Unit-1

Limits, Fits and Tolerances

Engineering Metrology
 Syllabus

Systems of Limits and Fits: Limits, fits, tolerance and allowance, theory
of limits and fits and their selection, hole basis and shaft basis system,
Indian standard system of limits and fits, simple problems.
Limit Gauges: Taylor's principle of limit gauging, plug gauges, ring
gauges. Tolerance Limits of a process.
 Contents

• Limits
• Fits
• Tolerance & Allowance
• Theory of limits & fits and their selection
• Hole basis & Shaft basis system
• Indian standard system of limits and fits
• Simple problems
It is impossible to produce a component to an absolute or 100% dimensional accuracy.
The variations in size of the components are caused by the following factors.
1. Type of manufacture.
2. Method of machining.
3. Condition of machine.
4. Skill of machinist.
5. Time taken.
6. Geometry of the product.
7. Condition of measuring tools.
8. Condition of measuring.
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 natural variability will always exist.

Therefore depending upon the functional requirements of a work,

some variation is permitted on it.
This permissible variation is called tolerance.
Figure: Relationship between tolerance and cost
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.

 Classification of Tolerance
Tolerance can be classified under the following categories:
1. Unilateral tolerance
2. Bilateral tolerance

Unilateral Tolerance: When the tolerance distribution is

only on one side of the basic size, it is known as unilateral
tolerance. In other words, tolerance limits lie wholly on one
side of the basic size, either above or below it.
Bilateral Tolerance
When the tolerance distribution lies on either side of the basic size, it is
known as bilateral tolerance.
In other words, the dimension of the part is allowed to vary on both sides
of the basic size but may not be necessarily equally disposed about it.

a) Unilateral tolerance b) bilateral tolerance

Unilateral system is preferred in interchangeable manufacture, especially
when precision fits are required, because
(a)it is easy and simple to determine deviations,
(b)another advantage of this system is that ‘Go’ Gauge ends can be
standardized as the holes of different tolerance grades have the same
lower limit and all the shafts have same upper limit, and
(c)this form of tolerance greatly assists the operator, when machining of
mating parts. The operator machines to the upper limit of shaft (lower
limit for hole) knowing fully well that he still has some margin left for
machining before the parts are rejected.
 General Terminology in Fits
Basic size: Basic or nominal size is defined as the size based on which the
dimensional deviations are given. This is, in general, the same for both
components.
Actual size: Actual size is the dimension as measured on a manufactured part.
Limits of size: These are the maximum and minimum permissible sizes
acceptable for a specific dimension. The operator is expected to manufacture the
component within these limits. The maximum limit of size is the greater of the
two limits of size, whereas the minimum limit of size is the smaller of the two.
Tolerance: This is the total permissible variation in the size of a dimension, that
is, the difference between the maximum and minimum limits of size. It is always
positive.
Allowance: It is the intentional difference between the LLH and HLS. An allowance
may be either positive or negative. Allowance is the prescribed difference between the
dimensions of two mating part (hole and shaft) for any type of fit. It is intentional
difference between the lower limit of hole and higher limit of shaft.
Allowance = LLH − HLS
Grade: This is an indication of the tolerance magnitude; the lower the grade, the finer
the tolerance.
Deviation: It is the algebraic difference between a size and its corresponding basic
size. It may be positive, negative, or zero.
Upper deviation: It is the algebraic difference between the maximum limit of size and
its corresponding basic size. This is designated as ‘ES’ for a hole and as ‘es’ for a shaft.
Lower deviation: It is the algebraic difference between the minimum limit of size and
its corresponding basic size. This is designated as ‘EI’ for a hole and as ‘ei’ for a shaft.
The relationship of deviation with tolerance (IT)

For shaft IT= es-ei (upper deviation- lower deviation)

 es= IT+ei

For hole IT= ES-EI

Actual deviation: It is the algebraic difference between the actual size and its
corresponding basic size.

Fundamental deviation: It is the minimum difference between the size of a

component and its basic size. This is identical to the upper deviation for shafts and
lower deviation for holes.

Zero line: This line is also known as the line of zero deviation. The convention is to
draw the zero line horizontally with positive deviations represented above and negative
deviations indicated below. The zero line represents the basic size in the graphical
representation.

Shaft and hole: These terms are used to designate all the external and internal features
of any shape and not necessarily cylindrical.
 Basic shaft: Basic shaft is the shaft whose upper
deviation is zero. Thus the upper limit of the basic
shaft is same as the basic size. It is denoted by h.
Basic hole: basic hole is that hole whose lower
deviation is zero i.e lower limit is same as basic size
and denoted with H.
 Tolerance Zone: It is the zone between the maximum
and minimum limit size.
Fundamental Deviations of Shafts and Holes
 All these 25 deviations are represented with the alphabets. These
alphabets are case-sensitive. Block letters are used to represent the
hole and small letters are used to represent the shaft deviations. all
these deviations are in micrometres (Microns).
 Holes deviations: A, B, C, D, E, F, G, H, JS, J, K, M, N,
P, R, S, T, U, W, X, Y, Z, ZA, ZB, ZC
 Shafts deviations: a, b, c, d, e, f, g, h, js, j, k, m, n, p,
r, s, t, u, w, x, y, z, za, zb, zc
Fit: It is the relationship that exists between two mating parts, a hole and
a shaft, with respect to their dimensional difference before assembly.
Maximum and Minimum Metal limits(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.
Maximum and Minimum Metal Conditions

2
Clearance Fit
Clearance Fit: In this type of fit shaft is always
smaller than the hole, i.e the largest permissible
diameter is smaller than the diameter of the
smallest hole. Shaft can rotate or slide through
different degrees of freedom according to the
purpose of mating part.
1. Slide fit: very small clearance(Zero)- Example: Tailstock
spindle of lathe etc.
2. slide fit: small guaranteed clearance. The easy-slide has used
for non-regular motions and for slow regular motion.
Example: piston and slide valves etc.
3. Running fit: appreciable clearance. Running fit has large
clearance and it involves large temperature variations, high
running speeds, and heavy journal pressures. Example:crank
shaft in their main bearings, Gears, coupling etc.
4. Slack running fit: Considerable clearance between
mating parts. Example: Shaft of centrifugal pump etc.
5. Loose running Fit: Loose running fits are employed
for rotations at high speeds of the parts and have a
larger clearance where accuracy is not important.
Example: Latches, pivots, heat, parts affected by
corrosion, and contamination, etc.
Interference Fit: In Interference Fit, the
tolerance zone of the shaft goes above the
tolerance zone of the hole. This means the shaft
here is of large size, and the hole is of small size.
1. Force Fit: The mating parts are not required to be disassembled
during their total service life. Example: Gears&shafts etc.

2. Tight Fit: It provides minimal interference than force fits. Example:

Stepped pulley of a conveyor, cylindrical grinding of a machine, etc.

3. Heavy force and shrink fit: It refers to maximum negative

allowance which can be assembled by higher forces for cold forging
or hot forging. Driving fits are more reliable than tight fit. Example:
Shafts, gears, and bushes etc.
Transition fit : A fit between two parts in which
the width of the inner part is the same or slightly
exceeds that of the hole into which it is inserted,
requiring light force to assemble and disassemble.
1. Similar or wringing Fit: It provides very negligible
clearance or very small interference and assembly is
achievable with using a rubber mallet. Example: Gears,
Hubs, pulleys, bearing, etc.

2. Fixed or push fit: It provides a small clearance or

minimal interference fit which can be assembled or
disassembled using light pressing force. Example:
Driven bushes, armatures on shaft, plugs, etc.
IT5-7i
A fit is designated by 60 H8/c8, 60 mm lies in the diameter range 50 mm to
80mm. Upper deviation of the shaft c = -(95+0.8d) microns, IT8 = 25i, where
i= 0.45 +0.001D. Select the fit and show these upon the actual dimensions
of hole and shaft.
Determine the actual dimensions for a hole-shaft pair designated as 28 H7/f8.
Dimension 28 falls in the range of 18 to 30. Fundamental deviation for shaft is -
5.5D 0.41. IT7= 16 I and IT8 = 25 i, tolerance unit i=0.45 +0.001D.