Note Product: Cam Follower Customer: Bosch Limited Customer drawing number: F002F71011 SKF Product Designations: RV-2095001

Scope of the Document: This document covers the manufacturing challenges during the development of the F002F71011 Roller which thereby leads to the request for relaxation of OD Chamfer Tolerances This document also provides clarification to the ambiguous issues in the Bore Chamfer Tolerances of F002F71011 Roller Date: 25th of July 2013

Executive Summary: The following snapshots give us a quick glance of the areas of focus.

Fig 1 a: Customer finished drawing (F002F71011)

Fig 1 b: SKF Proposal (RV2095001)

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The Background: The following table provides an overall picture of the various inputs available to SKF and the different derived outputs.

Fig 2: Inputs and various possible outputs: Note: The Bore chamfer value in the Customer finished drawing is absent but is Proposed by SKF in the proposal drawing

3a

Customer Pre-stage Fig 3: Customer Drawings

3b Customer Finished

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The Challenge: 1. To achieve OD Chamfer Tolerance (illustrated in Fig 1 below, encircled in RED) specified by the customer and proposed in RV 2095001 considering the current process capabilities of SKF India Limited, Bangalore and its Turning supplier. 2. To clarify the ambiguity existing (encircled in BROWN) regarding the open tolerance of 0.3 X 45 degrees

Fig 4: SKF Proposed (RV 2095001) for F002F71011

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The Constraints: Considering the inputs and allowances as per the customer pre-stage and finished drawings 1. A simulation was conducted to derive the minimum and maximum possible chamfer values in the Finished stage 2. The following were the values of maximum and minimum chamfer values obtained in the OD and bore respectively

3. It can be observed that the range of the maximum and minimum chamfers for OD is 0.383 which is equivalent to a range of ~ 0.4 4. This range of 0.4 matches closely with the range obtained by simulating SKF Pre-sage and finished conditions whose values are 0.368 (as seen in Fig 2) 5. It can be observed that Tolerance band given in Fig 3b (Bosch drawings) is 0.1. But the simulation for the minimum and maximum possible OD chamfers Show that a minimum band of 0.2 would be necessary
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Therefore we recommend the following specification for OD chamfer in the finished drawing:

0.4 0.2

Case Studies Addressing Challenge 1

CHALLENGE 1:

Drawing Number: F002F71011

Parameters affecting the Final Bore and OD Chamfer: The table below shows the parameters that affect the Final Bore and OD Chamfer Tolerance specification. The values indicate the minimum base value and the tolerances (in bold) necessary for turning and grinding processes. Note that the specifications (and tolerances) in the grinding column in Fig 3 exactly match with the customer requirement.( Refer Fig 1 )

Sl.No

Parameter

Dim, with Tolerances Turning Grinding

-0.095/- 0.205

Remarks

Width
15.4

0.05

15.2

0.05 being the minimum tolerance required during the turning process
0.077/0.05

0.05

Bore

14.7

15

0.05 being the minimum tolerance required during the turning process

0.05

0/-0.027

OD OD Chamfer

20.3
0.1

20

0.05 being the minimum tolerance required during the turning process 0.1 being the minimum tolerance required during the turning process

0.74

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0.1

Bore Chamfer

0.75

0.1 being the minimum tolerance required during the turning process

Fig: Turning and grinding tolerances

The Turning Bore Chamfer and Turning OD Chamfer Tolerances along with the combination of other above mentioned parameter tolerances will lead to insurmountable challenges in achieving the Final bore and OD Chamfer Tolerances provided in the drawing This challenge will persist even if the grinding tolerances are tightened. Since the Bore and OD tolerances are extremely tight, the only parameter that is feasible for tightening and experimentation is the Grinding width Tolerance.

Following are the various ranges of maximum and minimum chamfer values upon keeping the Turned Specifications and Tolerances in Fig 3 as constant and varying the grinding tolerances

Simulation 1: Boundary Conditions: Turned and grinding specifications are as per Fig 4. Chamfer angles are constant as per the drawing at 45 degrees
OD Chamfer Min Max 0.224 0.592

Sl. No 1 2 3

Parameter Width OD Bore

Grinding Tolerances 15.2 -0.095/-0.205 20 0/-0.027 15 0.077/0.05

Fig : Simulation 1

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Observation 1: It can be observed that with the current specification the chamfer ranges fall out of the specified range of 0.4 0.1 for OD

Simulation 2: Grinding Width Tolerance reduced to 80 micron Boundary Conditions: Turned specifications are as per Fig 4. Chamfer angles are constant as per the drawing at 45 degree Width grinding specification reduced to 80 micron
OD Chamfer Min Max 0.237 0.563

Sl. No 1 2 3

Parameter Width OD Bore

Grinding Tolerances 15.2 -0.125/-0.205 20 0/-0.027 15 0.077/0.05

Fig : Simulation 2 Observation 2: It can be observed that with the current specification, although there is some improvement the chamfer ranges still fall out of the specified range of 0.4 0.1. Simulation 3: Grinding process centered and tolerances reduced to zero Boundary Conditions: Turned specifications are as per Fig 4. Chamfer angles are constant as per the drawing at 45 degrees Grinding specifications centered and tolerances reduced to zero.

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Sl No 1 2 3

Parameter Width OD Bore

Grinding Tolerances 15.05 0/0 19.9865 0/0 15.06 0/0

OD Chamfer Min Max

0.258

0.558

Fig : Simulation 3 Observation 3: It can be observed despite centering the process and reducing the tolerances to zero the Chamfer ranges still fall out of the specified range of 0.4 0.1

CHALLENGE 2: Clarification for Challenge 2 (Bore Chamfer Specified in SKF Proposal as 0.3 X 45)

1. It can be observed in the table below that the Bore chamfer range (encircled) is only 0.258

3. However the range of 0.258 is a result of providing only a unilateral tolerance of 0.1 (in the Customer pre-stage drawing) which is not feasible during turning 4. The range increased approximately to 0.4 when that unilateral tolerance is converted to a bi-lateral tolerance (which is feasible in turning) as seen below.

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BORE CHAMFER RANGE:

The Proposition for Challenge 2: The specification mentioned in the SKF Proposal drawing (Fig 1) is 0.3 X 45 degrees which is an open tolerance. Referring to the ISO standards for radii and chamfers it can be observed that the tolerances begin with values for a chamfer of 0.5.

Fig: ISO standards (taken from Bosch -248 drawing)

This implies that it is left to the discretion of the designer to provide the tolerances keeping in mind also that no sharp edges should result.

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As per our practices, we consider this value of 0.3 (open tolerance) to be 0.2 which makes the minimum and maximum values to be

0.1 and 0.5 respectively

It can be observed that in this case, by using 0.2 no sharp edges will result.

Conclusion:
OD:
Sl No 1 Type RV 2095001 Parameter OD Chamfer Existing Specification range Requested Specification range

0.3 ~0.5

0.2 ~0.6

BORE: We are stating that the open tolerance of 0.3 X 45 degrees provided in the SKF proposal drawing (as shown below)

Implies a tolerance of

0.2

viz. - The values range from

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0.1 mm to 0.5 mm
Approved by: TGG Nair Head, Application Development Center, TW CoE. TW Business Unit SKF Bangalore

COMMENTS:

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