LIMITS, FITS & TOLERANCE

 Terminology:- The terms related to limit system as

per BIS are as below;
 Size:- It is a number expressed
in a particular unit in the
measurement of length.
Hole
 Basic Size:- It is the size based
Size
Basic

Shaft on which the dimensional

deviations are given.

 Actual Size:- It is the size of the component by actual

measurement after it is manufactured. It should lie
between the two limits of size.
 Limits of size:- These are the extreme permissible
sizes within which the operator is expected to make
the component. Maximum limit of size is the greater
of the two limit size, whereas the Minimum limit of
size is the smaller of the two limit of size.
 Hole:- In the B.I.S. system of limits
and fits, all internal features of a
Hole component including those which
Basic size

Shaft are not cylindrical are designated

as ‘Hole’.
 Shaft:- In the B.I.S. system of limits and fits, all
external features of a component including those
which are not cylindrical are designated as ‘Shaft’.
  Tolerance:- It is the
Lower Deviation

Upper Deviation

difference between
Tolerance

maximum limit of size and

the minimum limit of size.
Hole It is always positive and is
expressed only as a number
Max.dia.

Min.dia.

Shaft without a sign.

 Zero line:- In graphical representation of the above

terms, the zero line represents the basic size. This line
is also called as the line of zero deviation.
 Upper Deviation  Fundamental deviation:-
Lower Deviation

There are 25 fundamental

Tolerance

Tolerance
deviations in the B.I.S.
system represented by letter,
Hole
symbols (Capital letters for
Holes and small letters for
Max.dia.

Min.dia.

Max.dia.
Min.dia.

Shaft Shaft)
  Fundamental Tolerance:-
Lower Deviation

Upper Deviation

This is also called as

Tolerance

‘grade of tolerance’. In the

Indian Standard System,
there are 18 grades
Hole
represented by number
Max.dia.

symbols, both for hole and

Min.dia.

Max.dia.
Min.dia.

Shaft shaft denoted as IT01, IT0,

IT1, IT2.....IT16. A high
number indicates more
tolerance
 FIT:- It is the relationship that exists between two
mating parts, a hole and shaft with respect to their
dimensional difference before assembly. Three types of
fit are given hereunder;
 Clearance fit:- It is a fit which
always provides clearance. Here
Clearanc
e fit the tolerance zone of the hole will
be above the tolerance zone of the
Hole Shaft
shaft. Maximum clearance is the
difference between the maximum
hole and minimum shaft.
Minimum clearance is the
difference between the minimum
hole and maximum shaft.
  Interference fit:- It is a fit
which always provides
Tolerance Zone of Tolerance Zone of
interference. Here the tolerance
Hole Shaft
zone of the hole will be below
the tolerance zone of the shaft.
Shaft
Maximum interference is the
Hole
algebraic difference between
the minimum hole and
maximum shaft. Minimum
interference is the algebraic
difference between the
maximum hole and minimum
shaft.
  Transition fit:- It is a fit which
Shaft
may sometimes provides
Hole Hole clearance and sometimes
interference. When this class of
Hole fit is represented graphically,
Shaft
Shaft
the tolerance zone of the hole
and shaft will overlap each
other.

Mass Production :- Mass production means

production of a unit, component or part in large
numbers.
Advantages:- 1.Time for the manufacture of
components is reduced
2.The cost of pieces is reduced. 3.
Spare parts can be quickly made
available. Disadvantages:-1. Special
purpose machines are necessary.
2.Jigs and Fixtures are
needed. 3. Gauges are to be used
instead of conventional precision
instruments. 4. Initial expenditure will be
very high.
 Interchangeability:- When components are mass
produced, unless they are interchangeable, the purpose of
mass production is not fulfilled. By interchangeability, we
mean that identical components, manufactured by
different personnel under different environments, can be
assembled and replaced without any further rectification
during the assembly stage, without affecting the
functioning of the component when assembled.
 Hole Basis System:- Where the
size of the hole is kept constant
and the size of the shaft is varied
to get the different class of fits,
then it is known as the hole basis
system.
 Shaft Basis System:- Where the
size of the shaft is kept constant
and the variations given to the
hole to get the different class of
fits, then it is known as the shaft
basis system.
GAUGES
Gauges are scale less inspection tools at rigid design which
are used to
check the dimensions of manufactured parts. Measurement
by gauges is
Easy and rapid. So they are suitable in mass production.
Instead of
measuring actual dimension of each part which is time
consuming and
Costly, the conformance of part with tolerance specification
can be
checked by gauges.
Types of Gauges
Plain gauges are used to check plain, i.e. unthreaded holes and shafts.
 Classification:
 1.According to Type
 (a)Standard Gauge: If a gauge is made as an exact copy of the mating part
 Of component to be checked, it is called standard gauge.
 A standard gauge can’t be used to check interference fit.
 It has limited application.
 (a)Limit Gauge: Two gauges are used to check each dimension of the
 Part i.e. upper and lower limit. These are “GO” and “NO-GO” gauges.
 GO gauges check MML and NO GO gauges check LML.
 These are widely used industries.
 A part is considered to be good if the GO gauge pass through the work and
 the NO GO gauge fails to pass under the action of its own weight. This
 Confirms the actual dimension of part with in the specified tolerances.
 If both the gauges fail, it indicates that hole is under size and shaft is
 Oversize.
According to Purpose:
a) Workshop gauge
b) Inspection gauge
c) Reference or master gauge
d) Purchase inspection gauge
2. According to the form of the tested surface:
a) Plug gauges for checking holes
b) Snap or Ring or Gap gauges for checking the shaft
3. According to their design:
a) Single limit or double limit gauges
b) Single ended or double ended gauges
c) Fixed and adjustable gauges
Taylor’s Principle of Gauge Design:
1. “Go gauges should be designed to check the Maximum Metal
Limit (MML) while the NO GO gauge should be designed to
check the Least Metal Limit (LML).”
GO plug gauge should correspond to LL of Hole.
NOGO plug gauge should correspond to UL of Hole.
GO snap gauge should correspond to UL of shaft.
NOGO snap gauge should correspond to LL of shaft.
The difference between the GO and NOGO plug gauge as well as
the difference in size between GO and NOGO snap Gauge is
approximately equal to the work tolerance.
2. “GO gauges should check all the related dimensions
(Roundness, size, location, straightness etc).
NOGO gauges should check only one element of the dimension
at a time.”
For
hole

For
shaft
First system
Second system
Fundamental Deviation
Numerical 1
Selective Assembly
In selective assembly components produced are
classified into groups according to their sizes by
automatic gauging. This is done for both Holes
and Shafts and then corresponding parts will be
matched properly.
It reduces chance of defective assembly and also the
cost of assembly as parts may be produced in wider
tolerances.
Ex: Assembly of piston with cylinder bores.
Determine dimension for G and 20g8.
Determine dimension for Q and 40f7.