MODULE 3

TOLERANCES AND ALLOWANCES

or machine to turn it out exactly 2.50000 in. is quite another matter. In general, the closer the
dimension must be to precisely 2.5 in., which would be called the nominal size, the more costly
will be the manufacture.

If the designer does not know something about the natural variability of a process, he is
not able to specify the best tolerance. We have seen something of the ways in which the strength
of a material of the same specification varies. Similarly, a 2.5-in. part leaves the machine with a
dimension greater or less than 2.5 in. by some amount which may be anything from less than a
millionth of an inch to more than several hundredths.

How far off will it be? This question can be answered statistically if enough information
about the process is known. Without statistics, a satisfying answer cannot be given. For this
reason, machine designers need to interest themselves in statistical analysis applied to
manufacturing.

TOLERANCE

First, let us define tolerance, which is the stated permissible variation of the size of a
dimension. If a particular dimension is to fit inside of, or outside of, another dimension, as a pin
in a hole, this permissible variation or tolerance is important. If no fit is involved, as in the external
diameter of some rods-for example, dimension d, it would be unwise, unnecessary, and
uneconomical to insist that the final size be very close to the nominal size. Thus, if there is no
1
fit, a liberal tolerance of the order of ±0.010 in. or 64 in. in machining work could be permitted.

Such tolerances are frequently cared for by a blanket note on the drawing; for example,
"Tolerances not specified to be ±0.010 in.” The tolerance may be:

(a) Bilateral, where the size of a part is permitted to be either larger or smaller than the
given dimension. For example,
9 1
± 32, 1.062 ± 0.010
16

(b) Unilateral, where the size of a part may be larger only, or smaller only, than the
given dimension. For example,

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1.062+0.010
−0.000, 1.060+0.000
−0.010

Unilateral tolerances are generally used on those dimensions involved in a fit such as a
pin in a hole. See Fig. 3.1.

ALLOWANCE

For fitting dimensions (a fit of mating parts is involved), the tolerance, which depends in
part upon service needs, should be chosen with some knowledge of the natural spread of the
processes that produce the mating dimensions. If a pin is to turn freely in a hole, the pin must
be somewhat smaller than the hole. In manufacture for interchangeable assembly, the difference
in size is cared for by the allowance, which, for running fits, is the minimum specified difference
between the dimensions of the pin (male part) and the hole (female part). It is not the same in
general as the actual minimum difference.

When the pin is larger than the hole, the allowance is as before the difference in sizes for
the tightest fit, a difference also called the interference of metal,𝑖 (or negative allowance).

FITS

There are several systems of tolerances and allowances. Many companies have drawn
up standards to be used in their own practice. In this country, the American Standards
Association, ASA Standard B4.1-1955, has classified running and sliding fits as follows:

RC 1; close-sliding fits. For accurate location of fitting parts without perceptible play.

RC2; sliding fits. These fits move and turn easily but are not intended to run freely. With
a small temperature change in the larger sizes, this fit may seize.

RC 3; precision-running fits. For precision assemblies operating at low speed, light load,
and small temperature change.

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RC 4; close-running fits. For cases of accurate location and minimum play, but for
moderate speed, journal pressure, and temperature rise.

RC 5 and RC6; medium-running fits. Suitable for higher running speed and heavy journal
pressure.

RC7; free-running fits. Suitable for large temperature variations and where wider
tolerances are permissible.

RC8 and RC9; loose-running fits. For use with commercial cold-rolled shafts and tubing.

The same standard B 4.1-1955 also gives tables of limit dimensions for clearance location
fits, transitional location fits (accuracy of location is important but can tolerate either small
interference or small clearance), interference location fits accuracy of location of prime
importance), and other information; those concerned with actual design should have a copy of
the standard. The ASA fits are based on the basic hole system; the nominal size is the minimum
hole diameter. In the basic hole system, the tolerance on the hole is always positive (with zero
negative tolerance), measured from the basic size, and the tolerance on the shaft is all negative
for working fits. The basic hole system has an advantage over the basic shaft system in that the
hole produced by a standard reamer may be made the minimum hole size. Also, there is the
matter of inspecting with go and no-go gages. Generally, the mating parts are not so sensitive
to clearance but that a plant can adhere to some preferred tolerances on the basic hole system,
thereby materially reducing the number of gages needed for inspection. In short, the engineer
should not scatter tolerances for a particular size of hole all over the spectrum but should
conform to company standards as far as possible. Depart from such choices only for a confirmed
engineering reason.

Table 1, from the ASA Standard B 4.1-1955, defines the details of the various classes of
fits. The columns headed “Hole” are the tolerance limits on the hole; the columns headed "Shaft"
give the same for the shaft (for example, a 0.1-in. shaft of class RC1 has a maximum diameter
of 0.1 -0.0001 = 0.0999 in., a minimum diameter of 0.1 -0.00025 = 0.09975 in.). The allowance,
as defined above, is the numerically smaller number in the "Shaft" column (for example, the
allowance for a 0.1-in. nominal diameter, RC 1 fit, is 0.0001 in.). There is no rule that says the
values in the standard must be used, but most of the quoted values are part of an ABC (American,

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British, Canadian) agreement. Think of a standard as what appeared to be a good engineering

Table 1
Running and Sliding Fits

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Design Problem No. 1

Given 7/8-in pin on its mating hole, how much larger than the pin must the hole be assuming
loose running fit RC9?

Solution: 7/8-in = 0.875 in.

For Hole: 0.875 +0.005 = 0.880 in maximum

0.875 + 0 = 0.875 in minimum

Hole Tolerance =0.880 - 0.875 = 0.005 in

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For Shaft: 0.875 -0.007 = 0.868 in

0.875 -0.0105 = 0.8645 in

Shaft Tolerance = 0.868 -0.8645 = 0.0035 in

Allowance = minimum of hole - maximum of shaft

= 0.875 -0.868

= 0.007 in

PRESS AND SHRINK FITS

When the hole is smaller than the shaft, it will take force or pressure to put the cold parts
together. When this occurs, the allowance is said to be negative and is termed the interference
of metal. The ASA Standard B 4.1-1955 gives details for five classes of interference fits, from
which Table 2 is taken:

FN 1, for light drive fits, thin sections, long fits, cast-iron external member;

FN 2, for medium drive fits, ordinary steel parts, shrink fits on light sections, the tightest
fit it is advisable to use with a high-grade cast-iron external member;

FN 3, for heavy drive fits, heavy steel parts, shrink fits in medium sections;

FN 4 and FN 5, for force fits when the parts can safely withstand high stress.

Shrink fits (heating the hub or cooling the shaft or both) can be used where pressing the
fit is impractical. The mating parts may be sorted into size groups so that the amount of the
interference of metal does not vary greatly, obtaining a selected average interference 𝑖 of metal,.

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Table 2
Force and Shrink Fits (Interference Fits)

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Design Problem No. 2

Given 1-in pin on its mating hole, determine the dimension of hole and shaft using class FN3.
Solution: For 1 in. nominal size,

For Hole: 1 + 0.0008 = 1.0008 in maximum

1-0 = 1.0 in minimum

Hole Tolerance = 1.0008 - 1.0 = 0.0008 in

For Shaft: 1 +0.0021 = 1.0021 in maximum

1 + 0.0016 = 1.0016 in minimum

Shaft Tolerance = 1.0021 - 1.0016 = 0.0005 in

Allowance = minimum of hole - maximum of shaft

= 1.0 - 1.0021

= -0.0021 in

STRESSES DUE TO THE INTERFERENCE OF METAL.

The tight fits may produce large bursting pressures on the part with the hole. The stresses
in the hub can be estimated with reasonable accuracy from the thick-cylinder equations. For a
quick check on the safe side, one can assume that the shaft is rigid and all the deformation
occurs in the hub.

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𝐸𝑖
𝑆=
𝐷

Where: S=stress in psi or ksi

𝑖 =interference in inches

D=hole/hub diameter in inches

E=Modulus of Elasticity of hub material in psi or ksi

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