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Introduction
It is important to ensure that parts fit into each
other in order to have proper operation.
Tolerances are important because of their
impact on the proper functioning of a product,
part interchangeability and manufacturing.
Generally, the smaller the tolerance, the higher
the production costs.

Tolerances in Engineering

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Overview
It is practically impossible to produce any part to
exact dimension irrespective of the methods of
manufacturing.
Designer provides some deviation from the
desired size.
The desired size is known as basic size.
The permissible deviation of a dimension from
the desired size is known as tolerance.
The amount of tolerance permitted should
provide for the satisfactory functioning of the
parts concerned.
Tolerances in Engineering

Overview
The basic or nominal size Dn is usually
designated by a zero line 0.
The deviations are specified from the zero line
and can be either side of the zero line.
The difference between the maximum limit of
size Dmax and the nominal size is called the
upper deviation and that between the minimum
limit of size Dmin and the nominal size is called
lower deviation.

Tolerances in Engineering

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Overview
Tolerances solve the problem of inter-
changeability between parts in mass production
and assemblies
The exact size of the parts cannot be
manufactured (there is no perfect machine nor
process)
Tolerance is the allowed variation (mostly angles
and dimensions) of a parameter in a specific
dimension
Tolerance is indirectly a measure of quality, the
smaller the tolerance the higher the quality and
the higher the cost

Overview
Tolerances (limits) and fits must be considered during
the following:
Design (calculations, applications, optimisation of shape,
size, strength)
Material (selection availability, cost, machinability)
Process (selection of machine tool and sequence of
operations)
Condition of machining (selection of parameters)
Economical optimisation (permissible variation of each
dimension, fitting conditions of related parts)
To maintain a constant quality over a wide range of
sizes, some adjustment of the tolerance in relation to
the basic size is vital.

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Selection of tolerances
The selection of the tolerance on a part
depends on:
The nominal size.
Manufacturing method used.
Accuracy and quality desired.
Type of fit required.

Tolerances in Engineering

Fits
Fit is the term used to signify the relative degree of
tightness or looseness of assembled parts, which
decides the relative movement between mating parts.
Clearance fit two assembled parts are always free
to move relative to each other. E.g. door hinges, shaft
and bearing.

Tolerances in Engineering

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Fits
Interference fit mating parts are joined tightly
together and no relative motion is possible, used for
permanent or semi-permanent assembly of parts.

Tolerances in Engineering

Fits

Transition fit limits of size that either a clearance or an

interference may result when two specific parts are
assembled. The clearance zones overlap. Sometimes
required that the shaft is larger than the hole and
sometimes smaller than the hole.

Tolerangineeringces in E

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Fits
The disposition of the tolerance band with respect to
basic size determines the class of fit
The distance (fundamental deviation, FD) is indicated
by letter symbols

+
Distance, FD
nominal size

Geometric tolerance

Geometric tolerance is defined as the total amount

that the dimension of a manufactured part can vary.

Example:
Tolerance = 25.05 24.90 = 0.15

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Geometrical Tolerances
These set limits to variations with regards to
principal geometrical tolerances:
Straightness
- 50 A where A is a datum
Concentricity
50 A

Symmetry
50 A

Geometrical Tolerances

Cylindricity
angularity
Flatness
Roundness (o)
Perpendicularity
Parallelism

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Geometrical Tolerances

Geometrical Tolerances

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Surface Roughness and quality

Surface texture results from the processing of the material.
It is the microscopic contour of (metal) parts finished by various
manufacturing processes and its related to the tolerance of the
part.
It can be assessed visually or by measurement
Measured surface roughness is standardised

L, sampling length y

dL

stylus transducer amplifier recorder

integrator

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Typical applications

Flexible shaft coupling

Friction stir welding tool holder and tool coupling

Questions and comments?

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