TOLERANCE – the amount of variation from the specified dimension

in the manufactured part.

ALLOWANCE – the intension difference between the dimension of

the two mating part.

LIMIT – the maximum and the minimum sizes indicated by a

tolerance dimension.

MAXIMUM LIMIT OF SIZE - the greater of the two limit of size

MINIMUM LIMIT OF SIZE – the smaller of the two limit of size

BASIC SIZE – is the size referred to in order to fix the limits of size by
the application of the allowance and tolerance. The basic size is the
same for each mating part.

SHAFT – the term used by convention to designate external features

of a part including part which are not cylindrical.
HOLE – the term used by convention to designate all internal
features of a part including part which are not cylindrical.

DEVIATION – the algebraic difference between the size and the

corresponding basic size.

ACTUAL DEVIATION – the algebraic difference between the actual

size and the corresponding basic size.

UPPER DEVIATION – the algebraic difference between the maximum

limit of size and the corresponding basic size. ES for hole es for shaft.

LOWER DEVIATION - the algebraic difference between the minimum

limit of size and the corresponding basic size. EI for hole ei for shaft.
FUNDAMENTAL DEVIATION – the one of the two deviations being the one
nearest to the zero line which is conventionally chosen to define the
position of the tolerance zone in relation to zero line.

ZERO LINE – the straight line to which the deviations are referred. The
zero line is the line of zero deviation and represents the basic size.

GRADE OF TOLERANCE – is an indication of the degree of accuracy of

manufacture and is designated by the letter IT followed by the number.

STANDARD TOLERANCE UNIT – it is the unit used to calculate the various

grade of tolerance for a given basic size. It is designated by letter I.
MINIMUM CLEARANCE – In clearance fit, the difference between the
minimum size of the hole and the maximum size of the shaft.

MAXIMUM CLEARANCE – In a clearance or a transition fit the difference

between the maximum size of the hole and the minimum size of the shaft.

MINIMUM TERFERENCE– In an interference fit the difference between the

maximum size of the hole and the minimum size of the shaft.

MAXIMUM INTERFERENCE – in an interference and transition fit the

difference the minimum size of the hole and the maximum size of the shaft
before assembly

FITS - The relationship resulting from the difference, before assembly ,

between the sizes of the two parts which are to be assemble
CLEARANCE FIT – where it is necessary to have a movement between
parts, the hole will need to be larger than the male component.

INTERFERENCE FIT - where parts are required to fit together. This fit
in which the shaft is always larger than female component.

TRANSITION FIT – the tolerance zones for the hole and the shaft
overlap so that a small clearance or small interference may result on
assembly depending upon the actual size of the hole and shaft.
A basic dimension is the dimension, as worked out by
purely design considerations. Since the ideal
conditions of producing basic dimension, do not exist,
the basic dimension can be treated as theoretical or
nominal size, and it has only to be approximated.

SHAFT

HOLE Basic Dimension /

Basic Size
Clearance Fit
In this type of fit, the largest permitted shaft diameter
is smaller than the diameter of the smallest hole, so that the
shaft can rotate or slide through with different degrees of
freedom according to purpose of the mating members.

SHAFT

HOLE
Transition Fit
In a fit of this type the diameter of the largest allowable
hole is greater than that of the smallest shaft, but the smallest
hole is larger than the largest shaft, so that small positive or
negative clearance between the shaft and hole members are
employable.

SHAFT

HOLE
Interference Fit
- the difference between the sizes of a hole and a shaft which
are to be assembled together when the shaft is larger than the hole.

SHAFT

HOLE
 Lower Tolerance
Deviation Upper of Hole
Deviation Hole

Zero Line

Maximum Shaft
Minimum Tolerance of
Diameter
Diameter Shaft
 HOLE Tolerance Grade SHAFT Tolerance Grade

HOLE HOLE
ZERO
LINE
SHAFT SHAFT

HOLE BASIS SYSTEM HOLE BASIS SYSTEM

•Lower deviation of hole is zero. “H” Hole •Upper deviation of shat is zero. “h” Shaft
•1 is Clearance Fit •1 is Clearance Fit
•2 is Transition Fit •2 is Transition Fit
•3 is Interference Fit •3 is Interference Fit
Example: Calculate the limits of tolerance and allowance for a 60mm
shaft and hole pair designated H7 / m6.

Solution:

Step 1. Find out in which range does 60mm lies. In this, case it is
between
50 – 80 mm.

Step 2. Calculate the value of geometric mean (D). Use the formula
below.
__________
D = √50 x 80 = 63.25

Step 3. Calculate the value of tolerance unit. Use the equation below.
3____
I = 0.45 √ D + 0.001 D

3________
I = 0.45 √ 63.25 + 0.001 (63.25)
= 1.856
Step 4. Calculate tolerance grade (IT7)

IT7 = 16I = 16 x 0.001856

= 0.0297 mm.

Step 5. Calculate tolerance grade (IT6)

IT6 = 10I = 10 x 0.001856

= 0.019 mm.

Step 6. Calculate the fundamental deviation.

Hole – H

F.D. = 0

Shaft – m

F. D.= 0.024D + 12.6

= 0.024 (63.25) + 12.6
= 0.0141 mm.
Step 7. Calculate the shaft limits of sizes.

HOLE
Lower limit of size = Basic Size
= 60 mm

Upper limit of size = Basic Size + Tolerance

= 60 mm + 0.030 mm
= 60.030 mm

SHAFT
Upper Limit of Size = Basic Size + FD + Tol
= 60 mm + 0.014 + 0.019
= 60.033

Lower Limit of Size = Basic Size + F.D.

= 60 mm + 0.014 mm
= 60.0141 mm
 F.D. = + F.D. = 0 F.D. = -
TOLERANCE TOLERANCE

FUNDAMENTAL
DEVIATION FUNDAMENTAL
DEVIATION

BASIC
SIZE
TOLERANCE

LLS = Basic Size + F.D. LLS = Basic Size ULS = Basic Size - F.D.
ULS = LLH + Tol. ULS = Basic Size + Tol. LLS = ULH - Tol.

LEGEND:
- TOLERANCE

- FUNDAMENTAL DEVIATION
 INTERFERENCE TRANSITION CLEARANCE
F.D. = + F.D. = 0 F.D. = -
FUNDAMENTAL
TOLERANCE
DEVIATION TOLERANCE FUNDAMENTAL
DEVIATION
BASIC SIZE

TOLERANCE

ULS = BASIC SIZE + F.D. + TOL ULS = BASIC SIZE ULS = BASIC SIZE – F.D.
LLS = BASIC SIZE + F.D. LLS = BASIC SIZE - TOL LLS = BASIC SIZE - F.D. - TOL

LEGEND:
- TOLERANCE
- FUNDAMENTAL DEVIATION
 FUNDAMENTAL DEVIATION
MINIMUM MAXIMUM INTERFERENCE
CLEARANCE MAXIMUM (ALLOWANCE)
MAXIMUM CLERANCE
(ALLOWANCE) INTERFERENCE
(ALLOWANCE)
TOLERANCE

MAXIMUM
CLEARNCE
MINIMUM
H
INTERFENCE
L LIMITS OF OVERSIZE
BASIC SIZE

SIZE FOR HOLE

UNDERSIZE HOLE
LIMITS OF
HOLE
SIZE FOR
SHAFT

CLEARANCE TRANSITION INTERFERENCE

SYMBOLS INDICATING TOLERANCE ZONES

HOLE SHAFT
Standard tolerance Unit
 General Cases
Above (a) Up to (b)
  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
 SHAFT HOLE
FORMULA FOR DEVIATION IN
TYPE SIGN TYPE SIGN MICRONS D in mm
d - D + 16 D 0.44

e - E + 11 D 0.41

f - F + 5.5 D 0.41

g - G + 2.5 D 0.34

h - H   0

js - JS + 0.5 ITn

___ K4 to K7:
K + K -
0.6 √ D all others: 0

m + M - 0.024D + 12.6

n + N - 0.04D + 21

p + P - 0.072D + 37.8
Geometric Mean between p&
r + R -
s or P & S

s + S - IT7 + 0.4D

t + T - IT7 + 0.63D

u + U - IT7 + D
Tolerance Grade Value
1T 5 7I
1T 6 10I
1T 7 16I
1T 8 25I
1T 9 40I
1T 10 64I
1T 11 100I
1T 12 160I
1T 13 250I
1T 14 400I
1T 15 640I
1T 16 1000I
 With Holes
Type of
Cases of Fit REMARKS
Fit H6 H7 H8 H11

Shaft a - - - All Not widely used

Shaft b - - - - Not widely used

Shaft c - *c8 *c9 *c11 Slack running fit

Shaft d - *d8 *d8 *d11 Loose running fit

Shaft e E7 e8 e8 - Easy running fit

Shaft f *f6 *f7 *f8 - Normal running fit

Shaft g *g5 *g6 *g7 - Close running fit or sliding

Precision sliding fit time spigot

Shaft h *h5 *h6 *h7 *h11 and location fit

Push fit for very accurate location

Shaft j *j5 *j6 *j7 - with easy assembly and dis-
dismantling

Shaft k *k5 *k6 *k7 - Light keying fit

Shaft m *m5 *m6 *m7 - Medium keying fit

Heavy keying fit (for

Shaft n *n5 *n6 *n7 -
light assembly of making parts)

Light press fit with easy

Shaft p *p5 *p6 - - dismantling for non ferrous parts
Medium drive fit with easy
Shaft r *r5 *r6 - - dismantling

Shaft s *s5 *s6 *s7 - Heavy drive fit

Shaft t *t5 *t6 *t7 - Force fit for permanent assembly

Shaft u *u5 *u6 *u - Heavy force fit or shrink fit

 Data sheet 4500A – hole basis. Given that the basic size of
hole and shaft are 55mm diameter, and it is an interference
fit- hole/shaft H7/p6

1. The limit size.

2. The tolerance on the shaft.
3. The tolerance on the hole.
4. The upper and lower deviation on the shaft.
5. The upper and lower deviation on the hole.
6. The minimum interference.
7. The maximum interference of the shaft in the hole.
8. APPLICATION
• The limit size for the shaft p6
= 55.051 high limit
55.032 low limit

• The limit size of the hole H7 =

= 55.030 high limit
55.000 low limit
= 55.051 – 55.032
= 0.019mm

= 55.030 – 55.000
= 0.030mm
• The upper deviation on the shaft
= maximum size - basic size
= 55.051 – 55.000 = 0.051mm

• The lower deviation on the shaft

= minimum size – basic size
= 55.032 – 55.000 = 0.032mm
 
• The upper deviation on the hole
= maximum size – basic size
= 55.032 – 55.000 = 0.03Ø

• The lower deviation on the hole

= 55.000 – 55.000 = 0.000mm
 
= minimum shaft size – maximum hole size
= 55.032 - 55.030 = 0.002mm
 

= maximum shaft size – minimum hole size

= 55.051 - 55.000 = 0.051mm
 Tolerances
Table 1
HOLE BASIS SYSTEM
NOMINAL HOL
SIZE/MM HOLE SHAFT MICRON HOLE SHAFT SHAFT HOLE SHAFT
E

OVER UP TO AND
INCLUDING H-7 s6 p6 n6 k6 h6 g6 H-8 f7 H-9 e9 d10 H11 c11

+10 +20 +12 +10 +6 0 -2 +14 -6 25 -14 -20 +60 -60

0-3
0 +11 +6 +4 0 -6 -8 0 16 0 -39 -60 0 -120

+12 +27 +20 +16 +9 0 -4 +18 -10 30 -20 -30 +75 -170
3 to 6
0 +19 +12 +8 +1 -8 -12 0 -12 0 -50 -78 0 -145

+15 +32 +24 +19 +10 0 -5 +22 -13 +36 -25 -40 +90 -180
6 to 10
0 +23 +18 +10 +1 -9 -14 0 -28 0 -61 -98 0 -170

+18 +39 +29 +23 +12 0 -6 -27 -16 +43 -32 -50 +100 -95
10 to 18
0 +28 +18 +12 +1 -1 -17 0 -34 0 -75 -120 0 -205

+21 +48 +35 +28 +15 0 -7 +33 -20 +52 -40 -65 +130 -110
18-30
0 +35 +22 +15 +2 -13 -20 0 -41 0 -92 -149 0 -240

+25 +59 +42 +33 +18 0 -9 +39 -25 +62 -50 -80 +160 -120
30-40
0 +43 +26 +17 +2 -16 -25 0 -50 0 -112 -180 0 -280

+25 +59 +42 +33 +18 0 -9 +39 -25 +62 -50 -80 +160 -130
40-50
0 +43 +26 +17 +2 -16 -25 0 -50 0 -112 -180 0 -290

+30 +72 +51 +39 +21 0 -10 +46 -30 +74 -60 -100 +190 -140
50-65
0 +53 +32 +20 +2 -19 -29 0 -60 0 -134 -220 0 -330

+30 +78 +51 +39 +21 0 -10 +46 -30 +74 -60 -100 +190 -150
65-80
0 +59 +32 +20 +2 -19 -29 0 -60 0 -134 -220 0 -340

+35 +93 +59 +45 +25 0 -12 +54 -36 +87 -72 -120 +220 -170
80-100
0 +71 +37 +23 +3 -22 -34 0 -71 0 -159 -260 0 -390

100-120 0 +79 +37 +23 +3 -22 -34 0 -71 0 -159 -260 0 -400
 +40 +117 +68 +52 +28 0 -14 +63 -43 +100 -85 -145 +250 -200
120-140
0 +92 +43 +27 +3 -25 -39 0 -83 0 -185 -305 0 -450

+40 +125 +68 +52 +28 0 -14 +63 -43 +100 -85 -145 +250 -210
140-160
0 +100 +43 +27 +3 -25 -39 0 -83 0 -185 -305 0 -460
+40 +133 +68 +52 +28 0 -14 +63 -43 +100 -85 -145 +250 -230
160-180
0 +108 +43 +27 +3 -25 -39 0 -83 0 -185 -305 0 -480
+46 +151 +79 +60 +33 0 -15 +72 -50 +115 -100 -170 +290 -240
180-200
0 +122 +50 +31 +4 -29 -44 0 -96 0 -215 -355 0 -530
+46 +159 +79 +60 +33 0 -15 +72 -50 +115 -100 -170 +290 -260
200-225
0 +130 +50 +31 +4 -29 -44 0 -96 0 -215 -355 0 -550
+46 +169 +79 +60 +33 0 -15 +72 -50 +115 -100 -170 +290 -280
225-250
0 +140 +50 +31 +4 -29 -44 0 -96 0 -215 -355 0 -570

+52 +190 +88 +66 +36 0 -17 +81 -56 +130 -110 -190 +320 -300
250-280
0 +158 +56 +34 +4 -32 -49 0 -108 0 -240 -400 0 -620
+52 +202 +88 +66 +36 0 -17 +81 -56 +130 -110 -190 +320 -330
280-315
0 +170 +56 +34 +4 -32 -49 0 -108 0 -240 -400 0 -650

+57 +226 +98 +73 +40 0 -18 +89 -62 +140 -25 -210 +360 -360
315-355
0 +190 +62 +37 +4 -36 -54 0 -119 0 -265 -440 0 -720
+57 +244 +98 +73 +40 0 -18 +89 -62 +140 -25 -210 +360 -400
355-400
0 +208 62 +77 +4 -36 -54 0 -119 0 -265 -440 0 -760
+63 +272 +108 +80 +45 0 -20 +97 -68 +155 -135 -230 +400 -440
400-450
0 +232 +168 +10 +5 -40 -60 0 -131 0 -290 -480 0 -840
+63 +292 +108 +80 +45 0 -20 +97 -68 +155 -135 -230 +400 -480
450-500
0 +252 +168 +10 +5 -40 -60 0 -131 0 -290 -480 0 -880

ME
PRE LIGH COA
CLO DIU
CISI PRECI T RSE
FOR DRIV PUS SE SION M
TYPE OF FIT   LOCATIONAL ON   RUNN   RUN   RUN
CE E H SLID SLIDI RUN
ING NIN NIN
ING NG NIN
G G
G
 Tolerances
Table 2
SHAFT BASIS SYSTEM
NOMINAL
SIZE/MM SHAFT SHAFT MICRON SHAFT   SHAFT HOLE SHAFT HOLE

OVER UP TO AND
INCLUDING h6 S7 P7 N7 K7 H7 G7 h7 F8 h9 E9 D9 h11 C11
0 -14 -6 -4 0 +10 +12 0 +20 0 +39 +60 0 +120
0-3
-6 -24 -16 -14 +10 0 +2 -10 +6 -25 +14 +20 -60 +60
0 -15 -8 -4 +3 +12 +16 0 +26 0 +50 +78 0 +145
3 to 6
-8 -27 -20 -16 -9 0 +4 -12 +10 -30 +20 +30 -75 +70
0 -17 -9 -4 +5 +15 +20 0 +35 0 +61 +98 0 +170
6 to 10
-9 -21 -24 -19 -10 0 +5 -15 +13 -36 +25 +40 -90 +80

0 -21 -11 -5 +6 +18 +24 0 +43 0 +75 +120 0 +205

10 to 18
-11 -39 -29 -23 -12 0 +6 -18 +16 -43 +32 +50 -110 +95

0 -27 -14 -7 +6 +12 +28 0 +53 0 +92 +149 0 +240

18-30
-13 -48 -35 -28 -15 0 +7 -21 +20 -52 +40 +65 -130 +110
0 -34 -17 -8 +7 +25 +34 0 +64 0 +112 +180 0 +280
30-40
-16 -59 -42 -33 -18 0 +9 -25 +25 -62 +50 +80 -160 +120
0 -34 -17 -8 +7 +25 +34 0 +64 0 +112 +180 0 +290
40-50
-16 -59 -42 -33 -18 0 +9 -25 +25 -62 +50 +80 -160 +130
0 -42 -21 -9 +9 +30 +40 0 +76 0 +134 +220 0 +330
50-65
-19 -72 -51 -39 -21 0 +10 -70 +30 -74 +60 +100 -190 +140
0 -48 -21 -9 +9 +30 +40 0 +76 0 +134 +220 0 +340
65-80
-19 -78 -51 -39 -21 0 10 -70 +30 -74 +60 +100 -190 +150

0 -58 -24 -10 +10 +35 +47 0 +90 0 +159 +260 0 +390
80-100
-22 -93 -59 -45 -25 0 +12 -35 +36 -87 +72 +120 -220 +170

100-120 -22 -101 -59 -45 -25 0 +12 -35 +36 -87 +72 +120 -220 +180
 0 -77 -28 -12 12 +40 +50 0 +106 0 +185 +305 0 +450
120-140
-25 -117 -68 -52 -18 0 +14 -40 +43 -100 +85 +45 -250 +200

0 -85 -28 -12 12 +40 +50 0 +106 0 +185 +305 0 +460

140-160
-25 -125 -68 -52 -18 0 +14 -40 +43 -100 +85 +45 -250 +210

0 -93 -28 -12 12 +40 +50 0 +106 0 +185 +305 0 +480

160-180
-25 -133 -68 -52 -18 0 +14 -40 +43 -100 +85 +45 -250 +230

0 -105 -33 -14 +33 +46 +61 0 +122 0 +215 +355 0 +530
180-200
-29 -151 -79 -60 -33 0 +15 -46 +50 -115 +100 +170 -290 +240

0 -113 -33 -14 +33 +46 +61 0 +122 0 +215 +215 0 +550
200-225
-29 -59 -79 -60 -33 0 +15 -46 +50 -115 +100 +100 -290 +260

0 -123 -33 -14 +33 +46 +61 0 +122 0 +215 +215 0 +570
225-250
-29 -169 -79 -60 -33 0 +15 -46 +50 -115 +100 +100 -290 +280

0 -138 -48 -14 +16 +52 +69 0 +137 0 +240 +240 0 +620
250-280
-32 -190 -88 -66 -36 0 +17 -52 +56 -130 +110 +110 -320 300

0 -150 -48 -14 +16 +52 +69 0 +137 0 +240 +240 0 +650
280-315
-32 -202 -88 -66 -36 0 +17 -52 +56 -130 +110 +110 -320 +330

0 -169 -41 -76 +17 +57 +75 0 +151 0 +265 +265 +360 +720
315-355
-36 -226 -98 -73 -40 0 +18 -57 +62 -140 +125 +125 0 +360

0 -187 -41 -76 +17 +57 +75 0 +151 0 +265 +265 +360 +760
355-400
-36 -244 -98 -73 -40 0 +18 -57 +62 -140 +125 +125 0 +400

0 -209 -45 -17 +18 +60 +83 0 +165 0 +290 +480 0 +840
400-450
-40 -272 -108 -80 -45 0 +20 -63 +68 -155 +135 +230 -400 +440

0 -229 -45 -17 +18 +60 83 0 +165 0 +290 +480 0 +880

450-500
-40 -292 -108 -80 -45 0 +20 -63 +68 -155 +135 +230 -400 +480

CLOS PRECI MEDI COAR

PRECISI LIGHT
TYPE OF FORC DRIV E SION ON UM SE
  PUSH LOCATIONAL   RUNNIN   RUNN  
FIT E E SLIDI SLIDI RUNN RUNN
NG G ING
NG ING ING
 Gauges are inspection tools of rigid design,
without a scale, which serve to check the
dimension of manufactured parts. They can
only be used in determining whether the
inspected parts are made within the specified
limits.
Thus, gauges must conform with the shape
and form of the inspected parts (as mating
parts)
Plug gauges for hole inspection and
ring/snap gauges for shaft inspection.
Gauges are classified according to:
•Type
–Standard and limit gauges
–Limit gauges
•Purpose
–Workshop
–Inspection
–Reference or master gauge
•Form of tested surface
–Plug gauges (holes)
–Snap and ring gauges (shaft)
•Design
–Single limit and double limit
–Single ended and double ended
–Fixed and adjustable
GO NO GO NO GO

GO
Figure 1.0. An example of Plug
Gauges
A. Double Ended / Single Limit
B. Single Ended / Single Limit
C. Single Ended / Double Limit NO GO

GO
 GO NO GO
A
GO
NO GO
Figure 2.0. Examples of Ring / Snap Gauges.
A. Single Limit
B. Double Limit B
 CALCULATE THE LIMIT OF SIZE OF THE HOLE AND SHAFT FOR THE
FOLLOWING FIT AND DESIGN FOR GO AND NO GO GAUGE: 70mm H6 / k5
GEOMETRIC MEAN:
__________ ________ 6. MAXIMUM INTERFERENCE
D = √ 50 x 80 = √ 4000 = ULS (SHAFT) – LLS (HOLE)
D = 63.25 = 70.030 – 70
= 0.030 mm
TOLERANCE UNIT:
3 ___ 7. MAXIMUM CLEARANCE
I = 0.45 √ D + 0.001 D = ULS(HOLE) – LLS (SHAFT)
I = 0.00405 mm = 70.041 – 70.002
= 0.039 mm
TOLERANCE GRADE
IT6 = 10I = 0.041mm
IT5 = 7I = 0.028 mm

UNDAMENTAL DEVIATION
A. HOLE
FD = 0 mm
B. SHAFT
FD = 0.6 (D) = 0.002 mm

IMIT OF SIZE
A. HOLE: LLS = 70 mm
ULS = BS + TOL = 70 + 0.041
= 70.041 mm

B. SHAFT: LLS = BS + FD = 70 + 0.002

= 70.002 mm
ULS = LLS + TOL = 70.002 + 0.028
= 70.030 mm
 DESIGN FOR GO AND NO GO GAUGE H6 / k5 FOR GAP GAUGE

GIVEN: NO GO GAUGE:
The high limit of the size is the low limit of the
THE LIMIT OF SIZE FOR THE SHAFT shaft . The low limit of the size is the low limit of
LLS = 70.002 mm the shaft minus the gauge tolerance
ULS = 70.030 mm
TOL = 0.028 mm LLS = LLS OF SHAFT – 10% OF TOL
LLS = 70.002 – 0.1 (0.028)
LLS = 70.002 – 0.0028
LLS = 69.9992 mm
GO GAUGE:
The high limit of size is the high limit of ULS = LLS OF SHAFT
the shaft. The lower limit of the size is the ULS = 70.002 mm
high limit of the shaft minus the gauge tolerance

ULS = ULS OF SHAFT

ULS = 70.030 mm
LLS = 70.030 – 10% of TOL
LLS = 70.030 – 0.1(0.028)
LLS = 70.0272 mm
 GO GAUGE
GO GAUGE

69.992 0.0028 70.0272 0.0028

70.002 70.030

70.030 70.030

70.002 0.028 70.002 0.028

SHAFT
SHAFT
DESIGN FOR GO AND NO GO GAUGE H6 / k5 FOR PLUG GAUGE

GIVEN:

THE LIMIT OF SIZE FOR THE HOLE

LLS = 70.000 mm
ULS = 70.041 mm
TOL = 0.041 mm

NO GO GAUGE:
GO GAUGE:
The low limit of the size is the high
The low limit of size is the low limit of the
limit of the hole. The high limit of
Hole. The high limit of the size is the low
the size is the high limit of the hole
limit of the hole plus the gauge tolerance
plus the gauge tolerance
LLS = LLS OF HOLE
LLS = ULS OF HOLE
LLS = 70.000 mm
LLS = 70.041 mm
ULS = LLS OF HOLE + 10% OF TOL
ULS = 70.000 + 0.1 (0.041) ULS = ULS OF HOLE + 10% OF TOL
ULS = 70.041 + 0.1 (0.041)
ULS = 70.000 + 0.0041
ULS = 70.0041 mm ULS = 70.041 + 0.0041
ULS = 70.0451 mm
 HOLE
HOLE

70 0.041 70 0.041

70.041 70.041

70.041 70.0041

70.0451 0.0041 70 0.0028

NOT
GO GAUGE
GO GAUGE
• Tolerance – tolerance on a dimension is
the difference between the high and low
limits of its size

• Allowance – An intentional difference

between the hole and shaft dimension for
any type of fit.

• Fits – The relation resulting from the

difference between sizes of a hole and a
shaft before assembly
• Nominal Size – the nominal size of a dimension or part is
the size by which it is referred to as a matter of convenience.

• Basic Size – It is got to be a ascribed for the sake of

convenience and the size of a part in relation to which al
limits of variation are determined.

• Zero Line – This line which represents the basic size so that
deviation from the basic size is zero.

• Actual Size – This is the measured size

• Limits – These are two extreme permissible sizes for any

dimension
 There are some considerations in deciding the
limits necessary for a particular dimension.
These are as follows:

–Functional requirement – function of the

component, what it is required to do.

–Interchangeability – its replacement in the

event of failure.

–Economics – minimization of time and cost.

 Ideal conditions called for parts without
any kind of dimensional variations. However,
actual practice tells otherwise due to the
following:

•Variation in the properties of materials being

machined introduce errors.
•The production machine themselves have some
inherent inaccuracies built into them and have the
limitations to produce perfect parts.
•It is impossible for an operator to make perfect
settings. Set-up error can creep in depending on the
operators skill.
 Tolerance can be defined as the magnitude of permissible
variation of a dimension or other measured or control criterion
from specified value.

Unilateral Tolerance when tolerance distribution is on

only one size of basic size.

Basic Size ( 0 + 22µ)

Bilateral Tolerance when permissible variation is both

plus and minus or on both direction of basic size.

Basic Size ( +/- 22µ)

 Cost of production keeps on increasing tremendously
for very precise tolerance. As the tolerance approaches
zero, the task of achieving it becomes enormous and
finally impossible.
Functional dimensions are those which have to be
machined and fit with other mating components.

Non-functional dimensions are those which need

not be machined to a higher degree of accuracy.
These have no effects on the quality or performance
of the component or assembly.
Exercise No. 1: Calculate
the limits of tolerance and
allowance for a 90mm
shaft and hole pair
designated H7/p6.
Find the following:
• Find out in which range does 90mm lies.
• Calculate the value of geometric mean (D)
• Calculate the value of tolerance unit. (I)
• Calculate tolerance grade
» Hole/shaft
• Calculate the fundamental deviation.
» Hole/shaft
Calculate the limits of size.
Hole/shaft
• The maximum
• The minimum
• Application