Unit 7: Dimensional Accuracy: Dr. Basil Hamed Technical English

Unit 7: Dimensional
accuracy
Dr. Basil Hamed
Technical English
Islamic University of Gaza
February, 2017
‫‪Vocabulary‬‬
‫دقيق ‪,‬شديد العناية بالتفاصيل ‪Precise‬‬
‫‪Vary‬‬ ‫تنوع ‪,‬تفاوت‬
‫تغيير ‪,‬االختالف ‪Variation‬‬
‫‪Accurate‬‬ ‫دقيق ‪,‬مضبوط‬
‫تفاوت مسموح ميكانيكيا ‪,‬التسامح ‪Tolerances‬‬
‫‪Deviation‬‬ ‫إنحراف الضوء ‪,‬االنحراف‬
‫‪Permissible‬‬ ‫مسموح ‪,‬جائز‬
‫‪Insufficient‬‬ ‫غير كاف‬
‫‪Bind‬‬ ‫ربط‬
‫‪Expands‬‬ ‫توسع‬
‫تقلص ‪,‬انكماش ‪Contracts‬‬
‫‪Basil Hamed‬‬ ‫‪2‬‬
A. Precision and tolerance
It is impossible to produce components with
dimensions that are absolutely precise, with
sizes exactly the same as those specified in a
design. This is because all production processes
are imprecise to a certain extent. Therefore,
the sizes of several components produced from
the same design will vary (differ). Although the
variation may only be a few hundredths of a
millimetre, sizes will not be 100% accurate
(exact) compared with the design.
Basil Hamed 3
A. Precision and tolerance
Because engineers know that accuracy cannot
be perfect, in designs they often specify
tolerances -that is, acceptable variations in
precision. Instead of giving one precise size, a
tolerance specifies a range of acceptable sizes-
an allowed amount of variation. This is often
given as a deviation (difference) from a
precise size.
Basil Hamed 4
A. Precision and tolerance…
The drawing on the side shows a
shaft with a specified diameter of
88 mm, plus or minus (±) 0.05
mm. This means the diameter may
deviate 0.05 mm either side of
this size. Therefore, diameters of
87.95 mm and 88.05 mm, which
are slightly inaccurate, are still
permissible (allowed), as they
are within tolerance. However,
diameters of 87.94mm or
88.06mm are not permissible-
they are outside tolerance.
Basil Hamed 5
A. Precision and tolerance…
When the permissible deviation in size is very small, we

say it is a tight tolerance (or a close tolerance). A
large permissible deviation is a loose tolerance. For
example:
 Machining a metal component to a tolerance of
±0.1 mm is relatively easy to do, so this tolerance
is loose. But a tolerance of just ±0.01 mm is a
tight tolerance in metalworking.
 In a concrete structure, ±10mm is a loose
tolerance. But ±1mm is tight, because it is difficult

to place wet concrete accurately.
Basil Hamed 6
B. Fit
When one component goes through another, such as a shaft or
a bolt going through a hole, the two must fit together- their
sizes and shapes must match. The key question is, how tightly
(or loosely) should they fit together? There are two main types
of fit:
A clearance fit allows a component to slide or turn freely, by
leaving clearance (a gap) between itself and the sides of the
hole. This distance must be quite precise. If there is
insufficient clearance - if the gap is too small - the
component will fit too tightly. As a result, the component will
bind - it will not be able to slide or turn freely. In other
words, there will not be enough play. However, if there is too
much clearance, there will be too much play and the
component will be able to move too much.
Basil Hamed 7
B. Fit…
An interference fit is a very tight fit which does
not allow a component to move freely inside a
hole. This type of fit can be achieved by forcing
the component into the hole. Alternatively, the
metal around the hole can be heated so that it
expands (increases in size due to heat). After
sufficient expansion, the component is placed
in the hole. The metal then cools and contracts
(decreases in size due to cooling). The
contraction results in a tight fit. An example of
an interference fit is a train wheel fitted on an
axle.
Basil Hamed 8
7.1 Find words and expressions with similar meanings
to the words and expressions below. Sometimes there
is more than one possible answer.
1. allowed permissible 6. deviation between

2. Exact maximum and minimum
3. Differ 7. an acceptable deviation
4. Exactness 8. an unacceptable deviation
5. not exact 9. little deviation allowed
10.large deviation allowed
Basil Hamed 9
7.2 Match the related sentences.
1.It'll bind. A. The bolt will have to turn in the hole.
2.It'll contract. B. The bolt won't be able to turn freely
3.It'll expand. enough in the hole.
4.There'll be too C. The bolt won't fit tightly enough in
much play. the hole.
5.It needs a D. The wheel will have to fit very tightly
clearance fit. on the axle.
6.It needs an E. The hole will widen with the high
interference fit. temperature.
F. The shaft will shorten and narrow
slightly as it cools.
Basil Hamed 10
7.3 Complete the article about engine
blueprinting using the words in the box.
Clearances, minus, plus, range,
variation, fit, permissible
precise, tolerances, within
Blue Printing for performance

The advantage of racing in a kart class with a
standard engine spec seems obvious – everyone
has the same power, so it's driving talent that
makes the difference. But things aren't quite that
simple.
Basil Hamed 11
7.3 Continue
No two standard engines are identical. There will
always be a slight (1) ............... in the size of
engine parts, since they are manufactured, not to
perfectly (2) ............. dimensions, but to specified
(3) ................ Although these differences may only be
(4) ............ or (5) ............... . a few hundredths of a
millimetre, they will nevertheless result in a slight
performance gap between any two engines.
Basil Hamed 12
7.3 Continue
One way round this problem (if you have the cash) is
to have your engine blueprinted. The process is
perfectly legal, as the sizes of all parts remain (6)
....................... the tolerances that are (7)
.................... for the standard engine specification.
However, by carefully matching pairs or groups of
parts that are all in either the lower or upper half of
the tolerance (8) ...................... , a blueprinted engine
is built to (9) ................... . together very precisely,
thanks to almost perfect (10) ..................... between
moving parts.
Basil Hamed 13
End of
Unit Seven
Basil Hamed 14

Unit 7: Dimensional Accuracy: Dr. Basil Hamed Technical English

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Unit 7: Dimensional

When the permissible deviation in size is very small, we

tolerance. But ±1mm is tight, because it is difficult

1. allowed permissible 6. deviation between

Blue Printing for performance

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