1.

1 Introduction

Todays technologies require increasingly exact dimensions. What is

more, many of todays parts are made by different companies in different
locations; therefore these parts must be specified so they will be
interchangeable.
The techniques of dimensioning parts to ensure interchangeability is called
tolerancing. Each dimension is allowed a certain degree of variation
within a specified zone, called tolerance. For example, a parts dimension
as 100 0.50, which yields a tolerance of 1.00 mm.
Dimensions should be given as large a tolerance as possible without
interfering with the function of the part to reduce production costs.
Manufacturing to close tolerances is expensive.

1.2 Tolerance Dimensions

Several acceptable methods of specifying tolerances are as shown in

Fig.1.1. When plus - and - minus tolerancing is used, tolerance are
applied to a basic dimension. When dimensions allow variation in only
one direction, the tolerancing is unilateral. Tolerancing that permits
variation in either direction from basic dimension is bilateral.
Tolerances may also be given in the form of limits; that is , two
dimensions are given that represent the largest and smallest sizes permitted
for a feature of the part. The customary methods of indicating toleranced
dimensions are shown in Fig, 1.2.

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Figure 1.1 Methods of positioning and indicating tolerances in unilateral,
bilateral, and limit forms.

Figure 1.2 The large limits are placed either above or to the left, While
the plus limits are placed above the minus limits.
1.3 Mating Parts
Many parts are parts that fit together within a prescribed degree of
accuracy (Fig. 1.3). The upper piece is dimensioned with two
measurements that indicate the upper and lower limits of the size. The

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notch is slightly larger, allowing the parts to assembled with a clearance
fit.

Figure 1.3 Each of these mating parts has a tolerance of 0.003, where
the allowance between the assembled parts is 0.002.

Figure 1.4 The allowance between these assembled parts is +0.003, and
the maximum clearance is 0.007.
An example of mating cylindrical parts is shown in Fig. 1.4A; Fig. 1.4B
illustrates the meaning of the tolerance dimensions. The size of the shaft
can vary in diameter from 1.500 in. (maximum size) to 1.498 in.
(minimum size). The difference between these limits on a single part is a
tolerance of 0.002 in. The dimension of the hole in Fig.1.4A are given
with the limits of 1.503 and 1.505, for a tolerance of 0.002 (the difference
between the limits as illustrated in Fig.1.4B).

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1.4 Metric Limits and Fits
This section will cover the metric system as recommended by the
International Standards Organization (ISO), which has been presented by
the ANSI B4.2 in the American Standards. These fits usually apply to
cylinders - holes and shafts. However, these standard tables can also be
used to determine the fits between any parallel surfaces, such as a key in a
slot.

1.4.1 Metric Definitions of Limits and Fits

Some of the definitions given below are illustrated in Fig. 1.5.

BASIC SIZE is the size from which the limits or deviations are assigned.
Basic sizes, usually diameters, should be selected from Table 1.1 under the
column heading first Choice.

DEVIATION is the difference between the hole or shaft size and basic size.

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 Figure 1.5 Terms related to metric fits and limits.

UPPER DEVIATION is the difference between the maximum permissible

size of a part and its basic size.

LOWER DEVIATION is the difference between the minimum permissible

size of a part and its basic size.

FUDAMENTAL DEVIATION is the deviation closest to the basic size. In

the note 40H7, the H (an uppercase letter) represents the fundamental
deviation for a hole. In the note 40g6 (a lowercase letter) represents the
fundamental deviation for a shaft.

TOLERANCES is the difference between the maximum and minimum

allowable sizes of a single part.

INTERNATIONAL TOLERANCE (IT) GRADE is a group of tolerances

that vary in accordance with the basic size and provide a uniform level of
accuracy within a given grade. In the note 40H7, the 7 represents the IT
grade. There are eighteen IT grades IT01, IT0, IT1, IT2,.. IT16.

TOLERANCE ZONE is the zone that represents the tolerance grade and
its position in relation to the basic size. This is a combination of the
fundamental deviation (represented by a letter) and the international
tolerance grade (IT number). In note 40H8, the H8 indicates the tolerance
zone.

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 Figure 1.6. Symbols and their definitions as applied to holes and shafts.

HOLE BASIS is a system of fits based on the minimum hole size as the
basic diameter. The fundamental deviation for a hole basis system is an
uppercase letter, H, for example (Fig. 1.6).

SHAFT BASIS is a system of fits based on the maximum shaft size as

the basic diameter. The fundamental deviation for a shaft basis system is
an lowercase letter, h, for example (Fig. 1.6).

CLERANCE FIT is a fit that results in a clearance between two

assembled parts under all tolerance conditions.

INTERFEREANCE FIT is a fit between two parts that requires they be

forced together when assembled.

TRANSITION FIT is a fit that results in either a clearance or an

interference fit between two assembled parts.

TOLERANCE SYMBOLES are notes used to communicate the

specifications of tolerance and fit (Fig. 1.6). The basic size is the primary
dimension from which the tolerances are determined; therefore it is the
first part of the symbol. It is followed by the fundamental deviation letter

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and the IT number to give the tolerance zone. Uppercase letters are used
to indicate the fundamental deviation for holes, and lowercase letters are
used for shafts.

Figure 1.7 Three methods of giving tolerance symbols.

The methods of specifying tolerance information on the drawing are shown

in Fig. 1.7. Parenthetical information is for reference only. The upper and
lower limits are found in Table 1.1.
Table 1.1 Selected ISO fits - Hole Basis (BS 4500A).

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1.5 Preferred Sizes and Fits
The preferred basic sizes for computing tolerances are shown in Table 1.2.
Under the First Choice heading, each number increases by about twenty
- five percent of the preceding number. Each number in the Second
Choice column increases by about twelve percent. To reduce expenses,
you should, where possible, select basic diameters from the first column
since these correspond to standard stock sizes for round, square, and
hexagonal metal products.

Table 1.2 Preferred Sizes.

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 Preferred fits for clearance, transition, and interference fits are shown in
Table 1.3 for hole basis and shaft basis fits.

1.5.1 PREFERRED FITS - HOLES BASIS SYSTEM

Fig. 1.8 illustrates the symbols used to show the possible combinations of
fits when using the hole basis system. There is a clearance fit between the
two mating parts (Fig.1.8A), a transition fit ( Fig. 1.8B), and an
interference fit (Fig. 1.8C).

Figure 1.8 Types of fits for a Hole Basis System..

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 Figure 1.9 The preferred fits for a hole basis system.
This technique of representing fits is used in Fig. 1.9 to show a series of
fits for a hole basis system. Note that the lower deviation of the hole is
zero; in other words, the smallest size of the hole is the basic size. The
different sizes of the shafts give a variety of fits c11 to u6, where there is a
maximum of interference. These fits correspond to those given in
Table.1.3.

Table 1.3 Description of Preferred Fits.

1.5.2 PREFERRED FITS - SHAFT BASIS SYSTEM

Fig. 1.10 illustrates the symbols used to show the possible combinations
of fits when using the shaft basis system , where the largest shaft size is

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the basic diameter. The variation in the fit such as a clearance fit between
the two parts, a transition fit, and an interference fit is caused by varying
the size of the holes. Note that also the upper deviation of the shaft is
zero; in

Figure 1.10 The preferred fits for a shaft basis system.

other words, the largest size of the hole is the basic size. The different
sizes of the holes give a variety of fits; from a clearance fit of C11/h11 to
an interference fit of U7/h6.

1.6 Chain Dimensions

When parts are dimensioned to locate surfaces or geometric features by a
chain of dimensions (Fig. 1.11A), variation may occur that exceed the
tolerances specified. As successive measurements are made, with each
based on the preceding one, the tolerances may accumulate, as shown in
Fig. 1.11A. For example, the tolerance between surfaces A and B is
0.002 between A and C, 0.004 and between A and D , 0.006.

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 This accumulation of tolerances can be eliminated by measuring from a
single plane called a datum plane. A datum plane is usually on the object,

Figure 1.11 Chain dimensions give a variation of 0.006 at D instead of

0.002 when referenced to a single datum surface as in B.

but it could be on the machine used to make the part. Since each of the
planes in Fig. 1.11B was located with respect to a single datum, the
tolerances between the intermediate planes are a uniform 0.002, which
represents the maximum tolerance.

1.7 Conical Tapers

Taper is a ratio of the difference in the direction of two circular sections of
a cone to the distance between the sections. A method of specifying a
conical taper by giving a basic diameter and a basic taper is shown in
Fig.1.12. The basic diameter of 20 mm. Is located midway in the length of
the cone with a toleranced dimension. Fig. 1.12 also shows how to find
the radial tolerance zone.

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Figure 1.12 Taper is indicated with a combination of tolerances and taper
symbols. The variation in diameter at any points is 0.06 mm.

1.8 Tolerance Notes

All dimensions on a drawing are toleranced either by the rules previously
discussed or by a note placed in or near the title block. For example, the
note TOLERANCE +0.40 mm, might be given on a drawing for less
critical dimensions.
Some industries may give dimensions in inches where decimals are carried
out to two, three, and four decimal places. A note for dimensions with
two and three decimal places might be given on the drawing as
TOLERANCES XX.XX 0.10; XX.XXX0.005. Tolerances of four
places would be given directly on the dimension lines.

The most common method of noting tolerances is to give as large a

tolerance as feasible in a note, such as TOLERANCES 0.05 , and to give
the tolerances for mating dimensions that require smaller tolerances on the
dimension lines.
Angular tolerances should be given in a general note in or near the title
block; such as ANGULAR TOLERANCES0.5o or 30. Angular

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tolerances less than this should be given on the drawing where these
angles are dimensioned. Tolerances of tolerancing angles are shown in
Fig. 1.13.

Figure 1.13 Different techniques to tolerance angles.

1.9 General Tolerances Techniques

All dimensions on a drawing are understood to have tolerances; and the
amount of tolerance must be noted. Tolerances may be specified by (1)
applying them directly to the dimensions, (2) giving them in specification
documents, or (3) giving them in a general note on the drawing.

1.10 Worked Example Problems

The following problems are given and solved as examples of determining
the sizes and limits and the applications of the proper symbols to mating
parts. The solution of these problems requires the use of the preferred
sizes Table 1.1, Table 1.2 of the ISO, and Table 1.3 of preferred fits.

EXAMPLE 1 (Fig. 1.14)

Given: Hole basis system, normal running fit, basic diameter = 39 mm.

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 Figure 1.14 Worked example 1.

SOLUTION: Use a basic diameter size of 40 mm (Table 1.1) and fit of

H8/f7 (Table 1.3).
Hole: Find the upper and lower deviations of the hole from Table 1.2,
under H8 and across from 40 mm. These deviations are +39 and 0 (note
that these deviations are in microns).
Thus, the hole limit sizes are:
Upper limit diameter = 40.039 mm.
Lower limit diameter = 40.000 mm.
Shaft: The upper and lower deviations of the shaft from Table 1.2, under
f7 and across from 40 mm. These deviations are -25 and -50 (again note
that these deviations are in microns).

Thus, the shaft limit sizes are:

Upper limit diameter = 39.975 mm.
lower limit diameter =39.950 mm.
Symbols: The method of noting the drawings are shown in Fig. 1.14 . Any
of these methods is appropriate.

EXAMPLE 2 (Fig. 1.14)

Given: Hole basis system, normal running fit, basic diameter = 39 mm.

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 Figure 1.15 Worked example 2.

SOLUTION: Use a basic diameter size of 40 mm (Table 1.1) and fit of

H8/f7 (Table 1.3).
Hole: Find the upper and lower deviations of the hole from Table 1.2,
under H8 and across from 40 mm. These deviations are +39 and 0 (note
that these deviations are in microns).
Thus, the hole limit sizes are:
Upper limit diameter = 40.039 mm.
Lower limit diameter = 40.000 mm.
Shaft: The upper and lower deviations of the shaft from Table 1.2, under
f7 and across from 40 mm. These deviations are -25 and -50 (again note
that these deviations are in microns).
Thus, the shaft limit sizes are:
Upper limit diameter = 39.975 mm.
lower limit diameter =39.950 mm.
Symbols: The method of noting the drawings are shown in Fig. 1.14 . Any
of these methods is appropriate.

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