GOVT.

POLYTECHNIC, SECT-26
PANCHKULA

DEPARTMENT OF MECHANICAL ENGINEERING

Er. PAWAN KUMAR BALODA

LECTURER (MECHANICAL ENGG.)
SUBJECT : MECHANICAL ENGG. DRAWING
SEMESTER : 3RD
MECHANICAL ENGG. DRAWING

CHAPTER 1: Limits, Fits and Tolerances

 INTRODUCTION

• No two parts can be produced with identical measurements by

any

manufacturing process.

• In any production process, regardless of how well it is designed or how carefully

it is maintained, a certain amount of variation (natural) will always exist.

 INTRODUCTION

Variations arises from;

• Improperly adjusted machines

• Operator error

• Tool wear

• Defective raw materials etc.

Such variations are referred as ‘assignable causes’ and can be identified

and controlled.
 INTRODUCTION

• It is impossible to produce a part to an exact size or basic size,

some

variations, known as tolerances, need to be allowed.

• The permissible level of tolerance depends on the functional

requirements, which cannot be compromised.

 INTRODUCTION

• No component can be manufactured precisely to a given dimension; it can only

be made to lie between two limits, upper (maximum) and lower (minimum).

• Designer has to suggest these tolerance limits to ensure satisfactory operation.

• The difference between the upper and lower limits is termed

permissive

tolerance.
 INTRODUCTION

Example

Shaft has to be manufactured to a diameter of 40 ± 0.02 mm.

The shaft has a basic size of 40 mm.

It will be acceptable if its diameter lies between the limits of sizes.

Upper limit of 40+0.02 = 40.02 mm

Lower limit of 40-0.02 = 39.98 mm.

Then, permissive tolerance is equal to 40.02 − 39.98 = 0.04 mm.

 Need of Limit, Fits and Tolerances

Mass Production And Specialization

Standardization
Interchangeability
 Tolerance
s

• To satisfy the ever-increasing demand for accuracy.

• Parts have to be produced with less dimensional variation.

• It is essential for the manufacturer to have an in-depth knowledge of

the tolerances to manufacture parts economically, adhere to quality and reliability

• To achieve an increased compatibility between mating parts.

 Tolerance
s

• The algebraic difference between the upper and lower acceptable dimensions.

• It is an absolute value.

• The basic purpose of providing tolerances is to permit dimensional variations in

the manufacture of components, adhering to the performance criterion.

 Tolerances
Classification of Tolerance

1. Unilateral tolerance

2. Bilateral tolerance

3. Compound tolerance

4. Geometric tolerance
 Tolerance
s
Classification of Tolerance
1. Unilateral tolerance

• When the tolerance distribution is only on one side of the basic size.
Either positive or negative, but not both.

Tolerances (a) Unilateral (b) Bilateral

1. Unilateral tolerance: Below zero line: Negative
1. Unilateral tolerance: Above zero line: Positive
2. Bilateral tolerance
When the tolerance distribution lies on either side of the basic size.

• It is not necessary that Zero line will divide the tolerance zone equally on both sides.
• It may be equal or unequal
 Classification of Tolerance

3. Compound tolerance

Tolerance for the dimension R is

determined by the combined effects of

tolerance on 40 mm dimension, on 60o, and

on 20 mm dimension
 Classification of Tolerance
4. Geometric tolerance

Geometric dimensioning and tolerancing (GD&T) is a method of defining

parts based on how they function, using standard symbols.

 Classification of Tolerance
4. Geometric tolerance

• Diameters of the cylinders need be concentric with each other.

• For proper fit between the two cylinders, both the centres to be in line.
• This information is represented in the feature control frame.
• Feature control frame comprises three boxes.
 Classification of Tolerance

4. Geometric tolerance

• First box: On the left indicates the feature to be controlled,

represented symbolically (example: concentricity).
• Centre box: indicates distance between the two cylinders, centres cannot be
apart by more than 0.01 mm (Tolerance).
• Third box: Indicates that the datum is with X.
 MAXIMUM AND MINIMUM METAL CONDITIONS

Consider a shaft having a dimension of 40 ± 0.05 mm and Hole having a dimension of 45 ± 0.05
mm.

For Shaft
Maximum metal limit (MML) = 40.05 mm
Least metal limit (LML) = 39.95 mm

For Hole
Maximum metal limit (MML) = 44.95 mm
Least metal limit (LML) = 45.05 mm
 FITS
The Assembly of Two Mating Parts is called Fit.
 RUNNING FIT: One part assembled into other so as to allow motion eg. Shaft
in bearing
 PUSH FIT : One part is assembled into other with light hand pressure & no
clearance to allow shaft to rotate as in locating plugs.
 DRIVING FIT : One part is assembled into other with hand hammer or
medium pressure. Eg pulley fitted on shaft with a key
 FORCE FIT: One part is assembled into other with great pressure eg. Cart
wheels, railway wheels
 FITS

• The degree of tightness and or looseness between the two mating parts.

Three basic types of fits can be identified, depending on the actual limits of the
hole or shaft.

1. Clearance fit

2. Interference fit

3. Transition fit
 FITS

1. Clearance fit Upper limit of shaft is less than the lower limit of the hole.

The largest permissible dia. of the shaft is smaller than the dia. of the smallest hole.
E.g.: Shaft rotating in a bush
 FITS
2. Interference fit Upper limit of the hole is less than the lower limit of shaft.

• No gap between the faces and intersecting of material will

occur.
• Shaft need additional force to fit into the hole.
 3. Transition fit
Dia. of the largest permissible hole is greater than the dia. of the smallest
shaft.

• Neither loose nor tight like clearance fit and interference fit.
• Tolerance zones of the shaft and the hole will be overlapped between the interference and
clearance fits.
 FITS
Detailed classification of Fits
 FITS
Applications
 FITS
Applications
 FITS
Application of Fits
General Terminology in Fits

30
Clearance Fit (e.g.:
H7/f6)

31
Clearance Fit (pl.
H7/f6)

32
Clearance Fit (pl.
H7/f6)

33
 Tolerance Grade

• Tolerance grades indicates the degree of accuracy of manufacture.

• IS: 18 grades of fundamental tolerances are available.

• Designated by the letters IT followed by a number.

• The ISO system provides tolerance grades from IT01, IT0, and IT1 to IT16.

• Tolerance values corresponding to grades IT5 – IT16 are determined using the

standard tolerance unit (i, in μm), which is a function of basic size.

 Tolerance Grade

• D= diameter of the part in mm.

• 0.001D = Linear factor counteracts the effect of measuring inaccuracies.

• Value of tolerance unit ‘i ’ is obtained for sizes up to 500 mm.

• D is the geometric mean of the lower and upper diameters.

• D=
 Tolerance Grade

Standard tolerance units

Tolerances grades for applications
General Terminology
 General Terminology

• Basic size: Exact theoretical size arrived at by design. Also called as nominal size.

• Actual size: Size of a part as found by measurement

• Zero Line: Straight line corresponding to the basic size. Deviations are measured

from this line.

• Limits of size: Maximum and minimum permissible sizes for a specific dimension.

• Tolerance: Difference between the maximum and minimum limits of size.

• Allowance: LLH –HLS

 General Terminology

• Deviation: Algebraic difference between a size and its corresponding basic size.

It may be positive, negative, or zero.

• Upper deviation: Algebraic difference between the maximum limit of size and

its corresponding basic size.

Designated as ‘ES’ for a hole and as ‘es’ for a shaft.

• Lower deviation: Algebraic difference between the minimum limit of size and

its corresponding basic size.

Designated as ‘EI’ for a hole and as ‘ei’ for a shaft.

 General Terminology

• Actual deviation: Algebraic difference between the actual size and

its

corresponding basic size.

• Tolerance Zone: Zone between the maximum and minimum limit size.
 Hole Basis and Shaft Basis Systems

• To obtain the desired class of fits, either the size of the hole or the size of the
shaft must vary.

Two types of systems are used to represent three basic types of fits, clearance,

interference, and transition fits.

(a) Hole basis system

(b) Shaft basis system.

 Hole Basis systems

• The size of the hole is kept constant and the shaft size is varied to
give

various types of fits.

• Lower deviation of the hole is zero, i.e. the lower limit of the hole is same as

the basic size.

• Two limits of the shaft and the higher dimension of the hole are varied

to obtain the desired type of fit.

 Hole Basis systems

(a) Clearance fit (b) Transition fit (c) Interference fit

 Hole Basis systems

This system is widely adopted in industries, easier to manufacture shafts

of

varying sizes to the required tolerances.

Standard-size plug gauges are used to check hole sizes accurately.

 Shaft Basis systems

• The size of the shaft is kept constant and the hole size is varied to
obtain

various types of fits.

• Fundamental deviation or the upper deviation of the shaft is zero.

• System is not preferred in industries, as it requires more number of standard-

size tools, like reamers, broaches, and gauges, increases manufacturing and

inspection costs.
 Shaft Basis systems

(a) Clearance fit (b) Transition fit (c) Interference fit

 Tolerance symbols

Used to specify the tolerance and fits for mating components.

Example: Consider the designation 40 H7/d9

• Basic size of the shaft and hole = 40 mm.

• Nature of fit for the hole basis system is designated by H

• Fundamental deviation of the hole is zero.

• Tolerance grade: IT7.

• The shaft has a d-type fit, the fundamental deviation has a negative value.

• IT9 tolerance grade.

 Tolerance symbols

• First eight designations from A (a) to H (h) for holes (shafts) are used
for

clearance fit

• Designations, JS (js) to ZC (zc) for holes (shafts), are used for interference or

transition fits
 Tolerance symbols

• Fundamental Deviation: Deviation either the upper or lower deviation, nearest to the

zero line. (provides the position of the tolerance zone).

It may be positive, negative, or zero.

• Upper deviation: Designated as ‘ES’ for a Hole and as ‘es’ for a shaft.

• Lower deviation: Designated as ‘EI’ for a Hole and as ‘ei’ for a shaft.
 • Upper deviation: Designated as ‘ES’ for a Hole and as ‘es’ for a shaft.
• Lower deviation: Designated as ‘EI’ for a Hole and as ‘ei’ for a shaft.

Typical representation of different types of fundamental deviations

(a) Holes (internal features) (b) Shafts (external features)
Fundamental deviation for
shafts and holes of sizes
from above 500 to 3150 mm
 Tolerance Grade

• BIS: 18 grades of fundamental tolerances are available.

• Designated by the letters IT followed by a number.

• ISO/BIS: IT01, IT0, and IT1 to IT16.

• Tolerance values corresponding to grades IT5 – IT16 are determined using the

standard tolerance unit (i, in μm)

 Tolerance Grade

Tolerance unit,

• D= diameter of the part in mm.

• 0.001D = Linear factor counteracts the effect of measuring inaccuracies.

• Value of tolerance unit ‘i ’ is obtained for sizes up to 500 mm.

• D is the geometric mean of the lower and upper diameters.

• D=
 Tolerance Grade

D=

The various steps specified for the diameter steps are as follows:

• 1–3, 3–6, 6–10, 10–18, 18–30, 30–50, 50–80, 80–120

• 120–180, 180–250, 250–315, 315–400, 400–500

• 500–630, 630–800, and 800–1000 mm.

 Tolerance Grade

Standard tolerance units

Maximum and Minimum Metal
Conditions
 Let us consider a shaft having a dimension of 40 ± 0.05 mm.
 The maximum metal limit (MML) of the shaft will have a dimension of 40.05
mm because at this higher limit, the shaft will have the maximum possible
amount of metal.
 The shaft will have the least possible amount of metal at a lower limit of
39.95 mm, and this limit of the shaft is known as minimum or least metal
limit (LML).
 Similarly, consider a hole having a dimension of 45 ± 0.05 mm.
 The hole will have a maximum possible amount of metal at a lower limit of
44.95 mm and the lower limit of the hole is designated as MML.
 For example, when a hole is drilled in a component, minimum amount of
material is removed at the lower limit size of the hole. This lower limit of the
hole is known as MML.
 The higher limit of the hole will be the LML. At a high limit of 45.05 mm, the
hole will have the least possible amount of metal.
17
Chapter 2
Couplings
 Couplings
Coupling is a device used to connect two shafts together
at their ends for the purpose of transmitting power.
Coupling

Pump Motor
 Uses of Coupling
To provide connection of shafts of units
made separately
To allow misalignment of the shafts or to
introduce mechanical flexibility.
To reduce the transmission of shock loads.
To introduce protection against overloads.
To alter the vibration characteristics.
Types of coupling
 Rigid
 Flexible
 Universal

Rigid coupling

Flexible coupling
Universal coupling
 Rigid coupling Flange

Hub
Rigid couplings are used when Key

precise shaft alignment is required

Driven
Simple in design and are more Shaft

rugged
Driving
Shaft
 Generally able to transmit more
power than flexible couplings

Shaft misalignments cannot be

compensated Flanged Coupling
 Flexible Coupling
A flexible coupling permits with
Flange
in certain limits, relative rotation
Flange
and Driving Driven
Shaft
 variation in the alignment of Shaft

shafts
Pins (Bolts) covered by rubber
washer or bush is used connect
flanges with nuts
Pin
Bush
The rubber washers or bushes
act as a shock absorbers and
insulators.
 Universal Coupling
It is a rigid coupling that connects
two shafts, whose axes intersect if
extended. It consists of two forks
which are keyed to the shafts. The
two forks are pin joined to a central
block, which has two arms at right
angle to each other in the form of a
cross (Fig.). The angle between the
shafts may be varied even while the
shafts are rotating.
 Oldham’s Coupling
It is used to connect two parallel shafts whose axes are
at a small distance apart. Two flanges, each having a
rectangular slot, are keyed, one on each shaft. The two
flanges are positioned such that, the slot in one is at right
angle to the slot in the other. To make the coupling, a
circular disc with two rectangular projections on either
side and at right angle to each other, is placed between
the two flanges. During motion, the central disc, while
turning, slides in the slots of the flanges. Power
transmission takes place between the shafts, because of
the positive connection between the flanges and the
central disc.
 Advantages and Limitations
Advantages
Torsionally stiff
No lubrication or maintenance
Good vibration damping and shock absorbing qualities
Less expensive than metallic couplings
More misalignment allowable than most metallic couplings
Limitations
Sensitive to chemicals and high temperatures
Usually not torsionally stiff enough for positive displacement
Larger in outside diameter than metallic coupling
Difficult to balance as an assembly