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 DIMENSIONAL AND GEOMETRIC TOLERANCES

DIMENSIONS AND TOLERANCES

1. Nothing can be made to an exact size.
2. The closer to an exact size an item or feature must be, the more expensive the item or
feature becomes!

Controlling these Problems

• Tolerance all Dimensions on an Engineering Drawing
An upper and lower limit about a nominal size within which the actual measured size falls
• It is impossible to manufacture parts with the exact dimensions and shape. So there is a
deviation from the nominal size.
• When two parts have to fit in a certain way, then the dimensions of each component have
to be between certain limits in order to reach the desired functional demands, and the
parts also will be interchangeable.
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• Parts cannot be manufactured to perfection, so tolerances are applied to appropriate

dimensions
• A dimension’s nominal value is the target value for the part to be manufactured to
• A tolerance is a specified amount of deviation that nominal value can have and still be
considered “Good”. The tolerance values are created from standard fit tables, machining
standards and from experience.
• Specifically tolerance those dimensions which differ from the general tolerances. These are
normally functional dimensions.
• Indicate General Tolerances in a table near the Title Block.
• Do not tolerance Standard Components because their relevant standards prescribe the
required tolerances. Just indicate the ISO standard of the component.
 The manufacture of a dimension within narrow limits is difficult and expensive. Therefore,
only the functional dimensions should have such tolerances that the part just meets all
functional demands. The other dimensions should have tolerances that match a particular
production process.
 So the Drawing Office Practice is to only specifically tolerance those dimensions which differ
from the General Tolerances. A general tolerance is indicated in a table near the title block.
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Tolerancing Terms and Definitions

• Dimension: A numerical value expressed in appropriate units of measure to define the size
or geometric characteristic, or both, of a part or part feature.
• Nominal Size: The desired size
• Actual Size: The measured size upon inspection
• Feature: The general term applied to a physical portion of a part such as a surface/face,
hole or slot
• Feature of Size: A feature that can be measured. Usually one cylindrical or spherical
surface, or a set of two planar parallel surfaces, each of which is associated with a size
dimension
• Limits of Size: The specified maximum and minimum sizes.
• LMC: The condition in which a feature of size contains the least amount of material.
(largest hole, smallest shaft or the lightest part)
• MMC: The condition in which a feature of size contains the maximum amount of
material. (smallest hole, largest shaft or the heaviest part)
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• Tolerance: The total amount by which a specific dimension is permitted to vary

• Tolerance, Unilateral: A tolerance in which variation is permitted in one direction only from
the specified dimension.
• Tolerance, Bilateral: A tolerance in which variation is permitted in both directions from the
specified dimension.

Origin-Based Dimensional Limits

• Linear dimensions are terminated at each end with an arrowhead except when it is
necessary to establish the origin from which an inspection measurement must be taken.
• The dimensions associated with the origin define the tolerance zone within which the
elements of the associated feature must lie. This principle is extremely important when the
resultant form, orientation or function of one feature depends upon its relationship to a
second feature.

Origin-Based Dimensional Limits

Dimension
.246 - .250
origin symbol

.562 + .003

1.744 - 1.750

1.875 + .062

30º + .5º
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Fits
• A fit is a combination of an external and an internal dimension (shaft and hole), both
with different tolerances
• Three kinds of fits:
1. Clearance Fit: Shaft maximum limit < Hole minimum limit
2. Interference Fit: Shaft minimum limit > Hole maximum limit
3. Transition Fit: Where neither of the above conditions exist

ISO Tolerances and Fits

• The number of combinations to form fits is almost infinite
• ISO developed a coding system for small tolerances (micrometers ~ 0.001 mm) to reduce
the number of possibilities
• Tolerance standard tables for external dimensions (shafts) and for internal dimensions
(holes)

A system of 18 grades of tolerances related to part size ranges (basic size range); 0-3 mm,
3-6 mm, 6- 10 mm, etc.
The 18 grades are identified by numbers (code number):
i. 01, 0, 1-5: small tolerances (precision)
ii. 6-10: normal tolerances (normal)
iii. 11-16: coarse tolerances (coarse)

 Every IT number corresponds with a certain tolerance size for certain ranges of dimensions.
For example, for a shaft or hole of 50 mm diameter or 100 mm diameter would vary as
shown:
IT number Width of tolerance field (µm)
(30 – 50 mm) (80 – 120 mm)
5 11 15
6 16 22
7 25 35
8 39 54
9 62 87
10 100 140
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 For the same IT number (code number) the size of the tolerance field for larger dimensions
is larger as well.
 The tolerance field increases with increasing IT number for a given size.

ISO Tolerances
• The standard tolerances to go with the code number is denoted by the letter code
• To differentiate between holes and shafts, upper and lower case are used:

 Capital letters – Holes (H)

 Lower case letters – Shafts (h)
External Dimensions (Shafts)
• a/g: actual size smaller than basic size
• h: actual size smaller than or equal to the basic size
• j: actual size smaller or larger than the basic size
• k/z: actual size larger than the basic size

o The letter code gives the type of tolerance, in other words, it gives the position of the
tolerance field with respect to the basic size.

o These standard tolerances are related to the zero line (giving the basic size) by a letter code,
I.e. deviation. The deviation referred to is the one nearest the zero line. That is upper or
lower and this is referred to as the Fundamental Deviation.
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Internal Dimensions (Holes)

• A/G: actual size larger than the basic size
• H: actual size larger than or equal to the basic size
• J/K: actual size smaller or larger than the basic size
• M/Z: actual size smaller than the basic size

ISO Tolerances
• The ISO standards tabulates all the deviations for all:
 Tolerance classes
 Diameter ranges
 Tolerance zones (tolerance fields)

Method of Tolerancing
1. Putting the actual upper and lower limit on the drawing
2. Putting the tolerance above the basic size
3. Quoting a size tolerance code from the ISO standards 40 H7 (Hole)
 A drawing usually has a defined set of general tolerances. Specific tolerances can be given in
one of the ways shown.
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Specifying Fits
• Two systems to specify fits:
 Hole basis system
 Shaft basis system

• Hole basis is the preferred system

• An enormous number of combinations of deviations and tolerances possible

 The hole basis system: the hole is an H-type of tolerance, the shaft tolerance type
determines the kind of fit.
 The Shaft basis system: the shaft is an h-type of tolerance, the type of hole tolerance
determines the kind of fit.
 Because shafts are easier to machine accurately than holes, fits usually relate to a specific
hole size, that is using ‘H’ type tolerance which have ‘zero’ deviation.
 To limit on the fits to use preferred set of limits and fits have been developed.
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Depending on type of industry, use few

selected fits.

For example, Electronics industry:

Use SBS: Shafts h11, h9, h7, h6

Holes E10, E9, F8, G7, H7, H6, P7

Combinations:
E10/h11, E10/h9 precise loose/very easy
 Other industries similar running
‘standards’, vary for each E9/h9, E9/h7 easy running
company depending on: F8/h7, F8/h6 normal running
- Policy G7/h7 precision running
- Type of equipment H6/h6 sliding
- Level of trained personnel P7/h6 press
- etc.

Dimensional Tolerances
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Geometric Tolerances

• Besides error in dimensions, two other types of error can occur:

• Error of Form

Non Circular

• Error of Position

Wrong Place

• Geometric Dimensioning and Tolerancing standards establish the philosophy, tools, and
methodology to define specific two and three-dimensional tolerance zones and/or
boundaries within which variations in size, form, location, orientation, and functional
relationships may be established and controlled.
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Definition
• Geometric tolerance of a feature (point, line, axis, surface) specifies the
tolerance zone in which the feature is required to contain.e.g. to be straight
within 0.01

Material Condition Modifiers

• When it is desirable to control part features for size, functional relationships, and/or
location, it is important to know under which conditions the control is required. For
example, the tolerance zone restricting the location and orientation for the axis of a hole
may vary, depending upon whether the hole is at its upper or lower size limit.

• Three possibilities exist; controls may apply at maximum material condition, least material
condition, or regardless of feature size.

Four different kinds of Geometric Toerances:

• Form: controls the shape of a feature

• Orientation: controls the orientation and form
• Location: controls position, orientation and form
• Run-out: controls position, orientation and form

Geometric Characteristic Symbols

• There are fourteen
geometric characteristic
symbols used in the
application of geometric
dimensioning and
tolerancing.
• They are divided into five
separate categories:
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Tolerance of Form
 Flatness: all points on a given surface lie between two parallel planes
 Straightness: all points on a given line must lie between two parallel lines
 Circularity: all points on a given circle must lie between two concentric circles
 Cylindricity: all points on the sides of a cylinder must lie between two concentric
cylinders
 Form tolerances are completely defined on their own.

Datum Feature Symbols

 Plane surface or axis
 Designated in order that some other feature(s) may
relate to it

 Orientation and position tolerances require more

information, that is a reference to a datum feature.
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The Feature Control Frame

 Each geometric tolerance is made up of three parts, which can be displayed on a

drawing as follows:

 In accordance with ISO, the geometrical tolerance is displayed in a rectangular box, divided
in two or three compartments. A leader is placed between the box and the related feature.
In the first compartment contains the symbol of the geometric characteristic being
toleranced.
 In the second compartment the tolerance is printed. The optional third compartment
contains a reference by letter to the reference feature. The reference feature is indicated by
the same letter in a box, connected to the relevant surface by a solid equilateral triangle.
 The box containing the tolerance may be connected by a second leader ending in a solid
equilateral triangle on the datum surface.

The feature indicated shows:

- perpendicular tolerance, with value 0.02
-Related to datum A

 More than one datum can be specified by adding another box. The direction the tolerance
is to apply is in the direction of the leader.
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Feature Control Frame Placement

 In Example #1 the feature control
frame is associated with a feature
(2D Tolerance Zone). Therefore,
control is applied to the surface
elements.

 In Example #2 the feature control

frame is related to a feature of size
(3D Tolerance Zone). Therefore, the
control applies to the axis of the
part (the actual size—at any
measuring location must be within
limits of size, but regardless of
feature size, there is a 0.2mm
tolerance for straightness of the
axis).

Advantages of using Geometrical Tolerances

1. Convey briefly and precisely complete geometrical requirements on drawings

2. Symbols and boxes eliminate need for lengthy descriptive notes and corresponding
dimensions, thus drawings are much clearer to read
3. Symbols are internationally recommended, thus language barrier is minimised and
misunderstanding eliminataed
4. One type of geometrical tolerance can control another form e.g squareness can control
flatness and straightness
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End

Thank You