Limits, Fits, Tolerances
Introduction
• No two things in nature can be identical.
• Every process is a combination of three elements viz.
Man, machine, Material.
• The three elements are subject to inherent and
characteristic variation, resulting in variation of size of
output component.
• If process is under control size of variation will be within
reasonable limits.
• In a process under control , most of the items will be
symmetrically distributed about the mean value and
remaining within expressible limits.
• Tolerances must be allowed as it is impossible to
produce an item to an exact size.
• A given dimension is allowed to lie between two limits
i.e. maximum and minimum. Difference between these
two limits is called permissive tolerance.
• Tolerance distribution on one side of the basic size is
called unilateral tolerance. If permissible variation is
both plus and minus, it is called bilateral tolerance.
Need for Tolerances
• Cost of attempting to produce to a specified
definite size without variation would be too
high.
• Interchangeable production and continuous
assembly require some standard procedure to
be followed.
Criteria of Success of System of Limits and Fits
• It should be based on some standard so it can be
understood by all.
• Range of the sizes covered by each system should be
sufficient for most purposes.
• For any basic size it must be possible to select from a
carefully designed range of limits and fits the most
suitable one for a given application.
• Number of limits and fits should be reduced and be
adequate to cover all applications.
Tolerances
• Defined as the magnitude of permissible variation of a
dimension from the specified value.
• Formulation of tolerances should be given due
consideration as it is not an arbitrary matter.
• Functional requirement is the primary consideration in
formulation of tolerances.
• Other factors Standardization, manufacturing needs etc.
also influence choice of tolerances. At times the primary
functional requirements sometimes needs compromise
with these factors.
Ways of Expressing Tolerances.
• Tolerances are basically specified in two forms:-
i. Unilateral Tolerances
ii. Bilateral Tolerances
• Unilateral tolerances is indicated when machining of
mating parts is called for. Here tolerance as related to
basic dimension is specified in one direction only.
+0.02 −0.01
eg. 25+0.01 , 25−0.02
• In Bilateral tolerances , the total tolerance is specified on
both sides (plus and minus) of the basic dimension.
+0.02
eg. 25±0.02 , 25−0.01
Types of Fits
1) Trial and Error:
2) Interchangeable assembly
3) Selective Assembly
Interchangeability
• An interchangeable part is one which can be substituted
which can be substituted for similar part manufactured
to the same drawings.
• Any one component selected at random should
assemble with any other mating component, that too
selected at random.
• Such a system if ensured it is known as interchangeable
system.
• Interchangeable assemblies require processes whose
process capability is equal to or less than process
capability of mating parts.
Advantages…
i. No time lost in fitting mating components.
ii. Increased output with reduced production
cost.
iii. Specialized operation since division of labor
takes place.
iv. Possibility of replacement of worn out parts
Selective Assembly
• Components produced are classified into groups
according to their sizes based on automatic gauging.
• This is done for both mating parts, holes and shafts,
and only matched groups of mating parts are
assembled.
• Results in complete protection against defective and
reduces matching cost as the parts must be
produced with wider tolerances.
Limits
• Limits are the two extreme permissible sizes,
between which the actual size of the
dimension may lie.
• Limits are fixed with reference to the basic size
of that dimension.
• Upper Limit for that dimension is the largest
size permitted and lower Limit is the smallest
size permitted for that dimension.
1)Upper deviation:
• Algebraic difference between the upper limit of size and
corresponding basic size.
• Positive when maximum limit of size is greater than the
basic size and negative when the upper limit of size is less
than basic size.
• Denoted by ‘ES’ for hole and ‘es’ for shaft.
2) Lower deviation:
• Algebraic difference between lower limit of size and
corresponding basic size.
• Positive when maximum lower limit of size is greater than
the basic size and negative when Maximum lower limit of
size is less than the basic size.
• Denoted b ‘EI’ for Hole and ‘ei’ for shaft.
• For shaft:
IT = es - ei ( upper deviation – lower deviation)
es = ei+IT
Where, IT = shaft tolerance
• For Hole:
IT = ES – EI
ES = EI + IT
Where, IT = Hole tolerance
3) Fundamental Deviation:
• It is that one of the two deviations (either upper or lower)
which is nearest to the zero line for either hole or shaft.
• Fundamental deviation for the ole is denoted by capital
letters A,B,C,…,Zc and for shaft is denoted by the small
letters a,b,c, ….., Zc
4) Basic Shaft:
• Shaft whose upper deviation is zero.
• Denoted by ‘h’
5) Basic Hole:
• Hole whose lower deviation is zero.
• Denoted by ‘H’.
6) Tolerance Zone:
• Zone bounded by two limits of size of a part in the
graphical representation of tolerance.
• Defined in magnitude and position in relation to zero line.
7) Tolerance Grade:
• Indication of degree of Accuracy of manufacture.
• Designated as ‘IT’ (International Tolerance grade) followed
by a number.
• Tolerance grades are IT01, IT0, IT1 up to IT16, larger the
number larger will be the tolerance.
Types of Fits
• There are 3 basic types of Fits:
i. Clearance Fit ii. Transition Fit
iii. Interference Fit
• These are further classified as follows:
Clearance Fit Transition Fit Interference Fit
Slide Fit Push Fit Force Fit
Easy Slide Fit Wringing Fit Tight Fit
Running Fit Shrink Fit
Slack Running Fit
Loose Running Fit
Clearance Fit
• In this type of fit shaft is always smaller than the hole i.e.
the largest permissible shaft diameter is smaller than
diameter of smallest hole.
• Tolerance Zone of Hole is above that of the Shaft.
Interference Fit
• In this type of Fit minimum permissible diameter of the
shaft is larger than the maximum allowable diameter of
the hole.
• Shaft and the Hole are intended to be attached
permanently and used as Solid component.
Transition Fit
• Transition fit lies midway between clearance and
interference fit.
• In this type the size limits of mating parts are so
selected that either clearance or interference may
occur depending upon the actual sizes of the parts.
Allowance
• Prescribed difference between the dimensions of two
mating parts for any type of fit.
• The allowance maybe positive or negative. Positive
allowance is called clearance and negative allowance
is called interference.
System of Obtaining different Types of Fits
• There are two system of fits for obtaining clearance,
interference, or transition.
i. Hole basis System. ii. Shaft basis System.
I. Hole basis System
• Hole s kept constant and the shaft size is varied to
give the various types of fits.
• Lower deviation of the Hole is zero.
• The high limit of the hole and the two limits for the
shaft are then varied to give the desired type of fit.
II. Shaft basis System
• Shaft is kept constant and the sizes of the hole are
varied to give various types of fits.
• Upper deviation of shaft is zero
• Fits are obtained by varying the lower limit of the
shaft and both .of the hole
Standard Limit Systems
• Aim of any general system of Standard fits and limits
are to provide guidance to user in:
i. Selecting the basic functional clearances and
interferences for a given application or type of fit.
ii. Establishing Tolerances which will provide a
reasonable economical balance between fits,
consistency and cost.
Indian Standard System of Limits and Fits( IS-919 and 2709)
• Consists of a combination of 18 grades of fundamental
tolerances and 23 types of fundamental deviation.
• The 18 grades of fundamental tolerance are designated
as IT01, IT0, IT1 to IT16.
• Fundamental deviations are indicated by the letter
symbol ( Capital Letters for ′𝐴 𝑡𝑜 𝑍𝑐 ’ for holes and small
letters ‘𝑎 𝑡𝑜 𝑧𝑐 ’ for shafts)
• These are 𝐴, 𝐵, 𝐶, 𝐷, 𝐸 , 𝐹, 𝐺, 𝐻, 𝐽𝑠 , 𝐽, 𝐾, 𝑀, 𝑁, 𝑃, 𝑅, 𝑆, 𝑇, 𝑈,
𝑉, 𝑋, 𝑌, 𝑍 , 𝑍𝐴 , 𝑍𝐵 ,𝑍𝐶 .
• General rule is that Hole limits are identical with the shaft
limits of the same symbol (letter and grade) but dispersed
on either side of the Zero Line.
• Numerical values of standard tolerances are determined in
′ ′ ′
terms of standard tolerance unit 𝑖 , where 𝑖 ′ is
expressed by the formula
3
𝑖 = 0.45 𝐷 + 0.001𝐷,
where D is the Geometric Mean of lower and upper
diameter of a particular diameter step in which diameter lies.
• Steps specified by IS 919 are:
1-3, 3-6, 6-10, 10-14, 14-18, 18-30, 30-50, 50-80, 80-120,
120-180, 180-250, 250-315 etc.
• For tolerances IT01to IT5 the tolerances in microns are
calculated as follows
𝐼𝑇01 = 0.3 + 0.08𝐷 ( Tolerance)
𝐼𝑇0 = 0.5 + 0.02𝐷 (Tolerance)
𝐼𝑇1 = 0.8 + 0.02𝐷 (Tolerance)
• The values for IT 2 to IT4 are regularly scaled
approximately geometrically between IT1 and IT5.
Designation of Holes and Shafts
• A hole or a shaft is completely described if the
basic size, followed by the appropriate letter
and the number of tolerance grade is given:
i. A 50 mm H hole, with tolerance grade of IT7
is written as 50H7.
ii. A 50 mm f shaft with the tolerance grade IT8
is written as 50f8.
iii. If basic size is 50mm, the hole is H7 and the
shaft is f8, the fit can be indicated as 50H7f8
Newall System
• The Newall system provides a range of clearance,
transition and interference fits for sizes upto 12”.
• It is a hole basis system which stipulates two grades of
holes, specified with bilateral tolerances, together with
6 grades of shaft tolerances.
• The system specifies too few fits and those listed are not
congruent with modern ideas as regards their basic
deviation.
• The system served a useful purpose in the past but is
not considered suitable for modern production.
• It has two grades of bilateral holes (A and B), Two
grades of interference fits (F and D), one transition fit
(P), and three clearance fits (Z, Y and X)
• The diameter steps specified are
1" 9 1 2 1
0 − , − 1, 1 −2", 2 −3,3 − 4",
1
2 16 16 16 16
4 − 5“
16
• The limits are calculated as follows
A: +0.0006 𝐷, −0.0003 𝐷
B: +0.0008 𝐷, −0.0004 𝐷
F: +0.003𝐷0.75 , 0.022𝐷0.87
D: +0.0012𝐷0.75 , +0.0008𝐷0.7
P: −0.0002 𝐷, −0.0006 𝐷
Z: −0.0005 𝐷, −0.001 𝐷
Y: −0.001 𝐷, −0.0018 𝐷
X: −0.00125 𝐷, −0.0025 𝐷,
Where D = Geometric mean of diameter steps
Selection of Tolerance
• Amount of tolerance depends upon:-
1. Functional requirements of mating
components.
2. Manufacturing Process available
3. Cost of manufacturing
Tolerance build up (Tolerance Accumulation)
• If a part comprises of several steps, each step having
some tolerance over its length, overall tolerance on
complete length will be the sum of tolerance on
complete length.
• Note: The effect of accumulation of tolerances can be
minimized by adopting progressive dimensioning from the
datum.(fig 4.4 slide 37)
Compound Tolerance
• Compound tolerances are those that can be derived
considering the effect of tolerances of more than one
dimension.
• For example, in the figure given
Tolerance on dimension 𝑙 depend on
the tolerances on 𝐿, ℎ, 𝑎𝑛𝑑 θ.
Prob: Four parts with the following dimensions
are to be assembled in random. What should be
the Tolerance on the Assembled length.
+0.02
Part 1:25 mm
−0.01
Part 2: 18.91 ± 0.03
+0.05
Part 3:62.17
−0.07
Part 4: 42.25±0.04
Gauges
• Inspection tools of rigid design, without a scale,
which serve to check the dimension of manufactured
part.
• Gauges do not indicate the actual value of the
inspected dimension on the work.
• They can only be used for determining as to whether
the inspected parts are made within the specified
limit.
Classification of Gauges
• Gauges are classified as follows
1. According to type
Standard and limit gauges
Limit gauges
2. According to purpose
Workshop
Inspection
Reference or Master gauges
3. According to the form of the tested surface
Plug gauges for checking holes
Snap gauges and ring gauges for checking shafts.
4. According to their design
Single Limit and Double Limit Gauges
Single ended and Double ended gauges
Maximum or Minimum Metal Limits
Maximum Material Limit:
• The designation applied to that of the two limits
which corresponds to the maximum material size for
the feature.
• Upper limit of size for shaft or lower limit size for hole.
Least Material Limit:
• The designation applied to that of the two limits which
correspond to the minimum material size of the
feature.
• Lower Limit of size for shaft and upper limit of size for
hole.
Limit Gauges
• ‘Go’ and ‘No Go’ gauges should be designed to check the
minimum material limits which are checked as below
• ‘Go’ Limit: This designation is applied to that limit of the
two limits of size which corresponds to the maximum
material considerations i.e. upper limit of a shaft and
lower limit of a hole.
• ‘No Go’ Limit: this designation is applied to that limit of
the two limits of size which corresponds to the minimum
material condition i.e. the lower limit of a shaft and the
upper limit of a hole
• With reference to the figure in slide 46 the following
observations can be made
i. The ‘Go’ plug gauge is the size of the minimum limit
of the hole, while the ‘No Go’ corresponds to the
maximum limit.
ii. The ‘Go’ snap gauge is of a size corresponding to
the maximum limit of the shaft, while the ‘No Go’
snap gauge corresponds to the minimum limit.
Note: The difference in size between ‘Go’ and ‘No Go’
snap gauges, as well as the difference in size of the ‘Go’
and ‘No Go’ plug gauges is approximately equal to the
tolerances of hole or shaft.
Taylors principle:
• States that ‘Go’ gauges should check all the possible
elements at a time (Roundness, size, location) and the
‘No Go’ gauge should check only one element of the
dimension at a time.
Example
• To ‘Go’ plug gauge must be of corresponding section
and preferably full length of hole so that straightness of
hole can also be checked.
• In this ay the ‘Go’ gauge controls diameter in any given
section but also ensures both align ability.
Wear Allowance Consideration on Gauge Makers
Tolerance
• Permissible deviation in accuracy must be assigned as
gauge maker can’t make accurate gauges.
• Measuring surfaces of ‘Go’ gauges are subjected to wear
due to constant rubbing with the surfaces being inspected
reducing the size of ‘Go’ plug gauges and increasing size of
‘Go’ snap gauges.
• For prolonged life service of gauges wear allowance is
added in a direction opposite to wear.
• ‘Go’ plug gauges are made with two positive deviation,
while ‘Go’ snap gauges are made with two negative
deviations.
• For both GO and NO GO gauges a tolerance of
10% of work tolerance is prescribed.
• In case the Work tolerance is greater than 0.09
mm we prescribe a wear allowance of 10% of
gauge tolerances for GO gauges.
Note: with regards to numericals in gauge
design use the above rue only incase information
is not provided with regards to wear allowance.
Thank You
