Chapter 1 INTRODUCTION TO TOLERANCES AND FITS

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Chapter 1 INTRODUCTION TO TOLERANCES AND FITS

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1.1. TERMINOLOGIES IN TOLERANCES AND FITS

1.1.1. Size / Dimension

1.1.2. Limiting deviation

1.1.3. Tolerance

1.1.4. Fit

1.1.5. Diagram of disposition of tolerance zones for fit

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1.1.1. Size / Dimension

a) Nominal size

b) Actual size

c) Limits of size

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1.1.1. Size / Dimension
a) Nominal size
Nominal size is the exact theoretical size arrived at by design.
It is obtained by calculation for strength and chosen in series

of Standard preferred sizes

Designation : D, d

D (For hole or enveloping surface)

d (For shaft or enveloped surface)

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 Ra5 Ra10 Ra20 Ra40 Ra5 Ra10 Ra20 Ra40 Ra5 Ra10 Ra20 Ra40 Ra5 Ra10 Ra20 Ra40
1 1 1 1 10 10 10 10 100 100 100 100 1000 1000 1000 1000
Nominal 1,1
1,05
1,1 11
10,5
11 110
105
110 1120
1060
1120
size 1,2 1,2
1,15
1,2 12 12
11,5
12 125 125
120
125 1250 1250
1180
1250
1,3 13 130 1320
1,4 1,4 14 14 140 140 1400 1400
1,5 15 150 1500
1,6 1,6 1,6 1,6 16 16 16 16 160 160 160 160 1600 1600 1600 1600
1,7 17 170 1700
1,8 1,8 18 18 180 180 1800 1800
1,9 19 190 1900
2,0 2,0 2,0 20 20 20 200 200 200 2000 2000 2000
2,1 21 210 2120
2,2 2,2 22 22 220 220 2240 2240
2,4 24 240 2360
2,5 2,5 2,5 2,5 25 25 25 25 250 250 250 250 2500 2500 2500 2500
2,6 26 260 2650
2,8 2,8 28 28 280 280 2800 2800
3,0 30 300 3000
3,2 3,2 3,2 32 32 32 320 320 320 3150 3150 3150
3,4 34 340 3350
3,6 3,6 36 36 360 360 3550 3550
3,8 38 380 3750
4,0 4,0 4,0 4,0 40 40 40 40 400 400 400 400 4000 4000 4000 4000
4,2 42 420 4250
4,5 4,5 45 45 450 450 4500 4500
4,8 48 480 4750
5,0 5,0 5,0 50 50 50 500 500 500 5000 5000 5000
5,3 53 530 5300
5,6 5,6 56 56 560 560 5600 5600
6,0 60 600 6000
6,3 6,3 6,3 6,3 63 63 63 63 630 630 630 630 6300 6300 6300 6300
6,7 67 670 6700
7,1 7,1 71 71 710 710 7100 7100
7,5 75 750 7500
8,0 8,0 8,0 80 80 80 800 800 800 8000 8000 8000
8,5 85 850 8500
9,0 9,0 90 90 900 900 9000 9000
9,5 95 950 9500 6
 a) Nominal size
R R R R R R R R R R
Ra5 Ra10 Ra20 Ra40 Ra5 Ra10 Ra20 Ra40 Ra5 Ra10 Ra20 Ra40
10 10 10 10 100 100 100 100 1000 1000 1000 1000
10,5 105 1060
11 11 110 110 1120 1120
11,5 120 1180
12 12 12 125 125 125 1250 1250 1250
13 130 1320
14 14 140 140 1400 1400
15 150 1500
16 16 16 16 160 160 160 160 1600 1600 1600 1600
17 170 1700
18 18 180 180 1800 1800
19 190 1900
20 20 20 200 200 200 2000 2000 2000
21 210 2120
22 22 220 220 2240 2240
24 240 2360

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End Home
1.1.1. Size / Dimension

b) Actual size

Actual size is the dimension as measured on a manufactured

part .

Designation: Dt , dt

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1.1.1. Size / Dimension
c) Limits of size

+ Maximum limit of size

Designation : Dmax , dmax

+ Minimum limit of size

Designation : Dmin , dmin

+0,018

-0,040
-0,073
0
Ø18

Ø30

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1.1.2. Limiting deviation
a) Upper limiting deviation
Designation : ES, es
Hole upper deviation : ES = Dmax  D
Shaft upper deviation : es = dmax  d
b) Lower limiting deviation
Designation : EI , ei
Hole lower deviation: EI = Dmin  D
Shaft lower deviation: ei = dmin  d
+0,018

-0,040
-0,073
0
Ø18

Ø30

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 1.1.3. Tolerance

Tolerance is the difference between the maximum limit of size

and the minimum limit of size.
It is an absolute value without sign.
• + Hole tolerance : TD = Dmax  Dmin
= (ES + D)  (EI + D)
= ES  EI
• + Shaft tolerance : Td = dmax  dmin = es  ei

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 1.1.3. Tolerance

* Designating sizes on drawings includes :

 Nominal size.
 Limiting deviations (upper and lower deviations).

Ø1400,0125
-0,008
Ø40 -0,033

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 1.1.4. Fit
When two mating parts are to be assembled, the relation
resulting from the difference between their sizes before assembly
is called a fit.

Enveloping part
Enveloping surface
Enveloping d=D Enveloped surface
surface

Enveloping part d=D

Enveloped part
Enveloped surface Enveloped part

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1.1.4. Fit

- Concept of fit only exists in mass production.

- Basic sizes of mating parts are the same : D = d

3 types of fit can be distinguished:

• a) Clearance fit

• b) Interference fit

• c) Transition fit

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a) Clearance fit
Designation: S (Clearance)
Applied : For movable joints (running, sliding or both)
between the mating components

Smax
Smin
TD
Td
Dmax

dmax
Dmin

d=D

dmin
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a) Clearance fit

+ Maximum clearance: Smax = Dmax – dmin = (ES + D) – (ei + d)

= ES – ei

+ Minimum clearance: Smin = Dmin – dmax = EI – es

Smax + Smin
+ Average clearance: Stb =
2
+ Tolerance of fit: Ts = Smax – Smin = TD + Td

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b) Interference fit
Designation : N (Interference)
Applied : For fixed joints excluding relative motion between
the mating components

Nmax
Nmin

Td
TD
d=D

dmax
Dmax

dmin
Dmin

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b) Interference fit

+ Maximum interference: Nmax = dmax – Dmin = es – EI

+ Minimum interference: Nmin = dmin – Dmax = ei – ES

Nmax + Nmin
+ Average interference: Ntb =
2
+ Tolerance of fit: TN = Nmax – Nmin = TD + Td

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c) Transition fit

It is a fit where both clearance and interference may occur in

the coupling.

Nmax

Smax
TD Td
Dmax

d=D

dmax
Dmin

dmin
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c) Transition fit

Applied : For fixed joints only in conjunction with an additional

fastener, such as a key, pin, screw …

+ Maximum clearance: Smax = Dmax – dmin = ES – ei

+ Maximum interference: Nmax = dmax – Dmin = es – EI

+ Tolerance of fit TS,N = Smax + Nmax = TD + Td

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1.1.5. Diagram of disposition of tolerance zones for fit

0,009
D = 50 d = 50
+0,025
0 0,025

mm
TD
ES =+25

Line 0
EI = 0
es = -9

Td
D = d = Ø Ø 50mm

ei = -25

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1.1.5. Diagram of disposition of tolerance zones for fit

0,009
D = 50 d = 50 0,025
+0,025
0

μm μm μm

TD TD TD

Zero line Zero line Zero line

Td Td
Td

Clearance fit Interference fit Transition fit

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 1.2. THE CONCEPT OF INTERCHANGEABILITY

Interchangeability is an ability that an part (a component)

can be replaced at random by another of the same type without
any need for adjustment or repairing.
Two modes of assembly :
a) Full Interchangeability
The production of mating parts can be carried at different places
Benefits Reducing manufacturing and assembly time considerably

The replacement of worn-out or defective parts becomes very easy

 Applied for standardized or spare parts.

b) Partial Interchangeability
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 b) Partial Interchangeability / Group Interchangeability

mm
III
T’D II
III’
I Line 0
II’
TD Smin T’d Smax
I’
D = d = Ø 30mm

Td

Group I : 30  DI  30,01

D = 30  D = 30
+0,010 +0,030
0 0 Group II : 30,01 < DII  30,02
Group III : 30,02 < DIII  30,03

Group I’ : 29,984  dI’  29,994

0,006 Group II’ : 29,994 < dII’  30,004
d = 30 0,016  d = 300,016
+0,014

Group III’ : 30,004 < dIII’  30,014

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 b) Partial Interchangeability / Group Interchangeability

• The tolerances of mating parts are allowed to increase in

order to meet machining requirements.
• Machined parts are measured and sorted into groups by
dimension prior to assembly process.
• Defect rate probability could be higher than usual.

 Applied for assembly process in a factory’s production line.

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