molding
Polyethylene 0.3mm
Polystyrene
.15mm
Surface finish, roughness
Die Casting Good 1-2m
Investment Good 1.5-3
Sand Casting Poor 12-25
Grinding 0.008mm
Lapping 0.005mm
Machining
Machining
Abrasive processes
Metal forming
Cold rolling Good 1-3
Hot rolling Poor 12-25
Drilling +0.08, -0.03mm
Milling 0.08mm
Turning 0.05mm
Casting
Boring Good 0.5-6
Drilling Medium 1.5-6
Milling Good 1-6
Turning Good 0.5-6
Abrasive Processes
Grinding Very Good 0.1-2
Lapping Excellent 0.05-0.5
6. FRICTION, WEAR AND
LUBRICATION
6.1 Friction
6.2 Wear
6.3 Lubrication
Introduction
Tribology the study of friction,
wear and lubrication of interacting
surfaces in relative motion.
6.1 Friction
Barreling in compression test
In forging, rolling, sheet metal
forming and machining
Friction the resistance to relative
motion between two bodies in
contact.
Force to overcome friction
Static (s) and Kinetic () frictions
6.2 Wear
Wear Mechanism
Adhesion Wear
Abrasion
Oxidation and other chemical reaction
Diffusion
Other types of Wear galling, fretting,
erosion etc.
Protection from friction and
wear
Proper material selection
Surface treatment
Smoother surface (dry)
Rough surface (lubrication)
Proper operating condition (speed,
temperature and pressure)
6.3 Lubrication
Fluid Film Lubrication
thick-film or hydrodynamic lubrication.
Viscosity of a lubricant
Results erosion
Thin-film lubrication
Friction increases
Mixed-film lubrication
Boundary Lubrication presence of
boundary layer that carry normal force
Extreme pressure lubrication for high T and P
Solid Lubrication
Lubricants in Manufacturing
Functions of Metal Working Lubricants
Separate surfaces
Protect surfaces
Remain stable and durable
Cools the materials
Not Health-hazard
Inexpensive
Mineral oil, Natural oil, synthetic fluids,
Compounded lubrication, Aqueous
lubrication, and coating and barrier.
