Machine Design I

ME 202

Spring (2022 – 2023)

Prof. Dr. Mohamed Omar Hendy

Lecture (5)
Tolerances & Fits
 Specifications and Standard
The primary aim of modern manufacturing is to produce products of high quality products. All components must be
manufactured in accordance with the specifications.

1. Specifications
Specifications used in manufacturing include
Size, location, surface finish, material … etc. If the product is used as a component in other products or by
various manufacturers, the specifications become a standard for those particular items. For an example, a
bolt can be manufactured having any number of threads, diameters, and pitch. If a bolt's specifications meet
their particular needs, other manufacturers may want to produce it. In order for the bolt to be
interchangeable with a nut, the thread sizes must be compatible. Hence, this particular thread specification
becomes standardized throughout the industry.
2. Standardization
Standardization is act of conforming to a standard, which is established by authority as a
fixed rule or measure. Standard are established in the fields of products, materials,
processes, equipment, and procedures by the National and International Organizations
such as:
1. International Standard Organization (ISO)
2. Egyptian Standards Organization (ESO)
3. British Standard Organization (BSO)
4. Dutch Industrial Normalization (DIN).
5. American Standard Manufacturing Engineering (ASME)
6. Japanese Standard (JS)
3. Dimension
Introduction
An Engineering drawing of a manufactured part is intended to convey information from the manufacturer
and information inspector. It must contain all information necessary for the part to be correctly
manufactured. It must also enable the inspector to make precise determination of whether or not the part
acceptable.

Drawings and Tolerances:

Drawings must convey three essential types of information:
1. The material to be used.
2. The dimensions of the part.
3. The shape of the part.
Materials
These are usually covered by separate specifications or supplementary documents,
such as the National and International Standards. The drawing needs only to make
reference to such specifications. For example: St.37 in accordance DIN
17175.
Dimensions
A dimensions is a geometrical characteristic, of which the size is specified, such as
diameter, length, angle, location or center distance, as shown
The drawing is intended to specify a value for all dimensions necessary for the manufacture and
inspection of the part.
It is difficult to produce any part to an exact dimension. For example, it is very
difficult to obtain a length 80 mm must take place even on the most accurate machines tolerances
on the dimension of the part, say 80±0.01 mm.
Thus we specify all bars longer than 79.99 mm and shorter than 80.01mm are acceptable.
Tolerance
The tolerance on a dimension is the total permissible variation in its size, which is
equal to the difference between the limits of size. For example as shown in Fig. 11
the tolerance on the center distance (dimension 40±0.2) is 0.4 mm.

2 Holesⱷ 10±0.1 ( tolerance 0.2) Tolerance 0.6

20.0
19.4

40±0.2
Tolerance 0.4
 Limit of Size
The limit of size, often referred to as the limits, are the maximum and minimum
permissible sizes for a specific dimension. In the following figure the width 19.4 –
20.0, is expressed directly as limits of size, whereas the center distance between
holes is expressed with a bilateral tolerance, and the limits are 40.2 and 39.8 as
shown Fig.12.
Limits of size ( high limit placed above low limit)

20.0
19.4

40±0.2
Limits are 40.2 and 38.8

Allowance
An allowance is a prescribed difference between the maximum size of an external feature and
the minimum size of mating internal feature. It is therefore the
minimum clearance or maximum interference which exists between such features when they are
assembled
Tolerances Calculation
Tolerances are the maximum permissible variations of the part size
A dimension given in drawing cannot be obtained exactly in manufacturing. The actual size
( I ) is either greater or smaller than the wanted size. In order to indicate the accuracy of
the size, the maximum limit ( g ) and the minimum limit ( k ) must be stated in the
drawing. Within these limits the actual size ( I ) must be.
The difference between the two limit lines is called tolerance ( T ).
Definitions:

Au T Ao Ao

A=0 A=0 Au T Dg

N Dk Dg N Dk

Dg …….. Maximum limit

Dk ……. Minimum limit
Ao ……… Upper allowance
Au ……… lower allowance
T ………. Tolerance
N ……….. Nominal size
Tolerance zones
The zone of tolerance is definitely determined by its magnitude and its position relative to the zero line.

+
+

0
0

-
-

Position of the tolerance zones with respect to the zero-line

Degree of Accuracy
The system of tolerances provides 16 degrees of accuracy, the'' standard tolerances''. The standard
tolerances valid for the whole nominal size range, are designated [ IT 1 to IT 16 ].
The position of the zone with respect to the zero-line is designated by a letter. The outside element dimensions we use Capital
English letters (Hole), The inside element dimensions we use small English letters (Shaft).
 Exercises

1) A shaft and holes are produced in large quantities to be assembled together. The shaft
diameter is given by 45H7, and that the hole is given by 45 g6.
Determine:
a. The maximum and minimum dimensions for the shafts and holes given: 45 g6, 80 H7, 50 S8,
60 U6, 65 e7, f8
b. The tolerances of the holes and shafts given in (a) and draw sketch of the tolerance zone
respect to zero line.
Thank you