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Question 2 - Tolerance Analysis using dimension chains marks] Consider a dimensional chain given in Figure Q2 with dimensions shown in Table Q2. A3 A4 A5 A2 A1 ΑΔ Figure Q2 Second from the last digit of the student number upxxxxxx [33 Table Q2 2 3 4 5 6 7 8 9 0 A1 138 136 134 151 152 149 147 143 128 119 A2 2 4 4 3 3 2 3 2 3 2 A3 5-0.12 5-0.12 6-0.12 4.5-0.12 5-0.12 4-0.12 5-0.12 5-0.12 4-0.12 4-0.12 A4 151 151 151 164 166 160 161 156 140 130 A5 5-0.12 5-0.12 6-0.12 4.5-0.12 5-0.12 4-0.12 5-0.12 5-0.12 4-0.12 4-0.12 ΑΔ 1+0.7 Allocate standard tolerances using the full interchangeability (Worst Case Scenario) method. 1. Identify the dimension chain, the type of the links and check the nominals. [11 marks] 2. Calculate the tolerances for all non-standard links. [11 marks] 3. Calculate and check the tolerance limits [11 marks] Question 3 - Selective Assembly marks] [34 A company intending to produce components for a fit with guaranteed clearance and interference as given in Table Q3 (Jmin, Jmax or Smin, Smax respectively). It has been experiencing problems when machining both holes and shafts caused by lack of process capability, see the available Manufacturing Methods in Table Q3. Maintaining fit characteristics transform the tolerances to suit the company's capability implementing Selective Assembly method. Table Q3 Third from the last Manufacturing method Fit requirements, µm Clearance Interference digit of the student Nominal size, mm System Hole Shaft Jmin Jmax Smin Smax number upxxxxxx 0 026 Drilling (IT13) Rough Turning (IT12) 70 ☐ 260 Hole Precision 1 015 Reaming (IT8) 37 53 Shaft Turning (IT7) Rough Rough 2 040 Broaching 90 190 Hole Turning (IT11) (IT10) 34 08 Honing (IT5) Grinding (IT6) 3 9 Shaft 4 030 Boring (IT9) Turning (IT8) 30 73 Hole 5 064 Milling (IT9) Turning (IT8) 72 147 Shaft Diamond Precision 6 012 58 72 Hole Boring (IT6) Turning (IT7) Broaching 7 010 Turning (IT9) 54 77 Shaft (IT8) 8 025 Honing (IT8) Precision Turning (IT7) 35 59 9 020 Drilling (IT11) Rough Turning (IT10) Hole 47 147 Shaft 1. Determine tolerances of the mating parts based on the manufacturing methods [4 marks] 2. Select the best (most economical) standard fit to satisfy the clearance/interference requirements and system [10 marks] 3. Calculate the number of groups required for selective assembly [2 marks] 4. Using an appropriate scaling factor, make an annotated tolerance diagram with all required groups and indicate all upper and lower limit deviations [10 marks] 5. Calculate the new (expanded) hole and shaft tolerances and limits [4marks] 6. Calculate the maximum and minimum clearance or interference for each group [4 marks]

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