LIMITS AND TOLERANCES

Version 0.1

MED161Q,
EGP1501,
EDG1501
By Irshaad
Mahomed
 Introduction - 1
• No two parts can be produced with identical measurements by any
manufacturing process.

• Regardless of how well a production process is designed, a certain

amount of variability will always exist: Natural and Characteristic

• Natural variability is random in nature, and is the cumulative effect

of many small, essentially uncontrollable causes.

• Characteristic variability arises from improperly adjusted machines,

operator error, tool wear/tear, or defective raw materials.

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 Introduction - 2
• Characteristic variability is generally large compared to the natural
variability.

• Characteristic variability is of two types: random and deterministic.

• The deterministic type has an assignable cause that can be

identified and controlled. The random type has no assignable cause.

• Therefore, if the deterministic type of variability is kept under

control or eliminated, variation in component dimension (amongst
other aspects) can be maintained as best as possible to the design
specification.

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 Introduction - 3
• Some variability in dimension must be tolerated during manufacture, since
this is unavoidable, however precise the process may be.

• The permissible tolerance depends on the functional requirements of the

assembly/component. This is a constraint.

• The manufacture of components can only be stated between two limits:

– upper limit (maximum allowable dimension)

– lower limit (minimum allowable dimension)

• The permissible tolerances are suggested by the designer. Inputs may also
be obtained from the workshop, manufacturing, service-repair, or
customer feedback, amongst others.

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 Example 1
• When the permissible tolerance is sufficiently greater than the process
variation, no difficulty arises, this is explained by the following example:

– A shaft machined using a robotic lathe must have a diameter of 40 mm.

– The minimum diameter allowed for the manufactured shaft is 39 mm and the
maximum is 41 mm.
– The robotic lathe manufactures the 40 mm shaft to a 97% statistical output of
39.5mm.
– This means out of 100 manufactured shafts, the dimension output will be 39.5mm
for 97 shafts.
– This is within the required tolerance i.e. between 39 and 41 mm.
– We can also state:
• Basic size = 40 mm
• Upper deviation = 41 – 40 = 1 mm and
• Lower deviation = 39 - 40 = - 1mm

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 Example 1 – cont.
– The allowed tolerance on the manufacture of the machined shaft is
40 ± 1 mm.
– We also have tolerance on the design of a machined shaft. This will be
considered under Fits.

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 Example 2
• Given the following tolerance: 40+0.05
+0.02 mm

• We can state the following:

– Basic size 40 mm

– -Upper deviation is +0.05 mm

– -Lower deviation is +0.02 mm

– Upper limit is 40 + 0.05 = 40.05 mm

– Lower limit is 40 + 0.02 = 40.02 mm

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 Tolerance - 1
• Tolerance is defined as the magnitude of
permissible variation of a dimension from a
specified value.

• Tolerance can also be defined as the total

variation permitted between an upper and lower
limit.

• Tolerances permit dimensional variation in

manufacture of components while ensuring
design intent and performance.
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 Tolerance - 2
• Tolerances is dictated by the following:

– Functional requirement of the machine

– Tooling methods
– Manufacturing equipment

• To maintain component consistency (e.g. a ¼”

brass pipe from EU or ZA must be of identical
dimension and tolerance. This is achieved by
adherence to a Standard, e.g. ANSI, ASME etc.
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 Tolerance - 3
• Decreasing tolerance, i.e. increasing dimensional accuracy
generally requires increased manufacturing costs.
• This is a broad reason why well machined, smoothly functioning
component assemblies have high manufacturing and quality
costs.

Dawaheed, M. (n.d.). Chapter 5. Retrieved March 2011, from Islamic University

of Gaza: http://site.iugaza.edu.ps/aabuzarifa/files/METRO20152_CH52.pdf
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 Tolerance - 4
• We will consider only two types of tolerance categories:
1. Unilateral
2. Bi-lateral

A description of the Unilateral tolerance category is now

explained.

Unilateral tolerance: When the tolerance distribution is

specified only to one side of the basic size.
e.g. 40+0.05
+0.02 , 40 +0.05
−0.00 , 40 +0.00
−0.02

(i.e. Unilateral tolerance is either above or below the basic

size)
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 Tolerance - 5
• We will consider only two types of tolerance categories:
1. Unilateral
2. Bi-lateral

A description of the Bi-lateral tolerance category is now explained.

Bilateral tolerance: When the tolerance distribution is specified on

either side of the basic size.
e.g. 40+0.05 +0.04 +0.2
−0.05 , 40−0.01 , 40−0.15

(i.e. Bi-lateral tolerance is both above and below the basic size,
When the tolerance above and below the basic size is equal then we
have bi-lateral symmetric)

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 Tolerance Stack-up – Example 3
• Determine the effect of accumulative
tolerances on a manufactured
component. (See image on the right)

• Tolerances format shown:

– Unilateral
– Bilateral
– Bilateral (symmetric)
• Overall component length:
– 100 +40 +45 + 40 = 225 mm • Progressive dimensioning is
• Cumulative upper tolerance: preferred, can you
– +0.005 + 0.01 + 0.01 + 0.03 = 0.055 mm
demonstrate this?
• Cumulative lower tolerance:
– (-0.002) + (-0.02) + (-0.01) + (-0.03) = -0.062 mm • i.e. dimension the given
• The overall component dimension: part from a common datum
– 40+0.055
−0.062 mm
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