LIMITS

As already stated every manufacturing process is a combination of three elements

man, materials and machine. A change in any one or all of these will result in changes
in sizes of manufactured parts. In mass production, where large number of parts are to
be made by different operators on different machines, it is impossible to make all parts
exactly alike and to exact dimensions. The difference in dimension does exist because
of these variables. Also, perfect size is not only difficult but a costly affair.

It is, therefore obvious that some permissible variation in dimension has to be

allowed to account for variability.

The dimension of the manufactured part can thus only be made to lie between two
limits, maximum and minimum.

Limits contd...

Therefore, the ranges of permissible difference in dimension have been standardized

under the name limits.

The limits of size of a dimension of a part are two extreme permissible sizes, between
which the actual size of the dimension may lie.

They are fixed with reference to the basic size of that dimension. The high limit (upper
limit) for that dimension is the largest size permitted and low limit is the smallest size
permitted for that dimension.
 TOLERANCE
The permissible variation in size or dimension is called
tolerance. Thus, the word tolerance indicates that a
worker is not expected to produce the part to the exact
size, but definite small size error is permitted.

The difference between the upper limit (high limit) and the lower limit of a dimension
represents the margin for variation in workmanship, and is called a Tolerance Zone.
Tolerance can also be defined as the amount by which the job is allowed to go away
from accuracy and perfectness without causing any functional trouble, when assembled
with its mating part and put into actual service.

For example, a shaft of 25 mm basic size may be written as 25 ± 0.02.

The maximum permissible size (upper limit)=25.02 mm and minimum permissible size
(lower limit) =24.98 mm
Then, Tolerance=Upper limit-Lower limit=25.02 - 24.98=0.04 mm.

Tolerance is the total amount a dimension may vary and is the difference between the
upper (maximum) and lower (minimum) limits.

Tolerances are used to control the amount of variation inherent in all manufactured parts.
In particular, tolerances are assigned to mating parts in an assembly.

One of the great advantages of using tolerances is that it allows for interchangeable parts,
thus permitting the replacement of individual parts.

Tolerances are used in production drawings to control the manufacturing process more
accurately and control the variation between parts.
Systems of writing tolerances
There are two systems of writing tolerances:
(i) Unilateral system
(ii) Bilateral system
Unilateral system
In this system, the dimension of a part is allowed to vary only on one side of basic size
i.e., tolerance lies wholly on one side of the basic size either above or below it.
Examples of unilateral tolerances

Unilateral system is preferred in interchangeable manufacture, especially when

precision fits are required, because:

(i) It is easy and simpler to determine deviations.

(ii) Another advantage of this system is that GO gauge ends can be standardized as
the holes of different tolerance grades have the same lower limit and all the
shafts have same upper limit.

(iii) This form of tolerance greatly assists the operator, when machining of mating
parts. The operator machines to the upper limit of shaft (lower limit of hole)
knowing fully well that he still has some margin left for machining before the
parts are rejected.
 Bilateral system
In this system, the dimension of the part is allowed to vary on both the sides of the
basic size i.e., the limits of tolerance lie on either side of the basic size; but may not be
necessarily equally disposed about is.

In this system it is not possible to retain the same fit when tolerance is varied and the
basic size of one or both of the mating parts is to be varied. This system is used in mass
production where machine setting is done for the basic size.

Relationship between Tolerance and Cost

The relationship between tolerance and cost of production is shown in the figure. If the
tolerances are made closer and closer, the cost of production goes on increasing, because
to manufacture the component with closer tolerances we need:

(i) Precision machines, tools, materials

(ii) Trained and highly skilled operators
(iii) Tight inspection and more precise testing and inspection devices. It needs more
concentration of the operators, frequent checking and more time which slows down
the rate of production.
(iv) Close supervision and control is essential.
Tolerance representation
Direct limits or as tolerance values
applied directly to a dimension.

Geometric tolerances
Notes referring to specific
condition.

Tolerance representation
Plus/Minus
 Important terms
Nominal size
a dimension used to describe the general size usually expressed in common fractions.
Basic size
the theoretical size used as a starting point for the application of tolerances.
Actual size the measured size of the finished part after machining.

Limits
the maximum and minimum sizes shown by the tolerance dimension.
Allowance
is the minimum clearance or maximum interference between parts.
Tolerance
is the total variance in a dimension which is the difference between the upper and lower limits. The
tolerance of the slot in Figure is .004" and the tolerance of the mating part is .002".
 Fit

Fit may be defined as a degree of tightness or looseness between two mating parts to
perform a definite function when they are assembled together.
It is the relationship between two mating parts with respect to the amount of play or
tightness which is present when they are assembled together.

Clearance fit occurs when two toleranced mating parts will always leave a space or clearance
when assembled.
Interference fit occurs when two toleranced mating parts will always interfere when assembled.
Transition fit occurs when two toleranced mating parts will sometimes be an interference fit and
sometimes be a clearance fit when assembled.
 Clearance fit exists when the
shaft and the hole are at their
maximum metal conditions.

The tolerance zone of the hole is above that of the shaft as shown in the figure

Maximum clearance. It is the difference between the minimum size of shaft and
maximum size of hole.
Minimum clearance . It is the difference between the maximum size of shaft and
minimum size of hole.
Slide fit. This type of fit has a very small clearance, the minimum clearance being
zero. Sliding fits are employed when mating parts are required to move slowly in
relation to each other e.g. Tailstock spindle of lathe, feed movement of the spindle
quill in a drill machine, sliding change gears in quick change gear of centre lathe etc.
Easy slide fit. This type of fit provides for small guaranteed clearance. It serves to
ensure alignment between the shaft and hole. It is applicable for slow and non regular
motion, for example, spindle of lathe and dividing heads, piston and slide valves, spigots
etc.

Running fit. Running fit is obtained when there is appreciable clearance between the
mating parts. The clearance provides a sufficient space for a lubrication film between
mating friction surfaces. It is employed for rotation at moderate speed, e.g., gear box
bearings, shaft pulleys, crank shafts in their main bearings etc.

Slack running fit. It is obtained when there is a considerable clearance between the
mating parts. This type of fit may be required as compensation for mounting errors e.g.
Arm shaft of IC engine shaft of centrifugal pump etc.

Loose running fit. Loose running fit is employed for rotation at very high speed, e.g.,
idle pulley on their shaft such as that used in quick return mechanism of a planer.

Interference fit. In this type of fit the minimum

permissible diameter of the shaft is larger than the
maximum allowable diameter of the hole. Thus the shaft
and hole members are intended to be attached
permanently and used as a solid component.

Elastic strains developed on the mating surfaces during the process of

assembly prevent relative movement of the mating parts. For example, steel
tyres on railway car wheels, gears on intermediate shaft of trucks, bearing in
the gear of a lathe head stock, drill bush in jig plate, cylinder liner in block,
steel rings on a wooden bullock cart wheels etc.
Force fit. Force fits employed when the mating parts are required to be
disassembled during their total service life. In this case the interference is
quite appreciable and, therefore, assembly is obtained only when high
pressure is applied. This fit , thus, offers a permanent type of assembly, e.g.
forging machine etc.xc
Tight fit. It provide less interference than force fit. Tight fits are employed for mating
parts that may be replaced while overhauling of the machine, for example, stepped
pulleys on the drive shaft of conveyer, cylindrical grinding machine etc.

Heavy force and shrink fit. It refers to maximum negative allowance. Hence
considerable force is necessary for the assembly. The fitting of the frame on the rim can
also be obtained first by heating the frame and then rapidly cooling in its position.

Transition fit. Transition fit lies mid way between clearance and interference fit. In this
type the size limits of mating parts (shaft and hole) are so selected that either clearance
or interference may occur depending upon the actual sizes of the parts.

Push fit and wringing fit are examples of this type of fit.

In this type of fit the tolerance zones of the hole and shaft overlap completely or in part.

Wringing fit. A wringing fit provides either zero

interference or a clearance these are used where
parts can be replaced without difficulty during
minor repairs.
Push fit. The fit provides small clearance. It is
employed for parts that must be disassembled.

During operation of machine for example change gears, slip bushing etc.
Allowance. Allowance is prescribed difference between the dimensions of
two mating parts for any type of fit.
It is intentional difference between lower limit of hole and higher limit of
shaft.
The allowance may be positive or
negative. The positive allowance is
called clearance and the negative
allowance is called interference.
 Metric Limits and Fits
Basic size
Deviation
Upper Deviation
Lower Deviation
Fundamental Deviation
Tolerance
Tolerance zone
International Tolerance
grade
Hole basis
Shaft basis

Difference between Tolerance and Allowance

Tolerance
1. It is the permissible variation in
dimension of a part (either a hole
or a shaft).
2. It is the difference between
higher and lower limits of a
dimension of a part.
3. The tolerance is provided on a
dimension of a part as it is not
possible to make a part to exact
specified dimension.
4. It has absolute value without
sign.
Allowance
It is the prescribed difference between the
dimensions of two mating parts (hole and
shaft).
It is intentional difference between the
lower limit of hole and higher limit of
shaft.
Allowance is to be provided on the
dimension of mating parts to obtain
desired type of fit.
Allowance may be positive (clearance) or
negative (interference).
 Symbols and Definitions
Methods

Typical representation of different types of fundamental deviations

(a) Holes (internal features) (b) Shafts (external features)
 Tolerance Grades

• The ISO system of limits and fits comprises 18 grades of fundamental tolerances
to indicate the level of accuracy of the manufacture.
• The ISO system provides tolerance grades from IT01, IT0, and IT1 to IT16 to
realize the required accuracy.
• Tolerance values corresponding to grades IT5–IT16 are determined using the
standard tolerance unit (i, in μm), which is a function of basic size.

• D is the geometric mean of the lower and upper diameters of a particular

diameter step within which the given or chosen diameter D lies

Tolerance Grades
Standard Hole basis table; limits

Hole basis system; fits

Shaft basis system; fits
 Geometric Dimensioning and Tolerancing
GDT is a method of defining parts based on how they function, using standard
ASME/ANSI symbols.

Within the last 25 years there has been considerable interest in GDT, in part because of
the increased popularity of statistical process control. This control process, when
combined with GDT, helps reduce or eliminate inspection of features on the
manufactured object. The flipside is that the part must be toleranced very efficiently;
this is where GDT comes in.

Another reason for the increased popularity of GDT is the rise of worldwide standards,
such as ISO 9000, which require universally understood and accepted methods of
documentation.

GDT-Symbols
THANK YOU