INTERFERENCE FITS

CONTENTS:
¾ INTRODUCTION
¾ ISO TOLERANCES
¾ STANDARDISED FITS
¾ GEOMETRICAL TOLERANCING
¾ EXAMPLES OF FITS
¾ LAMÉ PROBLEM
¾ MAXIMUM STRESS AND DEFORMATION
¾ ENGINEERING CALCULATIONS
¾ APPENDIX
 INTRODUCTION
Interference fits are based on the standardised
tolerance system of shafts and holes.

This system is to be introduced, giving an overview of

the ISO tolerance grades and, additionally, shape and
position tolerances of typical machine components.
The roughness grades will be also given.

The preferred fits using the basic-hole system will be

further discussed and some examples will be shown.

Then, the Lamé equations for thick walled cylinders – a

model for interference fits – will be shown.

Finally, the load-carrying capacity and stresses in

components of the interference joint will be presented.
 ISO TOLERANCES

Tolerance is the difference between the maximum and

minimum size limits of a component.

International Tolerance Grade Numbers

(IT = International Tolerance) are used to specify the
size of the tolerance area (zone).

Note that the tolerance is the same for the internal

dimension (hole) and external one (shaft) that have the
same tolerance grade number.
 ISO TOLERANCES
The ISO standard (ISO 286) implements 20 IT tolerances
(grades of accuracy) as shown in table below:
ISO grade number Application

IT01, IT0, IT1, IT2, Precision

IT3, IT4, IT5,IT6 instruments
IT5, IT6, IT7, IT8, General industry
IT9, IT10, IT11, IT12
IT11, IT12, IT13, Semi-finished
IT14, IT15, IT16 products
IT16, IT17, IT18 Structural
engineering
 ISO TOLERANCES
Tolerance area depends on both nominal size
and IT grade (ACCURACY COSTS)
Nominal Sizes [mm]

over 6 10 18 30 50 80 120 180

incl. 10 18 30 50 80 120 180 250
IT
Tolerance area [µm]
Grade
5 6 8 9 11 13 15 18 20
6 9 11 13 16 19 22 25 29
7 15 18 21 25 30 35 40 46
8 22 27 33 39 46 54 63 72
9 36 43 52 62 74 87 100 115
10 58 70 84 100 120 140 160 185
11 90 110 130 160 190 220 250 290
12 150 180 210 250 300 350 400 460
 ISO TOLERANCES

M A C H IN IN G P R O C E S S A S S O C IA T E D W IT H T O L E R A N C E G R A D E S

IT G ra d e 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
L a p p in g
H o n in g
S u p e rfin is h in g
C ylin d e ric a l g rin d in g
D ia m o n d tu rn in g
P la n g rin d in g
B ro a c h in g
R e a m in g
B o rin g , T u rn in g
S a w in g
M illin g
P la n in g , S h a p in g
E xtru d in g
C o ld R o llin g , D ra w in g
D rillin g
D ie C a s tin g
F o rg in g
S a n d C a s tin g
H o t ro llin g , F la m e c u ttin g
 ISO TOLERANCES
MACHINING PROCESS ASOCIATED WITH THE ROUGHNESS AVERAGE Ra
 ISO TOLERANCES
TOLERANCE LIMITS FOR SHAFTS
Nominal sizes in mm
Over 6 10 14 18 24 30 40 50 65 80 100 120 140 160 180 200 225
Incl. 10 14 18 24 30 40 50 65 80 100 120 140 160 180 200 225 250
GRADE Upper tolerance limits in µm
a -280 -290 -300 -310 -320 -340 -360 -380 -410 -460 -520 -580 -660 -740 -820
c -80 -95 -110 -120 -130 -140 -150 -170 -180 -200 -210 -230 -240 -260 -280
d -40 -50 -65 -80 -100 -120 -145 -170
f -13 -16 -20 -25 -30 -36 -43 -50
g -5 -6 -7 -9 -10 -12 -14 -15
GRADE Lower tolerance limits in µm
j5, j6 -2 -3 -4 -5 -7 -9 -11 -13
k5-k7 1 2 3 4
n 10 12 15 17 20 23 27 31
p 15 18 22 26 32 37 43 50
s 23 28 35 43 53 59 71 79 92 100 108 122 130 140
u 28 33 41 48 60 70 87 102 124 144 170 190 210 236 258 284
z 42 50 60 73 88 112 136 172 210 258 310 365 415 465 520 575 640

Notes:
1. Only chosen diameters and grades have been shown
2. The h grade shafts have 0 upper limit of tolerance
3. The js grade shafts have lower/upper limit of tolerance equal to ± 0.5 T
 ISO TOLERANCES
TOLERANCE LIMITS FOR HOLES
Nominal sizes in mm
Over 6 10 14 18 24 30 40 50 65 80 100 120 140 160 180 200 225
Incl. 10 14 18 24 30 40 50 65 80 100 120 140 160 180 200 225 250
GRADE Lower tolerance limits in µm
A 280 290 300 310 320 340 360 380 410 460 520 580 660 740 820
C 80 95 110 120 130 140 150 170 180 200 210 230 240 260 280
D 40 50 65 80 100 120 145 170
F 13 16 20 25 30 36 43 50
G 5 6 7 9 10 12 14 15
GRADE Upper tolerance limits in µm
J7 8 10 12 14 18 22 26 30
K7 5 6 6 7 9 10 12 13
N7 -4 -5 -7 -8 -9 -10 -12 -14
P7 -9 -11 -14 -17 -21 -24 -28 -33
R7 -13 -16 -20 -25 -30 -32 -38 -41 -48 -50 -53 -60 -63 -67

Notes:
1. Only chosen diameters and grades have been shown
2. The H grade holes have 0 lower limit of tolerance
3. The Js grade holes have lower/upper limit of tolerance equal to ± 0.5 T
 STANDARDISED FITS

There are two standardised fit systems:

• basic-hole fit e.g. H7/k6 (hole symbol Hn, where n is
the ISO tolerance grade for hole; shaft symbol is xm, with
m denoting the ISO tolerance grade for shaft)
• basic-shaft fit e.g. K7/h6 (shaft symbol hn, where n
is the ISO tolerance grade for shaft; hole symbols are Am
till ZCm, with m denoting the ISO tolerance grade for hole)
Because of the more expensive fabrication of holes
preferred are:
• basic-hole fits
• wider tolerance zones of hole than those for the
shaft
Both systems are shown in following figures.
STANDARDISED FITS
BASIC-HOLE FITS
STANDARDISED FITS
BASIC-SHAFT FITS
 STANDARDISED FITS

PREFERRED FITS (BASIC-HOLE SYSTEM)

Description Hole Shaft
Loose Running H11 c11
Free Running H9 d9
Easy Running - Good quality easy to do- H8 f8
Sliding H7 g6
Close Clearance - Spigots and locations H8 f7
Location/Clearance H7 h6
Location- slight interference H7 k6
Location/Transition H7 n6
Location/Interference- Press fit which can be separated H7 p6
Medium Drive H7 s6
Force H7 u6
 GEOMETRICAL TOLERANCING
Shape and position frame with symbol identifications:
 GEOMETRICAL TOLERANCING
Typical shape tolerances for chosen fabrication processes:
Manufacturing Geometric tolerance feature in µm/mm of length or diameter
process Flatness of Parallelism Straightness Parallelism Parallelism Roundness
surface of cylinders of cylinders of flat of
or cones on or cones surfaces cylinders
diameter
(cylindricity,
conicity)
Turn
Bore 50 100 100 100 100 40

Fine turn
Fine bore 30 40 40 50 50 30

Cylindrical
grind 30 50 50 50 50 20

Fine
cylindrical 20 20 20 30 20 10
grind
 EXAMPLES OF FITS

Scheme of clearance fit (basic hole system)

zero line
basic
hole

shaft
 EXAMPLES OF FITS

Clearance fit calculations

Specification: 40H9/d9
Hole Shaft
Tolerance grade: 0.062 mm 0.062 mm
Upper deviation: 0.062 mm - 0.080 mm
Lower deviation: 0.000 mm - 0.142 mm
Max diameter: 40.062 mm 39.920 mm
Min diameter: 40.000 mm 38.858 mm
Max clearance: 0.202 mm
Min clearance: 0.080 mm
 EXAMPLES OF FITS

Scheme of transition fit (basic-hole system)

zero line
basic
shaft hole
 EXAMPLES OF FITS

Transition fit calculations

Specification: 40H7/j6
Hole Shaft
Tolerance grade: 0.025 mm 0.016 mm
Upper deviation: 0.025 mm 0.009 mm
Lower deviation: 0.000 mm -0.004 mm
Max diameter: 40.025 mm 40.009 mm
Min diameter: 40.000 mm 39.996 mm
Max clearance: 0.029 mm
Max interference: 0.009 mm
 EXAMPLES OF FITS
Scheme of interference fit (basic-hole system)

shaft

zero line
basic
hole
 EXAMPLES OF FITS

Interference fit calculations

Specification: 40H7/p6
Hole Shaft
Tolerance grade: 0.025 mm 0.016 mm
Upper deviation: 0.025 mm 0.042 mm
Lower deviation: 0.000 mm 0.026 mm
Max diameter: 40.025 mm 40.042 mm
Min diameter: 40.000 mm 40.026 mm
Max interference: 0.042 mm
Min interference: 0.001 mm
 LAMÉ PROBLEM
Lamé problem concerns the solution for stress and strain in thick-
walled cylinders under internal or external pressure. Note that the
thick-walled cylinder – as opposed to the thin walled ones, in which
the constant figures for stress can be assumed – have the wall
thickness greater than 0.1 times the nominal radius of cylinder.
Bushing

Scheme of interference fit

Mating surface Sleeve

where
interference
pressure acts
 LAMÉ PROBLEM
Dimensions of components of the interference fit:
a) before assembling; b) after assembling

d – diameter dx ≈ dSi ≈ dBe

B – bushing
S – sleeve
e – external
i – internal
 LAMÉ PROBLEM

Normal forces applied to an element of sleeve or bushing

 LAMÉ PROBLEM
The equilibrium condition in radial direction produces the
following equation

dϕ
d
(σ r ⋅ r ⋅ dϕ ⋅ dl ) ⋅ dr − 2 ⋅ σ t ⋅ dl ⋅ dr ⋅ sin = 0
dr 2
with
dϕ dϕ
sin =
2 2
one obtains
dσ r
σt = σr + ⋅r
and dr
dσ t dσ r d σ r2
= 2⋅ + 2
⋅r
dr dr dr
LAMÉ PROBLEM
The elastic deformation of an element in
circumferential (tangential) direction is

εt =
(r + u ) ⋅ dϕ − r ⋅ dϕ u
=
r ⋅ dϕ r
For the radial direction we have
du d (ε t ⋅ r ) dε t
εr = = = ⋅ r + εt
dr dr dr
where

ε r = ⋅ (σ r −ν ⋅ σ t )
1
E
ε t = ⋅ (σ t −ν ⋅ σ rt )
1
E
dε t 1 ⎛ dσ t dσ r ⎞
= ⋅⎜ −ν ⋅ ⎟
dr E ⎝ dr dr ⎠
 LAMÉ PROBLEM
From previous equations follows
⎛ dσ r dσ t ⎞
r ⋅⎜ µ ⋅ − ⎟ + (1 + µ ) ⋅ (σ r − σ t ) = 0
⎝ dr dr ⎠
and finally we have an linear homogenous differential equation
d σr
2
dσ r
r ⋅
2
2
+ 3⋅ r ⋅ =0
dr dr
The solution of the above equation is
C2
σ r = C1 + 2
r
with
dσ r C2
= −2 ⋅ 3
dr r
and
C2
σ t = C1 − 2
r
 LAMÉ PROBLEM
The boundary conditions for the sleeve are
σ r = − p for r = rx = d x / 2
σ r = 0 for r = rSe = d Se / 2
The integration constants are therefore
r 2
r ⋅r 2 2
C1 = p ⋅ 2 x
; C2 = p ⋅ x Se
rSe − rx2
r −r2
Se x
2

Finally we have for the sleeve

1 ⎡ ⎛ rSe ⎞ ⎤
2

σr = p⋅ ⋅ ⎢1 − ⎜ ⎟ ⎥
⎢⎣ ⎝ r ⎠ ⎥⎦
2
⎛ rSe ⎞
⎜⎜ ⎟⎟ − 1
⎝ rx 1⎠ ⎡ ⎛ rSe ⎞ 2 ⎤
σt = p ⋅ ⋅ ⎢1 + ⎜ ⎟ ⎥
⎢⎣ ⎝ r ⎠ ⎥⎦
2
⎛ rSe ⎞
⎜⎜ ⎟⎟ − 1
⎝ rx ⎠
 LAMÉ PROBLEM
The boundary conditions for the bushing are
σ r = − p for r = rx = d x / 2
σ r = 0 for r = rBi = d Bi / 2
The integration constants are therefore
rx2 rx2 ⋅ rBi2
C1 = p ⋅ 2 ; C2 = p ⋅ 2
rBi − rx2
rBi − rx2
Finally we have for the bushing
1 ⎡ ⎛ rBi ⎞ ⎤
2

σr = p⋅ ⋅ ⎢1 − ⎜ ⎟ ⎥
⎢⎣ ⎝ r ⎠ ⎥⎦
2
⎛ rBi ⎞
⎜⎜ ⎟⎟ − 1
⎝ rx ⎠
1 ⎡ ⎛ rBi ⎞ ⎤
2

σt = p ⋅ ⋅ ⎢1 + ⎜ ⎟ ⎥
⎢⎣ ⎝ r ⎠ ⎥⎦
2
⎛ rBi ⎞
⎜⎜ ⎟⎟ − 1
⎝ rx ⎠
 LAMÉ PROBLEM

The distribution of the circumferential and radial stresses

for shaft with hole (note the radial direction of stresses σBr
and σSr)
 LAMÉ PROBLEM

The distribution of the circumferential and radial stresses

for shaft without hole (note the radial direction of stresses
σBr and σSr)
 MAXIMUM STRESS AND DEFORMATION
The maximum reduced stress – according to the maximum stress
theory (Tresca theory) – occurs in the mating surface of the outer and
inner member of the interference fit (sleeve and bushing):
• the maximum reduced stress for sleeve

2 2⋅ p rx
σ S max = p⋅ = > 0; ε S =
⎛ rx ⎞
2
1− ε S rSe
1 − ⎜⎜ ⎟⎟
⎝ rSe ⎠
• the maximum reduced stress for bushing

2 2⋅ p rBi
σ B max = p ⋅ = 2 < 0; ε B =
⎛ rBi ⎞
2
ε B −1 rx
⎜⎜ ⎟⎟ − 1
⎝ rx ⎠
where εS and εB denote the the geometrical factor for sleeve and
bushing. 3
2
 MAXIMUM STRESS AND DEFORMATION

The total diametral interference δ follows from the above given solution to
the Lamé problem

⎡ 1 ⎛ rx2 + rSe2 ⎞ 1 ⎛ rx2 + rBi2 ⎞⎤

δ = 2 ⋅ rx ⋅ p ⎢ ⋅ ⎜⎜ν S − 2 2 ⎟⎟ − ⋅ ⎜⎜ν B − 2 2 ⎟⎟⎥
⎣ ES ⎝ rx − rSe ⎠ E B ⎝ rx − rBi ⎠⎦

Where ES and EB denote the Young’s moduli and νS and νB are for the
Poisson’s ratios of sleeve and bushing, respectively.

If both members are of the same material the above formula is simplified
to the form

2 ⋅ rx ⋅ p ⎛ rx2 + rBi2 rx2 + rSe2 ⎞

δ= ⋅ ⎜⎜ 2 2 − 2 2 ⎟⎟
E ⎝ rx − rBi rx − rSe ⎠
 MAXIMUM STRESS AND DEFORMATION

The interface pressure is, therefore, to be computed utilising the

rearranged formulae:
• in the case of the different materials of sleeve and bushing

δ
p=
⎡ 1 ⎛ rSe2 + rx2 ⎞ 1 ⎛ rx2 + rBi2 ⎞⎤
2 ⋅ rx ⋅ ⎢ ⋅ ⎜⎜ 2 −ν S ⎟⎟ + ⋅ ⎜⎜ 2 2 −ν B ⎟⎟⎥
⎝ rSe − rx ⎠ E B ⎝ rx − rBi
2
⎣ ES ⎠⎦

• in the case of the same material of both members

δ ⋅ E ⎡ (rSe2 − rx2 )⋅ (rx2 − rBi2 )⎤

p= ⋅⎢
(
2 ⋅ rx ⎣ 2 ⋅ rx2 ⋅ rSe2 − rBi2 ) ⎥
⎦
 ENGINEERING CALCULATIONS
The calculations of the interference fit embrace the two following criteria:
• Load carrying capacity of the joint against axial force Fa, torsion
Mt, or both these loads, which result in the shear stress τ on the
interface of mating members

(M t / rx )2 + Fa2
τ=
2 ⋅ π ⋅ rx ⋅ l
This shear stress is being carried by the friction forces and,
therefore, the condition is
τ < µ ⋅ pmin
• Strength of the coupled members, which give the condition
pmax < σ des
In above formulae l is the length of joint, µ denotes the friction coefficient
and σdes stands for the design stress (with proper safety factor included).
Note that the maximum pressure is to be taken in strength calculation,
and the minimum one is responsible for load carrying of the fit.
 ENGINEERING CALCULATIONS
The friction coefficient depends on materials of sleeve and bushing and
on their lubrication as given in following table
Surfaces
Materials
dry lubricated
Steel/steel 0.065-0.16 0.055-0.12
Steel/cast iron
0.15-0.2 0.03-0.06
Steel/bronze
Cast iron/cast iron
0.15-0.25 0.02-0.1
Cast iron/bronze
The ultimate stress depends also on materials used and the type of load
Ultimate stress [MPa] for type of load
Material
static oscillating impact
Steel 100-180 70-120 40-60

Cast iron 70-80 50-60 20-30

Bronze 30-40 20-30 10-20

 ENGINEERING CALCULATIONS
The effective diametral interference δeff is still less than the geometrical one δ.
This results from the shearing of the asperities (peaks of the surface roughness)
during assembling. It has been shown that about 60% of the heights of asperities
Rp above the mean line is sheared – see figure below.

Thus, the effective interference of sleeve and bushing is

δ eff = δ − 0.6 ⋅ (R pB + R pS )
 APPENDIX

The uniform distribution of pressure (pm, following from

interference of components and their elastic
deformation) occurs only for torsion and axial force
loading of the joint.

If bending or radial loading act, the change of pressure

∆p is to be taken into consideration. The two following
figures represent the most common cases.

The bending moment for these cases equals to

Fa ⋅ d a
Mx =
2
APPENDIX

Fz1 = Fr

Fr ⋅ l
M x1 = M x −
2
APPENDIX

l⎡ ⎛ l⎞ ⎤
Fz1 = ⎢ Fr ⎜ e2 + ⎟ − M x ⎥
e⎣ ⎝ 2⎠ ⎦

l⎡ ⎛ l⎞ ⎤
Fz 2 = ⎢ Fr ⎜ e1 + ⎟ − M x ⎥
e⎣ ⎝ 2⎠ ⎦

M x1 = Fz1 ⋅ e1

M x 2 = Fz 2 ⋅ e2
 APPENDIX

The pressures in the points 1, 1’, 2, and 2’ are

p1 = pm + ∆p1
p1' = pm − ∆p1
p2 = pm + ∆p2
p2 ' = pm − ∆p2
Where
M x1 Fz1 M x2 Fz 2
∆p1 = X 3 + Y 2 + x 3 + y 2
df df df df
M x2 Fz 2 M x1 Fz1
∆p2 = X 3 + Y 2 + x 3 + y 2
df df df df
The coefficients X, Y, x, y are given in the following table
 APPENDIX
Correction coefficients for contact pressure
Dimensions Coefficients
di/df df/da lf/df X Y x y
0 0.3 0.50 16.10 5.17 -14.80 -2.49
0.75 8.58 3.64 -5.76 -1.52
1.00 6.74 3.06 -2.23 -0.90
1.50 6.36 2.85 0.19 -0.15
0.5 0.50 16.20 5.18 -14.70 -2.48
0.75 8.83 3.67 -5.62 -1.49
1.00 7.11 3.13 -2.05 -0.86
1.50 6.81 2.95 0.27 -0.11
0.8 0.50 16.50 5.20 -14.60 -2.46
0.75 9.42 3.75 -5.30 -1.44
1.00 7.97 3.28 -1.65 -0.76
1.50 7.81 3.15 0.42 -0.04
0.5 0.3 1.00 7.64 3.22 -1.81 -0.80
0.5 1.00 8.26 3.32 -1.53 -0.73
0.8 1.00 9.86 3.59 -0.50 -0.57