PPT 3 (1)

INTERCHANGEABILITY
Interchangeability refers to the substitution of similar part

manufactured to the same drawing. It is used for assembling a
number of parts taken at random from the stock to build up a
complete assembly without fitting or adjustment.
In industries, hundreds of components are manufactured in large

numbers. For complete interchangeability, collect part at randomly
from the constituent parts to assemble. The assembly will function
satisfactorily, without the use of any cutting / finishing tools.
SELECTIVE ASSEMBLY
Today the consumer not only wants quality, precision and trouble-free
products but also wants them at attractive prices. This has become
possible only by adopting automatic gauging for selective assembly.
The parts manufactured to wide tolerances fit. They are manufactured
in precision laboratory to very close tolerances. This idea of part
inspection is identified as ‘good’ or ‘bad’. Good parts are used for
assembly and scrape the bad parts. In selective assembly, the
components produced by a machine are classified according to size
into several groups. This is done both for hole and shaft and then the
corresponding groups will match properly.
SINE BAR
Common design of the Sine bar is shown in Fig. Few holes are drilled in
the sine bar to reduce the weight and also for easy handling. The distance ‘l’,
between the axes of the cylinders will be set exactly to 100, 200 or 300 mm in
metric system. Measurement of external and internal tapers may best be
carried out with the help of simple standard pieces of equipment such as
rollers and spheres. Trigonometric calculations are employed in all these
instances.
Sine bars in conjunction with slip gauges constitute a very good device
for the precise measurement of angles. The arrangement is based on
the fact that for any particular angle ‘θ’ the sides of a right angled
triangle will have precise ratio, i.e.,
Opposite side h
Sin θ= =
Hypotenuse l
If ‘h’ and ‘l’ could be measured accurately, ‘θ’ can be also obtained
accurately. The value ‘h’ is built up by slip gauges and the value ‘l’ is
constant for a given sine bar. Sine bars are used either for measuring
angles very accurately or for locating any work to a given angle with in
very close limits. For precision work, the upper face of the sine bar
must be parallel with the plane passing through the axes of both
cylinders. The top and bottom faces of the sine bar also must be
parallel so that the top or bottom face could be used as working
surfaces. A small setting error has much less influence on the
accuracy of measuring a small angle than for a large angle.
Sine bars are made from high carbon, high chromium, corrosion
resistant steel which can be hardened, ground & stabilized.
PROPERTIES OF SINE BAR
1 The distance between centres (l) must be precisely known.
2 The axes of rollers must be parallel to each other.
3 The upper surface of the sine bar must be flat and parallel.
4 The rollers must be of identical diameters and round to within a close
tolerance.
SOURCES OF ERRORS IN SINE BAR

1. Constant Angle Error:
This is caused if the working surface and the cylinder axes are not parallel.
2. Progressive Angle Error:
This is due to the error in cylinder centre distance.
3. Gauge block tolerance accumulation is also a source of progressive error.
Use of sine bar
(i) Measuring an unknown angle
(ii) Locating any work to a given angle
(iii) For Large and Heavy Component

(i) Measuring an unknown angle
Thus, the angle of the job ‘θ’ is obtained by
−1 h Where h – height of slip gauges

θ= 𝑆𝑖𝑛
𝑙 l - distance between roller of sine bar
A similar setup is made for this purpose. It is made with the help
of angle plate and clamping the sine bar to an approximate value
of the angle of the job. A dial indicator is moved on the surface of
the job, after locating the job on the surface of the sine bar. The
slips are adjusted so that the dial indicator reads zero when moved
across the work surface.
(ii) Locating any work to a given angle
Where
θ - setting angle
l - distance between roller of
sine bar
For larger work, the sine bar principle can be extended by making use of
sine-centres.
A surface plate is used for this purpose. A set up is made after
building the pile of slips to value ‘h’. A dial indicator is moved on
the surface of the job, after locating the job on the surface of the
sine bar. The slips are adjusted so that the dial indicator reads zero
when moved across the work surface. Thus, the height ‘h’ can be
calculated as
h=𝑙 sin θ
(iii) For Large and Heavy Component
𝑅1 − 𝑅 2
sin θ =
𝑙
Reason of not using Sine bar beyond 45 degree
Differentiating the equation w.r.t. θ

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INTERCHANGEABILITY

Interchangeability refers to the substitution of similar part

In industries, hundreds of components are manufactured in large

SOURCES OF ERRORS IN SINE BAR

(i) Measuring an unknown angle

(ii) Locating any work to a given angle

(iii) For Large and Heavy Component

Thus, the angle of the job ‘θ’ is obtained by

−1 h Where h – height of slip gauges

Differentiating the equation w.r.t. θ

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