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 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

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:

.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.

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:

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