Engineering Measurements

Dr. Raouf Tawfik

 Fits and Tolerance
• Interchangeability: the possibility of replacing part or unit
of a M/C during assembly or subsequent repair without
restoring to fitting operations.
• Nominal size: it is the dimension of a part of M/C
specified in the part drawing or size which is used for
general purpose.

• Tolerance : it is the max. permissible variation of the size

of the part.

• Fits: The fit limits the permitted dimension differences of

two parts which belong together.
Types of Fit
 Types of fits

Clearance fits Transition fits Interference fits

• Clearance:
• Hole bigger than the shaft, or outside
dimension bigger than inside dimension.
• Sg = max. clearance = difference of min.
allowance of the shaft and max. allowance
of the hole.
• Sk = min. clearance = difference of max.
allowance of the shaft and min. allowance
of the hole.
Interference:
• Hole, smaller than the shaft, or inside dimension
smaller than outside dimension.

• Ug = max. interference = difference of max.

allowance of the shaft and min. allowance of the
hole.

• Uk = min. interference = difference of min.

allowance of the shaft and max. allowance of the
hole.
• Transition Fit:

• Between the mating members is play (clearance

or interference)
• Depending on the actual sizes of the mating
members, clearance or interference can be. In
transition fits the zones of tolerances overlap.
Interference Pit: the fitting members have
oversize before mating. After mating there is
surface pressure between the. surfaces of the
fitting members.
 Systems of Fits
• According to the zones of tolerances, we can
use many combinations of shaft and hole
tolerances to realize a certain fit. Since we
need for every diameter and every tolerance a
special gauge, we must try to use a minimum
of zones of tolerances to realize our mainly
used fits.
For this, two systems of fits have been devised:
Basic hole system and Basic shaft system.

Basic Hole System.

Basic shaft system
• Zones of tolerances for shafts in the basic
hole system

In the basic hole system, the zone of

tolerances of the hole touches the zero-
line (H-zone). The fit wanted, is realized by
the shaft-tolerance. The basic hole system
is mainly used, because for every nominal
size of the hole ;only one tool and one
gauge; (for tolerance H) is needed.
• Zones of tolerances for holes In the basic
shaft system

The zone of tolerance of the shaft touches the

zero-line with it e upper limit (h-zone). The
different fits (of same nominal size) are realized by
the size of the hole. The basic shaft system is used
for shafts which are mated with machine part *with
different fits. We use the basic shaft system when
we can use drawn shafts.
 Zones of Fit-tolerances

The zone of fit-tolerance is limited by max.

and min. clearance respectively by max.
and man. interference. The absolute
magnitude is called fit-tolerance. The zone
of fit-tolerance marks the magnitude and
the position of the fit-tolerance (Tf) before
the mating members are fitted together.
Determination of the fit-tolerance Tf

Tf = TH + TS = Sg - Sk
Tf = TH + TS = Sg - Ug
Tf = TH + TS = Ug - Uk
 Standardization:
are  [ISO] and [ISA] and [DIN]. Grade of fit [21 – grade]

for hole {A,B,C, … G} …….. clearance

{H, …, M} …….. transition
{N, ……….,Z} ……. interference

for shaft {a, b, c, ….. g} ……clearance

{h, …, m} …….transition
{n, ………., z} ……. interference

(N. B) all letters except for [ I, L, O, W, Q]

 Grade of accuracy
IT 1, IT 2, IT3, …. IT 16

• Increasing the accuracy

• (1 : 3) for the high accuracy as measuring instrument
• (4 : 5) for the normal measuring instrument
• (6 : 8) for the machining.
• (9 : 16) for the forming and casting operation

 refers to the circle section and 6 * 6 refers to the

square section and 6 * 8 refers to the rectangular
 Deviation
• The upper deviation: it is difference between the
upper limit of W.P and its normal size.

• The lower deviation: it is the difference between

the lower limit of W.P and its nominal size.
Tolerance = (U,D) – (L.D)

• Example : φ 70 + 10
m the normal size = 70 mm the U.D = + 10 μm
the L.D = -10 μ
the tolerance = U.D – L.D = + 10 - (-10) = 20 μm.
Grade of accuracy:
in which the grade of accuracy depends on
a) W.P diameter.
b) unit of accuracy (i)

where: (i = 0.45 * [d] ^ 1/3 + 0.001 * d m)

if  from the measure table lies between d1 & d2

 d = [d1 * d2] ^ 0.5 in mm
 the tolerance
= unit of accuracy * no. of units
= i * no. of unit
where no. of units is extracted from the following table
Grade of IT5 IT6 IT7 IT8 IT9 IT10 IT11
accuracy
No. of units 7 10 16 25 40 64 100
• Define  50 n6 and  50 N7 ?
•  50 n6 : it is defined as the dimeter of the shaft is 50 mm
and its grade of fit is n and its grade of accuracy is 6th .
•  50 N7 : it is defined as the diameter of the hole is 50
mm and its grade of fit is N and its grade of the accuracy
is 7th .

calculate the tolerance for  105 in the 8th of the

grade of accuracy ?
 d = [d1 * d2] ^ 0.5
= [80 * 120] ^ 0.=98 mm …
 I = .45 * [d]^.3333 + .001 * d
= .45 * [98]^.3333 + .001 * 98
= 2.17 m
from the above table we find that : w.r. to 8th … no. of the units
= 25
 the tolerance = 2.17 * 25 = 54
Ex) calculate Ra and T for  100 H8 / f6 ?

From table w.r. to the hole :

 100 H8 = 100 [h. D. = +45 and l.d. = 0]

 T = 54 m  Ra = 0.18 * [ .25 * T ] ^1.1

= 3.15 m

W.r.t the shaft:  100 f7 = 100 [h.d.

= -36 and l.d. = -71]

 T = -36 – (-71) = 35 m  Ra = 1.96 m

d) Block Gauge
Is called Slip gauge OR Johnson gauge
Is considered as the set of blocks are kept inside a
box to prevent the corrosion and friction.

Metric :
(1) 47 pieces
(2) 76 pieces
(3) 103 pieces
Metric : 47 pieces

Pitch Dim in mm No. of

pieces
--- 1.005 1
0.01 1.01, 1.02, 1.03, …………., 1.09 9
0.1 1.1, 1.2, 1.3, ………………, 1.9 9
1 1, 2, 3, 4, …………………., 24 24
25 25, 50, 75, 100 4
2.39 kg 47
Pitch Dim in mm No. of
pieces
--- 1.005 1
0.01 1.01, 1.02, 1.03, …………….., 1.49 49
0.5 0.5, 1, 1.5, ……………………., 9.5 19
10 10, 20, 30, 40, 50 5
--- 25, 100 2
2.06 kg 76
Pitch Dim in mm No. of
pieces
--- 1.005 1

0.01 1.01, 1.02, 1.03, …………….., 1.49 49

0.5 0.5, 1, 1.5, ………, 9.5, ………., 24.5 49

25 25, 50, 75, 100 4

3.46 kg 103
Pitch Dim in mm No. of
pieces
0.00 1.0025, 1.005, 1.0075 3
2
0.101, 0.102, ….., …. 0.109 9
5
0.11, 0.12, …………., 0.19 9
0.00
0.05 1
1
0.1, 0.2, 0.3, ………..., 0.9 9
0.01
1, 2, 3, 4 4
0.1
1
There’re 4- types of block gauge are :-

1) Reference (AA) or (OO) + 0.025  m.

2) Calibration (A) or (O) + 0.05  m.

3) Inspection m. (B) or (1) + 0.01 

m. 4) Workshop gauge block (C) or (2) + 0.2 

EX.: It is required to form the dimension
45.425 mm by using the block gauge?
Steps of solution
i) Select the block of 0.005 or 1.005 mm
ii) Select the block of 0.02 or 1.02 … , … 0.42 or 1.42 mm
iii) and so on until we get on 45.425 mm as shown …

from 47 pieces [1.005 + 1.02 + 1.4 + 17 + 25] #

from 76 pieces [1.005 + 1.42 + 3 + 40] #
from 103 pieces [1.005 + 1.42 + 18 + 25]
the best selection is 103 and 76 pieces

It uses in many purposes such as:

* Inspect the parallel in two surfaces ..
* Inspect the height, length, inner diameter
* Estimate the difference between any surface w.r. to the
standard one
Its function: to compare the unknown dimension with known dimension
Let Gearing ratio = I = O/P / IP
= R * Alfa / S
S = m * Z2 * Beta / 2
S = m * Z3 * Alfa / 2
m: is the module
Alfa / Beta = Z2/Z3
Alfa = Beta * Z2/Z3
B = S / (m*Z1/2) Rad.
Alfa = (2*S*Z2/m*Z1*Z3)
Alfa R/S = 2R/m * (Z2/Z1*Z3)
I = 2*R/m * (Z2/Z1*Z3)
Types of comparators
1) Mechanical
a) Horizontal
b) Vertical
2) Optical
3) Air gap

Types of gauges:
1) Go - side
2) Not Go - side
Gauges are divided into:
1) Gauges for checking holes (plug gauge):
a) Double end plug gauge
b) Single end plug gauge.

2) Gauges for checking shafts (Snap – gauge):

a) Double end snap
b) Single end snap.
The last is called adjustable snap

3) Gauge for checking thread

a) Thread gauge …
b) Ring gauge …

4) Gauges for checking taper (external & internal)

Plug gauges for checking holes
For the fit  100 H8 /f7 is given:
Tolerance IT8 = 54  m and IT7 = 35  m and H.D of
shaft (f7) = -36  m and L.D of hole (F8) =
+36 m and tolerance of gauge = 5  m and
tolerance of comparators = 2  m and Z (wear
tolerance) = 3.5 and y (max. tolerance of wear) = 3 
m. Determine the following:

1) Draw the position of tolerance felds for shaft

and hole w.r. to zero line.
2) Determine the type of fit.
3) Mark and calculate values of Max. and Min.
clearance or interference.
4) Explain the meaning of each letter and digit used
to describe the fit  100 H8 / f7 ?
5) Determine the high and low limit of hole and shaft ?
6) Write numerical values of dimensions of hole and
shaft.
7) Draw and introduce names of checking (gauging)
instruments for hole  100 H8 and shaft  100 f7.
8) Transfer the fit from BHS to BSS.
9) Compare between both fits.
10) Find the arithmetic average heights of surface
finishing.

• Design the required gauge to check the hole

dimension and shaft dimension.

• Determine what will be the change in clearance if

the working temperature will increase about 25o
C. The coefficient of linear expansion of shaft
and hole are  (shaft) = 11.5 * E-6 o C^-1 and 
(hole) = 18 * E-6 o C^-1
Solution
1) The position of tolerance fields :
2) Type of fit is the clearance.
3) Max. clearance = 54 + 71 = 125 m and Min.
clearance = 36 m.
4)  100 H8 / f7
 : refer to circular section
100 : refer to nominal size drawing dimension
H : refer to grade of fit for the hole (Base letter) give BHS
f : refer to grade of fit for the shaft
8 : refer to grade of clearance for the hole
7 : refer to grade of clearance for the shaft
5) w.r. to hole : high limit =  100.054 mm and low
limit =  100.000 mm
w.r. to shaft : high limit =  99.964 mm and low
limit =  99.929 mm

6) The numerical values of dimension of hole  100

mm ^ (+ 54, 0) mm
The numerical values of dimension of shaft  100
mm ^ (-36, -71) mm

7) For checking the hole by using plug gauge (single

1 and Double 2)
For checking the shaft by using span gauge
(single 1 and Double 2)
8) To transfer from BHS to BSS  [H8 /f7 ….. F8/h7]
we find that the case of fit does not change but max.
and min. clearance may be changed but in this Ex. The
max. and min. clearance is the same values

9) The arithmetic average heights of surface finish Ra =

0.18 * (T / 4) ^ 1.1
w.r. to hole: R a = 0.18 * (54 / 4 ) ^ 1.1 = 3.1524 m.
x.r. to hole : R a = 0.18 * (35 / 4 ) ^ 1.1 = 1.957 m.

10) Design the required gauge to check the hole and

shaft as :
For the Hole
D (plug Gauge) = 100.054 [ + 2.5 m] mm

D (comparator) = 100.054 [ + 1 m] mm

w.r. to Go side dim. (Hole H8)

D (Plug Gauge) = (100.000 + z) [ +2.5 m ] mm

D (used comparator) = 100.054 + z) [ + 1 m ] mm

D (New comparator) = 100.054 –y) [ + 1 m ] mm

 For the Shaft
D (Snap Gauge) = (100.000 – L.D of shaft) [ + 2.5 m] mm

D (comparator) = (100.000 – L.D of shaft) [ + 1 m] mm

w.r. to Go side dim. (Shaft H8):-

D (Snap Gauge) = (100.000 – U.D of shaft – z1)

[ + 2.5 m] mm

D (used comparator) = (100.000 – U.D of shaft – z1)

[ + 1 m] mm

D (New comparator) = (100.000 – U.D of shaft – y1)

[ + 1 m] mm
Go to page no (7) To extract the other dimension of each :-

For the Snap gauge (Assume the selection is the double side type)
D a=b c V L
95 : 103
22 14 147 225
mm

For the plug gauge (Assume the selection is the double side type)

11 12 s L
D

75 : 100
32 20 32 86
mm
12) L = L *  * T
fir the shaft :
D (Max.) = 99.97 mm D = D (Max.) * 11.5 * E-6 * 25 = 0.02874
mm
D (after heating) = D (before heating) +  D
 D = 99.97 + 0.02874 = 99.9987 H.D = (99.7 – 100) * 1000 = 1.3
m
D (Min.) = 99. 929 mm D = D (Min.) * 11.5 * E-6 * 25 = 0.02874
mm
D (after heating) = D (before heating) +  D
 D = 99.929 + 0.02873 = 99.9577L.D = (99.9577 – 100) * 1000 =
-42.3 m
Tolerance of the shaft is = 41 m
For the hole :
D (Max.) = 100.054 mm D = D (Max.) * 18 * E-6 * 25 =
0.04502 mm
D (after heating) = D (before heating) +  D
D = 100.054 + 0.04502 = 100.09902 mm
H.D = (100.09902 – 100) * 1000 = 99.02 m
D (Min.) = 100 mm D = D (min.) * 18 * E-6 * 25 = 0.045 mm
D (after heating) = D (before heating) +  D
D = 100 + 0.045 = 100.045 mm L.D = (100.045 – 100) *
1000 = 45 m
Tolerance of the is 54.02 m
No effect on the tolerance from T.
Thread Measurements
Types of Threads
The various types of threads in common use are as
follows :
i) British association (B.A) thread. They are rounded V
threads. They have fine pitches. They are used on
screws for precision work such as instruments.
h = 0.6 p
H = 1.136 p

H1 = 0.236 H
Where
P = pitch
H = depth of thread.
B.A. Thread.
ii) V threads. Fig. Shows a single V thread.

The thread angle is 60o. V thread are stronger

than square threads and can be easily cut with
the machine or with the help of a tap and die. In
this thread,

h = 0.866 p.
V. Thread.
iii) British standard Whitworth (B.S.W) thread.

They are round V threads and have an angle of

55o. Is rounded top or crest is not so easily
abraled as in V thread and

h = 0.64 p

H = 0.96 p

H1 = H
6
B.S.W. Thread.
iv) Square thread.
The section of there thread is square. The
mechanical efficiency of this thread is more than
V threads. It is most commonly used for driving
purposes and transission of motion. Square
threads can be used be used in lathe, vices and
screw jack.
In this thread.
p
Depth of thread, h 
2
p
Width of thread, 
2
Where p = pitch.
Square Thread.
v) Acme thread.
This thread is stronger than square threads and
can be easily produced as dies may be used in
cutting this thread.
p
In this thread, h  mm.
+ 0.25
2
Thread angle = 29o

The thread is used on lead screws of lathes as is

easier to engage a splint with this thread
Acme Thread.
vi) Buttress thread
These threads are used to reset axial loads in
one direction only. The spindles of bench vices
have butters threads. Buttress thread has the
efficiency of square thread

In this thread, h = height (depth) of thread .

3
 p
4
Buttress Thread.
vii) Knuckle thread.
It can easily resist great strain and rough use. It
can be easily cast or rolled but cannot be easily
made on machine. It is used in railway carriage
coupling screws and in electric bulbs and
sockets, and o n objects made up of glass,
plastics etc. In this thread

p
Radius at top and bottom =
2
p
Depth ( ) =
2
American (National) standard thread. This thread is

similar to V thread in which 60o angle has been

retained but the top and root have been flattened.

This thread is used for nuts bolts screws and tapped

holes. In this thread

H = 0.866 p

3
h= H
4
American (National) Standard Thread.
Metric thread.
1.25C means metric thread of 12 mm diameter of
threaded part and 1.25 mm pitch. C stands for coarse
thread. If the thread is fine, letter f is used.×Metric
threads are designated by the letter M followed by
diameter and pitch, the two being separated by the
sign X. For example M 12

In this thread

H = 0.866 p
Metric Thread.
Indian Standard Institute also adopted metric system
of screw threads as the Indian standard thread on
29th April 1958.

Screw-thread pitch diameter measurement by means

of measuring wires
 Table Fine Series
Minor diameter
Designation Pitch p mm Stress tea mm
bolt mm nut mm
M 8 ×1 1 6.773 6.918 39.2
M 10 × 1.25 1.25 8.466 8.647 61.6
M 12 × 1.25 1.25 10.466 10.647 92.1
M 14 × 1.5 1.5 12.160 12.376 125
M 16 × 1.5 1.5 14.160 14.376 167
M 18 × 1.5 1.5 16.160 16.376 216
M 20 × 1.5 1.5 18.160 18.376 272
M 22 × 1.5 1.5 20.160 20.376 333
M 24 × 2 2 21.546 21.835 384
M 27 × 2 2 24.546 24.835 496
M 30 × 2 2 27.546 27.835 621
M 33 × 2 2 30.546 30.835 761
M 36 × 2 3 32.319 32.752 865
M 39 × 3 3 35.319 35.752 1028