25-Feb-2011 Tolerancing

Tolerancing

Interchangeability of manufactured parts is a critical element of present day production.

The production of closely mating parts, although theoretically possible, is economically
unfeasible. For this reason, the engineer, designer or drafter specifies an allowable
deviation (tolerance) between decimal limits.

The definition of a Tolerance, per ASME Y14.5.5M-1994, is the total amount a specific
dimension is permitted to vary. For instance, a dimension shown as 1.498” to 1.502”
means that it may be 1.498” or 1.502” or anywhere between these dimensions. Since
greater accuracy costs money, you would not callout the tightest possible tolerance, but
instead would callout as generous a tolerance as possible.

Definition of Terms

Example 1

Maximum Material Condition (MMC) – Is the condition where a feature of a finished

part contains the maximum amount of material. That is, the largest shaft or smallest
hole. See Example 1.

Least Material Condition (LMC) - Is the condition where a feature of a finished part
contains the least amount of material. That is, the smallest shaft or the largest hole.
See Example 1.

Nominal Size – Approximate size used for the purpose of identification such as stock
material.

Basic Size – Is the theoretical exact size from which limits of size are determined by
the application of allowances and tolerances.

Tolerance – The total amount by which a given dimension may vary or the difference
between the limits.

Limits – The extreme maximum and minimum sizes specified by a toleranced

dimension.

Allowance – An allowance is the intentional difference between the maximum material

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limits (minimum clearance or maximum interference) of mating parts.
Refer to Example 1 above: MMC of the hole – MMC of the shaft = Allowance.
MMC Hole = 1.250
- MMC Shaft = 1.248
Allowance = .002

Fits
Clearance fit – A clearance fit results in limits of size that assure clearance between
assembled mating parts.
Refer to Example 1 above: LMC of the hole – LMC of the shaft = Clearance.
LMC Hole = 1.251
- LMC Shaft = 1.247
Clearance = .004

Interference fit (also referred to as Force fit or Shrink fit)– interference fit has limits of
size that always result in interference between mating parts. For example, a hole and
shaft, the shaft will always be larger than the hole, to give an interference of metal that
will result in either a force or press fit. The effect would be an almost permanent
assembly for two assembled parts.

Example 2
Least amount of Interference is:
LMC Shaft = 1.2513
- LMC Hole = 1.2506
Min Interference = .0007

Greatest amount of Interference:

MMC Shaft = 1.2519
- MMC Hole = 1.2500
Max Interference = .0019

Transition fit – A transition fit might be either a clearance or interference fit. That is, a
shaft may be either larger or smaller than the hole in a mating part.

Example 3

LMC Hole = 1.2506

- LMC Shaft = 1.2503
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Positive Clearance = .0003
MMC Shaft = 1.2509
- MMC Hole = 1.2500
Negative Allowance (Interference) = .0003

Basic Hole System – The basic hole system is used to apply tolerances to holes and
shafts assemblies. The minimum hole is assigned the basic diameter (basic size) from
which the tolerance and allowance are applied. This system is widely used in industry
due to standard reamers being used to produce holes, and standard size plugs used to
check hole sizes accurately.
Computed Clearance Fit using Basic Hole System
.500 = hole basic size .500 basic hole
.002 = Allowance (decided) - .002 allowance
.498 Maximum shaft
Step 1 Step 2
If tolerance of part is = .003 then:
.498 maximum shaft .500 basic hole
-. 003 tolerance +.003 tolerance
.495 minimum shaft .503 maximum hole
Step 3 Step 4
Calculate clearances:
.500 smallest hole (MMC) .503 largest hole (LMC)
-. 498 largest shaft (MMC) -.495 smallest shaft (LMC)
.002 minimum clearance .008 maximum
clearance
Step 5 Step 6

Drawing annotation of tolerance

Example 3

Basic Shaft System – The basic shaft system can be used for shafts that are
produced in standard sizes. When applying this system, the largest shaft is assigned
the basic size diameter from which the allowance for the mating part is assigned. Then,
tolerances are applied on both sides and away from the assigned allowance. One
situation for using the basic shaft system is when a purchased motor, with an attached
shaft, from which a mating hole must be calculated.
Computed Interference fit using Basic Shaft System
.500 = shaft basic size .500 basic shaft
.002 = Allowance (decided) - .002 allowance
.498 Maximum hole
Step 1 Step 2
If tolerance of part is = .003 then:

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.498 maximum hole .500 basic shaft
-. 003 tolerance +.003 tolerance
.495 minimum hole .503 maximum shaft
Step 3 Step 4
Calculate clearances:
.498 largest hole (LMC) .495 smallest hole (MMC)
-. 500 smallest shaft (LMC) -.503 largest shaft (MMC)
- .002 minimum interference -.008 maximum
interference
Step 5 Step 6

Drawing annotation of tolerance

Example 4

Preferred precision fits – The American National Standards Institute publishes the
“Preferred Limits and Fits for Cylindrical Parts” (ANSI B4.1-1967) to define terms and
recommending standard allowances, tolerances, and fits for mating parts. The chart
data is provided in thousandths (.001) of an inch. For example: -1.2 and -2.2 (See
Example 5) for calculation purposes would be -.0012 and -.0022.

Running and Sliding fits (RC1-RC9)

Loosest of the class fits, used when a shaft is must move freely inside a hole or
bearing, and the positioning of the shaft is not critical. This fit would always allow a
clearance between shaft and hole.

Clearance locational fits (LC1-LC11)

Tighter than RC fits, but the shaft and hole may be the same size. LC fits allow the
shaft to be located more accurately than the RC fits but may still be loose. With this fit,
a shaft would move less freely inside a hole.

Transition locational fits (LT1-LT6)

These fits are a compromise between LC and LN (interference/force) fits. These fits
would allow either a small amount of clearance or interference.

Interference locational fits (LN1-LN3)

Used where accuracy of location is the prime importance such as alignment of dowel
pins and other devices where location relative to another part is of prime importance.

Force and shrinks fits (FN1-FN5)

With this fit, the shaft is always considered larger than the hole. These fits are used to
transmit torque such as a motor shaft to a bearing.

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Limits Calculations Using ANSI B4.1 Standard Tables
Class RC6 Clearance Fit

Partial Table from ANSI B4.1

Example 5

A nominal hole size of .8750 Diameter and a RC6 Class Fit has been selected.
Hole nominal size range = .71 – 1.19
Minimum clearance = .0016
Maximum clearance = .0048
Tolerance of hole = +.0020, -.0000
Tolerance of shaft = -.0016, -.0028
Calculations:
Hole: Basic size .8750 .8750
Tolerance +.0020 -.0000
Maximum hole .8770 Minimum hole .8750

Shaft: Basic size .8750 .8750

Tolerance -.0016 -.0028
Maximum shaft .8734 Minimum shaft .8722

Limits of size for Hole and Shaft

Example 5

Limit Calculations when one Design Feature Exists

When calculating the limit tolerances for features that mate with purchased parts, the
purchased part size must be known. This may be obtained be requesting a drawing
from a vendor or, a caliper or micrometer can be used to obtain an accurate size.
Example:

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A shaft diameter of .2500 is to be pressed into a part using a FN4 interference (force)
fit.
Limits of size for the shaft diameter are .2500 and .2495.
The table shows a minimum acceptable interference of .0006 and maximum
interference of .0016.
Calculations:
Maximum shaft: . 2500
Maximum interference: -. 0016
Minimum hole: . 2484

Minimum shaft: . 2495

Minimum interference: -. 0006
Maximum hole: .2489

References:
Dimensioning and Tolerancing, ASME Y 14.5M-1994, The American Society of
Mechanical Engineers.
Technical Drawing Tenth Edition, Frederick E. Giesecke, Prentice Hall, Upper Saddle
River, NJ 07458.
Geometric Dimensioning and Tolerancing, 2003, David A. Matson, Goodheart-Wilcox
Co. Inc., Tinley Park, Illinois.

Prepared by Bill Bussard

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