Tolerance and Allowances

Topic: Tolerance and Allowance
Objectives: At the end of this lesson, the student should be able to;
 Differentiate the difference between tolerances and allowances.

 Have adequate knowledge on how to apply and specify tolerance in a machine part.
Tolerance. It is the difference between the upper limit and lower limit of a dimension. In other
words, it is the maximum permissible variation in a dimension. The tolerance may be unilateral
or bilateral.
Method of assigning tolerances. When all the tolerance is allowed on one side of the nominal
size, e.g. 20+0.000
−0.004 then it is said to be unilateral system of tolerance. The unilateral system is
mostly used in industries as it permits changing the tolerance value while still retaining the same
allowance or type of fit. When the tolerance is allowed on both sides of the nominal size, e.g.
+0.002
20−0.002 , then it is said to be bilateral system of tolerance. In this case + 0.002 is the upper limit
and – 0.002 is the lower limit. The method of assigning unilateral and bilateral tolerance is
shown in Fig. 3.2 (a) and (b) respectively.
Tolerance zone. It is the zone between the maximum and minimum limit size, as shown in Fig.
3.3.
Allowance. It is the difference between the basic dimensions of the mating parts. The allowance
may be positive or negative. When the shaft size is less than the hole size, then the allowance is
positive and when the shaft size is greater than the hole size, then the allowance is negative.
Other Important Terms used in Limit System

Nominal size. It is the size of a part specified in the drawing as a matter of convenience.
Basic size. It is the size of a part to which all limits of variation (i.e. tolerances) are applied to
arrive at final dimensioning of the mating parts. The nominal or basic size of a part is often the
same.
Actual size. It is the actual measured dimension of the part. The difference between the basic
size and the actual size should not exceed a certain limit, otherwise it will interfere with the
interchangeability of the mating parts.
Limits of sizes. There are two extreme permissible sizes for a dimension of the part as shown in
Fig. 3.1. The largest permissible size for a dimension of the part is called upper or high or
maximum limit, whereas the smallest size of the part is known as lower or minimum limit.
Zero line. It is a straight line corresponding to the basic size. The deviations are measured from
this line. The positive and negative deviations are shown above and below the zero line
respectively.
Upper deviation. It is the algebraic difference between the maximum size and the basic size. The
upper deviation of a hole is represented by a symbol ES (Ecart Superior) and of a shaft, it is
represented by es.
Lower deviation. It is the algebraic difference between the minimum size and the basic size. The
lower deviation of a hole is represented by a symbol EI (Ecart Inferior) and of a shaft, it is
represented by ei.
Actual deviation. It is the algebraic difference between an actual size and the corresponding
basic size.
Mean deviation. It is the arithmetical mean between the upper and lower deviations.
Fundamental deviation. It is one of the two deviations which is conventionally chosen to define
the position of the tolerance zone in relation to zero line, as shown in Fig. 3.4.
The degree of tightness or looseness between the two mating parts is known as a fit of the
parts. The nature of fit is characterised by the presence and size of clearance and interference.
Clearance. It is the amount by which the actual size of the shaft is less than the actual size of the
mating hole in an assembly as shown in Fig. 3.5 (a). In other words, the clearance is the
difference between the sizes of the hole and the shaft before assembly. The difference must be
positive.
Interference. It is the amount by which the actual size of a shaft is larger than the actual finished
size of the mating hole in an assembly as shown in Fig. 3.5 (b). In other words, the interference
is the arithmetical difference between the sizes of the hole and the shaft before assembly. The
difference must be negative.
Sample Problem: The dimensions of the mating parts, according to basic hole system, are given
as follows:
Hole: 25.00 mm Shaft: 24.97 mm
25.02 mm 24.95 mm
Find the hole tolerance, shaft tolerance and allowance.
Solution.
Lower limit of hole = 25.00 mm Lower limit of shaft = 24.95 mm
Upper limit of hole = 25.02 mm Upper limit of shaft = 24.97 mm
Hole tolerance
We know that hole tolerance
= Upper limit of hole – Lower limit of hole
= 25.02 – 25 = 0.02 mm Answer.
Shaft tolerance
We know that shaft tolerance
= Upper limit of shaft – Lower limit of shaft
= 24.97 – 24.95 = 0.02 mm Answer.
Allowance
We know that allowance
= Lower limit of hole – Upper limit of shaft
= 25.00 – 24.97 = 0.03 mm Answer.
Activity No. 2
Comprehension Test
Instruction: Answer the following questions based on what you have learned in this topic
specifically tolerances and allowances.
1.) What are fits and tolerances? How are they designated?
Answer.
2.) What do you understand by the nominal size and basic size?
Answer.
3.) Write short notes on the following:

(a) Interchangeability;
Answer.
(b) Tolerance
Answer.
(c) Allowance
Answer.
(d) Fits
Answer.
Assignment No. 2
Objective Type Question

Instruction: Encircle the correct answer.
1.) In a unilateral system of tolerance, the tolerance is allowed on
(a) one side of the actual size (b) one side of the nominal size
(c) both sides of the actual size (d) both sides of the nominal size
2.) The algebraic difference between the maximum limit and the basic size is called
(a) actual deviation (b) upper deviation
(c) lower deviation (d) fundamental deviation
3.) A basic shaft is one whose
(a) lower deviation is zero (b) upper deviation is zero
(c) lower and upper deviations are zero (d) none of these
4.) A basic hole is one whose
(a) lower deviation is zero (b) upper deviation is zero
(c) lower and upper deviations are zero (d) none of these
Problem Solving
Instruction: Make sure to show your solution. Strictly, no solution no credit.
5.) A journal of basic size of 75 mm rotates in a bearing. The tolerance for both the shaft and
bearing is 0.075 mm and the required allowance is 0.10 mm. Find the dimensions of the shaft
and the bearing bore.
Answer.
6.) A medium force fit on a 75 mm shaft requires a hole tolerance and shaft tolerance each equal
to 0.225 mm and average interference of 0.0375 mm. Find the hole and shaft dimensions.
Answer.
7.) Calculate the tolerances, fundamental deviations and limits of size for hole and shaft in the
following cases of fits:
(a) 25 H 8 / d 9; and (b) 60 H 7 / m 6
Answer.
8.) Find the extreme diameters of shaft and hole for a transition fit H7/n6, if the nominal or basic
diameter is 12 mm. What is the value of clearance and interference?
Answer.

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Topic: Tolerance and Allowance

 Differentiate the difference between tolerances and allowances.

Other Important Terms used in Limit System

3.) Write short notes on the following:

Objective Type Question

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