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Chapter 10
Tolerancing
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2. Tolerancing
Tolerances are used to control the variation in size that exists on all manufactured parts.
The amount that a size is allowed to vary depends on the function of the part & its assembly.
electric drill vs. jet engine
The more accuracy required in a part (smaller tolerance) the greater the cost.
Tolerances allow for interchangeable parts, which permits the replacement of individual parts in an assy. instead of replacing the whole system if a part goes bad or fails.
So, with interchangeable parts, if a bearing wears out, a replacement bearing having the same specifications will work in the system.
In the 1800’s nuts and bolts were made in sets to ensure assembly.
In the early days of the industrial revolution, all parts were homemade and hand assembled,. Each part was made perfectly to fit with its mating part.
For example, a wagon smith would make a wheel for a wagon. The spokes, hub, and rim were all cut to fit one wheel. The steel hoop was hand fitted to the specific wheel, heated, then forced over the assembly. When it cooled, it would shrink and squeeze the assembly together.
Today, 1 company would make the spokes, another would make the hubs, and yet another might make the rim. The solution lies in dimensioning and tolerancing to make sure that the parts will fit together, even though they are made by different companies.

3. Tolerance
Tolerance is the total amount a dimension may vary. It is the difference between the maximum size and the minimum size.
Tolerances can be expressed on a drawing in several ways:
direct limits, or as tolerance values applied directly to a dimension. (Fig. 10.8)
geometric tolerances (Fig )
notes referring to specific conditions
A general tolerance note in the titleblock. (Fig. 10.7)

4. Dimensions Limit dimensions: Plus/minus dimensions: unilateral
bilateral

5. Tolerancing Terms
Nominal size: the “name” or general size. Often expressed as a fraction.
Basic size: the theoretical size used as a starting point for the application of tolerances. Nominal size in decimal format.
Actual size: the measured size of the finished part.
Limits: the maximum & minimum sizes shown by the toleranced dimension.
Allowance: the min. clearance or max. interference between 2 parts.
MMC: the condition of a part in which it contains the most amount of material.
EX: biggest shaft or smallest hole.
LMC: the condition of a part in which it contains the least amount of material.

6. Tolerance, MMC, LMC? Limit dimensions: Plus/minus dimensions:
unilateral
bilateral

7. Complete Worksheet TOL-1
Remember x.xxxx
I.e
I.e

8. Fit Fit: the degree of tightness between mating parts.
The three most common types of fit found in industry are:
Clearance fit - there is always a space between the 2 mating parts. (shaft is smaller than the hole)
Interference fit - the 2 mating parts always interfere with one another in assembly. (shaft is bigger than the hole)
Transition fit - sometimes a clearance fit & sometimes an interference fit between the mating parts.

9. Clearance Fit

10. Interference Fit

11. Do on own page 335, Figure 10.1a Hole Tolerance? Shaft Tolerance?
Minimum clearance?
Maximum clearance?
Allowance?

12. Complete Number 1 of Worksheet 66

13. ANSI Standard Fits
A group of English usit tolerance relationships called preferred precision fits have been developed. They are specified in ANSI B4.1.
The five classes are:
Running & sliding fits (RC)
Clearance locational fits (LC)
Transition locational fits (LT)
Interference locational fits (LN)
Force or shrink fits (FN)
These tolerances are specified in Appendix 5 through 9, pages a25-a32. The values in these tables are given in THOUSANDTHS of an inch. Example: 1.2 =

14. Class RC9: Running & Clearance Fit Basic DIA = 2.0000
Hole
Shaft
Shaft Tolerance =
Hole Tolerance =
Max. Clearance =
Min. Clearance =

15. Class FN2: Medium Drive fit Basic DIA = 0.5000
Hole
Shaft
Shaft Tolerance =
Hole Tolerance =
Max Interference =
Min Interference =

16. Complete Worksheets Tol-2, Tol-3 and 66

17. Metric Fit - Terms
Basic size: size to which limits of deviation are assigned. (Fig.10.1, p 343)
Must be same for both parts
Basic sizes selected from chart in Table 10.2
Deviation: difference between the actual size and the basic size. (Fig )
Upper deviation: difference between the max. size limit & the basic size.
Lower deviation: difference between the min. size limit & the basic size.
Fundamental deviation: the deviation closest to the basic size. (Fig )
Capital H indicates Hole
Lowercase letter, I.e. f , indicates shaft
IT values larger than IT16 can be found as:
IT17 = IT12 x 10
IT18 = IT12 x 10

18. Metric Fit – Terms cont’d
International Tolerance Grade (IT): a group of tolerances that vary depending upon the basic size, but have the same level of accuracy within a given grade. (Fig 10.18)
There are 18 IT grades. The smaller the grade number, the smaller the tol. zone.
See Appendix 10 for IT grades.
IT values larger than IT16 can be found as:
IT17 = IT12 x 10
IT18 = IT12 x 10

19. Preferred Metric Fits
There are 2 systems used to indicate preferred fits in the metric system.
Hole basis: the system of fits where the min. hole size is the basic size. The fundamental deviation for a hole basis system is indicated by a capital “H”.
EX H8
(50 = DIA in mm) (Basic size)
(H = using Basic Hole system) (fundamental deviation)
(8 = closest running fit) (IT grade)
For mating part 50H8/f7 (Appendix 11)
Hole Limits?
Shaft Limits?
Fit?
50H8 50 = basic size
H = fundamental deviation
8 = IT grade
50f7 50 = basic size
f = fundamental deviation
7 = IT grade

20. Preferred Metric Fits
The second system used to indicate preferred fits in the metric system.
Shaft basis: the system of fits where the max. shaft size is the basic size. The fundamental deviation for a shaft basis system is indicated by a lowercase letter.
EX. 50h7
(50 = DIA in mm) (Basic size)
(h = using Basic Shaft system) (fundamental deviation)
(7 = closest running fit)
(IT grade)
For mating part 50F8/h7 (Appendix ?)
Limits and Fits?
Hole Limits?
Shaft Limits?
Fit?

21. Try the following problem
Basic DIA 41mm
Use Hole Basis System
Sliding
50H8 50 = basic size
H = fundamental deviation
8 = IT grade
50f7 50 = basic size
f = fundamental deviation
7 = IT grade
50 H9/d9 50 = basic size
H9 = hole tolerance
d9 = shaft tolerance
H9/d9 = the fit

22. Try the following problem
Basic DIA 41mm
Use Shaft Basis System
Sliding
50H8 50 = basic size
H = fundamental deviation
8 = IT grade
50f7 50 = basic size
f = fundamental deviation
7 = IT grade
50 H9/d9 50 = basic size
H9 = hole tolerance
d9 = shaft tolerance
H9/d9 = the fit

23. Try the following problem
Basic DIA 58mm
Use Shaft Basis System
Force Fit
50H8 50 = basic size
H = fundamental deviation
8 = IT grade
50f7 50 = basic size
f = fundamental deviation
7 = IT grade
50 H9/d9 50 = basic size
H9 = hole tolerance
d9 = shaft tolerance
H9/d9 = the fit

24. Look Up
What type of fit is a 6 H7/s6?
Hole or Shaft Basis System?

25. Complete Worksheets Tol-4 and 67