Toler Ancing

TOLERANCING
BY MS CHATAIKA MF
Purpose
What will we learn in this lesson ?
We will learn about tolerancing and how
important this technique is to mass production.
Key points
If a feature’s size is toleranced, it is allowed to
vary within a range of values or limits.
Tolerancing enables an engineer to design
interchangeable or replacement parts.
INTRODUCTION
It is difficult to manufacture a component to an
exact design size or shape, to take account of this a
tolerance is permitted
This tolerance is intended to allow for reasonable
inaccuracy in manufacturing or positioning and is
defined as:
The maximum amount of deviation from the given
basic design size which is permissible if the
component or assembly is to function as planned
Tolerances of size
Tolerances of size are indicated by the maximum
and minimum permitted sizes called limits of
size
A designer must ensure that all parts will fit
together in the required manner
A particular fit will depend on the prescribed
maximum and minimum limits of size of the two
separate components which are to be assembled
Choosing the correct tolerance
Choosing the correct tolerance for a particular
application depends on:
 the design intent (end use) of the part
 cost
 how it is manufactured
 experience
Tolerancing Standards
Standards are needed to;
Make it possible to manufacture parts at different
times and in different places that still assemble
properly.
Establish dimensional limits for parts that are to be
interchangeable.
The most common standard agency is;
International Standards Organization (ISO).
Shaft-Hole Assembly
 Both the shaft and the hole are allowed to vary
between a maximum and minimum diameter.
Tolerance Types
The tolerancing methods presented are:
Limit dimensions
Plus or minus tolerances
Limit Dimensions
Limits are the maximum and minimum size that a
part can obtain and still pass inspection.
For example, the diameter of a shaft might be
specified as follows.
Plus or Minus Tolerances
Plus or minus tolerances give a basic size and the
variation that can occur around that basic size.
Types of fits
 Fit – the relative motion between a shaft and a
hole resulting from the final size achieved in
manufacture.
Engineering fits are classified into three
categories:
i. Clearance fit
ii. Interference fit
iii. Transition fit
Types of fits cont-
Clearance fit- this is a fit which always provides a
clearance, hence the shaft is always smaller than
the hole into which it fits.
 Clearance is the positive difference between the
sizes of the hole and the shaft.
 Typical applications are – rotating shafts,
bearings, loose pulleys, fast pulleys, etc.
Types of fits cont-
Interference fit- This is a fit which always provides
an interference, hence the shaft is always bigger
than the hole into which it fits.
Interference is the negative difference between the
sizes of the hole and the shaft.
Typical applications – pressed in bushes or sleeves,
crank pins, shrunk on couplings, railway wheels
shrunk on to axles, etc.
Types of fits cont-
Transition fit- This is a fit which may provide
either a clearance or an interference, hence the
shaft may be bigger, smaller or the same size as
the hole into which it fits.
Typical applications- bushes, pins, fasteners, keys,
etc.
Hole-Basis / Shaft-Basis Systems
Metric limits and fits are divided into two different
systems;
the hole-basis system and
 the shaft-basis system.
Hole-basis system
Hole-basis system:- a system of fits in which the
basic diameter of the hole is constant while the
shaft size varies with different types of fit.
The minimum limit of hole is the basic size.
This system is used when you want the basic size to
be attached to the hole dimension.
Hole-basis system cont-
This system is more economical than the shaft-
basis as only one size of drill or reamer need to be
used to produce different fits, the size being
machined to the required sizes, thus making
manufacture and measurement much easier.
Shaft-basis system
Shaft-basis system:- a system of fits in which the
hole size is varied to produce the required type of
fit, while the basic diameter of shaft is kept
constant.
The maximum limit of the shaft is the basic size.
This system is used when you want the basic size to
be attached to the shaft dimension.
This system tends to be less economical as a series
of drills is required.
Exercise
Identify the type of fit and the system used to
determine the limits of the following shaft and hole
pairs
Shaft Hole Type of Fit System
9.972 - 9.987 10.000 - 10.022 Clearance Hole
60.002 - 60.021 60.000 - 60.030 Transition Hole
39.984 - 40.000 39.924 - 39.949 Interference Shaft
Selecting Tolerances
Tolerances will govern the method of
manufacturing.
When the tolerances are reduced, the cost of
manufacturing rises very rapidly.
Specify as generous a tolerance as possible

without interfering with the function of the
part.
Selecting Tolerances cont-
Choosing the most appropriate tolerance depends
on many factors such as;
length of engagement
bearing load
speed
lubrication
temperature
humidity
and material
Experience also plays a significant role.
Definitions
Limits: The limits are the maximum and
minimum size that the part is allowed to be.
Basic Size: The basic size is the size from which
the limits are calculated.
It is common for both the hole and the shaft and
is usually the closest fraction.
Tolerance: The tolerance is the total amount a
specific dimension is permitted to vary.
Definitions cont-
Shaft – a member that fits into another member;
may be stationary or rotating.
Hole – the member that fits or houses the shaft;
may be stationary, rotating or the space between
two restrictions into which a member has to fit.
Definitions cont-
Deviation – difference between basic size and
actual size.
Upper deviation: The upper deviation is the
difference between the basic size and the
permitted maximum size of the part.
Lower deviation: The lower deviation is the
difference between the basic size and the
minimum permitted size of the part.
Definitions cont-
Maximum Material Condition (MMC): The MMC
is the size of the part when it consists of the most
material.
Least Material Condition (LMC): The LMC is the
size of the part when it consists of the least
material.
Skip to next part of the exercise
Exercise
Fill in the
following
table.
Shaft Hole
MMC .51 .49
LMC .47 .50
Definitions cont-
Maximum Clearance: The maximum amount of
space that can exist between the hole and the
shaft.
Minimum Clearance (Allowance): The minimum
amount of space that can exist between the hole
and the shaft.
Exercise
Fill in the
following
table.
Max. Clearance .50 - .47 = .03

Min. Clearance .49 - .51 = -.02
Tolerance Accumulation
The tolerance between two features of a part depends
on the number of controlling dimensions.
Tolerance Accumulation cont-
As the number of controlling dimensions increases,
the tolerance accumulation increases.
Exercise
What is the tolerance accumulation for the
distance between surface A and B for the following
dimensioning method?
70  0.3
Remember, even if the dimension does not have a
stated tolerance, it has an implied tolerance.
The distance could be controlled by a single
dimension or multiple dimensions.
Exercise
If the accuracy of the distance between surface A and
B is important, which dimensioning method should be
used?
Summary
It costs more to produce to a narrow tolerance,
therefore the amount of variation in size and
form, which is tolerated for an item without
sacrificing quality, is ideal and known as linear
and geometric tolerancing.
THE END

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TOLERANCING

Specify as generous a tolerance as possible

Max. Clearance .50 - .47 = .03

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