Dimensioning and Tolerancing Handbook Episode 3 Part 6 ppt

Floating and Fixed Fasteners 22-15 22.9 Projected Tolerance Zone When using fixed or double-fixed fasteners, a projected tolerance zone should be used regardless of whether the design is using threaded fasteners or alignment pins. Variation in the perpendicularity of the screw or pin could cause assembly problems. If a threaded fastener was out of perpendicular by the total amount of the positional tolerance of (∅.014), an interference problem could occur (see Figs. 22-15 and 22-16). Figure 22-15 Tapped hole out of perpendicular by ∅.014 Figure 22-16 Variation in perpendicular- ity could cause assembly problems Figure 22-14 Positional tolerance for clearance holes and nut plate rivet holes 22-16 Chapter Twenty-two Fig. 22-17 shows how a projected tolerance zone corrects the interference problem shown in Fig. 22- 16. The projected tolerance zone is applied to the threaded fastener or the pressed pin. The tolerance zone for the tapped hole extends through the mating parts clearance hole, thereby assuring the mating parts will fit. 22.9.1 Comparison of Positional Tolerancing With and Without a Projected Tolerance Zone This section compares two position tolerancing methods to locate size features for fixed fasteners. In the first method, we use a projected tolerance zone and calculate the functional tolerance zone using the fixed fastener formulas, as shown previously. We consider this a functional method for the case of a fixed fastener. In the second method, we convert the projected tolerance zone to a zone that is not projected, and consider this a nonfunctional method. As a comparison, we then calculate how much tolerance is lost when dimensioning nonfunctionally. Assuming a maximum orientation (perpendicularity) error, Fig. 22-18 shows the relationships between the functional (projected) tolerance zone, T f , and the nonfunctional tolerance zone, T nf (not projected). )2/( 2/ )2/( 2/ D nf T PD f T = + (22.1) Where D is the depth of the nonfunctional tolerance zone, and P is the projected height of the functional tolerance zone (see Fig. 22-18). Eq. (22.1) reduces to:       + = 1 2 D P T T f nf (22.2) THIS ON THE DRAWING MEANS THIS Figure 22-17 Projected tolerance zone example Floating and Fixed Fasteners 22-17 Figure 22-18 Projected tolerance zone — location and orientation components If we measure the orientation of a feature on a workpiece, we can verify the following relationship:       + = 1 2 ,, ,, D P actualnorientatiof T actualnorientationf T (22.3) where T nf, orientation,actual is the measured nonfunctional orientation error and T f, orientation,actual is the measured functional orientation error. If we tolerance functionally, the maximum allowable location tolerance, T f, location,maximum for a given (actual) orientation error in the functional tolerance zone is: actualnorientatiof T f T imumlocationf T ,,max,, −= (22.4) If we tolerance nonfunctionally, the maximum allowable location tolerance, T nf, location,maximum , for given (actual) orientation is: actualnorientationf T nf T imumlocationnf T ,,max,, −= (22.5) The difference between Eq. (22.4) and Eq. (22.5) represents the amount of allowable location tolerance that is lost by dimensioning nonfunctionally. actualorietationnf T nf T actualnorientatiof T f T imumlocationnf T imumlocationf T ,, ,,max,,max,, +−−=−=∆ (22.6) Substituting Eq. (22.2) and Eq. (22.3) into Eq. (22.6) gives: ( )       +       −=                   + +                   + −−= DP P actualnorientatiof T f T D P actualnorientatiof T D P f T actualnorientatiof T f T 2 2 ,, 1 2 ,, 1 2 ,, ∆ ∆ (22.7) 22-18 Chapter Twenty-two 22.9.2 Percent of Actual Orientation Versus Lost Functional Tolerance Fig. 22-19 demonstrates how much functional tolerance is lost as a function of actual orientation toler- ance. The Y-axis is the percent that the actual orientation tolerance contributes to the total tolerance. The X-axis is the ∆ value. 22.10 Hardware Pages Figure 22-19 Lost functional tolerance versus actual orientation tolerance The following pages show recommended tolerances for clearance holes C’Bores, C’Sinks, C’Bore Depths, and fasteners. See Tables 22-1, 22-2, and 22-3.) The following general notes apply as noted in Figs. 22-20, 22-21, and 22-22. GENERAL NOTES: 1. The hole charts reflect recommended tolerance for locating the hole pattern back to the datum surface (hole to surface). 2. The hole charts reflect recommended tolerance for hole-to-hole, and/or hole to a datum feature of size (datum holes). Using a positional tolerance of ∅.014 on both an N/C drilled and sheet metal punched holes enables us to standardize the clearance hole diameters. Hole diameters, counterbore diameters and depths, and countersink diameters were calculated using the positional tolerance and the toler- ances assigned to the hole diameters, counterbore diameters and depths, and countersink diameters. Note: It is not recommended that you use hole-to-hole tolerance greater than ∅.014, because as the hole-to-hole tolerance gets larger, the clearance hole must get larger to accommodate the additional tolerance. 3. Counterbore diameters and depths are calculated using a flat washer with a worst case (MMC) outside diameter, and a worst case thickness. C’Bore diameters are calculated, and the nearest frac- tional drill diameter is used. 4. Worst case flat head screw height above and below the surface is shown in Table 22-5, and is calculated for a positional tolerance of ∅.014. 5. Flat head screws are not recommended because of head height issues, and alignment issues. 6. Floating fasteners are not recommended because of the additional hardware required, and because of the difficulty of assembly. 7. For C’Bore depths, (see Table 22-4). For .060-56 threaded holes, the C’Bore depth is calculated using only a flat washer. For .086-56 through .500-20, the C’Bore depth is calculated using both a flat washer and a split washer. Floating and Fixed Fasteners 22-19 Fastener Clearance Clearance C’Bore C’Bore Size Hole Hole Hole Hole Diameter Size Diameter Size .AAA Tolerance .BBB Tolerance .060-56 UNF .076 (#48) +.005/ 002 .213 (#3) +/ 010 .086-56 UNC .104 (#37) +.005/ 002 .272 (I) +/ 010 .086-64 UNF .112-40 UNC .1285 (#30) +.005/ 002 .406 (13/32) +/ 010 .112-48 UNF .125-40 UNC .1406 (9/64) +.005/ 002 .438 (7/16) +/ 010 .125-44 UNF .138-32 UNC .154 (#23) +.005/ 002 .469 (15/32) +/ 010 .138-40 UNF .164-32 UNC .180 (#15) +.005/ 002 .531 (17/32) +/ 010 .164-36 UNF .190-32 UNC .2055 (#5) +.005/ 002 .594 (19/32) +/ 010 .190-36 UNF .250-20 UNC .266 (H) +.005/ 002 .781 (25/32) +/ 010 .250-28 UNF .312 -18 UNC .328 (21/64) +.005/ 002 .922 (59/64) +/ 010 .312-24 UNF .375-16 UNC .3906 (25/64) +.005/ 002 1.047 (1 3/64) +/ 010 .375-24 UNF .438-14 UNC .4531 (29/64) +.005/ 002 1.172 (1 11/64) +/ 010 .438-20 UNF .500-13 UNC .5156 (33/64) +.005/ 002 1.312 (1 5/16) +/ 010 .500-20 UNF 8. Floating and nonfloating nut plate rivet hole diameters, and C’Sink diameters are dependent on the nut plate design and size. (See section 22.8 for information on how to calculate rivet diameter and location tolerance.) 9. Hole-to-hole tolerance for clearance holes and for nut plate rivet holes must be calculated per section 22.7. 10. Projected tolerance zone (PTOL) is determined by the maximum thickness of the mating part. 11. When using floating and nonfloating nut plates, projected tolerance issues could cause interchange- ability issues. See section 22.9. Table 22-1 Floating fastener clearance hole and C’Bore hole sizes and tolerances 22-20 Chapter Twenty-two Figure 22-20 Floating fastener tolerance and callouts 22.10.1 Floating Fastener Hardware Pages Floating and Fixed Fasteners 22-21 Figure 22-21 Fixed fastener tolerance and callouts 22.10.2 Fixed Fastener Hardware Pages 22-22 Chapter Twenty-two Table 22-2 Fixed fastener clearance hole, C’Bore, and C’Sink sizes and tolerances Fastener Clearance Clearance C’Bore C’Bore C’Sink C’Sink Size Hole Hole Hole Hole Diameter Size Diameter Size Diameter Size .EEE Tolerance .CCC Tolerance .DDD Tolerance .060-56 UNF .0935 (#42) +.005/ 002 .228 (#1) +/ 010 .125 +/ 010 .086-56 UNC .120 (#31) +.005/ 002 .290 (L) +/ 010 .180 +/ 010 .086-64 UNF .112-40 UNC .144 (#27) +.005/ 002 .421 (27/64) +/ 010 .230 +/ 010 .112-48 UNF .125-40 UNC .1562 (5/32) +.005/ 002 .453 (29/64) +/ 010 .255 +/ 010 .125-44 UNF .138-32 UNC .1695 (#18) +.005/ 002 .484 (31/64) +/ 010 .285 +/ 010 .138-40 UNF .164-32 UNC .1935 (#10) +.005/ 002 .547 (35/64) +/ 010 .335 +/ 010 .164-36 UNF .190-32 UNC .221 (#2) +.005/ 002 .609 (39/64) +/ 010 .390 +/ 010 .190-36 UNF .250-20 UNC .2812 (9/32) +.005/ 002 .797 (51/64) +/ 010 .510 +/ 010 .250-28 UNF .312 -18 UNC .3438 (11/32) +.005/ 002 .938 (15/16) +/ 010 .640 +/ 010 .312-24 UNF .375-16 UNC .4062 (13/21) +.005/ 002 1.063 (1 1/16) +/ 010 .765 +/ 010 .375-24 UNF .438-14 UNC .4688 (15/32) +.005/ 002 1.188 (1 3/16) +/ 010 .815 +/ 010 .438-20 UNF .500-13 UNC .5312 (17/32) +.005/ 002 1.328 (1 21/64) +/ 010 .880 +/ 010 .500-20 UNF Floating and Fixed Fasteners 22-23 22.10.3 Double-fixed Fastener Hardware Pages Figure 22-22 Double-fixed fastener tolerance and callouts [...]... 138 -40 UNF 164 -32 UNC 1 935 (#10) +.005/-.002 33 5 +/-.010 221 (#2) +.005/-.002 39 0 +/-.010 2812 (9 /32 ) +.005/-.002 510 +/-.010 31 2 -18 UNC 31 2-24 UNF 34 38 (11 /32 ) +.005/-.002 64 0 +/-.010 37 5- 16 UNC 4 062 ( 13/ 21) +.005/-.002 765 +/-.010 468 8 (15 /32 ) +.005/-.002 815 +/-.010 531 2 (17 /32 ) +.005/-.002 880 +/-.010 0 86- 64 UNF 112-40 UNC 112-48 UNF 125-40 UNC 125-44 UNF 164 - 36 UNF 190 -32 UNC 190 - 36 UNF 250-20... Pan Head 160 +/-.010 125-44 UNF Socket head 210 +/-.010 138 -32 UNC Pan Head 170 +/-.010 138 -40 UNF 164 -32 UNC Socket head Pan Head 225 190 +/-.010 +/-.010 164 - 36 UNF Socket head 260 +/-.010 190 -32 UNC Pan Head 215 +/-.010 190 - 36 UNF Socket head 295 +/-.010 250-20 UNC Pan Head 290 +/-.010 250-28 UNF Socket head 39 5 +/-.010 31 2 -18 UNC 31 2-24 UNF Pan Head Socket head 34 0 475 +/-.010 +/-.010 37 5- 16 UNC Pan... 100 Degree Flat Head 060 - 56 UNF Above Surface 018 0 86- 64 UNF Below Surface -.025 112-40 UNC Above Surface 022 112-48 UNF 125-40 UNC Below Surface Above Surface -.0 23 020 125-44 UNF Below Surface -.0 26 138 -32 UNC Above Surface 022 138 -40 UNF Below Surface -.027 164 -32 UNC Above Surface 020 164 - 36 UNF Below Surface -. 031 190 -32 UNC 190 - 36 UNF Above Surface Below Surface 022 -. 032 250-20 UNC Above Surface... Table 22 -3 Double-fixed fastener clearance hole and C’Bore sizes and tolerances Fastener Size Clearance Hole Diameter CCC Clearance Hole Size Tolerance C’Sink Diameter EEE C’Sink Size Tolerance 060 - 56 UNF 0 86- 56 UNC 0 935 (#42) 120 ( #31 ) +.005/-.002 +.005/-.002 125 180 +/-.010 +/-.010 144 (#27) +.005/-.002 230 +/-.010 1 562 (5 /32 ) +.005/-.002 255 +/-.010 138 -32 UNC 169 5 (#18) +.005/-.002 285 +/-.010 138 -40... Surface -.040 31 2 -18 UNC Above Surface 022 31 2-24 UNF Below Surface -.040 37 5- 16 UNC Above Surface 020 37 5-24 UNF Below Surface -.0 53 438 -14 UNC 438 -20 UNF Above Surface Below Surface 020 -. 060 500- 13 UNC Above Surface 022 500-20 UNF 2 -.021 0 86- 56 UNC 1 .019 Below Surface 22.11 Above Surface Below Surface -. 064 References Orberg, Erik, Franklin D Jones, and Holbrook L Horton 1979 Machinery’s Handbook 21st... 250-20 UNC 250-28 UNF 37 5-24 UNF 438 -14 UNC 438 -20 UNF 500- 13 UNC 500-20 UNF Floating and Fixed Fasteners 22.10.4 Counterbore Depths - Pan Head and Socket Head Cap Screws Table 22-4 C’Bore depths (pan head and socket head) Fastener Size Type of Fastener C’Bore Depths DDD C’Bore Depths Tolerance 060 - 56 UNF Pan Head 080 +/-.010 0 86- 56 UNC Socket head Pan Head 100 120 +/-.010 +/-.010 0 86- 64 UNF Socket head... 23- 4 Figure 23- 3 Fixed fastener centered and shifted Figure 23- 4 Floating fastener centered and shifted Fixed and Floating Fastener Variation 23- 5 23. 4.1 Fixed Fastener Assembly Shift Fig 23- 5 shows a fixed fastener within an assembly and uses the following notation to develop equations for assembly shift, minimum gap, and maximum gap The minimum and maximum gaps between datum surfaces E and B occur... b) − 1.5(th + t p) ( 23. 1) Note that Eq ( 23. 1) gives the minimum gap if the parts touch as shown in Fig 25 -6 Since the minimum gap occurs when the pin and hole are both at LMC, the parts may be manually shifted to increase this gap The amount the parts can shift is (h + t h) − (p − tp)  23- 6 Chapter Twenty-three Figure 23- 6 Fixed fastener minimum assembly gap Fig 23- 7 shows the two parts shifted to a... UNC Pan Head 39 0 +/-.010 37 5-24 UNF Socket head 550 +/-.010 438 -14 UNC Pan Head 440 +/-.010 438 -20 UNF Socket head 63 0 +/-.010 500- 13 UNC Pan Head 530 +/-.010 500-20 UNF Socket head 750 +/-.010 22-25 22- 26 Chapter Twenty-two 22.10.5 Flat Head Screw Head Height - Above and Below the Surface Table 22-5 Flat head screw head height above and below the surface Flat Head Screw Head Height Above and Below Surface... assembly variation This chapter looks at shifting the mating parts to understand the maximum and minimum assembly variation 23. 4 Fixed and Floating Fasteners There are two types of fastening systems used to assemble parts: fixed fasteners and floating fasteners Fig 23- 3 illustrates a fixed fastener This is defined as a fastener where one of the parts has restrained fasteners such as screws in tapped holes . UNF .31 2 -18 UNC .34 38 (11 /32 ) +.005/ 002 . 938 (15/ 16) +/ 010 .64 0 +/ 010 .31 2-24 UNF .37 5- 16 UNC .4 062 ( 13/ 21) +.005/ 002 1.0 63 (1 1/ 16) +/ 010 . 765 +/ 010 .37 5-24 UNF . 438 -14 UNC . 468 8 (15 /32 ). .14 06 (9 /64 ) +.005/ 002 . 438 (7/ 16) +/ 010 .125-44 UNF . 138 -32 UNC .154 (# 23) +.005/ 002 . 469 (15 /32 ) +/ 010 . 138 -40 UNF . 164 -32 UNC .180 (#15) +.005/ 002 . 531 (17 /32 ) +/ 010 . 164 - 36 UNF .190 -32 . .1 935 (#10) +.005/ 002 .547 (35 /64 ) +/ 010 .33 5 +/ 010 . 164 - 36 UNF .190 -32 UNC .221 (#2) +.005/ 002 .60 9 (39 /64 ) +/ 010 .39 0 +/ 010 .190 - 36 UNF .250-20 UNC .2812 (9 /32 ) +.005/ 002 .797 (51 /64 )