Limits, Fits and Tolerance

Introduction
 No two parts can be produced with identical measurements by any manufacturing
process.

 In any production process, regardless of how well it is designed or how carefully it

is maintained, a certain amount of variation (natural) will always exist.

 Variations arises from;

• Improperly adjusted machines
• Operator error
• Tool wear
• Defective raw materials etc.

 Such variations are referred as ‘assignable causes’ and can be identified and
controlled.
 Introduction
 It is impossible to produce a part to an exact size or basic size, some variations,
known as tolerances, need to be allowed.

 The permissible level of tolerance depends on the functional requirements, which

cannot be compromised.

 No component can be manufactured precisely to a given dimension; it can only

be made to lie between two limits, upper (maximum) and lower (minimum).

 Designer has to suggest these tolerance limits to ensure satisfactory operation.

 The difference between the upper and lower limits is termed permissible
tolerance.
 Introduction
Example

Shaft has to be manufactured to a diameter of 40 ± 0.02 mm.

The shaft has a basic size of 40 mm.

It will be acceptable if its diameter lies between the limits of sizes.

Upper limit of 40+0.02 = 40.02 mm

Lower limit of 40−0.02 = 39.98 mm.

Then, permissive tolerance is equal to 40.02 − 39.98 = 0.04 mm.

 Tolerance

 The algebraic difference

between the upper and lower
acceptable dimensions.

 The basic purpose of

providing tolerances is to
permit dimensional variations
in the manufacture of
components, adhering to the
performance criterion.
 Systems of Writing Tolerances

 There are two systems of writing tolerances :

1. Unilateral tolerance

2. Bilateral tolerance
 Systems of Writing Tolerances

1. Unilateral tolerance :

 When the tolerance distribution is only on one side of the basic size.
Either positive or negative, but not both.

Unilateral Tolerance Bilateral Tolerance

a) Unilateral tolerance: Below zero line: Negative
b) Unilateral tolerance: Above zero line: Positive
2. Bilateral tolerance :
 When the tolerance distribution lies on either side of the basic size.

• It is not necessary that Zero line will divide the tolerance zone equally on both sides.
• It may be equal or unequal.
 Tolerance
Manufacturing Cost and Work Tolerance

 Tolerance is a trade-off between

the economical production and
the accuracy required for proper
functioning of the product.

Relationship between work tolerance and manufacturing cost

 Maximum And Minimum Metal Conditions
Consider a Shaft having a dimension of 40 ± 0.05 mm and a Hole having a dimension of 45 ± 0.05 mm.

For Shaft
Maximum metal limit (MML) = 40.05 mm
Least metal limit (LML) = 39.95 mm

For Hole
Maximum metal limit (MML) = 44.95 mm
Least metal limit (LML) = 45.05 mm
Conventional Diagram of Limits and Fits
 General Terminology
 Basic size: Exact theoretical size arrived at by design. Also called as nominal size.

 Actual size: Size of a part as found by measurement.

 Zero Line: Straight line corresponding to the basic size. Deviations are
measured from this line.

 Limits of size: Maximum and minimum permissible sizes for a specific dimension.

 Tolerance: Difference between the maximum and minimum limits of size.

 Tolerance Zone: Zone between the maximum and minimum limit size.

 Allowance: Lower Limit of Hole – Higher Limit of Shaft

 General Terminology
 Deviation: Algebraic difference between a size and its corresponding basic size.
It may be positive, negative, or zero.

 Upper deviation: Algebraic difference between the maximum limit of size and
its corresponding basic size.
Designated as ‘ES’ for a hole and as ‘es’ for a shaft.

 Lower deviation: Algebraic difference between the minimum limit of size and
its corresponding basic size.
Designated as ‘EI’ for a hole and as ‘ei’ for a shaft.

 Actual deviation: Algebraic difference between the actual size and its
corresponding basic size.

 Fundamental Deviation: It is the deviation closest to the basic size.

 Fits

 The degree of tightness or looseness between the two mating parts.

 Three basic types of fits can be identified, depending on the actual limits of the
hole or shaft.

1. Clearance fit

2. Interference fit

3. Transition fit
1. Clearance fit : Upper limit of shaft is less than the lower limit of the hole.

 The largest permissible dia. of the shaft is smaller than the dia. of the smallest hole.
 E.g.: Shaft rotating in a bush
2. Interference fit : Upper limit of the hole is less than the lower limit of shaft.

 Shaft need additional force to fit into the hole.

 E.g.: Bearings in castings, Dowel pins.
3. Transition fit : Dia. of the largest permissible hole is greater than the dia. of the smallest
shaft.

 Neither loose nor tight like clearance fit and interference fit.
 Tolerance zones of the shaft and the hole will be overlapped between the
interference and clearance fits.
Detailed classification of Fits
Clearance FIT
Applications
Interference FIT
Applications
Transition FIT
Applications
 Allowance
 The intentional difference kept between hole and shaft is called allowance
or the difference between maximum material condition of matting part is called
as allowance.

 For hole the maximum material condition is minimum limit. This indicates that
the maximum material will remain with the component, if it is manufactured at
minimum limit size.

 Similarly, for shaft maximum limit is the maximum material condition.

 If hole size is bigger than the shaft, the allowance is positive and if hole
size is smaller than shaft, the allowance is negative.
(a) Positive Allowance

(b) Negative Allowance

 Systems of Obtaining Different Types of Fits

 To obtain the desired class of fits, either the size of the hole or the size of the
shaft must vary.

 Two types of systems are used to represent three basic types of fits, clearance,
interference, and transition fits.

(a) Hole basis system

(b) Shaft basis system.
 Hole Basis System

Clearance fit Transition fit Interference fit

 Hole Basis System

 The size of the hole is kept constant and the shaft size is varied to give various
types of fits.

 Lower deviation of the hole is zero, i.e. the lower limit of the hole is same as
the basic size.

 Two limits of the shaft and the higher dimension of the hole are varied to obtain
the desired type of fit.

 This system is widely adopted in industries, as it is easier to manufacture the

shafts of varying sizes to the required tolerances.

 Standard-size plug gauges are used to check hole sizes accurately.

 Shaft Basis System

Clearance fit Transition fit Interference fit

 Shaft Basis System

 The size of the shaft is kept constant and the hole size is varied to obtain
various types of fits.

 Fundamental deviation or the upper deviation of the shaft is zero.

 System is not preferred in industries, as it requires more number of standard-

size tools, like reamers, broaches, and gauges, increases manufacturing
and inspection costs.

 System is preferred for long shafts of full lengths i.e. if shaft is mating with at
least two parts having holes that need different types of fits. E.g. assembly of
piston pin with piston and connecting rod.
 Numerical Examples
1. A 50 mm diameter shaft is made to rotate in the bush. The tolerances for both
shaft and bush are 0.050 mm. Determine the dimension of the shaft and
bush to give a maximum clearance of 0.075 mm with the hole basis system.
Solution :-
In the hole basis system, lower deviation of hole is
zero, therefore low limit of hole = 50 mm.

High limit of hole = Low limit + Tolerance

= 50.00 + 0.050
= 50.050 mm = 50.050 × 10– 3 m

High limit of shaft = Low limit of hole – Allowance

= 50.00 – 0.075
= 49.925 mm = 49.925 × 10– 3 m

Low limit of the shaft = High limit – Tolerance

= 49.925 – 0.050 Fig: Shaft with Bush

= 49.875 mm = 49.875 × 10– 3 m

 Numerical Examples
2. Tolerances for a hole and shaft assembly having a nominal size of 50 mm are
as follows:
Solution :-
e) Since both maximum and minimum clearances are positive, it can be conclude
that the given pair has a clearance fit.
 Numerical Examples
3. For each of the following hole and shaft assembly, find shaft-tolerance, hole
tolerance and state whether the type of fit is ;

a) clearance,
b) transition, and
c) interference:
Solution :-
a) Hole : High limit of hole = 50.025 mm
Low limit of hole = 50.00 mm
Hole tolerance = 50.025 – 50.00
= 0.025 mm = 25 × 10– 6 m

Shaft : High limit of shaft = 50.05 mm

Low limit of shaft = 50.005 mm
Shaft tolerance = 50.05 – 50.005
= 0.045 mm 45 × 10– 6 m

If we choose high limit of hole with high limit of shaft

then,
Allowance = 50.025 – 50.05
= – 0.025 (Interference)
Similarly, if we choose low limit of hole and either high limit or
low limit of shaft, it is clear that there will be interference.
b) Hole : High limit = 30.05 mm
Low limit = 30.00 mm
Tolerance = 0.05 mm = 5 × 10– 5 m

Shaft : High limit = 30 – 0.02 = 29.98 mm

Low limit = 30 – 0.05 = 29.95 mm
Tolerance = 29.98 – 29.95
= 0.03 mm = 3 × 10– 5 m

If we select high limit of hole and high limit of shaft then,

Allowance = 30.05 – 29.98 = 0.07 mm

If we choose low limit of hole and high limit of shaft

then,
Allowance = 30.00 – 29.98 = 0.02 mm

Thus, we conclude that the type of fit is Clearance fit.

c) Hole : High limit = 25.04 mm
Low limit = 25.00 mm
Tolerance = 0.04 mm = 4 × 10– 5 m

Shaft : High limit = 25.06 mm

Low limit = 25.04 mm
Tolerance = 25.06 – 25.04
= 0.02 mm = 2 × 10– 5 m

If we select high limit of shaft and low limit of hole then,

Allowance = 25.00 – 25.06
= – 0.06 mm = – 6 × 10– 5 m

It is clear that for any combination of hole and shaft the

allowance will be negative.

Thus, we conclude that the type of fit is Interference fit.

 Designation of Holes, Shafts and Fits
 Example: Consider the designation 50 H8/f7

• Basic size of the shaft and hole = 50 mm.

• Nature of fit for the hole basis system is designated by H

• Fundamental deviation of the hole is zero.

• Tolerance grade: IT8.

• The shaft has a f-type fit, the fundamental deviation has a negative value.

• IT7 tolerance grade.

 Letter Symbols for Tolerances
 First eight designations from A (a) to H (h) for holes (shafts) are used
for clearance fits.

 Designations, JS (js) to ZC (zc) for holes (shafts), are used for interference
or transition fits.

 Fundamental Deviation: Deviation either the upper or lower deviation,

nearest to the zero line. (provides the position of the tolerance zone).
 It may be positive, negative, or zero.

 Upper deviation: Designated as ‘ES’ for a Hole and as ‘es’ for a shaft.

 Lower deviation: Designated as ‘EI’ for a Hole and as ‘ei’ for a shaft.
 • Upper deviation: Designated as ‘ES’ for a Hole and as ‘es’ for a shaft.
• Lower deviation: Designated as 'EI’ for a Hole and as ‘ei’ for a shaft.

Typical representation of different types of fundamental deviations

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

 Tolerance grades indicates the degree of accuracy of manufacture.

 IS: 18 grades of fundamental tolerances are available.

 Designated by the letters IT followed by a number.

 The ISO system provides tolerance grades from IT01, IT0, and IT1 to IT16.

 Tolerance values corresponding to grades IT5 – IT16 are determined using

the standard tolerance unit (i, in μm), which is a function of basic size.
 Tolerance Grade

 D = diameter of the part in mm.

 Value of tolerance unit ‘i ’ is obtained for sizes up to 500 mm.

 D is the geometric mean of the lower and upper diameters.

 D =

The various steps specified for the diameter steps are as follows:

 1–3, 3–6, 6–10, 10–18, 18–30, 30–50, 50–80, 80–120

 120–180, 180–250, 250–315, 315–400, 400–500
 500–630, 630–800, and 800–1000 mm.
 Tolerance Grade
Standard tolerance units

Note that here we are mainly concerned about IT7 and IT8, so kindly remember these
two values. For others, it will be mentioned in the question, if asked.
 Interchangeability

 Manufacturing a large number of parts, it is not economical to produce both the

mating parts by the same operator.

 Parts to be manufactured within min. possible time without compromising on

quality.

 To manufacture identical parts; mass production is the idea.

 The components are manufactured in one or more batches by different persons on

different machines at different locations and are assembled at one place.

 Manufacture of parts under such conditions is called interchangeable manufacture.

 Interchangeability

Interchangeability: Any one component selected at random should assemble

with any other arbitrarily chosen mating component.

Condition

Identical components, manufactured by different operators, using different

machine tools and under different environmental conditions, can be assembled
and replaced without any further modification during the assembly, without
affecting the functioning of the component when assembled.
 Selective Assembly

 In selective assembly, the parts produced are classified into groups according
to their size / dimensions by automatic gauging.

 Both the mating parts are segregated according to their sizes, and matched
with the groups of mating parts are assembled.

 This ensures protection and elimination of defective assemblies.

 Overall cost is reduced, as the parts are produced with wider tolerances.
 Numerical Problems
1. Calculate the limits of tolerance and allowance for a 25 mm shaft and hole pair
designated by H8d9.
Solution :
- 25 mm diameter lies in the standard diameter step of 18-30 mm
D= 18 × 30 =23.238
Fundamental tolerance unit = i = 0.453 𝐷 + 0.001D
i = 1.307 μ

For H8 hole

Fundamental tolerance (tolerance grade table) = 25i = 32.5~33μ = 0.033 mm

For ‘H’ Hole, fundamental deviation is 0 (from FD Table)

Hence, hole limits are 25 mm and 25 + 0.033 = 25.033

mm Hole Tolerance = 25.033 – 25 = 0.033 mm

For d9 shaft

Fundamental tolerance, (tolerance grade table) = 40i = 40 x 1.3 = 52μ = 0.052 mm

For ‘d’ shaft, fundamental deviation (from FD Table) = −16𝐷0⋅44 = – 0.064 mm

Hence, shaft limits are 25 – 0.064 = 24.936 mm and 25 – (0.064 + 0.052) = 24.884

mm

Shaft Tolerance = 24.936 – 24.884 = 0.052 mm

 Numerical Problems
2. Determine the tolerance on the hole and the shaft for a precision running
fit designated by 50 H7g6.
Given ;
1. 50 mm lies between 30 – 50 mm

2. i (microns) = 0.45𝐷1/3 + 0.001D

3. Fundamental deviation for ‘H’ hole = 0

4. Fundamental deviation for ‘g’ shaft = −2.5𝐷0⋅34

5. IT7 = 16i and IT6 = 10i
State the actual maximum and minimum sizes of the hole and shaft.
Also, determine the maximum and minimum clearances.
Solution :-

50 mm diameter lies in the standard diameter step of 30-50 mm

D= 30 × 50 = 38.7 mm
Fundamental tolerance unit = i (microns) = 0.45𝐷1/3 + 0.001D = 1.5597 μ

For H7 hole

Fundamental tolerance (tolerance grade table) = 16i = 24.9μ = 0.025 mm

For ‘H’ Hole, fundamental deviation is 0 (from FD Table)

+0 ⋅ 025
Hence, hole limits are 50−0.000 mm
For g6 shaft

Fundamental tolerance (tolerance grade table) = 10i = 16μ = 0.016 mm

For ‘g’ shaft, fundamental deviation is −2.5𝐷0⋅34 =9μ

− 0.009
Hence, shaft limits are 50−0.025 mm

Hole Tolerance = 25.033 – 25 = 0.033 mm

Hence, Maximum clearance = 50.025 - 49.975 = 0.05 mm.

Minimum clearance =
50.000 - 49.991 = 0.009 mm.
 Unsolved Problem
3. Calculate all the relevant dimensions of 35H7/f8 fit, dimension 35 mm falls
in the step of 30-50 mm. The fundamental deviation for f shaft is – 5.5D0.41.
i (in microns) = 0.45(D)1/3+0.001D, IT7=16i and IT8=25i.