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2.0 Limits, Tolerances, and Tits

Manufactured engineering parts which can be interchanged require precision (i.e. degree of
accuracy) to ensure their intended functioning. However, it is impossible to produce or
manufacture an engineering part to the exact dimensions specified by design. These
impossibilities could come as a result of inaccuracies during measurements and machining of
the parts during production. Therefore, the workman must be given some allowable margin to
enable him produce the given part. This allowable margin assists him to mass produce the given
part with dimensions falling within two acceptable limits – a maximum and a minimum.
The Limit is a system in which the variation in the dimensions of any given part is accepted
during production. But the deviations from the basic dimension are known as Tolerances. For
two mating parts (i.e. hole and shaft, key and groove, etc.), the relation between them is called
Fit.
Figure 2.0, shows a hole and a shaft used to illustrate the concept of limits and tolerances
(deviations) using a basic size

(a) (b)

Figure 2.0: (a) A mating hole and shaft, (b) The illustrative diagram for the basic size deviations and
tolerances.

In figure 2a, the basic size (i.e. it’s diameter) of the shaft is solely derived from design
calculation. If the shaft has to fit into the hole, then shaft’s basic size is also the hole’s basic
size. Considering either the hole or shaft, the maximum and the minimum diameters are the
two limits (i.e. the permissible sizes) within which the actual size (i.e. any hole or shaft
produced) is accepted.
The tolerance in each case, either the shaft or hole, is the difference between the acceptable
maximum and the minimum diameters of the shaft or the hole that may be produced. The
algebraic difference between the maximum limit of size (of the shaft’s or hole’s diameter) and
the corresponding basic size is the upper deviation, while the algebraic difference between
the minimum limit of size (of the shaft’s or hole’s diameter) and the corresponding basic size
is the lower deviation.

Free Lecture Notes on GRE-222 (Engineering Drawing IV) prepared by C. O. Eleghasim – Chapter 2 (Limits,
Tolerances, & Fits)
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Depending upon the actual limits of the hole or shaft sizes, fits may be clearance type, or
transition type, or interference fit. It is called Clearance Fit when a fit gives clearance between
a two mating parts. Also, it is called Interference Fit when the difference between the mating
parts is negative. For instance, when the diameter of the shaft is bigger than the hole. In this
case, the difference will be negative. Transition Fit may result in either an interference or a
clearance, depending upon the actual values of the tolerance of the individual parts. For
instance, a shaft may be smaller or larger than a hole but still fall between the prescribed
tolerances. When the shaft diameter is 29.95 and hole diameter is 30.05(+0.10 mm) will result
to a clearance fit. Also, If the shaft diameter is 30.00 and hole diameter is 29.95(-0.05 mm)
result to an interference fit.
2.1 Description of Tolerance Deviations
Tolerance is denoted by a letter symbol and a number symbol called the grade. There are
3 methods for placing tolerance on dimensions. They are:
2.1.1 Method 1: the tolerance dimension is given by its basic value, followed by a
symbol comprising of both a letter and a numeral. Examples are

The terms φ25H7, φ10H10 and 40C11 refer to internal features (holes and grooves),
because it is a standard practise to use capital letters for internal features. The capital
‘H’ and ‘C’ signify the tolerance deviation zone in each dimension. The number symbol

(a) (b) (c) (d)

Figure 2.1: (a) & (b) tolerance dimensions for internal features, (c) & (d) tolerance dimensions for
external features.

Free Lecture Notes on GRE-222 (Engineering Drawing IV) prepared by C. O. Eleghasim – Chapter 2 (Limits,
Tolerances, & Fits)
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7, 10 and 11 signifies the grade. On the other hand, small letter refers to external
features (shafts and projections). The terms 10h9, φ25h9, φ40h11 refer to external
features as shown in figure 2.1.
2.1.2 Method 2: the basic size and the tolerance values are indicated above the
dimension line, with the tolerance values being in size smaller than the basic size and
the lower deviation being indicated in line with the basic size. Examples are shown in
figure 2.2.

(a) (b)

(c) (d)

Figure 2.2: (a) Bilateral tolerance of equal variation, (b) Bilateral tolerance of unequal variation,
(c) Unilateral tolerance with zero variation in one direction, and (d) maximum and minimum
size indicated directly on size

2.1.3 Method 3: the maximum and minimum sizes are directly indicated above the
dimension line using tolerance symbols. This is well suited for assembled parts which
are dimensioned such that the fit is indicated by the basic size common to both the
components, followed by the hole tolerance symbol first and then followed by the shaft
tolerance symbol.
Using φ25 H7/h6, for example, it can be placed using any of the styles shown in figure
2.3.

Free Lecture Notes on GRE-222 (Engineering Drawing IV) prepared by C. O. Eleghasim – Chapter 2 (Limits,
Tolerances, & Fits)
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(a) (b)

(c)

Figure 2.2: Tolerance dimensioning of assembled parts

2.2 Calculation of Tolerance Deviations

Great care and judgement must be exercised when deciding the tolerance that may be placed
on various dimensions of a component. If the tolerances are to be minimum or the accuracy
requirement are severe, then the cost of production increases.
The tolerance to be placed on a dimension is a function of nominal size. A nominal size or
dimension is one that falls within a range in a step, where each step has various grades of
tolerance. Tables 2.1, shows 13 nominal steps for basic sizes from 1 mm to 500 mm. Each
nominal step has corresponding 18 grades of tolerance, designated as IT 01, IT 0 to IT 1 to
IT 16 known as fundamental tolerances.

Example 1: Calculate the fundamental tolerance of a shaft 125 mm and grade 9.

Solution: The shaft size, 125 lies in the basic step, 120 to 180 in table 2.1. The geometric
mean of the diameter is
D = √(120 x 180) = 147 mm
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The tolerance unit, i = 0.45 x √𝐷 + 0.001 D = 0.45 x √147 + 0.001 x 147
= 2.522 micron or 0.002522 mm
For grade 9, as per table 2.2, the value of tolerance is
IT (9) = 40i = 40 x 2.522 = 100 microns or 0.1 mm (tallies with the value in table 2.1)

Free Lecture Notes on GRE-222 (Engineering Drawing IV) prepared by C. O. Eleghasim – Chapter 2 (Limits,
Tolerances, & Fits)
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Table 2.1: Fundamental Tolerance grades for size from 1 to 500 mm

The fundamental tolerance values of different grades (designated IT) may be obtained either
from Table 2.1 or calculated from relations given in table 2.2, which measures tolerance
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using a unit i, given by the empirical relation. Where i = 0.45 x √D + 0.001 D, and it is
measured in microns and D is the geometric mean of the limiting values of the basic steps
in millimetres.

Table 2.2: Relation magnitude of IT Tolerances for grades 5 to 16 in i unit for sizes upto 500 mm

2.2.1 Determination of fundamental Deviations

To set size limits of tolerance, the upper and lower deviations (for both external and internal
features) must be determined. The symbol used for upper deviation is ES for holes and internal
features and es for shafts and external features. For lower deviation is EI for holes and internal
features and ei for shafts and external features. Table 2.3, shows the formulae for calculating

Free Lecture Notes on GRE-222 (Engineering Drawing IV) prepared by C. O. Eleghasim – Chapter 2 (Limits,
Tolerances, & Fits)
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the fundamental deviations (the upper and lower deviation) for shafts. The value of D is the
geometric mean diameter of the range in a step.
Table 2.3: Formulae for fundamental deviation for shafts upto 500 mm

The fundamental deviations for holes are derived from the formulae in table 2.3, corresponding
to the shaft with the following modifications:
(i) For holes of sizes above 3 mm and type N and grade 9 and above, the upper
deviation, ES is 0.
(ii) For holes’ size above 3 mm of type J, K, M and N of grades upto and inclusive
of 8 and for the types P to ZC of grades upto and inclusive of 7, the upper
deviation ES is equal to the lower deviation ei of the shaft of the same letter
symbol but one grade finer (less in number) and of opposite sign.
(iii) All the deviations for the types of holes mentioned in (i) and (ii) above, are
identical with the shaft deviation of the same symbol but disposed on the other

Free Lecture Notes on GRE-222 (Engineering Drawing IV) prepared by C. O. Eleghasim – Chapter 2 (Limits,
Tolerances, & Fits)
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side of the basic size (or zero line) in table 2.3. For example, the lower deviation
EI for a hole is equal to the upper deviation es of the shaft of the same letter
symbol but of opposite sign.

Example 2: Calculate the fundamental deviations for the shaft sizes and place the tolerances
on their dimensions: (a) 30 e8 and (b) 40 m6.
Solution:
(a) From table 2.3, the upper deviation (es) for type e shaft is
es = – 11D0.41
30 mm shaft falls within the basic step range of 18 to 30 mm. Therefore,
D = √(18 x 30) = 23.24 mm. Thus,
es = –11D0.41 = – 11 x 23.240.41 = – 40 micron = – 0.040 mm
From table 2.2, the fundamental tolerance for grade 8 is 25i. where i is the tolerance
unit given as:
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i = 0.45 x √𝐷 + 0.001D = 0.45 x √23.24 + 0.001 x 23.24 = 1.31 microns
therefore, the fundamental tolerance grade 8 which is 25i, becomes
IT (8) = 25 x 1.31 = 33 microns = 0.033 mm (tallies with table 2.1)
To determine the lower deviation (ei), we use the formula
ei = es – IT (for Shafts/External features) (2.0)
EI = ES – IT (for Holes/Internal features) (2.1)
For our example, we have the lower deviation
ei = (- 0.040) – (0.033) = - 0.073 mm
−0.040
The dimension for the shaft will be written as 30−0.073 mm

(b) From table 2.3, formula for calculating lower deviation of shaft with label m, is
given as:

ei = + (IT 7 – IT 6)
= + (16i – 10i) (from table 2.2)

Where i is the tolerance unit, determined using:

3
i = 0.45 x √𝐷 + 0.001D

Free Lecture Notes on GRE-222 (Engineering Drawing IV) prepared by C. O. Eleghasim – Chapter 2 (Limits,
Tolerances, & Fits)
 8

Again from table 2.1, the size 40 is in the range 30 and 50 mm, and hence the mean
diameter is D = √(30 x 50) = 38.73 mm.
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i = 0.45 x √38.73 + 0.001 x 38.73 = 1.56 microns
therefore
ei = + (16i – 10i) = + [16 x 1.56 – (10 x 1.56)] = 9.36 micron = 0.009 mm

or can be determined directly from table 2.1, by reading out for size 40, grade 7
minus size 40, grade 6 as follows:

ei = 25 – 16 = 9 microns = 0.009 mm

From table 2.1, the fundamental tolerance for size 40 and grade 6 is 9 microns.
Therefore, the upper deviations (es) is calculated from equation (2.0) as follows:

es = ei + IT = 0.009 + 0.009 = 0.018 mm

+0.018
The dimension for the shaft = 40+0.009 mm

Homework Assignment 1(Deadline: 1 week)

A bronze Housing has a hole opening of diameter 105 mm fitted with a bush (short
pipe made of rubber) of outer diameter 100 mm. A steel shaft 80 mm is fitted inside
the bush, with oil as the lubricant. Determine,

1. The working dimensions of the hole opening of the bronze Housing, if there is
an interference fit between the bush and Housing designated as H7/p6.
2. The working dimensions of the bush, if the fit between the bush and the shaft is
a normal running fit designated as H7/f7.
3. The maximum and minimum interference or clearance.
4. Make a free hand sketch of the bronze housing, the bush and shaft, if the
thickness of the housing is 50mm, the length of the shaft is 100 mm and the
length of bush is 50 mm.

Hint: The negative difference between the lower deviation of hole and
upper deviation of shaft, is the maximum interference. If the difference is
positive, it is minimum clearance. on the other hand, the negative difference
between the upper deviation of hole and lower deviation of shaft is the
minimum interference. But if the difference is positive, it is maximum
clearance.

Free Lecture Notes on GRE-222 (Engineering Drawing IV) prepared by C. O. Eleghasim – Chapter 2 (Limits,
Tolerances, & Fits)