Limits, Fits, and

Tolerances

1
 Introduction

Cross-section of a machine-tool slideway.

The width, depth, angles and other dimensions all

must be produced and measured accurately for the
machine tool to function as expected.
 Metrology
• Metrology is the science of measurement

• Dimensional metrology is that branch of Metrology

which deals with measurement of “dimensions“
of a part or workpiece (lengths, angles, etc.)

• Dimensional measurements at the required level of

accuracy are the essential link between the designers’
intent and a delivered product.
 Dimensional Metrology Needs
 Linear measurements
 Angular measurements
 Geometric form measurements
 Roundness
 Straightness
 Cylindricity
 Flatness, etc
 Geometric relationships
 Parallel, perpendicular, etc.
 Concentric, runout, etc.
 Controlled surface texture
Types of Measurement and Instruments Used
Basic Measurement Devices
 Analog and Digital Micrometers

(a) A vernier (analog) micrometer. (b) A digital micrometer with a range

of 0 to 1 in. (0 to 25 mm) and a resolution of 50 µin. (1.25µm). It is
generally easier to read dimensions on this instrument compared to the
analog micrometer.
Angle Measuring Instruments
Measuring Roundness
 Profile Measurement

Measuring gear-tooth thickness and profile with (a) a gear-tooth

caliper and (b) balls and a micrometer.
Source: American Gear Manufacturers Association.
 Introduction to Tolerances

Can more than one or multiple parts be produced with

exactly same dimensions?
Why?
 Tolerance
“the allowable deviation from a standard, eg: the range of variation permitted in
maintaining a specified dimension in a machined piece.”
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.
Why is it
necessary?
Consequences
Specificatio
n
Some Definitions
Dimensional Tolerances
Some of the dimensional tolerances terms are defined as follows:
Basic Size: The size with reference to which the limits of size are
fixed.
Actual Size: Actual measured dimension of the part.
Zero Line: It is a straight line corresponding to the basic size. The
deviations are measured from this line. The positive and negative
deviations are shown above and below the zero line respectively.
 Some Definitions
Limits of Size: The two extreme permissible sizes of a
part between which the actual size should lie.

Maximum Limit of Size: The greater of the two limits of size.

Minimum Limit of Size: The smaller of the two limits of size.

Shaft: A term used by convention to designate all

external
features of a part, including those which are not cylindrical.

Hole: A term used by convention to designate all internal

features of a part, including those which are not cylindrical.
 Some Definitions
Allowance: It is the difference between the basic dimensions of
the mating parts.
When the shaft size is less than the hole size, then the allowance is
positive and when the shaft size is greater than the hole size, then
the allowance is negative.
Tolerance: It is the difference between the upper limit and lower
limit of a dimension.
 Some Definitions
Tolerance Zone: It is the zone between the maximum and minimum
limit size.
Upper Deviation: It is the algebraic difference between the maximum
size and the basic size.
The upper deviation of a hole is represented by a symbol ES (Ecart
Superior) and of a shaft, it is represented by es.
Lower Deviation: It is the algebraic difference between the minimum
size and the basic size.
The lower deviation of a hole is
represented by a symbol EI (Ecart Inferior) and
of a shaft, it is represented by ei.

Shaft
 Geometric tolerances
 In certain circumstances, tolerances of size, which was discussed in previous
point are not sufficient to provide the required control of form or not sufficient to
ensure the acceptance of component.
 For example, in fig (a) the shaft has same diameter in all possible position but is
not a circular.
 Similarly, in fig.(b) the rib has the same thickness throughout but it is not a flat.
Also in fig. (c) The component i.e. circular shaft is circular in all cross-section but
it is not a straight.
 Geometric tolerances
 All above parts are unacceptable if they were checked only for dimensional
variation, thus here another tolerance come into picture which controls the shape
or form of component i.e. geometrical tolerance.
 Thus the geometrical tolerances are defined as the maximum permissible overall
variation of form or position of a feature.
 The geometrical tolerances are used:
1. To specify the required accuracy in controlling the form of component.
2. To ensure correct function position of components.
3. To ensure interchangeability of components.
4. To facilitate the assembly of mating of components.
 Indication of Geometric tolerances on a
drawing
 To eliminate the need to descriptive notes, geometrical tolerances
are indicated on drawings by symbols, tolerances and datums, all
contained in components of a rectangular frame as shown in fig.
 Advantages of using geometrical tolerances:
 Geometric tolerances convey very briefly and precisely, the
complete geometrical requirements on engineering drawings.
 The use of symbols and boxes eliminates the need for lengthy
descriptive notes and corresponding dimensions, because of which
the drawings are much clearer to read.
 The symbols used are internationally recommended.
 One type of geometrical tolerance can control another form. For
instance, sureness can correct flatness and straightness.
 Classification of Tolerance
Tolerance can be classified under the following categories:

1. Unilateral tolerance
2. Bilateral tolerance
3. Compound tolerance
 Specification of DT
Unilateral Tolerance
In this system, the dimension of a part is allowed to vary only on
one side of the basic size, i.e. tolerance lies wholly on one side of
the basic size either above or below it.

Bilateral Tolerance
In this system, the dimension of the part is allowed to vary on
both the sides of the basic size, i.e. the limits of tolerance lie on
either side of the basic size.
Specification of DT
 Tolerances
Compound Tolerance
When tolerance is determined by established tolerances on more
than one dimension, it is known as compound tolerance.
For example, tolerance for the dimension L is determined by the
combined effects of tolerance on D dimension, on Ø, and on h
dimension. The tolerance obtained for dimension L is known as
compound tolerance In practice, compound tolerance should be
avoided as far as possible.

28
Important Terms used in Limit System
 The following terms used in limit system (or interchangeable system)
are important from the subject point of view:
1. Limits of sizes: There are two extreme permissible sizes for a dimension of the
part as shown in Fig. 3.1. The largest permissible size for a dimension of the
part is called upper or high or maximum limit, whereas the smallest size of the
part is known as lower or minimum limit.

2. Allowance: It is the difference between the basic dimensions of the mating

parts. The allowance may be positive or negative. When the shaft size is less
than the hole size, then the allowance is positive and when the shaft size is
greater than the hole size, then the allowance is negative.
Important Terms used in Limit System
3. Nominal size: It is the size of a part specified in the drawing as a matter of
convenience.
4. Basic size: It is the size of a part to which all limits of variation (i.e. tolerances)
are applied to arrive at final dimensioning of the mating parts. The nominal or
basic size of a part is often the same.
5. Actual size: It is the actual measured dimension of the part. The difference
between the basic size and the actual size should not exceed a certain limit,
otherwise it will interfere with the interchangeability of the mating parts.
Important Terms used in Limit System
6. Tolerance: It is the difference between the upper limit and lower limit of a
dimension. In other words, it is the maximum permissible variation in a
dimension. The tolerance may be unilateral or bilateral. When all the tolerance
is allowed on one side of the nominal size, e.g. 20+0.000
−0.004
, then it is said to be
unilateral system of tolerance. The unilateral system is mostly used in
industries as it permits changing the tolerance value while still retaining the
same allowance or type of fit.
 When the tolerance is allowed on both sides of the nominal size, e.g. 20+0.002
−0.002
,
then it is said to be bilateral system of tolerance. In this case + 0.002 is the
upper limit and – 0.002 is the lower limit.
 The method of assigning unilateral and bilateral tolerance is shown in Fig. 3.2
(a) and (b) respectively.
Important Terms used in Limit System
7. Tolerance zone: It is the zone between the maximum and minimum limit size,
as shown in Fig. 3.3.

8. Zero line: It is a straight line corresponding to the basic size. The deviations
are measured from this line. The positive and negative deviations are shown
above and below the zero line respectively.
Important Terms used in Limit System
9. Upper deviation: It is the algebraic difference between the maximum size and the basic size.
The upper deviation of a hole is represented by a symbol ES (Ecart Superior) and of a shaft,
it is represented by es.
10. Lower deviation: It is the algebraic difference between the minimum size and the basic size.
The lower deviation of a hole is represented by a symbol EI (Ecart Inferior) and of a shaft, it
is represented by ei.
11. Actual deviation: It is the algebraic difference between an actual size and the corresponding
basic size.
12. Mean deviation: It is the arithmetical mean between the upper and lower deviations.
13. Fundamental deviation: It is one of the two deviations which is conventionally chosen to
define the position of the tolerance zone in relation to zero line, as shown in Fig. 3.4.
 Important Terms used in Limit System
14. Maximum limit of size (Is the maximum size permitted for the part)
15. Minimum limit of size (it is the minimum size permitted for the part limit of size)
16. Maximum material limit (condition) (is the condition of a part when it contains the most
amount of material. The MMC of an external feature (such as a shaft) is the upper limit. The
MMC of an internal feature(such as a hole) is the lower limit)
17. Minimum material limit (condition) (is the condition of a part when it contains the least
amount of material possible. The LMC of an external feature is the lower limit of the part.
The LMC of an internal feature is the upper limit of the part.)
 Exercis
e

Q1. Type?

Bilateral, Unilateral, Unilateral.

Q2. Tolerance?

0.015, 0.005, 0.004

Q3. Express in limit form?

Tolerance Stacks
Effect of Tolerance Stacking
 Fit
A fit may be defined as the degree of tightness
and looseness between two mating parts.
 Fits
 The degree of tightness or looseness between the two mating parts is known as a
fit of the parts. The nature of fit is characterised by the presence and size of
clearance and interference.
 The clearance is the amount by which the actual size of the shaft is less than the
actual size of the mating hole in an assembly as shown in Fig. 3.5 (a).
 In other words, the clearance is the difference between the sizes of the hole and
the shaft before assembly. The difference must be positive.
 Fits
 The interference is the amount by which the actual size of a shaft is larger than
the actual finished size of the mating hole in an assembly as shown in Fig.
3.5 (b).
 In other words, the interference is the arithmetical difference between the sizes
of the hole and the shaft, before assembly. The difference must be negative.
 Types of Fits
 According to Indian standards, the fits are classified into the following three
groups :
1. Clearance fit: In this type of fit, the size limits for mating parts are so selected
that clearance between them always occur, as shown in Fig. 3.5 (a). It may be
noted that in a clearance fit, the tolerance zone of the hole is entirely above the
tolerance zone of the shaft.

 In a clearance fit, the difference between the minimum size of the hole and the
maximum size of the shaft is known as minimum clearance whereas the
difference between the maximum size of the hole and minimum size of the
shaft is called maximum clearance as shown in Fig. 3.5 (a).
 The clearance fits may be slide fit, easy sliding fit, running fit, slack running fit
and loose running fit.
 Types of Clearance
Loose FitFit
It is used between those mating parts where no precision is
required. It provides minimum allowance and is used on loose
pulleys, agricultural machineries etc.

Running Fit
For a running fit, the dimension of shaft should be smaller
enough to maintain a film of oil for lubrication. It is used in
bearing pair etc.

Slide Fit or Medium Fit

It is used on those mating parts where great precision is
required. It provides medium allowance and is used in tool
slides, slide valve, automobile parts, etc.
 Types of Fits
2. Interference fit. In this type of fit, the size limits for the mating parts are so
selected that interference between them always occur, as shown in Fig. 3.5 (b).
It may be noted that in an interference fit, the tolerance zone of the hole is
entirely below the tolerance zone of the shaft.
 In an interference fit, the difference between the maximum size of the hole and
the minimum size of the shaft is known as minimum interference, whereas the
difference between the minimum size of the hole and the maximum size of the
shaft is called maximum interference, as shown in Fig. 3.5 (b).
 The interference fits may be shrink fit, heavy drive fit and light drive fit.
 Types of Interference Fit
Shrink Fit or Heavy Force Fit
It refers to maximum negative allowance. In assembly of the
hole and the shaft, the hole is expanded by heating and then
rapidly cooled in its position. It is used in fitting of rims etc.

Medium Force Fit

These fits have medium negative allowance. Considerable
pressure is required to assemble the hole and the shaft. It is
used in car wheels, armature of dynamos etc.

Tight Fit or Force Fit

One part can be assembled into the other with a hand hammer
or by light pressure. A slight negative allowance exists between
two mating parts (more than wringing fit). It gives a semi-
permanent fit and is used on a keyed pulley and shaft, rocker
arm, etc.
 Types of Fits
3. Transition fit: In this type of fit, the size limits for the mating parts are so
selected that either a clearance or interference may occur depending upon the
actual size of the mating parts, as shown in Fig. 3.5 (c). It may be noted that in
a transition fit, the tolerance zones of hole and shaft overlap.
 The transition fits may be force fit, tight fit and push fit.
 Transition Fit
It may result in either clearance fit or interference fit
depending on the actual value of the individual tolerances of
the mating components.
Transition fits are a compromise between clearance and
interference fits.
They are used for applications where accurate location is
important but either a small amount of clearance or
interference is permissible.
 Types of Transition Fit
Push Fit or Snug Fit
It refers to zero allowance and a light pressure is required
in assembling the hole and the shaft. The moving parts show
least vibration with this type of fit.

Force Fit or Shrink Fit

A force fit is used when the two mating parts are to be rigidly
fixed so that one cannot move without the other. It either
requires high pressure to force the shaft into the hole or the
hole to be expanded by heating. It is used in railway wheels, etc.

Wringing Fit
A slight negative allowance exists between two mating parts in
wringing fit. It requires pressure to force the shaft into the hole
and gives a light assembly. It is used in fixing keys, pins, etc.
 Basis of Limit System
 The following are two bases of limit system:
1. Hole basis system: When the hole is kept as a constant member (i.e. when the
lower deviation of the hole is zero) and different fits are obtained by varying
the shaft size, as shown in Fig. 3.6 (a), then the limit system is said to be on a
hole basis.
2. Shaft basis system: When the shaft is kept as a constant member (i.e. when the
upper deviation of the shaft is zero) and different fits are obtained by varying
the hole size, as shown in Fig. 3.6 (b), then the limit system is said to be on a
shaft basis.
 Basis of Limit System
 The hole basis and shaft basis system may also be shown as in Fig. 3.7, with
respect to the zero line.
 It may be noted that from the manufacturing point of view, a hole basis system is
always preferred.
 This is because the holes are usually produced and finished by standard tooling
like drill, reamers, etc., whose size is not adjustable easily. On the other hand, the
size of the shaft (which is to go into the hole) can be easily adjusted and is
obtained by turning or grinding operations.
Thank You
 International Standard System of Limits and Fits
 According to International standard [IS : 919 (Part I)-1993], the system of limits
and fits comprises 18 grades of fundamental tolerances i.e. grades of accuracy of
manufacture and 25 types of fundamental deviations indicated by letter symbols
for both holes and shafts (capital letter A to ZC for holes and small letters a to zc
for shafts) in diameter steps ranging from 1 to 500 mm.
 A unilateral hole basis system is recommended but if necessary a unilateral or
bilateral shaft basis system may also be used.
 The 18 tolerance grades are designated as IT 01, IT 0 and IT 1 to IT 16. These are
called standard tolerances.
 The standard tolerances for grades IT 5 to IT 7 are determined in terms of
standard tolerance unit (i) in microns, where

i (microns) = 0.45 3 𝐷 + 0.001 D

 where D is the size or geometric mean diameter in mm.

 International Standard System of Limits and Fits
 The following table shows the relative magnitude for grades between IT 5 and IT
16.

 The values of standard tolerances corresponding to grades IT 01, IT 0 and IT 1

are as given below:
 For IT 01, i (microns) = 0.3 + 0.008 D,
 For IT 0, i (microns) = 0.5 + 0.012 D, and
 For IT 1, i (microns) = 0.8 + 0.020 D,
 where D is the size or geometric mean diameter in mm.
 The tolerance values of grades IT 2 to IT 4 are scaled
approximately geometrically between IT 1 and IT 5.
 International Standard System of Limits and Fits
 For hole, H stands for a dimension whose lower deviation refers to the basic size.
 The hole H for which the lower deviation is zero is called a basic hole.
 Similarly, for shafts, h stands for a dimension whose upper deviation refers to the
basic size.
 The shaft h for which the upper deviation is zero is called a basic shaft.
 A fit is designated by its basic size followed by symbols representing the limits of
each of its two components, the hole being quoted first.
 For example, 100 H6/g5 means basic size is 100 mm and the tolerance grade for
the hole is 6 and for the shaft is 5.
Clearance fit Clearance
fit

Hole Shaft

Interference fit Tolerance Zone of Tolerance Zone of

Hole Shaft

Shaft

Hole
Transition fit
Minimum clearance

Maximum clearance

Minimum interference

Maximum interference
Symbols for Tolerances and Deviation and Symbols for Fits:
A fit (A fit is indicated by the basic size common to both components, followed by symbol corresponding to each component, the hole being quoted first)

Example: 50 H8 f7
Possibly 50 H8 –
f7 Or 50 H8/f7

Grades of tolerances:
Eighteen grades of tolerances are provided IT01, ITO and IT1 to IT16 The Table gives
the possible degrees of precision or grade of tolerance, achieved with different
machine tools.
 Table 1.1: degree of precision or grade of tolerance

Tolerance grade Intended for Applicable to components or machines

I T 01 Slip blocks, Reference gauges

IT0 Gauges
IT1

IT2 High quality gauges

IT3

IT4

IT5 Ball bearing

IT6 Grinding, Honing

Fits
IT7 Broaching

IT8 Center lathe turning

IT9 Worn automatic lathe

I T 10 Milling

I T 11 Drilling, Rough turning

I T 12 Light press work

I T 13 Not for fits Press work

I T 14 Die casting

I T 15 Stamping

I T 16 Sand casting
International Tolerance Grade Selection
Representation of Tolerance Tolerance Grade defines range of dimensions
2) Number or Grade (dimensional variation)
IT01, IT0, IT1, There are manufacturing constraints on tolerance
….IT16 grade chosen
Exampl
e
Position of the various tolerance zones for a given diameter in the ISO system
Position of the various tolerance zones for a given diameter in the ISO
system
•Table for fundamental
deviations for shafts
 Lower deviation ei

•Table for fundamental

deviations for shafts
•Table for fundamental
deviations for holes
•Table for fundamental
deviations for holes
Exampl
e Determine which type of fit is presented by H7/p6? For basic size of 30 mm determine the dimensions
of the hole and the shaft for the given fit. (Fit: 30 H7/p6)

Capital H means basic hole system and

upper deviation = zero

INTERFERENCE FIT Φ30.035

H7 : Tol Grade 7 for basic size 30 mean 21μ
Φ30.022
variation Φ30.021
Φ30.000
p6 : Tol Grade 6 for basic size 30 means
13μ variation
(p means lower deviation is 22 μ)

Fit: 60 H8/e6
Exampl
eCreating
System
a Clearance Fit using The Basic Hole

Given the following fit Φ40 – H11/c11

From table for hole diameter = 40 and H11 we find
Upper deviation = +160 μm & Lower deviation = 0
From table for shaft diameter = 40 and c11 we find
Upper deviation = -120 μm & Lower deviation = -280 μm
Calculations of dimension limits for hole and shaft
- Maximum hole diameter = 40 + 0.16 = 40.16 mm
- Minimum hole diameter = 40 + 0 = 40 mm
- Maximum shaft diameter = 40 +(-120) = 39.88 mm
- Minimum shaft diameter = 40 + (-280) = 39.72 mm

Maximum clearance = Maximum hole diameter – Minimum shaft diameter

= 40.16 – 39.72 = 0.44 mm

Minimum clearance = Minimum hole diameter – Maximum shaft diameter

= 40 – 39.88 = 0.12 mm
Allowances = minimum clearance = 0.12 mm = 120 μm
 Formulae for
fundamental
deviations of shafts
up to size 500 mm
Formulae for fundamental deviations of shafts up to size 500 - 3150 mm
EXAMPLEs
1. A dowel pin is required to be inserted in a base. For this application H 7 fit for hole and a p 6 fit for
the shaft are chosen. Find the upper and lower limits of the hole and also dowel pin, and the maximum
interference between dowel pin and the hole. The basic size of the fit is 50 mm.

2. Calculate the limits and allowance for a 25 mm shaft and hole pair designated by H8d9. Take the
fundamental deviation for ‘d’ shaft is -16D^0.44.

3. Determine the tolerances on the hole and the shaft for a precision running fit designated
by 50 H7g6, given;
50 mm lies between 30-50 mm
i (in microns)=0.45(D)1/3+0.001D
Fundamental deviation for ‘H’ hole=0
Fundamental deviation for g shaft =-2.5D0.34
IT7=16i and IT6=10i
State the actual maximum and minimum sizes of the hole and shaft and maximum and
minimum clearances.

4. Calculate all the relevant dimensions of 35H7/f8 fit, dimension 35 mm falls in the step of 30-50 mm.
The fundamental deviation for f shaft is – 5.5D0.41. i (in microns) =0.45(D)^1/3+0.001D, IT7=16i and
IT8=25i.