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Lesson III.
Management of Variability: Functional
Consequences of Tolerancing.
Dimensional/Size Tolerances,
Geometric Tolerances
and Surface Finishes

GRAPHICS ENGINEERING
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Lesson III.
Part I: Dimensional Tolerances
a.k.a. Size Tolerances

GRAPHICS ENGINEERING
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IS THIS INFORMATION ENOUGH FOR MANUFACTURING ?

BAGUETTES AND TOLERANCES

• LENGTH

• STRAIGHTNESS

• ROUGHNESS

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CONTENTS OF A TECHNICAL DRAWING

TECHNICAL DRAWING
Contents:

Representation (forms)

Standards Drawing identification info

Dimensions
Specifications
Surfaces
Deviations
Materials

NEED FOR TOLERANCES

FUNCTION
FUNCTIONAL DRAWING
PROJECT TOLERANCES
PERFORMANCE
Part Micro-geometric
Mechanism FORMS MANUFACTURING
Macro-geometric
DRAWING
SHAPING
PROCESSES

OTHER: COSTS, QUALITY

TYPES OF TOLERANCES
SURFACE
REQUIREMENTS:
DIMENSIONAL
Dimensions
TOLERANCES
Form Macro-geometric

Orientation GEOMETRIC
Position TOLERANCES
TOLERANCES
Finish
SURFACE FINISH:
Smoothness level Micro-geometric
External aspect
Mechanical strength
Resistance to external agents
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TERMINOLOGY ABOUT TOLERANCES (I)

 Tolerance of a -dimensional, geometric or surface

finish- feature: Admissible variation range for the nominal
value and geometry of that feature, within which its measured
value must lie. That range must be specified on the part/detail
drawings.

 Tolerance of a functional or assembly condition: Range

of positive and/or negative allowance values associated to an
assembly drawing, expressing the limits within which a certain
condition meets satisfactorily its functional and/or assembly
requirements.

TERMINOLOGY ABOUT TOLERANCES (II)

 Interchangeability: A property of parts and components

having associated indications of deviations in its characteristics,
according to which it is assured than the assembly and
functional conditions stay always inside an admissible variation
range, even if they haven’t been manufactured in the same
country, or by the same company, or in the same time slot.

 Mass -or serial- manufacturing: Production of parts,

components or sub-assemblies in series, defined by the same
product technical documentation, with a number of produced
units that is high enough to allow having specific tools,
equipment, machines and manufacturing and verification
systems available .

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TERMINOLOGY ABOUT TOLERANCES (III)

 Dimensional -or size- tolerances: Their goal is to define either

the admitted variability for a size characteristic of an element, or
the angle or separation distance between two geometrical
elements that can be related to each other.

 Geometric tolerances: Express the admitted variability for every

geometric characteristic of an element in a part, in order to be
able to evaluate separately each one of the geometric errors that
affect the functional conditions, thus providing a higher quality to
the design than by applying a dimensional tolerance.

 Tolerance zone: Region of space, defined by an ideal surface or

volume, that represents the range of values which the real
element subject to that tolerance must be comprehended.

TERMINOLOGY ABOUT TOLERANCES (IV)

 Geometrical product specification: Group of activities

performed concurrently by a multidisciplinary team, integrated
by all areas involved in the product’s design and development,
aiming to define the admissible tolerances when operational
requirements, manufacturing and control restrictions, costs
and quality interact with each other.

 Tolerance assignment: The process of distributing or

assigning the tolerance amount from the functional condition
among the functional elements participating in such condition.

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ISO TERMINOLOGY FOR DIMENSIONAL TOLERANCES (I)

 Hole: Container space comprehended between two parallel faces or
tangent planes of a part. The ‘hole’ term is in general used to refer to
any internal measurement (hollow space).

 Shaft: Content space comprehended between two parallel faces or

tangent planes of a part. The ‘shaft’ term is in general used to refer to
any external measurement (space with material).

Shaft Hole

Shaft-Hole assembly

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ISO TERMINOLOGY FOR DIMENSIONAL TOLERANCES (II)

 Dimensional -or size- tolerances: Their goal is to define either the admitted
variability for a size characteristic of an element, or the angle or separation
distance between two geometrical elements that can be related to each other.
 Actual size: The value obtained as a result after a measurement operation.
 Basic size: The value to which the limit measures are related to.
 Limits: The two extreme admissible values (maximum and minimum), between
which the effective value must lie.
 Unit: The calculation unit for dimensional tolerances is the micrometer (1 μ =
10-6 m). Tolerances in drawings must be in the same units as the dimensions.
T

Maximum size
Actual size
Minimum size
Basic size

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ISO TERMINOLOGY FOR DIMENSIONAL TOLERANCES (III)

 Difference or deviation: The algebraic difference between a size (effective,
maximum, etc.) and its corresponding basic size. It can be (+), (-), or zero.

 Upper deviation (es): The algebraic difference between the maximum size
and its corresponding basic size.

 Lower deviation (ei): The algebraic difference between the minimum size
and its corresponding basic size.

 Tolerance: The variation or uncertainty level that is admitted in manufacturing

an element, that is, the difference between the accepted maximum and
minimum sizes. It is also the algebraic difference between the upper and lower
deviations.

 Standard limit or Fundamental deviation: Zero line

Maximum size
Any of the two deviations, conventionally

Minimum size
Tolerance
chosen to define the position of the tolerance
zone respect to the reference (or zero) line.
The deviation with the lower absolute value
will be chosen, with (+), (-), or zero value.
Lower deviation (ei)

Upper deviation (es)

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DIMENSIONAL TOLERANCES AND MANUFACTURING PROCESSES

TOLERANCES: Admissible variations in surface sizes that make possible to
reduce manufacturing costs without affecting part interchangeability.

TYPES OF TOLERANCES: Micro-geometric (Surface Finishes) and Macro-

geometric (Dimensional Tolerances and Geometric Tolerances).

DISPERSION ZONE: Interval between the admissible maximum and

minimum values of a certain size.

The minimum tolerance

value will be given by the Sand casting
AMPLITUDE OF DISPERSION ZONE

manufacturing process. Metallic mould casting

Pressure casting
The maximum Rolling

tolerance value will be Milling and Turning

given by the usefulness Grinding

of the part.

Tolerance zone
T

for a part

MANUFACTURING PROCESSES
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THE ISO TOLERANCE SYSTEM – ELEMENTS (I)

TYPES OF SIZES: Holes (internal) and Shafts (external).

Shaft Hole

Shaft-Hole assembly
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THE ISO TOLERANCE SYSTEM – ELEMENTS (II)

DEVIATIONS: Upper deviation, Lower deviation, Tolerance, Standard limit

or Fundamental deviation

Zero line
Maximum size

Actual size
Min. size

Upper deviation (-) Upper deviation (0)

Lower deviation (-) Lower deviation (+)
Actual size (-) Upper deviation (+)

Standard limits or Fundamental deviations: (a), (d), (e)

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THE ISO TOLERANCE SYSTEM – ELEMENTS (III)

TOLERANCE ZONE. Defined by two factors: RANGE and POSITION.
Range of the tolerance zone, or International Tolerance Grade: Depends
on the basic size (13 size groups) and on the functional usefulness (18 grades).

Grade 10

This graphical representation

refers to the basic size group
from 18 to 30 mm

Tolerances
Tolerances

Grade 6

Basic size IT Grades

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THE ISO TOLERANCE SYSTEM – ELEMENTS (IV)

Grade 10

This graphical representation

refers to the basic size group
from 18 to 30 mm
Tolerances
Tolerances

Grade 6

Basic size Tolerance grades

Size groups are: (0 – 3), (3 – 6), (6 – 10), (10 – 18), (18 – 30), (30 – 50), (50 – 80),
(80 – 120), (120 – 180), (180 – 250), (250 – 315), (315 – 400) and (400 – 500) mm.

Tolerance grades are: IT01, IT0, IT1, IT2, IT3, IT4, … IT16
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TOLERANCE VALUES BY GROUP AND GRADE

INTERNATIONAL TOLERANCE GRADES
DIAMETER 
IT IT IT IT IT IT IT IT IT IT IT IT IT IT IT IT IT IT
GROUPS (mm)
01 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

To and including  3 0,3 0,5 0,8 1,2 2 3 4 6 10 14 25 40 60 100 140 250 400 600

> 3 a 6 0,4 0,6 1 1,5 2,5 4 5 8 12 18 30 48 75 120 180 300 480 750

> 6 a 10 0,4 0,6 1 1,5 2,5 4 6 9 15 22 36 58 90 150 220 360 580 900

> 10 a 18 0,5 0,8 1,2 2 3 5 8 11 18 27 43 70 110 180 270 430 700 1.100

> 18 a 30 0,6 1 1,5 2,5 4 6 9 13 21 33 52 84 130 210 330 520 840 1.300

> 30 a 50 0,6 1 1,5 2,5 4 7 11 16 25 39 62 100 160 250 390 620 1.000 1.600

> 50 a 80 0,8 1,2 2 3 5 8 13 19 30 46 74 120 190 300 460 740 1.200 1.900

> 80 a 120 1 1,5 2,5 4 6 10 15 22 35 54 87 140 220 350 540 870 1.400 2.200

> 120 a 180 1,2 2 3,5 5 8 12 18 25 40 63 100 160 250 400 630 1.000 1.600 2.500

> 180 a 250 2 3 4,5 7 10 14 20 29 46 72 115 185 290 460 720 1.150 1.850 2.900

>  250 a 315 2,5 4 6 8 12 16 23 32 52 81 130 210 320 520 810 1.300 2.100 3.200

> 315 a 400 3 5 7 9 13 18 25 36 57 89 140 230 360 670 890 1.400 2.300 3.600

> 400 a 500 4 6 8 10 15 20 27 40 63 97 155 250 400 630 970 1.550 2.500 4.000

Numerical values in μm for the fundamental tolerances

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THE ISO TOLERANCE SYSTEM – ELEMENTS (V)

Position of the tolerance zone, or Fundamental Difference: Depends on
the coupling characteristics, and it may be above, over, or below the zero line (28
positions).
It’s defined by the Fundamental Difference/Deviation, and it’s identified with one
or two letters, upper-case for holes (A – ZC) and lower-case for shafts (a – zc).
The letter ‘ h ’ / ‘ H ’ is characterized by having zero Upper/Lower Deviation.

Reference deviation = ld
Positive deviations

Shafts

Zero line
Negative deviations

Basic size

This graphical representation refers to the basic size group

from 6 to 10 mm

Reference deviation = ud

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THE ISO TOLERANCE SYSTEM – ELEMENTS (VI)

Position of the tolerance zone, or Fundamental Difference:

Reference deviation = Ld

This graphical representation refers to the basic size group

from 6 to 10 mm

Positive deviations
Zero line

Negative deviations

Basic size
Holes
Reference deviation = Ud

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TYPES OF FITS (I)

a) Clearance Fit (mobile). (Minimum and maximum clearance).

Cmax
Cmin

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TYPES OF FITS (II)

b) Interference Fit (fixed). (Minimum and maximum interference).

Imax
Imin
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TYPES OF FITS (III)

c) Transition Fit. (Maximum clearance and maximum interference).

Cmax
Imax

Shaft

Hole

Shaft
Shaft
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ALLOWANCE CALCULATION FOR A FIT

a) Clearance fit c) Interference fit

c) Transition fit

Shaft’s tolerance zone

Hole’s tolerance zone
Allowance for the fit

Maximum and minimum clearance for the fit

Maximum and minimum interference for the fit

http://www.amesweb.info/FitTolerance/FitTolerance.aspx
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GRAPHICAL REPRESENTATION OF A FIT

Ud

Zero line
ud

ld
Tolerance

Fit Allowance

Cmin

Tolerance
Cmax

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ISO FIT SYSTEMS: WHY?

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ISO FIT SYSTEMS: SHAFT-BASIS OR BASIC SHAFT (I)

A) Basic Shaft or Shaft-Basis System.
The basic element is a shaft with a fundamental deviation ‘ h ’. Clearance and
interference fits are obtained by associating holes with different fundamental
deviations to that ‘ h ’ shaft.

HOLE

‘ h ’ shaft

Basic size

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ISO FIT SYSTEMS: SHAFT-BASIS OR BASIC SHAFT (II)

Zero line

Basic Shaft

Clearance fits Transition fits Interference fits

Internal sizes
(Holes)

Positive deviations
Negative deviations

Basic size
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ISO FIT SYSTEMS: BASIC HOLE OR HOLE-BASIS (I)

B) Basic Hole or Hole-Basis System.

The basic element is a hole with a fundamental deviation ‘ H ’. Clearance and
interference fits are obtained by associating shafts with different fundamental
deviations to that ‘ H ’ hole.

Basic size

‘ H ’ HOLE

Shaft

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ISO FIT SYSTEMS: BASIC HOLE OR HOLE-BASIS (II)

Zero line
Basic size

Basic
Hole

Clearance fits Transition fits Interference fits

Positive deviations
Negative deviations

Basic size
External sizes
(Shafts)

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ISO FIT SYSTEMS: WHY? BECAUSE OF COSTS!

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TOLERANCE INDICATION FOR A FIT

International Tolerance

PREFERRED FITS ACCORDING TO ISO

ISO Symbol
Description
Hole-Basis Shaft-Basis

Loose running fit for wide commercial tolerances or allowances on

H11/c11 C11/h11
external members.

Free running fit not for use where accuracy is essential, but good for
H9/d9 D9/h9 large temperature variations, high running speeds, or heavy journal
pressures.

Clearance Fits Close running fit for running on accurate machines and for accurate
H8/f7 F8/h7
location at moderate speeds and journal pressures.

Sliding fit not intended to run freely, but to move and turn freely and
H7/g6 G7/h6
locate accurately.

Locational clearance fit provides snug fit for locating stationary parts;
H7/h6 H7/h6
but can be freely assembled and disassembled.

Locational transition fit for accurate location, a compromise between

H7/k6 K7/h6
clearance and interference.
Transition Fits
Locational transition fit for more accurate location where greater
H7/n6 N7/h6
interference is permissible.

Locational interference fit for parts requiring rigidity and alignment

H7/p6 P7/h6 with prime accuracy of location but without special bore pressure
requirements.

Interference Fits Medium drive fit for ordinary steel parts or shrink fits on light sections,
H7/s6 S7/h6
the tightest fit usable with cast iron.

Force fit suitable for parts which can be highly stressed or for shrink
H7/u6 U7/h6
fits where the heavy pressing forces required are impractical.

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PREFERRED FITS (ISO 286-1:2010)

Note: For economic reasons, the first choice for a fit should, whenever possible, be made from the
tolerance classes shown with green color.

ISO 286-1 (2010) Geometrical product specifications (GPS) - ISO code system for tolerances on
linear sizes - Part 1: Basis of tolerances, deviations and fits.
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PREFERRED FITS ACCORDING TO ISO

AGUJERO ÚNICO EJE ÚNICO CARACTERÍSTICAS DEL ASIENTO EJEMPLOS

H8 X8 Prensado duro. Montaje a prensa.

Coronas de bronce, ruedas.
H8 u8 No necesita seguro.

H7 s6 Prensado. Montaje a prensa. Piñón motor.

H7 r6 Prensado ligero. Precisa seguro. Engranajes de máquinas.

H7 n6 Muy forzado. Montaje a martillo. Cojinetes especiales.

H7 k6 Forzado. Montaje a martillo. Rodamientos a bolas.

H7 j6 Forzado ligero. Montaje a mazo. Rodamientos a bolas.

H7 h6 Deslizante con lubricación. Ejes de lira.

H8 h9 Deslizante sin lubricación. Ejes de contrapunto.

H 11 h9 Deslizante. Ajustes corrientes Ejes de colocaciones.

H 11 h 11 Deslizante. Ajuste ordinario. Ejes-guías atados.

H7 g6 G7 h6 Giratorio sin juego apreciable. Émbolos de freno

H7 f7 F8 h6 Giratorio, con poco juego. Bielas, cojinetes.

H8 f7 F8 h9 Giratorio con poco juego. Bielas, cojinetes.

H8 e8 E9 h9 Giratorio con gran juego. Cojinetes corrientes

H8 d9 D 10 h9 Giratorio con mucho juego. Soportes múltiples.

H 11 c 11 C 11 h9 Libre, con holgura. Cojinetes de maquinaria agrícola

H 11 a 11 A 11 h 11 Muy libre. Avellanados. Taladros de tornillos.

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SELECTED ISO FITS: HOLE-BASIS

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SELECTED ISO FITS: SHAFT-BASIS

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TOLERANCE VERIFICATION

Tolerance verification is performed using fixed gauges (“GO – NO GO” gages),

either internal (plug gauges) or external (ring or snap -gap- gauges).

“NO GO” end

“GO” end

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TOLERANCE DIMENSIONING IN ASSEMBLY DRAWINGS

Hole
Shaft

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TOLERANCE DIMENSIONING IN PART/DETAIL DRAWINGS

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APPENDIX: GENERAL DIMENSIONAL TOLERANCES

UNE-EN 22768-1 - ISO 2768-1

Specification of tolerances in drawings must be complete, so that the dimensional

and geometrical features of all elements are guaranteed, without leaving details
to the subjective appreciation of workshops or verification departments.

The ISO 2768 standard establishes that linear and angular dimensions might
avoid being subject to individual tolerance indication, this being replaced by
general tolerances for all dimensions in the drawing.

It might happen that a class of general tolerances is chosen for a drawing, but for
some specific dimensions:
a) Lower (more precise) tolerance values than the general are required.
b) Higher (and cheaper) tolerance values might be used.

INDICATION IN DRAWINGS: Inside the title block, or in its vicinity, for

instance including the text: ‘ General Tolerances: ISO 2768-m ’ .
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Lesson III.
Management of Variability:
Functional Consequences of Tolerancing.
Dimensional/Size Tolerances, Geometric Tolerances
and Surface Finishes

Part I. Dimensional or Size Tolerances

Any questions, please ?

GRAPHICS ENGINEERING

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