Creating a 2.5" Diameter Clearance Fit Hole

Explanation:

If the process plan calls for a 2.5" diameter clearance fit hole, the best process plan is to drill a hole slightly larger than 2.5" diameter.

This recommendation adheres to the practice of rounding up the final size to prevent inefficiencies from preventing the attainment of the goal size due to potential drill wear or inaccuracy. This slight increase in diameter would accommodate any material that might expand, contract, or become distorted during manufacturing processes, ensuring a proper clearance fit.