Introduction

The standard reference temperature is 20 C for

industrial measurements and, consequently, for dimensions
defined by the system.
Due to the inevitable inaccuracy of manufacturing methods,
a part cannot be made precisely to a given dimension; the
difference between maximum and minimum limits of size is
the tolerance.
When two parts are to be assembled, the relation resulting
from the difference between their sizes before assembly is
called a fit.
How to decide tolerance?
Functional requirements of mating parts
Cost of production
Available manufacturing process
Choose as coarse tolerance as possible without
compromising functional requirements
Proper balance between cost and quality of parts

Terminologies
Basic size: Size of a part to which all limits of variation (i.e. tolerances) are
applied. Basic dimension is theoretical dimension.
Actual size: Actual measured dimension of the part.
The difference
between the basic size and the actual size should not exceed a certain limit,
otherwise it will interfere with the interchangeability of the mating parts
Limits of sizes: There are two extreme permissible sizes for a dimension of
the part. The largest permissible size for a dimension is called upper or high
or maximum limit, whereas the smallest size is known as lower or minimum
limit.
Tolerance is the difference between the upper limit and lower limit. It is the
maximum permissible variation in a dimension. The tolerance may be
unilateral or bilateral
Zero line: A straight line corresponding to the basic size. The deviations are
measured from this line.
Upper deviation: Is the algebraic difference between the maximum size
and the basic size.
Lower deviation: Is the algebraic difference between the minimum size
and the basic size.
Mean deviation: Is the arithmetical mean of upper and lower deviations.

Fundamental deviation: This is the deviation, either the upper or the lower
deviation, which is nearest one to zero line for either a hole or shaft.

Types of Fit

HOLE BASIS AND SHAFT BASIS SYSTEM

Why Hole basis System is preferred

Standard limit and fit system

Fig. 1.shows the schematic view of a standard limit and fit system. In this
figure tolerance is denoted as IT and it has 18 grades; greater the number,
more is the tolerance limit. The fundamental deviations for the hole are
denoted by capital letters from A and ZC, having altogether 25 divisions.
Similarly, the fundamental deviations for the shaft is denoted by small letters
from a to zc.

Here H or h is a typical case, where the fundamental deviation is zero having

an unilateral tolerance of a specified IT grade.

Therefore in standard limits and fit system we find that,

Standard tolerances

18 grades: IT01, IT0 and IT1-1T16

Fundamental deviations
25 types: A- ZC (For holes)
a- zc (For shafts)
The values of standard tolerances and fundamental deviations can be
obtained by consulting design hand book. It is to be noted that the choice of
tolerance grade is related to the type of manufacturing process; for example,
attainable tolerance grade for lapping process is lower compared to plain
milling. Similarly, choice of fundamental deviation largely depends on the
nature of fit, running fit or tight fit etc. The approximate zones for fit are
shown in Fig. 1.3.5. Manufacturing processes involving lower tolerance grade
are generally costly. Hence the designer has to keep in view the
manufacturing processes to make the design effective and inexpensive.
Sample designation of limit and fit, 50H6/g5.
The designation means that the nominal size of the hole and the shaft is 50
mm. H is the nature of fit for the hole basis system and its fundamental
deviation is zero. The tolerance grade for making the hole is IT6. Similarly,
the shaft has the fit type g, for which the fundamental deviation is negative,
that is, its dimension is lower than the nominal size, and tolerance grade is
IT5.

For Your Information only

Example

Tolerance Sink
A design engineer keeps one section of the part blank
(without tolerance) so that production engineer can dump
all the tolerances on that section which becomes most
inaccurate dimension of the part.
Position of sink can be changing the reference point.
Tolerance for the sink is the cumulative sum of all the
tolerances and only like minded tolerances can be added
i.e. either equally bilateral or equally unilateral
Example

Gauge Design
Snap Gauge

Ring Gauge

Plug Gauge