Unit 17 Calculating Hole Sizes And Location Tolerances

The unit gives methods and formulae for calculating the size of holes and their center distances, or positional tolerances. The use of these methods will ensure free assembly of mating parts with fastening devices such as screws, bolts, rivets, pins, studs or bosses. The formulae presented are designed, to produce a metal-to-metal fit at the maximum material sizes. Therefore all parts manufactured using these formulas should assemble with no interference and no clearance when holes are at their minimum size and external features or fastening devices are at their maximum sizes. In some applications it may be desirable to make further allowances, such as a small increase in hole diameter or reduction in the location tolerance, to provide enough clearance under the least favorable conditions of size and position. In the formulae in this work unit the following symbols are used: H = minimum diameter of holes F = maximum dimension across the tolerance zone for location of holes. T = maximum dimension across the tolerance zone for location of holes. Subscripts are used to refer to individual parts in an assembly, for example: H1 = minimum diameter of Holes in part # 1 H2 = minimum diameter of holes in part # 2 There are two separate conditions under which fasteners are used, described herein as the floating fastener condition and the fixed fastener condition. Each of these conditions will be treated separately. FLOATING FASTENER CONDTION-COORDINATE TOLERANCES The floating fastener type of assembly uses a fastening device, such as a bolt with a nut, which is free to float (not located in a fixed position) due to clearance holes in both of the assembled parts. Fig. 17-1 shows such an assembly, using one fastening device, where parts # 1 and # 2 are intended to be held in contact with one another along two of their sides.

FGI 17-1 BOLTED ASSEMBLY WITH FLOATING FASTENER

Fig. 17-2 and 17-3 show the two separate parts with coordinate tolerancing, resulting in square tolerance zones for location of holes, within which the axes of the holes must lie.

FIG. 17-2 DRAWING CALLOUT AND TOLERANCE ZONE FOR PART 1

FIG. 17-3 DRAWING CALLOUT AND TOLERANCE ZONE FOR PART 2 The least favorable assembly condition occurs when the clearance holes in the two parts are at their minimum sizes, and their axes are farthest apart. This occurs when they are at diagonally oppositie corners of the tolerance zones, as shown in Fig. 17-4.

FIG 17-4 HOLES IN EXTREME POSITIONS This condition is shown in an enlarged view in Fig. 17-5 with the two holes superimposed on one another. From this example the reader should see that the minimum size of the holes is equal to the maximum fastener size, plus the maximum dimension across the tolerance zone for location of holes. Expressed algebraically this is: H = F + T OR T = H F

FIG. 17-5 SUPRIMPOSED TOLERANCE ZONES For rectangular coordinate tolerances, which are equal in both directions, the tolerance zone is square as shown, and its maximum dimension is 1.4 times the coordinate tolerances. If we let these tolerances be represented by the letter C the formulae for hole size could be expressed as H = F + 1.4 C OR C = H F / 1.4

If unequal coordinate tolerances or polar coordinate tolerances are used, the formulae given in \unit 14 should be used to determine the maximum dimension across the tolerance zone. As an example, for the parts shown in Figs 17-2 and 17-3 the minimum hole diameter is H = F + 1.4 C = 12 + (1.4 x 0.24) = 12.34 FLOATING FASTENER CONDITIONPOSITIONAL TOLERANCEING RFS The use of positional tolerancing instead of coordinate tolerancing results in a round tolerance zone. The maximum dimension across the tolerance zone is therefore the value specified on the drawing. Calculations for positional tolerancing are considerably simpler than those for coordinate tolerancing. If desired, the specified positional tolerance could be 40% larger than the corresponding coordinate tolerances, without increasing the hole sizes or affecting assembly conditions. However, if the manufacturing process is such that the coordinate tolerances could easily be held in two directions, it is most likely that the same tolerance could just as easily be held in all directions. This being the case, a positional tolerance identical to the coordinate tolerance could be specified, resulting in smaller hole sizes and a better fir with less play in assembly. For positional tolerancing the same general formulae apply as for coordinate tolerancing; except that T represents the positional tolerance: H = F + T OR T = H F FIG. 17-6 shows two parts, similar to those in Fig 17-2 except with positional tolerances on an RFS basis. The positional tolerance has been raised to 0.34 mm to provide the same extreme assembly condition as in the example with coordinate tolerances. Fig 17-7 shows these parts with holes in an extreme position. In this example the minimum hole diameter for both parts is: H = F + T = 12 + 0.34 = 12.34

FIG 17-16 HOLES LOCATED BY POSITIONAL TOERANCES

FIG 17-7 PARTS WITH HOLES IN AN EXTREME POSITION FLOATING FASTENER CONDITIONPOSITIONAL TOLERANCING MMC. If MMC is specified with the positional tolerances, as shown in Fig 17-8, the calculations for the minimum hole size are exactly the same for the RFS condition. The difference in the requirement is that, on a RFS basis, as the size of the hole approaches its maximum diameter, more clearance is provided all around the fastener without the position of the hole changing. When MMC is specified this increase in clearance may be utilized to permit a greater variation in the position of the holes. This is illustrated in Fig. 17-9.

Fig. 17-8 POSITIONAL TOLERANCE ON MMC BASIS CALCULATING CLEARANCE The formulae given so far have been based on determining the minimum hole diameter, or the maximum permissible tolerance for location, which would just permit the parts to assemble without any clearance under extreme conditions. Clearance is usually expressed in terms of the difference between diameters, i.e., the difference between the diameter of a hole and the diameter of the mating part, which assembles into it. The same formulae can be used to determine the minimum clearance for any given drawing specifications. For example, in Fig 17-6 we saw how, with a positional tolerance of 0.34mm, the minimum hole diameter had to be 12.34mm. If a positional tolerance of 0.2 was substituted the

minimum hole required would be H = F+T = 12.2mm. Therefore a minimum 12.34mm hole would provide 0.14mm minimum clearance on diameter, or an extra 0.07mm all around. The maximum diametral clearance is: H F, where H = maximum diameter hole F = minimum diameter of fastener UNEQUAL TOLERANCES AND HOLE SIZES It is sometimes desirable to have different tolerances of location, or different hole sizes, in each of the assembled parts. One reason for this may be because one part already exists, and the other must be designed to mate with it, in such cases the hole sizes and the positional tolerances must be separated, and the previous formulae, H = F + T, Becomes H1 + H2 = 2F + T1 + T2 OR T1+ T2 = H1 + H2 2F

FIG. 17-9 EXTREME POSITON OF HOLES ON RFS AND MMC BASIS Therefore if two parts having the following tolerances have to be assembled with a minimum 12mm diameter bolt, we have Part #1 Part # 2 = 12.38 12.2 = 0.14 T2

H = minimum hole diameter T = positional tolerance

T2 = H1 + H2 2F T1 = 12.38 + 12.20 24.00 0.14 = 0.44 This is shown, with tolerances exaggerated for clarity, in Fig 17-10.

FIG. 17-10 TOLERANCE ZONES WHEN TOLERANCES ARE UNQUAL Note that with unequal tolerances the fastener moves off center in its extreme condition. The deviation of the fastener center from true position is H-F-T when based on the larger hole, or T- (H-F) when based on the smaller hole. The formulae should give the same result. Where there are three or more parts to be assembled together the general formulae above must be satisfied for any combination of two parts. This cannot necessarily be accomplished by calculating values for two of the parts and making the tolerance for a third part identical to one or other of them. Using the values shown I Fig. 17-10, if we tried to give a third part with a hole the same size as the one in part # 2 the resultant positional tolerance for that part would be: T2 + T3 = H2 + H3 2F T3 = 12.20 + 12.20 24.00 0.44 = -0.04 Calculating hole sizes and location tolerances In other words, the positional tolerance for hole # 3 would have to be less than zero, or would result in 0.04 interference with a zero positional tolerance. Either the hole sizes would have to be increased, or the positional tolerance for hole # 2 decreased. A suggested solution might be to reduce the positional tolerance for hole # 2, making the tolerances for #2 and # 3 equal. Thus if T2 and T3 are equal each tolerance is H2 + H3 2F = 12.20 + 12.20 24.00 = 0.2 2 2 Part # 1 would then always show a clearance around the fastener. All of the formulae explained in this unit are equally applicable to coordinate tolerancing, as long as it is remembered that tolerance T then represents the diagonal of the tolerance zone. FIXED FASTENER CONDITION Fixed fastener condition refers to the type of assembly where fasteners are fixed in position in one of the parts, such as parts assembled with screws, studs, bosses, etc. Fig. 17-11 shows two typical assemblies of this type.

FIG 17-11 FIXED FASTENER ASSEBLIES In such assemblies the hole in the part is tapped to receive a screw or threaded part, or reamed or bored to obtain a press fit for a stud. The assembly clearance is provided by the hole in the other part. The minimum size of this clearance hole is: H = F + T1 + T2 or If the same positional tolerance is specified for both parts: H = F + 2T

FIG 17-12 COMPARISON OF TOLERANCE ZONES FOR POSITIONAL AND COORDINATE TOLERANCE These formulae apply either to positional tolerancing, where T is the specified value, or to coordinate tolerancing, where T is the length of the diagonal of the tolerance zone. It should be noted that these formulae do not compensate for lack of perpendicularity of fixed fasteners, when the holes for such fasteners are not made perpendicular to the surface of the holes. To provide for such conditions extra hole clearance may be required. A more precise method described in work unit 23. MULTIPLE HOLE TOLERANCING The formulae already given in this unit may be applied to groups of any number of holes. However, with coordinate tolerancing there may be some difficulty in determining the true position and size of the tolerance zones.

POSITIONAL TOLERANCES There is no such problem with positional tolerancing, the true position is established for each hole by the true-position dimensions, and, if the same hole sizes and positional tolerances are intended to apply to all holes in the group, it is only necessary to make one set of calculations. For example, if two parts with the configuration of holes shown in Fig. 17-13 are to be assembled together with six bolts and nuts having a maximum diameter of 6.0mm, the minimum hole sizes will be: H = F+T = 6.00 + 0.25 = 6.25 The same formula applies if the holes are located from a circular or cylindrical datum, as shown in Fig. 17-14. In this case, if it is assumed that two such parts must be assembled together using 6.0mm bolts with the center holes aligned, the minimum hole size will be: H = F+T = 6.0 +0.1 = 6.1

FIG. 17-13POSITIONAL TOLERANCING FOR MULTI-HOLE PATTERNS

FIG 17-14 POSITIONAL TOLERANCING FOR HOLES LOCATED FROM A CYLINDER DATUM COORDINATE TOLERANCES Bolts may assemble in holes without necessarily requiring perfect alignment of the sides of the parts. In the example shown in Fig. 17-15 identical coordinate tolerances are used to locate the

holes relative to one another. When there is only one center dimension in each direction (i.e. between two holes) the tolerances can be equally divided. This results in a square tolerance zone for each hole.

FIG. 17-15 COORDINATE TOLERANCEING FOR MULTI-HOLE PATTERN In this case, using fasteners of 6.0mm maximum diameter, the minimum hole sizes must be: H = F + T = 6.0 + (1.4 x 0.25) = 6.35 The problem becomes more complicated in a larger group such as the group of nine holes, intended to assemble with 6mm fasteners, shown in Fig. 17-16. To simplify this part of the discussion, consider only the bottom row of three holes. Tolerances zones 0.25mm wide cannot be established for the first two holes, as in Fig 17-15, because calculations would show that the tolerance zone for the third hole would then become 0.75mm wide, and would require a minimum hole of 7.05mm diameter, (although such parts would assemble!). FIG. 17-16 COORDINATE TOLERANCING FORLARGE GROUP OF HOLES Instead, tolerance zones must be established on the basis of the largest tolerance between any two holes in line with one another. In this case the tolerance is 0.5mm based on the centre distance between the two outside holes of 500.5. the tolerance zones then appear as in Fig.17-17. The minimum hole size for all holes is: H = F + T = 6.0 + (1.4 x 0.5) = 6.7 With coordinate tolerancing, whenever a single group of feature consists of more than three features in a row, common point dimensioning, as shown in Fig. 17-18, should always be used rather than chain dimensioning. This method avoids the accumulation of more than two tolerances between any two features. Common point dimensioning is sometimes referred to as datum point dimensioning in ANSI standards. This does not necessarily mean that the feature from which such dimensions are taken is to be treated as a datum feature, but merely that all of the related dimensions are to be measured from the same (or common) point or feature. FIG. 17-18 COMPARISON BETWEEN CHAINAND COMMON POINT DIMENSIONING HOLE RELATED TO DATUM SURFACE: COORDINATE TOTLERANCES If a group of holes are dimensioned from the sides or other single datum features, and it is functionally necessary for the sides of mating parts to align in assembly, the tolerance zones cannot be split as shown in Fig. 17-15 and 17-17. The full tolerance must be applied to each hole axis. It is recommended that separate coordinate dimensions and tolerances be applied to each hole, as shown in Fig. 17-19. This enables each hole to be treated separately in the same manner as for single holes. The hole sizes or the coordinate tolerances can then be calculated from the formulae already given, for example: H = F + 1.4 C for floating fasteners H = F + 2(1.4C) for fixed fasteners Where C = the coordinate tolerance, if equal in both directions for both parts. In the example, with maximum 12mm floating fasteners, the minimum size for all holes would be: H = F + 1.4 C = 12 + 0.28 = 12.28

FIG. 17-19 SEPARATE LOCATION TOLERANCES FOR EACH HOLE Chain dimensioning is not recommended because, with accumulating tolerances, the hole sizes would have to become progressively larger. For example, in Fig 17-20, the minimum sizes for the three holes would be 12.28, 12.45 and 12.63 respectively.

FIG 17-20 LARGE TOLERANCING ZONES RESULTING FROM CHAIN DIMENSIONING