# P23993 Design for Quality Assignment Answers

P23993 – Design for Quality

Question 1

Consider a tolerance chain given in Figure Q1 with dimensions shown in Table Q1.

Figure Q1

Table Q1

 Last digit of the student number upxxxxxX 1 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 AΔ 1+0.7

1. Allocate tolerances using Worst Case – Average Tolerance Grade Method [20 marks]

2. Allocate tolerances using RSS method [13 marks]

Question 2 – Selective Assembly

A company intending to produce components for a fit with guaranteed clearance / interference as given in Table Q2 (Jmin, Jmax or Smin, Smax respectively). It has been experiencing problems when machining both holes and shafts caused by lack of process capability, see Manufacturing Methods in Table Q2. Maintaining fit characteristics transform the tolerances to suit company's capability implementing selective assembly method.

Table Q2 for P23993 Design for Quality Assignment Answers

 Second from the last digit of the student number upxxxxXx Nominal size, mm Manufacturing method Fit requirements System Hole Shaft Clearance Interference Jmin Jmax Smin Smax 0 Ø26 Drilling (IT13) Rough Turning (IT12) 70 260 42 272 Hole 1 Ø15 Reaming (IT8) Precision Turning (IT7) 30 48 37 53 Shaft 2 Ø40 Rough Broaching (IT10) Rough Turning (IT11) 90 190 24 136 Hole 3 Ø8 Honing (IT5) Lapping (IT6) 2 7 3 9 Shaft 4 Ø30 Boring (IT9) Turning (IT8) 30 73 34 74 Hole 5 Ø64 Milling (IT10) Precision Turning (IT7) 55 135 72 147 Shaft 6 Ø12 Diamond Boring (IT6) Precision Turning (IT7) 58 72 48 59 Hole 7 Ø10 Broaching (IT8) Turning (IT9) 42 69 54 77 Shaft 8 Ø25 Honing (IT8) Polishing (IT7) 35 59 33 54 Hole 9 Ø20 Drilling (IT11) Rough Turning (IT10) 3 83 47 147 Shaft
1. Determine tolerances of the mating parts based on the manufacturing methods [4 marks]
2. Calculate the number of groups [4 marks]
3. Calculate upper and lower limit deviations for the hole and the shaft [8 marks]
4. Draft the tolerances, indicating the groups [8 marks]
5. Calculate maximum and minimum interference / clearance for each group [10 marks] Question 3 – Quality control

You are employed as a quality engineer and you have been asked to help in designing a limit gauge for quality control of machined shafts. Your company quality policy requires prevention of acceptance of any defective parts.

a. Using the appropriate approach allocate the tolerances for ‘GO’ and ‘NOT-GO’ ends of a snap gauge for controlling diameter of a shaft ØAB . Support your answer with all relevant tolerance diagrams.

Table Q3

 Third from the last digit of the student number upxxxXxx Shaft diameter ØA, mm Tolerance B 1 10 h10 2 20 h9 3 30 h8 4 40 h7 5 50 h6 6 60 h10 7 70 h9 8 80 h8 9 90 h7 0 100 h6

[20 marks]

b. Using the diagram from part (a) showing the allocation of Limit Gauge tolerances, give an example of a situation where a shaft with a particular actual dimension is made in the tolerance, but when inspected by this Limit Gauge (worn, but still within the gauge tolerance), might be misjudged as bad. Plot it on the tolerance diagram. [13 marks]

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