DIMENSIONAL TOLERANCE

AND GD&T – PRACTICAL

APPROACH

1
2
3
 WHY TOLERANCES ARE MUST?

Machining a part to absolute dimensional accuracy is impossible in an

average workshop. Because it depends upon the following factors:
* Type of manufacture

* Method of machining

* Condition of machine

* Skill of the machinist

* Time taken

* Geometry of the product

* Condition of measuring tools

* Condition of measuring (METHOD)

4
 LIMITS OF SIZE

Limits are the extreme permissible dimensions of a given

part.

There are two extreme permissible sizes for a given

dimension.

The largest permissible size is called upper limit or

maximum limit and the smallest size is known as lower
limit or minimum limit.

5
 TOLERANCE

Tolerance is the permissible deviation in the

dimension of a component.

Mathematically,

Tolerance = upper limit size – lower limit size.

(i.e) The difference between upper limit dimension

and lower limit dimension on the basic size of a
component is termed as tolerance .

6
 EXAMPLE

Given dimension = 20 ± 0.02

Basic size / Nominal size = 20.00 mm

Maximum limit size = 20.02 mm

Minimum limit size = 19.98 mm

Tolerance = 20.02 – 19.98 = 0.04 mm

7
Types of tolerances:

Tolerance is basically specified in two forms.

i) Unilateral tolerance

ii) Bilateral tolerance

8
 UNILATERAL TOLERANCE:
If all the tolerance is allowed on one side of the
nominal dimension or size ,the system is unilateral
tolerance.

Examples:
+0.04
0.00
+0.02
– 0.04
i) 15 iii) 44

+0.05 – 0.01
0.00 – 0.02

ii) 10 iv) 20

9
 BILATERAL TOLERANCE

If the tolerance is allowed on either sides of the

nominal dimension or size, the system is said
to be bilateral tolerance.

Examples:
i) 15 ± 0.002
ii) 10 ± 0.03
iii) 50 ± 0.2

10
TERMINOLOGY OF LIMITS AND FITS

SHAFT :

A term used to designate all external features of a part

including those which are not cylindrical. It is denoted
by lower case alphabets.

A shaft is taken to refer any male component.

E.g. plugs, axles, spindles, locating spigots etc.

11
 TERMINOLOGY OF LIMITS AND FITS

HOLE:

A term used to designate all internal features of a part

including those which are not cylindrical. It is denoted
by upper case alphabets.

A hole is taken to refer any female component.

E.g. bore, recess, keyways, etc.

12
 TERMINOLOGY OF LIMITS AND FITS

NOMINAL SIZE (BASIC SIZE):

It is the design size of a component from which the

limits are derived by the application of tolerance.

Basic size is same for the hole and shaft.

ACTUAL SIZE:

The size of a finished component which is actually

measurable with any instrument is known as actual
size.

13
 TERMINOLOGY OF LIMITS AND FITS
ZERO LINE:

The line which represents the basic size of

component of two mating components in an assembly
on a drawing is known as zero line. In limits and fits,
all deviations are shown with respect to zero line.

DEVIATION:

The algebraic difference between the actual size of a

component and its basic size is known as deviation.

14
BASIC SIZE DEVIATIONS AND TOLERANCES

15
BASIC SIZE DEVIATIONS AND TOLERANCES

16
 FUNDAMENTAL DEVIATION

Fundamental deviation is that one of the two deviations - either

upper or lower - which is the nearest to zero line for either hole
or a shaft.

It fixes the position of tolerance zone with respect to the zero line.
In other words, it locates the tolerance zone w.r.t zero line.

17
 FUNDAMENTAL DEVIATION

In total, there are 28 fundamental deviations and are represented

by letter symbols. Upper case letters are used for representing
holes and lower case letters are for shafts.

A, B, C, D, E, F, G, H, J, K, M, N, P, R, S, T, U, V, X, Y, Z, CD, EF,
FG, JS, ZA, ZB, and ZC for HOLES

and

a, b, c, d, e, f, g, h, j, k, m, n, p, r, s, t, u, v, x, y, z , cd, ef, fg, js,

za, zb, zc for SHAFTS.

The letters I,L,O,Q,W are omitted to avoid confusion.

18
 TOLERANCE GRADE

●Tolerance grade is an indication of degree of accuracy of

manufacture and it is denoted by the letters IT followed by a number.
(IT stands for “International Tolerance” grade)

●It represents the magnitude of the tolerance zone or the amount of

variation allowed in the part size.

●In total, there are 20 grades of tolerance and they are denoted as IT0,
IT01, IT1, IT2………IT18.

●As the number gets higher, the tolerance amount increases.

19
 TOLERANCE GRADE
ISO Tolerances for Holes (ISO 286-2)
Nominal hole sizes (mm)
over 3 6 10 18 30 40 50 65 80 100 120 140 160 180 200 225 250 280 315 355
inc. 6 10 18 30 40 50 65 80 100 120 140 160 180 200 225 250 280 315 355 400
micrometres
28 34 43 53 66 79 94 110 129 142 161
E6
20 25 32 40 50 60 72 85 100 110 125
32 40 50 61 75 90 107 125 146 162 185
E7
20 25 32 40 50 60 72 85 100 110 125
95 115 142 170 210 250 292 335 390 430 485
E11
20 25 32 40 50 60 72 85 100 110 125
140 175 212 250 300 360 422 485 560 630 695
E12
20 25 32 40 50 60 72 85 100 110 125
200 245 302 370 440 520 612 715 820 920 +1 015
E13
20 25 32 40 50 60 72 85 100 110 125
18 22 27 33 41 49 58 68 79 88 98
F6
10 13 16 20 2 30 36 43 50 56 62
22 28 34 41 50 60 71 83 96 108 119
F7
10 13 16 20 25 30 36 43 50 56 62
28 35 43 53 64 76 90 106 122 137 151
F8
10 13 16 20 25 30 36 43 50 56 62
12 14 17 20 25 29 34 39 44 49 54
G6
4 5 6 7 9 10 12 14 15 17 18
16 20 24 28 34 40 47 54 61 69 75
G7
4 5 6 7 9 10 12 14 15 17 18
22 27 33 40 48 56 66 77 87 98 107
G8
4 5 6 7 9 10 12 14 15 17 18
8 9 11 13 16 19 22 25 29 32 36
H6
0 0 0 0 0 0 0 0 0 0 0
12 15 18 21 25 30 35 40 46 52 57
H7
0 0 0 0 0 0 0 0 0 0 0
18 22 27 33 39 46 54 63 72 81 89
H8
0 0 0 0 0 0 0 0 0 0 0

20
 TOLERANCE GRADE
ISO Tolerances for Shafts (ISO 286-2)
Nominal Shaft Sizes (mm)
over 3 6 10 18 30 40 50 65 80 100 120 140 160 180 200 225 250 280 315 355
inc. 6 10 18 30 40 50 65 80 100 120 140 160 180 200 225 250 280 315 355 400
micrometres
-270 -280 -290 -300 -310 -320 -340 -360 -380 -410 -460 -520 -580 -660 -740 -820 -920 -1050 -1200 -1350
a12
-390 -430 -470 -510 -560 -570 -640 -660 -730 -760 -860 -920 -980 -1120 -1200 -1280 -1440 -1570 -1770 -1920
-30 -40 -50 -65 -80 -100 -120 -145 -170 -190 -210
d6
-38 -49 -61 -78 -96 -119 -142 -170 -199 -222 -246
-20 -25 -32 -40 -50 -60 -72 -85 -100 -110 -125
e6
-28 -34 -43 -53 -66 -79 -94 -110 -129 -142 -161
-50 -60 -72 -85 -100 -110 -125
e13
-220 -270 -334 -410 -440 -520 -612 -715 -820 -920 -1015
-25 -30 -36 -43 -50 -56 -62
f5
-25 -32 -40 -49 -36 -43 -51 -61 -70 -79 -87
-10 -13 -16 -20 -25 -30 -36 -43 -50 -56 -62
f6
-18 -22 -27 -33 -41 -49 -58 -68 -79 -88 -98
-10 -13 -16 -20 -25 -30 -36 -43 -50 -56 -62
f7
-22 -28 -34 -41 -50 -60 -71 -83 -96 -108 -119
-4 -5 -6 -7 -9 -10 -12 -14 -15 -17 -18
g5
-9 -11 -14 -16 -20 -23 -27 -32 -35 -40 -43
-4 -5 -6 -7 -9 -10 -12 -14 -15 -17 -18
g6
-12 -14 -17 -20 -25 -29 -34 -39 -44 -49 -54
-4 -5 -6 -7 -9 -10 -12 -14 -15 -17 -18
g7
-16 -20 -24 -28 -34 -40 -47 -54 -61 -69 -75
0 0 0 0 0 0 0 0 0 0 0
h4
-4 -4 -5 -6 -7 -8 -10 -12 -14 -16 -18
0 0 0 0 0 0 0 0 0 0 0
h5
-5 -6 -8 -9 -11 -13 -15 -18 -20 -23 -25
0 0 0 0 0 0 0 0 0 0 0
h6
-8 -9 -11 -13 -16 -19 -22 -25 -29 -32 -36
0 0 0 0 0 0 0 0 0 0 0
h7
-12 -15 -18 -21 -25 -30 -35 -40 -46 -52 -57
0 0 0 0 0 0 0 0 0 0 0
h8
-18 -22 -27 -33 -39 -46 -54 -63 -72 -81 -89

21
TOLERANCE GRADE

22
Fundamental Deviations for HOLES

23
Fundamental Deviations for SHAFTS

24
25
 TOLERANCE GRADE

Common Applications:

● IT01 to IT6 – is used for gauges and instruments.

● IT5 to IT12 – is used for precision and general engineering

applications.

● IT11 to IT16 – is used for semi finished products.

● IT16 to IT18 – is used for structural engineering applications.

26
Tolerance grades vs manufacturing
methods

27
 TOLERANCE CLASS
Tolerance class is designated by the combination of
fundamental deviation and tolerance grade.
Examples:
I) 25H7 - It is the tolerance size of a hole whose basic size is
25mm. The fundamental deviation is represented by letter
symbol ‘H’ and grade of tolerance is represented by number
symbol 7.

II) 25e8 - It is the tolerance size of a shaft whose basic size is

25mm. The fundamental deviation is represented by letter
symbol ‘e’ and grade of tolerance is represented by number
symbol 8.
III) 40H8 - Basic size = 40 mm; Fundamental deviation = H;
Tolerance grade = 8.

iv) 40g7 - Basic size = 40 mm; Fundamental deviation = g;

Tolerance grade = 7.

28
 TERMINOLOGY OF LIMITS AND FITS
ALLOWANCE:

The difference between the minimum hole size and maximum

shaft size is known as allowance. An allowance may be either a
positive (+) or a negative (-) according to the type of fit required.

29
 FIT
● When two parts are to be assembled ,the relation resulting
from the difference between the sizes before assembly is
called a fit.
● There are three basic types of fits or engagements which
are possible to achieve by varying the amount of allowance
between the size of two mating parts.
They are:

1. Clearance fit.

2. Interference fit.

3. Transition fit.

30
 Designation of a FIT

A fit is expressed by writing the following three details in order.

1. The common basic size
2. The tolerance class symbol for the HOLE
3. The tolerance class symbol for the shaft

EXAMPLES:

30H7/g6 20H7/p6

50H6/f5 30H7/m6

31
Designation of a FIT
30H7/g6

32
Designation of a FIT

20H7/p6

33
Designation of a FIT
50H6/f5

34
Designation of a FIT
30H7/m6

35
 CLEARANCE FIT

●In clearance fit, the shaft is always smaller than the hole (ie) the
largest permissible shaft diameter is smaller than the diameter of
smallest hole.
●The allowance is always positive in value.
●Assembly/disassembly is possible by hand.
●Applications: For running & sliding assemblies.

36
CLEARANCE FIT

37
 CLEARANCE FIT EXAMPLE

Consider a shaft having a size as 20.00 -0.02/-0.04mm and

a hole of size 20.00 +0.00/+0.02mm.

Maximum clearance = Maximum limit of hole – Minimum limit of shaft.

= 20.02 – 19.96
= 0.06mm.

Minimum clearance = Minimum limit of hole – Maximum limit of shaft.

= 20.00 – 19.98
= 0.02mm.

In clearance fit the allowance has always positive value.

In this case, the actual clearance can vary between 0.02mm and
0.06mm.

38
 INTERFERENCE FIT
●In interference fit the shaft is always larger than the hole
(ie) the minimum permissible shaft diameter is larger than
the maximum limit of hole.
●The resulting allowance has always a negative value.
●Assembly/disassembly is possible only by using force.
●Applications: For permanent assemblies.

39
INTERFERENCE FIT

40
 INTERFERENCE FIT EXAMPLE
Consider a shaft having a size 20.00 +0.03/+0.02mm and
a hole as 20 +0.01/0.00mm.

Minimum interference = Maximum limit of hole –

Minimum limit of shaft.
= 20.01 – 20.02
= -0.01mm.
Maximum interference = Minimum limit of hole –
Maximum limit of shaft.
= 20.00 – 20.03
= -0.03mm.
In interference fit the allowance always have a negative
value.

41
 TRANSITION FIT
●In transition fit, the resulting fit between the mating parts could be
either a clearance fit or an interference fit depending upon the actual
sizes existing in the hole and shaft.
●The allowance varies from positive to negative corresponding to two
given set of dimensions.
●Assembly/disassembly is possible by light force.
●Applications: For semi permanent assemblies requiring close accuracy
and location.

42
 TRANSITION FIT EXAMPLE

Consider a shaft having size as Dia 20 +0.07/+0.02mm and

a hole as Dia 20.00 +0.05/0.00mm.

Maximum clearance = Maximum limit of hole – Minimum

limit of shaft.
= 20.05 – 20.02
= 0.03mm.

Minimum clearance = Minimum limit of hole – Maximum limit

of shaft.
= 20.00 – 20.07
= -0.07mm

43
TRANSITION FIT

44
FIT EXAMPLE

45
FIT EXAMPLE

46
CLEARANCE FIT

47
INTERFERENCE FIT

48
TRANSITION FIT

49
 HOLE BASIS SYSTEM

 In this system the Hole diameter is taken as standard

and diameter of shaft is varied to obtain different
types of fits as required for the concerned
application.
 Here the fundamental deviation of hole is zero (ie)
the lower limit of the hole is same as basic size. The
higher limit of hole and the two limit sizes of shaft are
then varied to give desired type of fit
 This is a standard practice followed in all industries.
 Hole “H” is called as basic hole.

50
 SHAFT BASIS SYSTEM
 In this system the Shaft diameter is taken as
standard and diameter of holes are varied to obtain
different types of fits as required for the concerned
application.
 Here the fundamental deviation of shaft is zero (ie)
the upper limit of the hole is same as basic size. The
lower limit of shaft and the two limit sizes of holes
are then varied to give desired type of fit
 This is not commonly followed in engineering
applications.
 Shaft “h” is called as basic shaft.

51
 WHY HOLE BASIS SYSTEM ?

 Because it is very convenient to make correct holes of

fixed sizes.

 Since holes are produced by drilling, reaming etc., their

sizes are not easily adjustable because size of such
tools are standard.

 On the other hand, size of shaft produced by turning

and grinding can be easily varied.

52
HOLE-BASIS AND SHAFT-BASIS SYSTEMS

53
COMMON TYPES OF “H” CLASS HOLES USED IN INDIAN
STANDARDS.

H5 – can be obtained by fine internal grinding or honing.

H6 – can be obtained by precision boring, internal grinding, honing

or hand reaming.

H7 – can be obtained by grinding, broaching, boring or reaming.

H8 – can be produced by boring or machine reaming.

H9 – drilling or boring can produce H9. This grade is mostly used

for circular fits.

H10 – used for milled widths not used for diameter fits.

H11 – useful only for coarse drilled or punched holes.

54
 CLEARANCE FITS IN HOLE BASIS SYSTEM

Shaft a, b, c gives large clearance and is therefore not widely

used.

Shaft d – used for loose running fit.

Shaft e – used for high speed heavily loaded
bearings.
Shaft f – used for normal Greece lubricated or oil
lubricated bearings.
Shaft g – used in precision equipments.
Shaft h – used for normal location spigot fits.

Example: H7/d5,H7/e6,H7/f6,H7/g6,H7/h6
Finer grades are used as precision sliding fits.

55
INTERFERENCE FITS IN HOLE BASIS SYSTEM

●Shaft (p) – gives a true interference fit.

●Shaft (r) – gives a medium interference fit.

●Shaft (s) – used for permanent assembly.

●Shaft (t, u, v) – gives large interference.

●Shaft (x, y, z) – not recommended for interference fit

because they give large interference.

Examples: H7/p6,H7/r5,H7/t6,H7/u7,H7/v5

56
 TRANSITION FITS IN HOLE BASIS SYSTEM

●Shaft j – used for location fits where slight

interference is permissible.

●Shaft k & m – used for location fits.

●Shaft n – gives clearance only on extreme

sizes.

Examples: H7/j6,H7/k5,H7/m6,H7/n6

57
58
General tolerances – IS 2102 / ISO 2768

59
General tolerances – IS 2102 / ISO 2768

60
61
62
63
64
 GEOMETRIC DIMENSIONING
& TOLERANCING

65
65
 Why Geometric Tolerancing ?

What features of
PART 1 need
some constraints
so that the
assembly will
work properly?

What happens if
the two shafts
are not parallel?
66 66

66
 The standards …

 ASME Y14.5M-1994
– (ASME Y14.5-2009)
• Very popular in the industries

 ISO 1101:2004
Based upon ASME Y14.5M
Official Title: Geometrical Product Specifications
(GPS)

 IS 8000 (Re affirmed 2005)

67
67
 GEOMETRIC CHARACTERISTIC CONTROLS
14 characteristics that may be controlled
TYPE OF TYPE OF CHARACTERISTIC SYMBOL
FEATURE TOLERANCE

FLATNESS
INDIVIDUAL (No STRAIGHTNESS
Datum FORM
Reference) CIRCULARITY
CYLINDRICITY
INDIVIDUAL or LINE PROFILE
RELATED PROFILE
FEATURES SURFACE PROFILE
PERPENDICULARITY
ORIENTATION ANGULARITY
PARALLELISM
RELATED
FEATURES CIRCULAR RUNOUT
RUNOUT
(Datum TOTAL RUNOUT
Reference
Required) CONCENTRICITY
LOCATION POSITION
SYMMETRY
68
68
 Feature control frame:

69
69
 Form tolerances:

70
70
 Straightness:
 A straightness tolerance specifies a
tolerance zone within which the
considered element or derived median
line must lie.

Straightness can be applied to axes as well as

surface elements.

71
71
 Straightness
● Straightness Applied to Cylindrical Surface

72
72
 How to measure ?

73
73
 How to measure ?

74
74
 Flatness:

 A flatness tolerance specifies a tolerance defined

by two parallel planes within which the surface
must lie.

75
75
 Flatness:

76
76
 Flatness – example:

Means what ?
77
77
 Meaning of Flatness tolerance:

Surface must lie between two parallel planes 0.2 mm

apart and must be within the limits of size.
Therefore, the limits of size must be greater than the
flatness tolerance.

78
78
 How to measure ?

79
79
 Circularity
● A circularity (roundness) tolerance specifies a
tolerance zone bounded by two concentric
circles within which each circular element of the
surface must lie, and applies independently at
any plane.

80
80
 Meaning of Circularity tolerance

Means what ?

81
81
 Meaning of Circularity tolerance

Each circular element of the surface in any plane perpendicular to a

common axis must be within the tolerance of size.

Circular elements must also lie between two concentric circles, one
having a radius 0.05 larger than the other.

82
82
 Meaning of Circularity tolerance

83
83
 How to measure ?

Using calipers is a common sight.

But is it right?

84
84
 The accurate method is …

85
85
 Cylindricity:
● A cylindricity tolerance specifies a tolerance
zone bounded by two concentric cylinders within
which the surface must lie.

 Cylindricity is a composite control of form which includes

circularity (roundness), straightness, and taper of a
cylindrical feature.
86
86
 Meaning of Cylindricity tolerance

Means what ?

87
87
 Meaning of Cylindricity tolerance

The cylindrical surface must be within the specified tolerance of size

and must lie between two concentric cylinders, one having a radius
0.05 larger than the other.
88
88
 Meaning of Cylindricity tolerance

89
89
 Measuring cylindricity . . .

90
90
 Orientation tolerances (related features):

91
91
 Parallelism Applied to a Plane Surface

The tolerance zone in this

example is defined by two
parallel planes oriented
parallel to the datum
reference plane.

92
92
 Parallelism Applied to axis from Plane Surface

The tolerance
zone in this
example is
defined by two
parallel planes
oriented parallel
to the datum
reference plane.

93
93
 Parallelism Applied to feature axis from datum
axis:

The tolerance zone in this example is defined by a cylinder

equal to the length of the feature, oriented parallel to the datum
reference axis.
94
94
 How to inspect parallellity . . .

95
95
 Perpendicularity

Perpendicularity is the condition of a surface, center plane, or

axis at right angle (90°) to the given datum.

96
96
 Meaning of Perpendicularity

97
97
 Perpendicularity – tolerance zones
(Applied to a surface):

The tolerance zone in this

example is defined by two
parallel planes oriented
perpendicular to the datum
reference plane.

98
98
 How to inspect perpendicularity . . .

99
99
 Angularity:

Angularity is the condition of a surface,

center plane, or axis at a specified angle
(other than 0° or 90°) to the specified
datum plane or axis.

100
100
 Meaning of Angularity . . .

101
101
 Comparison between conventional
method
conventional method and
: GD & T method
The tolerance zone is
wedge shaped.

Approaching the vertex,

the width of the wedge-
shaped tolerance zone
approaches zero.

The width of tol. zone

increases as the length
increases.

102
102
 Comparison between conventional
method and GD & T method:
GD & T method :

The tolerance zone

is uniform and
doesn’t vary based
on the length.

103
103
 How to inspect Angularity . . .

104
104
 Location tolerances (related features):

105
105
 Positional Tolerance:
 A positional tolerance defines a zone within which the
center, axis or center plane of a feature of size is
permitted to vary from true (theoretically exact)
position.

 Basic dimensions establish the true position from the

specified datum features and between interrelated
features.

106
106
 Positional Tolerance – How to interpret ?

107
107
 Using Position tolerance with Hole Patterns:

108
108
 Concentricity – Definition:
 Concentricity is the condition where the median
points of all diametrically opposed elements of a
cylinder (or a surface of revolution) are congruent
with the of a datum feature. A median point is the
mid-point is the mid point of a two point
measurement.

 The tolerance zone is a cylinder and the axis of

the tolerance zone coincides with the axis of
datum feature A.

109
109
 Concentricity - Example

Within the limits of size and regardless of feature size, all median points
of diametrically opposed elements must lie within a dia. 0.5 cylindrical
tolerance zone. The axis of the tolerance zone coincides with the axis of
datum feature A.

110
110
 Symmetry:
 Symmetry is the condition where the
median points of all opposed elements of
two or more feature surfaces are congruent
with the axis or centre plane of a datum
feature.

 Symmetry is similar to concentricity. The

difference is that while concentricity is
used on surface of revolution, symmetry is
used on planar features of size.

111
111
 Symmetry – Definition explained …

The median face of the slot should lie within two parallel planes set 0.08
mm apart, that are symmetrically positioned about the datum plane.
112
112
 Run out tolerances (related Features):

113
113
 Run out:

 Run out tolerances control surfaces

constructed around a datum axis and
those constructed at right angles to a
datum axis.

Circular run out Total run out

114
114
 Features Applicable to Run out tolerancing:

115
115
 Circular run out - Examples . . .

 At any circular
element measured,
the surface must be
within the specified
runout tolerance of
0.05 indicator
movement when the
part is rotated 360
degrees about the
datum axis.
116
116
 Total run out – examples …

 Here the dia. at middle is controlled with total

runout and dia. At the ends are controlled with
circular runoutsHow
. to inspect ?
117
117
Total run out measurement

118
Profile tolerances:

119
 Why profile tolerances ?

 The profile of a line is used to control all

forms other than straight and round lines.

120
Profile of a Line – How to check ?

121
Conclusion:

“ Use GD&T to effectively

communicate product
specifications to ensure the part
drawn, is the part made.”

122