JOMO KENYATTA UNIVBERSITY OF AGRICULTURE AND TECHNOLOGY

BSc MECHATRONIC ENGINEERING

EMG 2402 METROLOGY

LECTURE NOTES

BY Dr. J. MUTUA

DEPARTMENT OF MECHANICAL ENGINEERING

JAN 2022—MAY 2022

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 Limits, fits and limit gauges

Definitions
Shaft: this is a member which fits into another member. It may be stationary or in motion.
The popular concept is a rotating shaft in a bearing. However ‘shaft’ can also apply to member
which has to fit into a space between two restrictions.
Hole: It’s defined as the member which houses or fits the shaft. The term can be applied to
the space between two restrictions into which a member has to fit.
Basic Size: This is the size about which the limits of a particular fit are fixed. It is the same
for both the shaft and the hole. It is also called the nominal size. It is determined from design
calculations. The line corresponding to the basic size is called the zero line or line of zero
deviation.
Zero Line: It is a straight line to which deviations are referred to in graphical presentation of limits
and fits, it represents the basic size.
Actual size: It is the size obtained after manufacture.
Limits of size: These are the two extreme permissible sizes between which the actual size
is contained. The maximum size is called the upper limit and the minimum size is called the
lower limit.
Tolerance: The permissible variation of a size is called tolerance. It is the difference
between the maximum and minimum permissible limits of the given size. If the variation is
provided on one side of the basic size, it is termed as unilateral tolerance. Similarly, if the
variation is provided on both sides of the basic size, it is known as bilateral tolerance.
Deviation: This is the difference between the maximum, minimum, or actual size of a shaft
or hole and the basic size.
(i) Actual deviation: It is the algebraic difference between the actual size and
the corresponding basic size.
(ii) Upper deviation: It is the algebraic difference between the maximum limit of
the size and the corresponding basic size.
(iii) Lower deviation: It is the algebraic difference between the minimum limit of
the size and the corresponding basic size.

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 Figure Error! No text of specified style in document.-1 diagram illustrating basic size deviations and
tolerances

Allowance: concerns mating parts, and is the difference between the high limit of size of the
shaft and the low limit of size of its mating hole. An allowance may be positive or negative
Fit: It is the relationship existing between two mating parts with respect to the amount of
play or interference which is present when they are assembled together. It is the degree of
tightness or looseness between two mating parts to perform a definite function.
Engineering fits between two mating parts can be divided into three types:
2) Clearance fit: (Figure Error! No text of specified style in document.-2 a.), in which the shaft
is always smaller than the hole into which it fits; Types of clearance:

 Minimum clearance: is the difference between the minimum size of the hole
and the maximum size of the shaft in a clearance fit.

 Maximum clearance: It is the difference between the maximum size of the hole
and the minimum size of the shaft in a clearance or transition fit

3) Transition fit: (Figure Error! No text of specified style in document.-2b.), in which the shaft
may be either bigger or smaller than the hole into which it fits – it will therefore be
possible to get interference or clearance fits in one group of Assemblies

4) Interference fit: (Figure Error! No text of specified style in document.-2 c), in which the
shaft is always bigger than the hole into which it fits.

i) Minimum Interference: It is the magnitude of the difference (negative) between the

maximum size of the hole and the minimum size of the shaft in an interference fit before assembly.
ii) Maximum Interference: It is the magnitude of the difference between the minimum size
of the hole and the maximum size of the shaft in an interference or a transition fit before assembly

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 (a) (b (c)
)
Figure Error! No text of specified style in document.-2: Conventional representation Engineering Fits

Unilateral and Bilateral Limits

Unilateral limits (Figure Error! No text of specified style in document.-3 a): the maximum and
minimum limits of size are disposed on the same side of the basic while for bilateral limits ( Figure
Error! No text of specified style in document.-3 b), the limits are disposed above and below the basic size.
A unilateral tolerance varies in only one direction, while a bilateral varies in both directions.

(a) (b)

Figure Error! No text of specified style in document.-3: Unilateral and Bilateral Limits

Basis of Fits
Hole Basis
The size of the hole is kept constant; shaft size is varied to give different fits. In this system,
the lower deviation of the hole is zero. The letter symbol for this situation is ‘H’. The Hole Basis
system is preferred in most cases, since standard tools like drills, reamers, broaches, etc., are used
for making a hole. See the data sheet 4500A (selected ISO fits- Hole basis) extracted from BS 4500
provided.

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 Figure Error! No text of specified style in document.-4: Hole Basis fits C – clearance, T- transition I -
interference

Shaft Basis
The size of the shaft is kept constant; hole size is varied to give different fits. In this system, the
upper deviation of the shaft is zero. The letter symbol for this situation is ‘h’. The shaft basis
system is preferred by industries using semi-finished shafting as raw materials, e.g., textile
industries, where spindles of same size are used as cold-finished shafting and when several parts
having different fits but one nominal size is required on a single shaft.

Figure Error! No text of specified style in document.-5: Shaft Basis fits C – clearance, T- transition I -
interference

Table Error! No text of specified style in document.-1: Table 5.3 Selected types of fits required for shaft and
housings

Description Hole Shaft

Loose Running H11 c11
Free Running H9 d9
Loose Running H11 c11
Easy Running - Good quality easy to do- H8 f8
Sliding H7 g6
Close Clearance - Spigots and locations H8 f7
Location/Clearance H7 h6
Location- slight interference H7 k6
Location/Transition H7 n6
Location/Interference- Press fit which can be separated H7 p6
Medium Drive H7 s6
Force H7 u6

Example

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A journal bearing consists of a bronze bush of diameter 100 mm fitted into a housing and a steel shaft of
50 mm diameter, running in the bush, with oil as lubricant. Determine the working dimensions of (a) bore
of the housing, (b) bush and (c) shaft. Calculate the maximum and minimum interference or clearance

Bush and Bearing H7/P6

Bush and shaft H7/f7

Bush

Step 4: Calculate the interference/clearance

Limit Gauges
Gauges are inspection tool of rigid design, without a scale, which serves to check the dimensions of
manufacturing parts. Gauge do not indicate the actual value of the inspected part of the component. They
are used to determine whether the part is made within the specified limit. Components are manufactured
as per the specified tolerance limits, upper limit and lower limit. The dimensions of each component
should be within this upper and lower limit. If the dimensions are outside these limits, the components
will be rejected. Using any measuring instruments to check these dimensions will consume more time.
Again, the interest is not in knowing the amount of error in dimensions. It is just enough to know whether

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the size of the component is within the prescribed limits or not. For this purpose, a gauge known as limit
gauges is made. The common types are as follows:
(i) Plug gauges
(ii) Ring gauges
(iii) Snap gauges
(iv) Feeler gauge

Plug gauges
The ends are hardened and accurately finished by grinding. One end is the Go end and the other end is No
Go end as shown in Figure Error! No text of specified style in document.-6. Usually, the Go end will be equal
to the lower limit size of the hole and the No Go end will be equal to the upper limit size of the hole. If the
size of the hole is within the limits, the Go end should go inside the hole and No Go end should not go.

Figure Error! No text of specified style in document.-6: Plug Gauges

If the Go end does not go, the hole is under size and also if No Go end goes, the hole is over size. Hence, the
components are rejected in both the cases. The plug gauges can be of the following forms:
 Double ended plug gauges- In this type, the Go end and No Go end are arranged on both
ends of the plug. This type has the advantage of easy handling.

 Progressive type of plug gauges- both the GO end and NOGO end are arranged in the
same side of the plug. The plug gauge ends can be used progressively one after the other
while checking the hole saving time.

 Taper plug gauge- used to check tapered holes. It has two check lines. One is a GO line
and another is a NOGO line. During the checking of work, NOGO line remains outside the
hole and GO line remains inside the hole.

Figure Error! No text of specified style in document.-7:Taper Plug gauge

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 Ring gauge
Ring gauges are mainly used for checking the diameter of shafts having a central hole. The hole is
accurately finished by grinding and lapping after hardening process. The periphery of the ring is knurled
to give more grip while handling the gauges. Two ring gauges are made separately to check the shaft such
as GO ring gauge and NOGO ring gauge as shown in Figure Error! No text of specified style in
document.-8Figure Error! No text of specified style in document.-8

Figure Error! No text of specified style in document.-8: Ring gauges

But the hole of GO ring gauge is made to the upper limit size of the shaft and NOGO for the lower limit.
While checking the shaft, the GO ring gauge will pass through the shaft and NOGO will not pass. To identify
the NOGO ring gauges easily, a red mark or a small groove is cut on its periphery.

Snap gauge
Snap gauges are used for checking external dimensions. They are also called as gap gauges. The different
types of snap gauges are (Figure Error! No text of specified style in document.-9): Double ended snap gauge-
This gauge is having two ends in the form of anvils. Here also, the GO anvil is made to lower limit and
NOGO anvil is made to upper limit of the shaft. It is also known as solid snap gauges. Progressive snap
gauge- This type of snap gauge is also called caliper gauge. It is mainly used for checking large diameters
up to 100mm. Both GO and NOGO anvils at the same end. The GO anvil should be at the front and NOGO
anvil at the rear. So, the diameter of the shaft is checked progressively between these two ends. Adjustable
snap gauge- used for checking large size shafts made with horseshoe shaped frame of ‘I’ section. It has one
fixed anvil and two small adjustable anvils. The distance between the two anvils is adjusted by adjusting
the adjustable anvils by means of set screws. The adjustment can be made with the help of slip gauges for
specified limit of size.

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 Figure Error! No text of specified style in document.-9: Snap gauges

Design of Limit Gauge

The following are the factors considered in design of limit gauges
• Allocation of Tolerance
– Manufacturing Tolerance
– Wear Allowance
• Taylor’s Principle of gauge Design
• Fixing of Gauge elements with handles
– Taper lock design
– Trilock Design
• Provision of Guards
• Provision of Pilot Correct Centering
• Materials
• Hardness and Surface finish
• Rigidity
• Alignment of Gauge faces

Manufacturing Tolerance
• It is economically impractical to attempt to make “Go” and “Not Go” gauges exactly to the two limits of
work tolerance. Limit gauges are made 10 times more accurate than the tolerances they are going to
control.

Allocation of manufacturing tolerance

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 Wear Allowance
Measuring surfaces of GO gauges constantly rub against the surfaces of parts in inspection, thus they lose
their initial size due to wear. Therefore, to prolong the service life of gauges, wear allowance (i.e. 5% of

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work tolerance) is added to nominal dimension of GO plug gauge high and whereas subtracted from
nominal dimension of GO snap gauge. Wear allowance is not considered for NOT-GO gauge as it is not
subjected to much wear. 5% wear allowance is provided if working tolerance is greater than 0.09 mm.
Example

Taylor’s Principle
• Go Gauge should always be so designed that it will cover the maximum Metal Condition (MMC) of as
many dimensions as possible in the same limit gauge, whereas Not Go gauge to cover the minimum metal
condition of one dimension only.

To Check Circular Holes

Go Plug Gauge Should Have a Full Circular Section. Length should be equal to the length of the hole.

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To Check Circular Holes
Not Go Plug Gauge should be In the form of pin or bar.Should check the upper limit of the hole.

To Check Circular Shaft

• Snap Gauge Should be used as Not Go Gauge Should check the low limit of shaft• For non-circular shaft,
Snap gauge will not pass through

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Fixing with Handle
• Taper Lock Design
– Used for diameter up to 63.5 mm.
– Used for smaller size plain and screw gauges.
• Trilock Design
– Used for diameter from 63.5 mm to 203mm.
– Gauge is attached with handle with three lock nuts.

Provision of Pilot
• For closely toleranced parts Plug gauge doesn’t easily enter the hole so piloting is used

Thread or Screw Gauge

• Nuts and internal threads are checked with Plug thread gauge and screws with Ring thread gauge.
• Three types of Fit
– Close Fit
– Medium Fit
– Free Fit

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 Designing a Gauge
• Find tolerance for hole an shaft
• Find gauge tolerance
• Basic Size for “Go” Plug Gauge is LL of Hole
• Basic Size for “Go” Plug Gauge is HL of Hole
• For plug gauge:
– High limit of “Go” Plug gauge
– Low limit of “Go” Plug gauge
– High limit of “Not Go” Plug gauge
– Low limit of “Not Go” Plug gauge
• Repeat for Snap gauge
• Draw the Diagram of “Go”, “Not Go” Plug gauge and “Go”, “Not Go” Snap gauge

Tutorial questions
1. Outline the advantages and disadvantage of limit gauges
2. What materials are suitable for limit gages
3. Write a page about ‘care of limit gauges’

4. A 50mm H8-f7 fit is to be checked. Taking the gauge makers tolerance to be 10% of the
work tolerance, design plug gauge and gap gauge to check the fit.

5. A 100mm H7-p6 fit is to be checked. Taking the gauge makers tolerance to be 10% of the
work tolerance, design plug gauge and gap gauge to check the fit. Assume a wear
allowance of 5%.

The advantages of limit gauges can be summarised as follows:

1. Conveniently used in mass production for controlling various dimensions.
2. Can easily be used by semi-skilled people.
3. Economical in their own cost as well as engaging cost.
The followings are the limitations/disadvantages of limit gauges:
 Do not indicate the actual size of the component
 Susceptible for wear, expansion and collapse

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 Need for large space for storage of gauges
 Cannot handle finer quality jobs due to precision issues
 Require frequent checking of gauge dimensions

 Cost of the instrument

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