Assembly Fits

Nathan W. Hartman, Ed.D.

Department of Computer Graphics Technology
Purdue University

Some material provided by Dr. Theodore Branoff, NC State University

Tolerance Dimensioning
• Why do we need tolerance dimensioning?
– Interchangeable parts manufacturing
– Parts are manufactured at widely separate localities
– Effective size control
– Modern industry relies on it for subcontracting and
replacement parts
• Accuracy is Expensive
Recall…Some Fundamental Rules
• Dimensions shall be toleranced
• Dimensions shall be complete with no more
dimensions than necessary
• Drawings shall define functional requirements
without specifying manufacturing methods.
• Decimal dimensions shall be used.

Per ASME Y14.5M-1994

Specification of Tolerances

Limit Dimension Bilateral-Equal

Unilateral Bilateral-Unequal
Tolerance

• Tolerance is the total amount a specific

dimension is permitted to vary (difference
between the maximum and minimum limits).
• The dimension below has a tolerance of
.0003.
Maximum Material Condition
• When specifying tolerance dimensions, the
maximum material condition (MMC) means
the product or part contains the maximum
amount of material specified by the tolerance.
• The heaviest part.
Allowance
• Allowance is the minimum clearance or maximum
interference intended between the maximum material
condition (MMC) of mating parts.
• The allowance for the system below is: 25.000 -
24.890 = 0.110
More Terminology
• Nominal Size - General identification in
fractions (ex. 1-1/2 for 1.500).
• Basic Size - General identification in decimal
(ex. 1.500).
• Actual Size - Measured size.
• Limits - Maximum and minimum sizes
indicated by the tolerance dimensions.
Clearance Fit
• Space is always left between parts.
• What is the allowance in this case?
• 1.5000 – 1.4988 = .0012
Interference Fit
• Always an interference of material.
• What is the allowance in this case?
• 1.5000 – 1.5013 = -.0013 or just .0013
Transition Fit
• Fit might result in clearance or interference.
Line Fit
• Clearance or surface contact may result at assembly.
Basic Hole System (Hole Basis)
• The minimum size hole is taken as the basic size.
• Used when standard tools are used to produce holes
(reamers & broaches).
Basic Shaft System (Shaft Basis)
• The maximum shaft size is taken as the basic size.
• When several parts having different fits, but one
nominal size are required on a single shaft.
Specifying a Fit - Inches
Class RC 1

Nominal Standard • Determine type of fit and

Size Range Limits
Inches find corresponding table
Limits
of • Determine basic size
Clear. Hole Shaft
H5 g4 • Find size range on table
Over To • Determine tolerances for
0-0.12
0.1
0.45
+0.2
–0
–0.1
–0.25
Hole and Shaft
0.12-0.24
0.15
0.5
+0.2
–0
–0.15
–0.3
• Remember values are in
0.24-0.40
0.2 +0.25 –0.2 thousandths of an inch.
0.6 –0 –0.35
0.25 +0.3 –0.25
0.40-0.71
0.75 –0 –0.45
0.3 +0.4 –0.3
0.71-1.19
0.95 –0 –0.55
0.4 +0.4 –0.4
1.19-1.97
1.1 –0 –0.7
Specifying a Fit - Inches
Class RC 1 • RC1 - Close Sliding Fit
Nominal Standard
Size Range Limits • Basic size of 1.500
Inches
Limits • Upper tolerance on hole is
of
Clear. Hole
H5
Shaft
g4
+0.4 which is really
+0.0004
Over To

0.1 +0.2 –0.1

• Lower tolerance on hole is
0-0.12
0.45 –0 –0.25 -0.
0.15 +0.2 –0.15
0.12-0.24
0.5 –0 –0.3 • Upper tolerance on shaft is
0.2 +0.25 –0.2
0.24-0.40
0.6 –0 –0.35 -0.0004
0.25 +0.3 –0.25
0.40-0.71
0.75 –0 –0.45 • Lower tolerance on shaft is
0.71-1.19
0.3
0.95
+0.4
–0
–0.3
–0.55
-0.0007
0.4 +0.4 –0.4
1.19-1.97
1.1 –0 –0.7
Specifying a Fit - Inches
Class RC 1

Nominal Standard
Size Range Limits
Inches
Limits
of
Clear. Hole Shaft
H5 g4

Over To

0.1 +0.2 –0.1

0-0.12
0.45 –0 –0.25
0.15 +0.2 –0.15
0.12-0.24
0.5 –0 –0.3
0.2 +0.25 –0.2
0.24-0.40
0.6 –0 –0.35
0.25 +0.3 –0.25
0.40-0.71
0.75 –0 –0.45
0.3 +0.4 –0.3
0.71-1.19
0.95 –0 –0.55
0.4 +0.4 –0.4
1.19-1.97
1.1 –0 –0.7
Specifying Fits - Metric
• Determine type of fit and
Loose Running
find corresponding table
Basic
Size
Hole Shaft
• Determine basic size
Fit
H11 c11
• Find size range on table
1 Max 1.060 0.940 0.180
• Determine tolerances for
Min 1.060 0.880 0.060 Hole and Shaft

20 Max 20.130 19.890 0.370

Min 20.000 19.760 0.110

25 Max 25.130 24.890 0.370

Min 25.000 24.760 0.110
Specifying Fits - Metric
• Loose Running Fit
Loose Running
Basic
• Basic size of 25
Size
Hole Shaft
Fit
H11 c11

1 Max 1.060 0.940 0.180

Min 1.060 0.880 0.060

20 Max 20.130 19.890 0.370

Min 20.000 19.760 0.110

25 Max 25.130 24.890 0.370

Min 25.000 24.760 0.110
Functional Dimensioning
• Functional features come into contact with other parts
• Dimension and tolerance these features first
Tolerance Stack-up
• Tolerances taken in the same direction from one
point are additive
• Tolerances from different directions to the same
point become additive.
• Eventually when the stack-up exceeds feature
tolerances, the parts do not fit together
Tolerance Stack-up
Tolerance Stack-up
Tolerance Stack-up
Design Tolerance Distribution
Design Tolerance Distribution
5%
10% Manufacturing

Tooling
15%

Inspection

70%
Wear Allowance
How is this related to PLM?
• Understanding how parts fit together is critical for the
creation of complete product models.
• The ASME Y14.41 standard is being used more
frequently by industry.
• The development of the STEP standard increasingly
supports product manufacturing information
use of the
3D database throughout the enterprise.
• Industry is moving towards model-based definition of
critical product characteristics, including dimensioning
and geometric controls.
References
• Bertoline, G.R. & Wiebe, E.N. (2007). Fundamentals of
Graphic Communications (5e). McGraw-Hill: New York.
• Neumann, A. (1996). Geometric Tolerancing
Fundamentals Workbook
http://www.geotol.com/details.htm#gtfw
• ASME Y14.5
• ASME Y14.41
Acknowledgments
The author wishes to acknowledge the support from
the Society for Manufacturing Engineers -
Education Foundation, SME-EF Grant #5004 for
“Curriculum Modules in Product Lifecycle
Management.”