ENGINEERING TOLERANCING

Aim:
The aim of this section is to introduce the concepts of component and process variability and the allocation of component
tolerances. The ability to select suitable tolerances for the assembly of components should be developed, along with an
understanding of geometric tolerancing.

Introduction
Designers typically specify a components nominal dimensions such that it fulfils its requirements. In reality, components
cannot be made repeatedly to nominal dimensions, due to surface irregularities and the intrinsic surface roughness. Some
variability in dimensions must be allowed to ensure manufacture is possible. However, the variability permitted must not be
so great that the performance of the assembled parts is impaired. The allowed variability on the individual component
dimensions is called the tolerance. One of the tasks of the designer is to specify a dimension on a component and the
allowable variability on this value that will give acceptable performance.

Component Tolerances
Control of dimensions is necessary in order to ensure assembly and interchangeability of components. Generally,
tolerances are specified on critical dimensions of components. One method of specifying tolerances is to state the
nominal dimension followed by the permissible variation, so a dimension could be stated as 50.00 0.01mm. This means
that the dimension should be machined so that it is between 49.99mm and 50.01mm. Where the variation can vary either
side of the nominal dimension, the tolerance is called a bilateral tolerance. For a unilateral tolerance, one tolerance is
zero, e.g. 50.000.00+0.01.
Most organisations use general tolerances that apply to dimensions when tolerances are not specified explicitly on a
drawing. For machined dimensions a general tolerance may be 0.5mm.

Types of Fits
The degree of tightness or looseness between two mating parts is known as a fit of the parts. The nature of fit is
described by the size of clearance and interference. Basically, there are 3 types of fits:
Clearance fit: In this type of fit, the size limits for mating parts are so selected that clearance between them always
occurs. The difference between the minimum size of he hole and the maximum size of the shaft is known as minimum
clearance whereas the difference between the maximum size of the hole and minimum size of the shaft is called maximum
clearance. Depending on the size of the clearance, clearance fits may be sliding fit, easy sliding fit, running fit, slack
running fit and loose running fit.
Interference fit: Interference fits are those for which, prior to assembly, the inside component is larger than the outside
component. In an interference fit, the tolerance zone of the hole is entirely below the tolerance zone of the shaft. There is
some deformation of the components after assembly and a pressure exists at the mating surface. Depending on the level
of interference, interference fits may be shrink fit, heavy drive fit and light drive fit.
Transition fit: In this type of fit, the size limits for the mating parts are so selected that either a clearance or interference
may occur depending upon the actual size of the mating parts. The transition fits may be force fit, tight fit and push fit.
In addition to the cost, there are various factors to be considered in selecting a proper fit for an application. They are; (i)
length of engagement of parts, (ii) materials, (iii) lubrication, (iv) bearing pressure, (v) operating speeds, and (vi) ambient
conditions such as temperature and humidity.

Standard Fits for Holes and Shafts

In order to guarantee proper fits, tolerances for cylindrical components, e.g. shafts, fitting or rotating inside holes are
decided based on standard charts and guidelines. The tightness of fit will depend on the application.
e.g.
Gear located on to a shaft would require a tight interference fit.
The diameter of a journal bearing must be greater than the diameter of the shaft to allow rotation.
International standards have been developed, defining bands of tolerances for different types of fits. There are two
systems of tolerances:
1. Hole basis system
2. Shaft basis system
In the case of hole basis system, tolerance zone of the hole starts from the zero line and extends into the material of the
hole. In the case of shaft basis system, tolerance zone of the shaft starts from the zero line and extends into the material
of the shaft.
Usually, the hole based system is used because the holes are usually produced and finished by standard tooling like drills,
reamers, broachers, etc. On the other hand, the size of the shaft can be easily adjusted and is obtained by turning or

grinding operations. BS 4500 data sheets 4500A and 4500B list selected ISO clearance, transitional and interference fits
for internal and external components. When using the standard, upper case letters refer to the hole and lower case letters
to the shaft.
Example:
1.

Find the shaft and hole dimensions for a loose running fit with a 35mm diameter basic size. What is the minimum and
maximum clearance?

2.

Find the shaft and hole dimensions for a medium drive fit using a basic hole size of 70mm. What is the maximum and
minimum interference?

3.

A gear has to be shrunk on a shaft of basic size 120mm. An interference fit H7/u6 is being selected. Determine the
minimum and maximum diameter of the shaft and interference.

4.

A transition fit H7/n6 has been selected for a shaft and a hole where the nominal diameter is 12mm. Find the values
of clearance and interference.

5.

A bronze bushing is to be installed in a hole. A steel shaft is to rotate inside the bush. The bushing has a nominal
inner diameter of 50 mm and a nominal outer diameter of 62.5 mm.
a.

Specify the limits of size for the outer diameter of the bushing and the inner diameter of the sleeve so as to
provide a medium drive fit.

b.

Determine the limits of interference that would result in a close running fit between the shaft and the bush.

Geometric Tolerancing
Geometric Tolerancing is a method for precisely defining the geometry of mechanical parts. It introduces tools which allow
mechanical designers, fabricators, and inspectors to effectively communicate complex geometrical descriptions which are
not otherwise able to be described in a defined language
Geometric tolerancing allows the engineer to specify control over feature locations and deviations of form such as flatness,
parallelism and concentricity. Refer to the figures given for a description of various standard symbols used in geometric
tolerancing.

Glossary
Nominal size: It is the size of a part specified in the drawing as a matter of convenience.
Upper limit: The largest permissible size for a dimension of the part
Lower limit: The smallest permissible size for a dimension of the part
Tolerance: It is the difference between the upper limit and lower limit of a dimension.
Tolerance zone: It is the zone between the maximum and minimum limit size.