Tolerancing

• Tolerances:
• The primary purpose of tolerances is to permit variation in dimensions
without degradation of the performance beyond the limits established by
the specification of the design.

• Why tolerance is specified?

• Variation in the properties of the material being machined introduces errors.
• The production machines themselves have some inherent inaccuracies built
into them and have the limitations to produce perfect parts.
• It is impossible for an operator to make perfect settings. In sitting up the
machine, i.e. in adjusting the tools and work piece on the machine, some
errors are likely to creep in.

Tolerance is the difference between upper limit and lower limit of a component
Tolerance is the allowable variation for any given size in order to achieve a
proper function
• Limits :
– It is the allowable size of machined component
• Upper / Maximum Limit :
– It is allowable maximum size of a machined component
• Lower / Minimum Limit :
– It is allowable minimum size of a machined component.

• Optimum tolerance:
• A good designer must explore information and techniques available as
guidelines in the establishment of realistic and, where possible, optimum
engineering tolerance.

• A basic dimension
• is the dimension, as worked out by purely design consideration.
• If the fit between a shaft and hole is a clearance type, then for complete
interchangeable approach (refer to fig 4.2) tolerance in shaft =tolerance in
hole =half the maximum clearance –half the
• NOMINAL SIZE : The size used for general description. Example; 7/8 inch
Shaft, 25mm Shaft etc.
• BASIC SIZE : The size used when the nominal size is converted to the
decimal and from which deviation are made to produce limit dimension.
Example: .8750inch shaft which is the basic size for a 7/8 inch nominal
shaft.25mm nominal size which can be basic size of 24.950mm.
• BILATERAL TOLERANCE : It is a way to express tolerance by using both minus
and plus variations from a given size. Example;
inch. The limit dimensions are 1.120-1.130 mm. The tolerance is 0.010 mm
•

• UNILATERAL TOLERANCE : It is a way to express tolerance by using only

minus or plus variation from a given size.

• or
•

• mm.
• ALLOWANCE : An alternative expression for tightest possible fit, which is minimum
clearance or maximum interference

• BASIC-SHAFT SYSTEM : This is a system in which the basic size is included as one of
the limit dimensions of the shaft. But it is not for the hole.

• BASIC-HOLE SYSTEM : This is a system in which the basic size appears as one of the
limit dimensions of the hole. But it is not for the shaft.

• MINIMUM MATERIAL CONDITION : In this condition a hole is at its largest limit

dimension. A shaft is at its smallest limit dimension. This condition exists at
maximum clearance or minimum interference.

• MAXIMUM MATERIAL CONDITION : In this condition a hole is at its smallest limit

dimension. The shaft is at its largest limit dimension. This condition exists at
minimum clearance or maximum interference. See example under the Force fit
condition.
•
• Tolerance Zone: It is the zone between the maximum and minimum
• limit size.
• Deviation : It is the algebraic difference between the corresponding size
and the basic size
• Fundamental Deviation : It is the algebraic difference between the size
closer to the zero line and the basic size
• Upper Deviation: It is the algebraic difference between the maximum
size and the basic size.
• The upper deviation of a hole is represented by a symbol ES (Ecart
Superior) and of a shaft, it is represented by es.
• Lower Deviation: It is the algebraic difference between the minimum
size and the basic size.
• The lower deviation of a hole is represented by a symbol EI (Ecart
Inferior) and of a shaft, it is represented by ei.
 The fundamental tolerances factor i=0.45 +0.001D
The relative magnitude of each grade is given below
for size up to and including 500 mm.
 Fit
A fit may be defined as the degree of tightness and
looseness between two mating parts.
 Clearance Fit
In clearance fit, an air space or clearance exists between the
shaft and hole.
 Such fits give loose joint.
A clearance fit has positive allowance, i.e. there is minimum
positive clearance between high limit of the shaft and low limit
of the hole.
 Allows rotation or sliding between the mating parts.
FIT : The general term of fit to describe the range of tightness designed into
parts which assemble one into another. The fit can be explained under the
three categories.
• CLEARANCE FIT : A type of fit in which one part fits easily into another
with a resulting clearance gap. See the below example,
•
• A clearance fit. The shaft is always smaller than the hole
Tolerance on shaft :
• Tolerance on hole :
minimum clearance :
maximum clearance :
The............ clearance in for the tightest possible fit.
 Clearance fits
• Loose Fit
• It is used between those mating parts where no precision is required. It
provides minimum allowance and is used on loose pulleys, agricultural machineries
etc.

• Running Fit
• For a running fit, the dimension of shaft should be smaller enough to maintain
a film of oil for lubrication. It is used in bearing pair etc.

• Slide Fit or Medium Fit

• It is used on those mating parts where great precision is required. It provides
medium allowance and is used in tool slides, slide valve, automobile parts, etc.
 Interference Fit
A negative difference between diameter of the hole and the
shaft is called interference.
In such cases, the diameter of the shaft is always larger than
the hole diameter.
It used for components where motion, power has to be
transmitted.

Interference exists between the high limit of hole and low

limit of the shaft.
• FORCE (INTERFERENCE) FIT : A type of fit in which one part must be
forcibly fitted into another. See the below example
•
• An Force (interference) fit. when the shaft is always larger in diameter
than the hole parts must be assembled by pressure or heat expansion.
Tolerance on shaft :
Tolerance on hole :
minimum clearance :
maximum clearance :
Maximum clearance=Minimum interference
Minimum clearance=Maximum interference
 Interference fit

• Shrink Fit or Heavy Force Fit

It refers to maximum negative allowance. In assembly of the hole and the shaft, the
hole is expanded by heating and then rapidly cooled in its position. It is used in fitting
of rims etc.

• Medium Force Fit

These fits have medium negative allowance. Considerable pressure is required to
assemble the hole and the shaft. It is used in car wheels, armature of dynamos etc.

• Tight Fit or Force Fit

One part can be assembled into the other with a hand hammer or by light pressure.
A slight negative allowance exists between two mating parts (more than wringing fit).
It gives a semi- permanent fit and is used on a keyed pulley and shaft, rocker arm,
etc.
 Transition Fit
It may result in either clearance fit or interference fit
depending on the actual value of the individual tolerances of
the mating components.
Transition fits are a compromise between clearance and
interference fits.
They are used for applications where accurate location is
important but either a small amount of clearance or
interference is permissible.
• TRANSITION FIT : A type of fit in which loosest case provides a clearance
fit and the tightest case gives an interference fit. See the example below,
•
• A transition fit exist when the maximum clearance is positive and the
minimum clearance is negative
Tolerance on shaft :
Tolerance on hole :
minimum clearance :
• The tightest fit is ....... in interference.
maximum clearance:
• The loosest fit is ....... in clearance
Transition fits are used only for locating a shaft relative to a hole,
where accuracy is important but either a clearance or interference is
permitted
 Transition fit
• Push Fit or Snug Fit
• It refers to zero allowance and a light pressure is required in assembling the
hole and the shaft. The moving parts show least vibration with this type of fit.

• Force Fit or Shrink Fit

• A force fit is used when the two mating parts are to be rigidly fixed so that one
cannot move without the other. It either requires high pressure to force the shaft
into the hole or the hole to be expanded by heating. It is used in railway wheels,
etc.

• Wringing Fit
• A slight negative allowance exists between two mating parts in wringing fit. It
requires pressure to force the shaft into the hole and gives a light assembly. It is
used in fixing keys, pins, etc.