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Course Contents
1. Introduction
2. Dimensions, Surfaces, and Their Measurement
3. Metal Casting
4. Metal Forming
5. Material Removal Processes
6. Particulate Processing of Metals and Ceramics
7. Property Enhancing and Surface processing Operation
8. Assembly Technology
9. Manufacturing Systems and Their Support System
1

TYPES OF ERRORS

Dimension

Surface

Relative
position errors

Geometric
shape
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CHAPTER 2

CONTENTS OF CHAPTER 2
1. Dimension, Tolerance and Related Attributes
2. Conventional Measuring Instruments and Gages
3. Surfaces
4. Measurement of Surfaces
5. Effects of manufacturing Processes

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ROLES OF DIMENSIONS AND SURFACES

Factors determine the performance of a manufactured
product.
Dimensions: are linear or angular sizes of a component
specified on the part drawing -> determine how well the
component of a product fit together during assembly.
Surfaces of a component: affect product performance,
assembly fit, and aesthetic appeal.
A surface is the exterior boundary of an object with its
surrounding (other subjects, fluid, or space) -> encloses
the objects bulk mechanical and physical properties
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DIMENSION AND TOLERANCES

- Dimensions: (ANSI) a numerical value expressed in

appropriate units of measure and indicated on a drawing

and in other documents along with lines, symbols, and
notes to define the size or geometric characteristic, or
both, of a part or part feature.
- Unit for length in engineering drawing is mm (metric
system) or inch. On the drawing, if the unit is mm/inch ->
not necessary to write it down.

- Unit for angle is degree, minute, and second. Angle unit

is always written down.
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DIMENSION AND TOLERANCES

Nominal Dimension
Real Dimension

DIMENSION AND TOLERANCES

In practical, nearly impossible and very costly to make the
part to the exact dimension -> How to handle?
A limited variation is allowed from the dimension, and that
allowable variation is called a Tolerance.
A tolerance is the total amount by which a specific
dimension is permitted to vary. The tolerance is the
difference between the maximum and minimum limits.
Some methods to specify tolerance:
-

Bilateral tolerance

Unilateral tolerance

Limit dimension
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TOLERANCES
Nominal Dimension is 2,5

- Maximum and minimum allowed dimensions

- Upper and lower Variation

READ/UNDERSTAND TOLERANCE SYMBOLS

What is the meaning of 50 0,02 ?
Parts after manufacturing have diameters within the
range from 49,98 to 50,02 are acceptable. Parts
outside the range are unacceptable

50+0,02
0,023

50+0,02
+0,017

500,02
0,03

50,02
50,017
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WHY NEED TOLERANCE?

Interchange feature
- Randomly dont need to choose parts to assembly
- Satisfy assembly/fit requirements

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DIMENSION AND RELATED ATTRIBUTES

Platness surface error:
(Sai s mt phng)
Revolution surface error:

(Sai s mt tr)

Flatness ( phng)
Straightness ( thng)
Cylindricity ( tr)
Circularity ( trn)

Profile errors:

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FLATNESS ( PHNG)

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STRAIGHTNESS ( THNG)

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CIRCULARITY ( TRN)

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CYLINDRICITY ( TR)

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PROFILE BIN DNG

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Relative Position Error - Sai s v tr tng quan

Parallelism - song song
Perpendicularity - vung gc:
Concentricity - ng tm
Symmetricity - i xng
Run-out - o mt u

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PARALLELISM SONG SONG

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PERPENDICULARITY - VUNG GC

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Concentricity ng tm

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O HNG TM CIRCULAR RUNOUT

- Circular Run-out is the total of circular error and
concentric error

Circular Run-out
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O TON PHN TOTAL RUNOUT

TOTAL RUNOUT is the total of circular run-out and

straightness error

Total Runout
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Angular Tolerances Dung sai gc

Directed measurement: high requirement in producing of the

tip point

-> used undirected method: measure angle by length

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CONTENTS OF CHAPTER 2
1. Dimension, Tolerance and Related Attributes
2. Conventional Measuring Instruments and Gages
3. Surfaces
4. Measurement of Surfaces
5. Effects of manufacturing Processes

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MEASUREMENT AND GAGING

- Measurement: is procedure in which an unknown
quantity is compared with a known standard, using
an accepted and consistent system of units.
- Measurement provides a numerical value of the
quantity of interest, within certain limits of accuracy
and precision.
- Accuracy is the degree to which the measured value
agrees with the true value of the quantity of interest
(related to systematic error)

- Precision is the degree of repeatability in the

measurement process (related with random error).
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MEASUREMENT AND GAGING

- Gaging (gauging kim tra):
determine simply whether the part
characteristics meets or does not
meet the design specification.
- It is usually faster than measuring.
- What is the difference between
Measurement and gaging?

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PRECISION GAGE BLOCKS

The highest grade - the
master laboratory standard
- is made to a tolerance of
0.000,03mm (0.000,001in).

For best results, gage blocks

must be used on a flat
reference surface, such as a
surface plate - whose top
surface is finished to a flat
plane (usually made of granite
- hardness, nonrusting,
nonmagnetic, long wearing,
thermally stable, .)
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CONVENTIONAL MEASURING INSTRUMENTS AND

GAGES

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VERNIER CALIPER (THC CP)

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CALIPER (THC CP)

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DIGITAL VERNIER CALIPER (THC CP S)

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MICROMETER (PAN-ME)

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MICROMETER (PANME)

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DEEP GAUGE MICROMETER (PAN-ME O SU)

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COMPARATIVE INSTRUMENTS (NG H SO)

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LIMIT GAGES (DNG KIM - CALIP)

Snap gage
(Calip ngm)

Plug gage
(Calip nt)
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ANGULAR MEASUREMENT

Bevel Protractor with vernier scale

(Courtesy of L.S. Starrett Co.)

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CHAPTER 2
1. Dimension, Tolerance and Related Attributes
2. Conventional Measuring Instruments and Gages
3. Surfaces
4. Measurement of Surfaces
5. Effects of manufacturing Processes

39

SURFACES
- Surfaces: is what one touches when holding an object
- Nominal surface: representing the intended surface contour
of the part, defined by lines in eng. drawing
- Actual surface: determined by the process used to make it
- The variety of processes available in manufacturing result
in wide variations in surface characteristics.

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ILLUSTRATION OF NOMINAL AND ACTUAL SURFACES

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WHY SURFACE IS SO IMPORTANT?

- Engineering
- Friction and wear
- affect mechanical and physical properties
- Assembly
- Smooth surfaces make better electrical contacts
- Safety
- Commercial:
- Aesthetic reasons
- Repair and maintenance
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CHARACTERISTICS OF SURFACES

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TERMINOLOGY
Surface texture (Cu truc b mt)
o Surface roughness (Nham b mt)
o Waviness (Song b mt)
o Lay direction (Hng vt gia cng)
o Flaw (Khuyt tt)
Surface Integrity (Tinh tich hp lp b mt)
o Subsurface layer (Cu truc t vi lp ngay di b
mt)
o Hardness, Hardness change (Bin cng)
o Plastic Deformation (Bin dang deo); Residual
Stress (ng sut d)
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SURFACE MEASUREMENT
Two standards to evaluate surface roughness: Ra and Rz

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SURFACE MEASUREMENT

Rz

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TCVN OF SURFACE ROUGHNESS

Ch : Vi nhm th v siu tinh, vic kim tra s dng Rz.

i vi nhm tinh v bn tinh, Ra s c s dng
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EXAMPLE

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CONTENTS OF CHAPTER 2
1. Dimension, Tolerance and Related Attributes
2. Conventional Measuring Instruments and Gages
3. Surfaces
4. Measurement of Surfaces
5. Effects of manufacturing Processes

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SURFACE MEASUREMENT METHOD

Video-Clip

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CONTENTS OF CHAPTER 2
1. Dimension, Tolerance and Related Attributes
2. Conventional Measuring Instruments and Gages
3. Surfaces
4. Measurement of Surfaces
5. Effects of manufacturing Processes

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INFLUENCE OF MANUFACTURING PROCESSES TO

TOLERANCE
- Each process creates different dimension accuracy.
- Almost machining processes create high dimension
accuracy tolerance is about 0,05mm or smaller.
- Sand casting create lower dimension accuracy; tolerance
is normally bigger 10-20 time than machining processes.
Machining tolerance depends also on product dimension.
The bigger the product is the larger the tolerance is.
Table of conventional tolerance from machining processes

(Next)

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INFLUENCE OF PROCESSES TO TOLERANCE

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INFLUENCE OF PROCESSES TO SURFACE ROUGHNESS

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PICTURES TO SHOW SURFACE QUALITY

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SUMMARY OF CHAPTER 2
1. Definition of tolerance?
2. Comparing bilateral tolerance and unilateral tolerance.
Take an example to illustrate.
3. Concept of nominal surface (standard surface)
4. Why does surface has vital role?
5. Name some processes can made products with
surface quality: low, medium, high and very high

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END OF CHAPTER 2

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THC CP (VERNIER CALIPER)

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