Tolerancesmeaning

Even the best machine using the best cutting tools will eventually see some variance in its output due to factors like tool pressure and wear. Therefore, machining tolerance standards are essential in manufacturing, particularly for mating parts, or parts that must fit together. For example, a bushing meant to fit on a rod might have a tolerance of ±0.002″. If the inside diameter is cut too small, the bushing will not fit. If it’s cut too large, the fit will be sloppy, potentially rendering the part unusable.

Machining tolerance is defined as the total amount of variation a specific dimension can have from the given value. In other words, it’s the amount of acceptable variance in the dimension of a part. Machining tolerance is expressed in a few different ways:

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Machining tolerance is expressed in numerals with any number of decimal places. Having more decimal places in a dimension means there is a stricter tolerance band. For example, a tolerance of ±0.02″ has a much larger range than one that’s ±0.002″.

Tolerancespdf

If the part falls within the specified limits, it’s considered within the tolerance. Falling outside the tolerance can make the part unusable.

Tolerance calculation examples

Given: 85% of (x - y) = 35% of (x + y) Concept: The percentage of y to x is calculated as (y/x) × 100%. Solution: Solve the given equation for y/x:

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Tolerancesexamples

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Plating and finishing can also influence the machining tolerance and part dimensions. These processes add small, sometimes minuscule, quantities of material to the part’s surface, but it can still affect the overall dimensions. Any plating or finishing should be factored into the tolerance during the design process to ensure accuracy before production begins.

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Tolerance calculator

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4 types of tolerance

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Materials behave differently under stress, and some are easier to work with than others. These material properties must be taken into account when determining tolerances. These considerations largely depend on the material itself, but a few of the most integral include:

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Tolerancesand fits

The cost of materials and machining methods differ greatly. High-tolerance machining — with a narrow range in dimensions or four or more decimal places — tends to be more costly than parts with lower tolerances. With a larger room for error, you can spend less on precision machining.

Since no machine is capable of delivering the exact same result every time, designers and engineers set tolerances to establish the acceptable dimensional variation in a machined part. Having strict guidelines about machining tolerance is essential to set a controlled margin for error, especially in parts that are manufactured to fit together.

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Engineers and designers establish machining tolerances early on in a project. To do so, they must factor in considerations such as:

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Tolerance in engineering drawing

Another factor that influences typical machining tolerances is the machining method. Some methods allow you to achieve higher precision at a higher cost, while others are more cost-effective and suited to looser tolerance bands. A few of the most common machining types include:

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There are international standards for machining tolerances, expressed through ISO 2768. Precision levels, or tolerance classes, within ISO 2768 include f-fine, m-medium, c-coarse and v-very coarse. This standard covers the geometrical tolerances for linear dimensions, angular dimensions, external radii and chamfer heights, expressed through classes H, K and L.

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The tolerance band is the range of allowable dimensions in the tolerance. If there is a small difference between the upper and lower limits of the tolerance band, that means the machining tolerance is tight. The larger the difference in dimensions, the “looser” the tolerance band.

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Every manufacturer will establish unique machining tolerances for their parts, but a couple of general standards can be used as a guide.