System of Limits, Fits, Tolerance and Gauging

Limits & Fits:

Why study Limits &
Fits?
Exact size is impossible to achieve.
Establish boundaries within which deviation from perfect form is allowed but still the
design intent is fulfilled.

Enable interchangeability of components during assembly

Definition of
Limits:
The maximum and minimum permissible sizes within which the actual size of a
component lies are called Limits.

Toleranc
e:
It is impossible to make anything to an exact size, therefore it is essential to allow a
definite tolerance or permissible variation on every specified dimension.
 Why Tolerances are specified?
Variations in properties of the material being machined introduce errors.

The production machines themselves may have some inherent inaccuracies.

It is impossible for an operator to make perfect settings. While setting up the

tools and workpiece on the machine, some errors are likely to creep in.

𝜙 40
+0.05
- 0.05

Consider the dimension shown in fig. When trying to achieve a diameter of 40 mm (Basic
or Nominal diameter), a variation of 0.05 mm on either side may result.
 𝜙 40
+0.05
- 0.05

If the shaft is satisfactory even if its diameter lies between 40.05 mm & 39.95 mm, the
dimension 40.05 mm is known as Upper limit and the dimension 39.95 mm is known
as Lower limit of size.

Tolerance in the above example is (40.05-39.95) =0.10

mm

Tolerance is always a positive quantitative number.

 Tolerance
Unilateral Dimensions: Bilateral Tolerance:
Tolerance:
Unilateral
Tolerance:

𝜙 25
+0.18
+ 0.10

𝜙 25
- 0.10
- 0.20
 When the two limit dimensions are only on one side of the nominal size, (either above
or below) the tolerances are said to be unilateral.

For unilateral tolerances, a case may occur when one of the limits coincide with the
basic size.
 Bilateral Tolerance:

𝜙 40
+0.05
- 0.05

When the two limit dimensions are above and below nominal size, (i.e. on either side
of the nominal size) the tolerances are said to be bilateral.

Note:
Unilateral tolerances, are preferred over bilateral because the operator can machine to
the upper limit of the shaft (or lower limit of a hole) still having the whole tolerance left
for machining to avoid rejection of parts.
Fig: Schematic representation of
tolerances
Terminology of limit
systems:
 Shaft:
The term shaft refers not only to the diameter of a circular shaft but also to any external
dimension of a component.

Hole:
The term hole refers not only to the diameter of a circular hole but also to any internal
dimension of a component.

Nominal size:
It is the size of the component by which it is referred to as a matter of convenience.

Basic size:
A basic size for convenience may be defined as theoretical or nominal size which for the
practical reasons is only approximated or it is the size which would be obtained if
perfection were possible.
It is the size of a part in relation to which all limits of variation are determined.
Limits of size:
The two extreme permissible sizes of a component between which the actual size should lie
including the maximum and minimum sizes of the component.

Zero Line:
It is the line w.r.t which the positions of tolerance zones are shown.

Deviation:
It is the algebraic difference between a limit of size and the corresponding basic size.

Upper Deviation:
It is the algebraic difference between the maximum limit of size and the corresponding
basic size. It is denoted by letters ‘ES’ for a hole and ‘es’ for a shaft.

Lower Deviation:
It is the algebraic difference between the minimum limit of size and the corresponding
basic size. It is denoted by letters ‘EI’ for a hole and ‘ei’ for a shaft.
Fundamental Deviation:
It is the deviation, either upper or lower deviation, which is nearest to the zero line for
either a hole or a shaft. It fixes the position of the tolerance zone in relation to the zero
line.

Allowance:
It is the intentional difference between the hole dimensions and shaft dimension for any
type of fit.

Size of tolerance:
It is the difference between the maximum and minimum limits of size.

i.e. Tolerance T = ES – EI (for hole)

= es – ei (for shaft)
 System of
Fits:
When two parts are to be assembled, the relationship resulting from the difference
between their sizes before assembly is called a fit.

Types of Fit:

1. Clearance
Fit.
2. Interference
Fit.

3. Transition.
 1. Clearance Fit.

In this type of fit, the largest permitted shaft diameter is less than the smallest hole
diameter so that the shaft can rotate or slide according to the purpose of the assembly.
 2. Interference Fit.

It is defined as the fit established when a negative clearance exists between the sizes of
holes and the shaft. In this type of fit, the minimum permitted diameter of the shaft is
larger than the maximum allowable diameter of the hole.

In case of this type of fit, the members are intended to be permanently attached.

Ex: Bearing bushes, Keys & key ways, Steel rings on a wooden bullock cart
wheels
 3. Transition Fit:

In this type of fit, the diameter of the largest allowable hole is greater than the smallest
shaft, but the smallest hole is smaller than the largest shaft, such that a small positive or
negative clearance exists between the shaft & hole.

Ex: Coupling rings, Spigot in mating

holes, etc