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Activity 7.

3 Tolerances
Procedure

1. Consider the adjustable rocker arm represented in the drawing above. An axle is
to pass through the smallest hole. The manufacturer is considering buying bar
stock for the axle that is manufactured according to the following drawing using
the same general tolerances as those specified on the Rocker Arm Drawing.
Answer the following questions and SHOW YOUR WORK.

2012 Project Lead The Way, Inc.


Introduction to Engineering Design Activity 7.3 Tolerances Page 1

a. What is the tolerance (the acceptable amount of dimensional variation) for


the diameter of the rod?
xx=+_ .03
.530(.525+.005)
.005

b. What is the tolerance for the rod length?


3.03-2.97=.06

3+.03=3.03
3-.03=2.97

c. Is the fit between the rod and the hole a clearance fit, interference fit, or
transition fit? Explain your answer.
Clearance fit. The largest diameter for the rod and the smallest diameter
for the circle would fit.
d. What is the allowance between the rod and the smallest hole?
.531-.530=.001
e. If the design of the assembled machine requires that the rod is sized such
that the actual clearance between the rod and the hole is never greater
than 0.005 inches, will the current rod design meet the requirement?
Explain.
No it will not. .531-.530=.001 .536-.525=.011
f. The machine specification requires that the rod is no longer than 3.025
inches and no shorter than 2.955 in.
Let L represent the actual length of the rod. Write the length
constraint as a compound inequality.
L has to be greater than or equal to 2.955 and less than or equal to 3.025.
Will the stock rods always meet the length constraint? Explain.
g. If the stock rods do not always meet the machine specifications for rod
length, how can the manufacturer alter the rod part drawing such that the
rod length will always conform to the specifications?

2012 Project Lead The Way, Inc.


Introduction to Engineering Design Activity 7.3 Tolerances Page 2

2. Consider the axle pin and the body of the Automoblox vehicle (shown below).
The axle is designed to remain inserted into the body of the vehicle so that it
cannot be removed by a child.

a. What type of fit would you recommend for the axle and body? Why?
interference fit
b. Assume an interference fit is used and that the ideal interference between
the axle and the hole in the body of the vehicle is 0.005 inches. However,
the interference can increase to as much as .010 without damage to the
parts. With the addition of glue to help adhere the two pieces, an
interference of .002 can be used successfully. Assume that the specified
diameter of the axle is 0.300 inches as shown on the pictorial above. On
the images above indicate your recommendation for:
the specific tolerance to the axle diameter dimension
.0015
the diameter and associated tolerance for the hole in the bed
.300 to .315
c. Calculate the following for the exterior axle pin diameter using your
suggested dimension tolerances. SHOW YOUR WORK.
Specified dimension: 0.300 inches
Upper Limit: _______.315_________
Lower Limit: ________.305_______
Tolerance: _________.10________
d. Calculate the following for the diameter of the hole in the body using your
dimensioned part drawing. SHOW YOUR WORK.
2012 Project Lead The Way, Inc.
Introduction to Engineering Design Activity 7.3 Tolerances Page 3

Specified Dimension: _____.300___________ (if applicable)


Upper Limit: _________.310_______
Lower Limit: _______.300________
Tolerance: _______.10__________
e. Calculate the allowance between the hole and the axle pin diameter based
on your recommended dimensions and tolerances. SHOW YOUR WORK.
.315-.305 =.01

2012 Project Lead The Way, Inc.


Introduction to Engineering Design Activity 7.3 Tolerances Page 4

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