SIE 1010 Engineering Design Graphics

Lesson 5.2 Dimensioning and Tolerancing

Dr Ivan Lee
Ivan.Lee@SingaporeTech.edu.sg

Lesson Outline
Dimensioning

Units of Measurement
Terminology Associated with Dimensions
Arrangement, Placement and Spacing of Dimensions
Using Dimensions to Specify Size and Location of Features
Dimensioning Rules and Guidelines
Finish Marks

Tolerancing

Definitions
Tolerancing Methods and Tolerance Accumulation
Geometric Tolerances
Tolerancing of Mated Parts
Preferred Metric Limits and Fits

Variation in Part Sizes

In manufacturing, same process is typically employed to mass
produce a single part
Parts are then combined with other mass-produced parts to
create commercial products
Mass-produced parts must be interchangeable
However, parts produced by same manufacturing process are
not exactly the same slight variations in part size
Tolerancing a dimensioning technique used to ensure part
interchangeability by controlling variance in manufactured
parts

Tolerancing
Tolerance range within which a dimension is allowed to vary
Controls amount of variation on each manufactured part
Amount of variation depends on function of part and assembly
As long as size and location of part features fall within tolerance zone,
the part should function properly within an assembly

Critical to success of manufacturing

Ensures interchangeability of parts

Directly influences cost and quality of manufactured parts
Parts made to high accuracy are expensive
Depending on type of product, extremely accurate parts may not be
warranted
For example, parts for a plastic toy need not be as accurate as
automotive parts

Tolerance Definitions
Tolerance specifies total permissible variation of a size

Difference between upper and lower limits of size

Example of specification: 3.25 0.03
Basic size: 3.25
Upper limit (max value): 3.28
Lower limit (min value): 3.22
Tolerance: 0.06 (Upper Lower limits)
Actual part size can range anywhere between 3.22 and 3.28, and still
function properly

Basic size theoretical size from which tolerance is assigned

Actual size measured size of a finished part

Tolerancing
General rule
Tolerances should be stated as generously as possible while still
ensuring the part will function properly
Allows a wider variety of processes to manufacture the part, thereby
keeping part costs low

Manufacturing quality is a function of part accuracy

High quality parts small variations in size and shape
Tight tolerance zones need to control part variability in
manufacturing

Tolerance and Machining Process

Tolerance Declaration
Tolerances may be expressed in different ways
Direct tolerancing methods
General tolerance notes
Geometric tolerances

Direct Tolerancing Methods

Lower limit Upper limit

Upper limit
Lower limit

Limit dimensioning
Plus-and-minus dimensioning

General Tolerance Notes

General tolerances are given in a note or in the title block
Example of a general note for Metric dimensions
ALL METRIC DIMENSIONS TO BE HELD TO 0.05
For basic size = 65.00, upper limit = 65.05, lower limit = 64.95

Example for English dimensions

ALL DECIMAL DIMENSIONS TO BE HELD TO 0.002

Example for angular dimensions

ALL ANGULAR TOLERANCES 1 DEGREE

General Tolerance Notes

Tolerances may also be specified in terms of number of
decimal places found in the dimensions
Example of general note

UNLESS OTHERWISE SPECIFIED, TOLERANCES ARE AS FOLLOWS:

Millimetres:
X
= 0.5
X.X
= 0.25
X.XX
= 0.12

A tolerance added to a dimension always supersedes the

general tolerance

Tolerance Accumulation
When location of a feature depends on more than one
tolerance values tolerances will be cumulative
Chain dimensioning technique example (a)
Dimensions are specified in sequence relative to each other
Tolerance accumulation between surfaces X and Y is 0.03

Tolerance Accumulation
Base line dimensioning technique example (b)
All dimensions of a given type are specified from the same datum
Tolerance variation between surfaces X and Y is reduced to 0.02

Tolerance Accumulation
Direct dimensioning technique example (c)
Distance between features are directly dimensioned
Tendency for tolerance accumulation can be further controlled
Maximum variation between surfaces X and Y is 0.01

Geometric Tolerances
Geometric dimensioning and tolerancing (GDT) is a method
of defining parts based on how they function, using standard
ASME/ANSI symbols

Table height with flatness

Geometric D&T

Example of feature control frames

Five categories of geometric controls

Form
Orientation
Location/Position
Runout
Profile

Shaft with circularity control

Geometric Tolerances

Examples of geometric dimensioning and tolerancing

GDT symbols

Mated Parts
Tolerance of a single stand-alone part is of little importance
When it is mated with other parts in an assembly, tolerancing
becomes critical
Mated parts must be toleranced as a system to fit within prescribed
degree of accuracy
In the pulley assembly below, shaft must turn freely within bushing,
while bushing is force-fit into pulley

Pulley Support Assembly

Parts in an assembly must be
toleranced as a system to achieve
prescribed degree of accuracy

Pulley support assembly

Exploded view of pulley support assembly

Types of Fits
Fit refers to the degree of tightness or looseness between two
mating parts
Tolerances can be specified for mating parts to achieve desired fit

Different types of fits

Clearance fit
Interference fit
Transition fit
Line fit

Clearance Fit
Internal member (e.g., shaft) is always smaller than external member
(e.g., hole of bushing)
Shaft is free to turn inside bushing

Interference Fit
Internal member (e.g., bushing) is always larger than external member
(e.g., hole of pulley)
Requires two parts to be forced together, without using adhesive or
mechanical fasteners

Transition Fit
Ranges between a pure clearance fit and a pure interference fit
Either internal shaft or external hole may be larger, so parts either slide or
are forced together

If an assembly calls for transition fit, the two sets (hole, shaft) of
components can be measured and sorted into groups according to size
(e.g., small, medium, large)
Components are then assembled components from one group being
mated with corresponding components from matching group
Selective assembly method relatively inexpensive way to manufacture
clearance or interference fits

Line Fit
One of the limits on both
members (hole, shaft) are equal
This means shaft and hole may
have the same size

Allowance
Allowance is the tightest possible fit between two mated
parts
Allowance = Smallest hole size Largest shaft size

Clearance fit
Allowance: Minimum clearance between two parts (positive)

Interference fit
Allowance: Maximum interference between two parts (negative)

Mated Parts with Parallel Surfaces

Different types of fit
Typically refer to cylindrical features (shafts, holes)
May also apply to parts with parallel surfaces that fit inside one
another

Fit of mated parts with parallel surfaces

Basic Hole Systems

A reference system, or method of calculation, to relate
tolerances and allowance to a basic size
Applies to a system of mated parts to achieve a particular
type of fit (clearance, interference, transition)
Tolerances and allowances are pre-determined for a basic size based
on the desired fit

Two reference systems

English units
Metric units

Preferred Metric Limits and Fits

ANSI B4.2 1978 (1994), Preferred Metric Limits and Fits
Standards and tables for tolerancing fitted parts using metric units
A tolerance is specified using a special designation (e.g., 40H7)

Basic definitions
Basic size Size to which limits or deviations are assigned (40)
Deviation Algebraic difference between a size and the
corresponding basic size
Upper deviation Algebraic difference between max limit of size and
the corresponding basic size
Lower deviation Algebraic difference between min limit of size and
the corresponding basic size
Fundamental deviation Upper or lower deviation that is closest to
the basic size (H)

Illustration of Definitions
IT grade number
1. Establishes the magnitude of
a tolerance zone
2. A smaller number indicates a
smaller tolerance zone

Illustration of definitions for Metric Limits and Fits

Fundamental deviation
1. Establishes the position
of a tolerance zone with
respect to the basic size
2. Expressed by tolerance
position letters
3. Upper-case (e.g., H) for
hole dimensions; lowercase (e.g., h) for shaft
dimensions

Preferred Metric Limits and Fits

More definitions
Tolerance Difference between max and min size limits
Tolerance zone Represents the tolerance and its position in relation
to the basic size
International tolerance grade (IT) A group of tolerances that vary
depending on the basic size, but provide same relative accuracy
within a given grade; designated by 7 in 40H7 (IT7). There are 18 IT
grades: IT0, IT1, and IT01 to IT16. The smaller the grade, the smaller
the tolerance zone.
Hole basis System of fits where min hole size is equal to the basic
size; fundamental deviation for a hole basis system is H
Shaft basis System of fits where max shaft size is equal to the basic
size; fundamental deviation for a shaft basis is h

Tolerance Specification
Tolerance zone symbol

40 H 7

Internal Dimensions (Holes)

Basic size
Fundamental deviation (position letter)
International tolerance grade (IT number)

Tolerance zone symbol

40 g 6

External Dimensions (Shafts)

Basic size
Fundamental deviation (position letter)
International tolerance grade (IT number)

Fit Between Mated Parts

A fit between mated parts is designated as follows
Basic size common to both components
Tolerance symbol for internal part (hole)
Tolerance symbol for external part (shaft)

Hole tolerance
Shaft tolerance

Metric-unit fit designation

Preferred Basic Sizes

Whenever possible:
Standard, or preferred,
sizes of round metal parts
should be used
Basic size of mating parts
should be chosen from
the first choice sizes

Preferred Hole Basis Fits

Hole basis is
preferred in most
cases
Fits have a
fundamental
deviation of H
on the hole

Preferred Shaft Basis Fits

Shaft basis should be used when a
common shaft mates with different holes
Fits have a fundamental deviation of h
on the shaft

Description of Preferred Fits

Tolerance Calculation Example 1

Given:
Basic size: 50 mm
Fit type: Free running, H9/d9
Calculation method: Hole basis

Find:
Tolerance limits on hole
Tolerance limits on shaft
Allowance

ANSI Preferred Hole Basis

Metric Clearance Fits (ANSI B4.2-1978, R1984)

Tolerance Calculation Example 1

From ANSI Preferred Hole Basis Clearance Fits:

Tolerance limits on hole

Upper limit = 50.062
Lower limit = 50.000 (= basic size)

Tolerance limits on shaft

Upper limit = 49.920
Lower limit = 49.858

Allowance
Allowance = Hole min Shaft max = 50.000 49.920 = +0.080

Tolerance Calculation Example 2

Given:
Basic size: 30
Fit type: Medium drive, S7/h6
Calculation method: Shaft basis

Find:
Tolerance limits on hole
Tolerance limits on shaft
Allowance

ANSI Preferred Shaft Basis

Metric Transition and Interference Fits (ANSI B4.2-1978, R1984)

Tolerance Calculation Example 2

From ANSI Preferred Shaft Basis Interference Fits:

Tolerance limits on hole

Upper limit = 29.973
Lower limit = 29.952

Tolerance limits on shaft

Upper limit = 30.000 (= basic size)
Lower limit = 29.987

Allowance
Allowance = Hole min Shaft max = 29.952 30.000 = -0.048

Tutorial

Work on Tutorial 5 Questions

More on Geometric D&T

Five categories of geometric controls

Form
Orientation
Location/Position
Runout
Profile

Form Controls

Straightness of axis

Circularity

Form Controls

Flatness

Cylindricity

Orientation Controls

Parallelism

Orientation Controls

Perpendicularity

Angularity

Location Controls

Concentricity

Position Controls

Position: hole location from surfaces

Position: hole location from hole

Runout Controls

Circular runout

Profile Controls

Profile of a line

Profile of a surface

Key Learning Points

Engineering drawings must include all the information needed
to build a part, assembly or system
Dimensions and general notes are used to describe the size and
location of part features, and details related to construction or
manufacture of the part

A numerical value is associated with a dimension line

Defines the size, location, geometric characteristic, or surface texture
of a part or feature

Drawings are typically dimensioned using millimetres (Metric

system) or decimal inches (English system)
Terminology and guidelines for dimensioning should be
adopted for optimum readability

Key Learning Points

Tolerancing is a dimensioning technique used to ensure part
interchangeability
Controls the variance that exists in manufactured parts
Specifies a range within which a dimension is allowed to vary
If the size and location of part features fall within the tolerance zone,
the part should function properly (as designed) in an assembly

Tolerances may be expressed in different ways

Direct tolerancing, general tolerance notes, geometric tolerances
Dimensioning technique can affect accumulated tolerances
Mated parts must be toleranced as a system to achieve desired
accuracy and function

ANSI B4.2 1978 (1994) Prefered Metric Limits and Fits

Standards for tolerancing fitted parts using Hole basis or Shaft basis

References
Fundamentals of Graphics Communication, Sixth Ed
Gary R. Bertoline, Eric N. Wiebe, Nathan W. Hartman,
William A. Ross, McGraw-Hill Co., Inc, (2011)

Engineering Design Graphics, 2nd Edition

James M. Leake, Jacob L. Borgerson, John Wiley & Sons,
Inc., (2013)

Engineering Design Process

Yousef Haik, Brooks/Cole Thomson Learning, Inc., (2003)