MEDII Lecture Note 01 PDF

Lecture Note 01 on Standards, Tolerances, Limits and Fits
MEE 411: Mechanical Engineering Design II

Engr Prof Christopher Okechukwu Izelu
MEE 411
Mechanical Engineering Design II

Design of Machine Elements
LN01: Standards, Tolerances, Limits and Fits
Contents
 Introduction
 Standards
 Standardization
 Technical Standards
 Tolerances
 Limits and fits
1.0 Introduction
 The purpose of this lecture is to reinforce your previous knowledge of standards,
tolerances, limits and fits, gained in machine drawing, in view of their applications in
machine element design.
 Therefore, at the end of this lecture students should be able to define and use these
concepts, and numerous related others, and also, perform basic calculations involved
in the use of standards, tolerances, limits and fits in design.
1.1 Standards
 Standards are of different categories such as given, and explained as follows:

 Technical Standards
o A technical standard is an established norm or requirement about technical
systems.
o It is usually a formal document that establishes uniform engineering or
technical criteria, methods, processes and practices.
o It can also be a controlled artifact or similar formal means used for calibration.
o It is the main concern of this lecture.
 De facto standards
o This include norms such as a custom, settlement, company product, corporate
standard, e. t. c., which may be generally accepted and dominant, but not
regarded as technical standards.
 Reference Standards and certified reference materials
o These standards have an assigned value by direct comparison with a reference
base.
 Primary Standards
o A primary standard is usually under the jurisdiction of a national standards
body.
 Secondary, tertiary, check standards and standard materials
o These standards may be used for reference in a metrology system.
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1.2 Standardization
 Standardization is the process of developing and implementing technical standards.

 A technical standard may be developed privately or unilaterally, for example by a
corporation, regulatory body, military, etc.
 Standards can also be developed by groups such as trade unions, and trade
associations.
 Standards organizations often have more diverse input and usually develop voluntary
standards.
 These might become mandatory if adopted by a government, business contract, etc.
 The standardization process may be originated by edict, or may involve the formal
consensus of technical experts.
1.3 Technical standards
1.3.1 Types of technical standards
The primary types of technical standards are:
 Standard Specification
o A standard specification is an explicit set of requirements for an item, material,
component, system or service.
o It is often used to formalize the technical aspects of a procurement agreement
or contract.
o For example, there may be a specification for a turbine blade for a jet engine
which defines the exact material and performance requirements.
 Standard Test Method
o A standard test method describes a definitive procedure which produces a test
result.
o It may involve making a careful personal observation or conducting a highly
technical measurement.
o For example, a physical property of a material is often affected by the precise
method of testing: any reference to the property should therefore reference the
test method used.
 Standard Practice
o A standard practice or procedure gives a set of instructions for performing
operations or functions.
o For example, there are detailed standard operating procedures for operation of
a nuclear power plant.
 Standard Guide
o A standard guide is a general information or option which does not require a
specific course of action.
 Standard Definition
o A standard definition is a formally established terminology.
 Standard units
o In physics and applied mathematics, these are commonly accepted
measurements of physical quantities.
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1.3.2 Where to Obtain Technical Standards
Technical standard are available in:
 Public documents, which are available on the internet, university and public library,
government archives, etc.
 Published documents which are available for purchase.
 Private documents owned by an organization or corporation.
 Patent documents or documents open for public use, but with intellectual property
associated with them.
 Closed or controlled documents which contain trade secrets or classified
information.
1.3.3 Geographical Levels of Technical Standards
 When a geographically defined community needs to solve a community-wide

coordination or harmonization problem, it can adopt an existing standard, or produce
a new one.
 The main geographical levels of technical standards are:
o National Standards: These are documents prepared by national standards
organizations. For example, Telecommunications Industry Association
standards.
o Regional Standards: These are documents prepared by regional standards
organizations. For example, CEN (European Committee for Standardization)
standards.
o International Standards: These are documents prepared by international
standards organizations. Example, ISO (International Organization for
Standardization) and ANSI (American National Standards Institute) standards.
 National/Regional/International standards is one way of overcoming technical barriers
in inter-local or inter-regional commerce caused by differences among technical
regulations and standards developed independently and separately by each local
standards organization or company.
 Technical barriers arise when different groups come together, each with a large user
base, doing some well-established thing that between them is mutually incompatible.
Establishing national/regional/international standards is one way of preventing or
overcoming this problem.
1.3.4 Usage of Technical Standards
 The existence of a published standard does not imply that it is always useful or correct.
 For example, if an item complies with a certain standard, there is not necessarily
assurance that it is fit for any particular use.
 The people who use the item or service (engineers, trade unions, etc.) or specify it
(building codes, government, industry, etc.) have the responsibility to consider the
available standards, specify the correct one, enforce compliance, and use the item
correctly.
 Validation of suitability is necessary.
 Standards often get reviewed, revised and updated.
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 It is critical that the most current version of a published standard be used or
referenced.
 The originator or standard writing body often has the current versions listed on its web
site.
 A standard is useful if it is a solution to a coordination problem.
 It emerges from situations in which all parties can realize mutual gains, but only by
making mutually consistent decisions.
 As example:
Party Mutual Gain Problem Solution

Mechanical Suppliers interchange, Screw thread Screw thread standard
industry stock gains, e t c compatibility specifications
companies
1.4 Tolerances
1.4.1 Definition of Tolerances
 Engineering tolerance may be referred to as the permissible limit, or limits, of

variation in the following.
o A physical dimension
o A measured value, or physical property, of a material, manufactured object,
system, or service
o Other measured values, such as temperature, humidity, and so on
 In engineering and safety, it is a physical distance or space (tolerance), as in a truck
(lorry), train or boat under a bridge as well as a train in a tunnel.
 In mechanical engineering, it is the space between a bolt and a nut or a hole, etc.
 Dimensions, properties, or conditions may vary within certain practical limits without
significantly affecting performance of equipment or a process.
 Tolerances are specified to allow reasonable leeway for imperfections and inherent
variability without compromising performance.
 A variation beyond the tolerance (for example, a temperature that is too hot or too
cold) is said to be non-compliant, rejected, or exceeding the tolerance (regardless of
if this breach was of the lower or the upper bound).
 If the tolerance is set too restrictive, resulting in most objects run by it being rejected,
it is said to be intolerant.
1.4.2 Considerations when Setting Tolerances
 A primary concern is to determine how wide the tolerances may be without affecting
other factors or the outcome of a process.
 This can be done by the use of scientific principles, engineering knowledge, and
professional experience.
 Experimental investigation is very useful to investigate the effects of tolerances:
Design of experiments, formal engineering evaluations, e t c, can be adopted.
 A good set of engineering tolerances in a specification, by itself, does not imply that
compliance with those tolerances will be achieved.
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 Actual production of any product (or operation of any system) involves some inherent
variation of input and output.
 Measurement error and statistical uncertainty are also present in all measurements.
 With a normal distribution, the tails of measured values may extend well beyond plus
and minus three standard deviations from the process average.
 Appreciable portions of one (or both) tails might extend beyond the specified tolerance.
 The process capability of systems, materials, and products needs to be compatible
with the specified engineering tolerances.
 Process controls must be in place and an effective Quality Management System, such
as Total Quality Management, is needed to keep actual production within the desired
tolerances.
 A process capability index is used to indicate the relationship between tolerances and
actual measured production.
 The choice of tolerances is also affected by the intended statistical sampling plan and
its characteristics such as the Acceptable Quality Level.
 This relates to the question of whether tolerances must be extremely rigid (high
confidence in 100% conformance) or whether some small percentage of being out-of-
tolerance may sometimes be acceptable.
1.4.3 Mechanical Component Tolerances
 Dimensional tolerances are related to, but different from fits in mechanical
engineering, which are designed-in clearances, or interferences, between two
parts.
 Tolerances can be applied to any dimension.
 It is the total amount by which a dimension is allowed to vary.
 For fractional linear dimensions a bilateral tolerance of 1/64 inch is assumed.
 For the fit of a shaft/hole combination, the tolerance is considered to be unilateral,
that is, it is only applied in one direction from design size of the part.
 Standards for limits and fits state that tolerances are applied such that the hole-size
can only vary larger from design size and the shaft size smaller.
 The commonly used terms are:
 Nominal Size
o This is the size designation used for general identification.
o The nominal size of a shaft and a hole are the same.
o This value is often expressed as a fraction.
 Basic size
o This is the exact theoretical size of a part.
o It is the value from which limit dimensions are computed and a four decimal
place equivalent to the nominal size.
o It is the nominal diameter of the shaft (or bolt) and the hole, which is, in
general, the same for both components.
o For example, a nominal size of 1 ¼ is equivalent to the basic size of 1.2500.
 Design Size
o This is the ideal size for each component (shaft or hole) based upon a selected
fit.
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o The difference between the design size of the shaft and the design size of the
hole is equal to the allowance of the fit.
o The design size of a part corresponds to the Maximum Material Condition
(MMC).
o That is, the largest shaft permitted by the limits and the smallest hole.
o Emphasis is placed upon the design size in the writing of the actual limit
dimension, so the design size is placed in the top position of the pair.
 Basic-Hole System
o This is the most common system for limit dimensions.
o In this system the design size of the hole is taken to be equivalent to the basic
size ( D or d ) for the pair (Fig 1).
o This means that the lower (in size) limit of the hole-dimension is equal to the
design size.
o The basic-hole system is more frequently used since most hole-generating
devices, such as drills, reams, etc., are of fixed sizes.
o When designing using purchased or standard components, such as bearings,
bushings, etc., with fixed inner diameters, a basic-shaft system may be used.
Figure 1: Metric Nomenclature for limits and fits.
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 Lower deviation (  l )
o This is the difference between the minimum possible component size ( Dmin or
d min ) and the basic size ( D or d ).
o That is, for the hole:  l  Dmin  D , or Dmin   l  D , and for the shaft:
 l  d  d min , or d min  d   l .
 Upper deviation (  u )
o This is the difference between the maximum possible component size ( Dmax or
d max ) and the basic size ( D or d ).

o That is, for the hole, it is:  u  Dmax  D , or Dmax   u  D , and for the shaft,
it is:  u  d  d max , or d max  d   u .
 Fundamental deviation (  F )
o This is the minimum difference in size between a component and the basic size.
o This is identical to the upper deviation for shafts (  F   u  d  d max ), and the
lower deviation for holes (  F   l  Dmin  D ).
o If the fundamental deviation is greater than zero, the bolt will always be smaller
than the basic size and the hole will always be wider.
o Fundamental deviation is a form of allowance or clearance, rather than
tolerance.
 International Tolerance grade
o This is a standardized measure of the maximum difference in size between the
component and the basic size.
o For the hole, it is: D  Dmax  D , or Dmax  D  D , and for the shaft, it is:
d  d max  d , or d max  d  d .
 As example, if a shaft with a nominal diameter of 10 mm is to have a sliding fit within
a hole, then we may specify as follows:
o The shaft might be specified with a tolerance range from 9.964 to 10 mm, that
is, a zero fundamental deviation, but a lower deviation of 0.036 mm
o The hole might be specified with a tolerance range from 10.04 mm to
10.076 mm, that is, a fundamental deviation of 0.04 mm, and an upper
deviation of 0.076 mm.
 This would provide a clearance fit of somewhere between 0.04 mm (largest shaft
paired with the smallest hole, called the "maximum material condition (MMC)") and
0.112 mm (smallest shaft paired with the largest hole).
 In this case the size of the tolerance range for both the shaft and hole is chosen to be
the same (0.036 mm), meaning that both components have the same International
Tolerance grade, but this need not be the case in general.
 The machining industry uses the following standard tolerances when no other
tolerances are provided:
o 1 decimal pace (0.x), e.g. 0.2;
o 2 decimal places (0.0x), e.g. 0.01;
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o 3 decimal places (0.00x), e.g. 0.005; and
o 4 decimal places (0.000x), e.g. 0.0005.
1.4.4 International Tolerance Grades
 When designing mechanical components, a system of standardized tolerances called

International Tolerance grades are often used.
 On the basis of the IT grades, the standard (size) tolerances are divided into two
categories: hole and shaft.
 They are labeled with a letter (capitals for holes and lowercase for shafts), and a
number.
 For example: H7 (hole, tapped-hole or nut) and h6 (shaft or bolt).
 H7/h6 is a very common standard tolerance which gives a rather tight fit, but not so
tight that you cannot put the shaft in the hole, or turn the nut on the bolt, by hand.
 The tolerances work in such a way that for a hole, H7, means that the hole should be
made slightly larger than the base dimension (in this case for an ISO fit 10+0.015−0,
meaning that it may be up to 0.015 mm larger than the base dimension, and 0 mm
smaller).
 The actual amount bigger/smaller depends on the base dimension.
 For a shaft of the same size, h6 would mean 10+0−0.009, which is the opposite of
H7.
 This method of standard tolerances is also known as Limits and Fits and can be found
in ISO 286-1:2010.
 Table 1 summarizes the International Tolerance (IT) grades, and the general
applications of these grades:
Table 1: International Tolerance Grades

Measuring Tools Materials
IT Grade 01 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Fits Large Manufacturing Tolerances
 An analysis of fit by statistical interference is also extremely useful.

 It indicates the frequency (or probability) of parts properly fitting together.
1.4.5 Tolerance and Allowance
The terms are often confused, but sometimes a difference is maintained.
 Tolerance:
o This is an undesirable but permissible deviation from a desired dimension since
a component may not be made exactly to one specified dimension.
 Allowance:
o This is an intentional, desired difference between the dimensions of two mating
parts
o It is dependent on the type of fit specified.
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o It may be positive (+), which means that there is intended clearance between
parts; negative (-), which means that there is intended interference; or zero,
which means that the two parts are intended to be the same size.
o The last case is common to selective assembly.
o Allowance is also the minimum clearance or maximum interference between
parts.
1.4.6 Specification of Tolerances
 Ways of expressing tolerances include:

o direct limits or as tolerance limits applied to a dimension as shown in Fig 2a
and b;
o geometric tolerances as depicted in Fig 2c;
o a general tolerance note in the title block as illustrated in Fig 2d; and
o notes referring to specific conditions as stated in Fig 2e

(a) Direct Limits (b) Tolerance Limits
(c) Geometric Tolerance (d) General Tolerance
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General Tolerances could be in the form of a

note similar to the one shown below:
ALL DECIMAL DIMENSIONS TO BE

HELD TO .002”
Means that a dimension such as .500 would

be assigned a tolerance of 0.002, resulting
in a upper limit of .502 and a lower limit of
.498
(e) Notes Referring to Specific Conditions
Figure 2: Specification of Tolerances
1.5 Limits and Fits
 In mechanical engineering, limits and fits are sets of rules on how many thousandths
of an inch or mm measurement of a part is to be under or over the theoretical size to
achieve various sorts of fit such as sliding fit, rotating fit, non-sliding fit, loose fit, etc.
1.5.1 Limits
 Limit refers to the maximum and minimum sizes shown by tolerances.

 For the slot depicted in Fig 3, 0.502 is the larger value or the upper limit (LMC) and
0.498 the smaller value or the lower limit (MMC).
 In other words, tolerance is the total allowable variance in dimensions (upper limit –
lower limit); object dimension could be as big as the upper limit or as small as the
lower limit or anywhere in between.
Figure 3: Limit
1.5.2 Fits
 Fit refers to the degree of tightness between two parts.

 As depicted in Fig 4, the following are the different categories of fit.
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o Clearance Fit: This means the type of fit due to the tolerance of mating parts
that clears or leaves a space.
o Interference fit: This means the type of fit due to tolerance of mating parts
that interferes.
o Transition fit: This means the type of fit due to tolerance of mating parts that
sometimes interferes and sometimes clears.
 Refer to Fig 4b and c for fits of two mating parts.
(a) Fit tolerance
(b) Fit of a Bar and Slot
(c) Fit of a Shaft and Hole
Figure 4: Fit
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 Consider again basic-hole system or hole-basis of tolerances for a hole and shaft.
 For this system, the minimum size of hole is equal to the basic size of fit.
 That is, if the nominal size of a fit is ½ inch, then the minimum or basic size of the
hole in the system will be 0.500 inch.
 Refer to Fig 5a.
 Let Clearnce  Hole  Shaft such that C max  Dmax  d min , and C min  Dmin  d max .
 If C max  0 and C min  0 , that is, they are positive, then there is a clearance fit.
 If C max  0 and C min  0 , that is, they are negative, then there is an interference fit.
 If C max  0 and C min  0 , that is, either of them is positive or negative, then there is
a transition fit.
 Thus, the system tolerance is: TS  C max  C min ; the system allowance is: AS  C min
the minimum clearance.
d max .490
d min .485
Dmax .510
Dmin .505
(a) (b)
Figure 5: Hole-Basis System
 For instance, in Fig 5b:

o The maximum clearance is: C max  Dmax  d min  0.510  0.485  0.025 .
o The minimum clearance is: C min  Dmin  d max  0.505  0.490  0.015 .
o Since C max  0 and C min  0 , the type of fit is clearance.
 Thus:
o The system tolerance is: Ts  C max  C min  0.025  0.015  0.010 .
o The system allowance is: C min  0.015 .
1.5.3 Standard Fits
 The metric limits and fits based on Standard Basic Sizes is the ISO Standard.
 Note that:
o In the Metric system, nominal Size = Basic Size.
o For example, if the nominal size is 8, then the basic size is 8.
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 The preferred metric hole-basis system of fit is depicted in Fig 6.
 The preferred metric tolerance grades for limits and fits based on ANSI B4.2-1978 are
given in Table 2.
 The preferred metric fundamental deviations (allowance of clearance) are given in
Table 3.
Figure 6: Metric Preferred Hole-Basis System of Fit
Table 2: Tolerance Grades Table
Tolerance Grades (D or d)

Basic Sizes
IT6 IT7 IT8 IT9 IT10 IT11
0–3 0.006 0.010 0.014 0.025 0.040 0.060
3–6 0.008 0.012 0.018 0.030 0.048 0.075
6 – 10 0.009 0.015 0.022 0.036 0.058 0.090
10 – 18 0.011 0.018 0.027 0.043 0.070 0.110
18 – 30 0.013 0.021 0.033 0.052 0.084 0.130
30 – 50 0.016 0.025 0.039 0.062 0.100 0.160
50 – 80 0.019 0.030 0.046 0.074 0.120 0.190
80 – 120 0.022 0.035 0.054 0.087 0.140 0.220
120 – 180 0.025 0.040 0.063 0.100 0.160 0.250
180 – 250 0.029 0.046 0.072 0.115 0.185 0.290
250 – 315 0.032 0.052 0.081 0.130 0.210 0.320
315 – 400 0.036 0.057 0.089 0.140 0.230 0.360
Source: Preferred metric Limits and Fits based on ANSI B4.2-1978
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Table 3: Fundamental Deviation for Shafts
Upper Deviation (  u ) letter Lower Deviation (  l ) letter

Basic size
c d f g h k n p s u
0–3 -0.060 -0.020 -0.006 -0.002 0 0 0.004 0.006 0.014 0.018
3–6 -0.070 -0.030 -0.010 -0.004 0 0.001 0.008 0.012 0.019 0.023
6 – 10 -0.080 -0.040 -0.013 -0.005 0 0.001 0.010 0.015 0.023 0.028
10 – 14 -0.095 -0.050 -0.016 -0.006 0 0.001 0.012 0.018 0.028 0.033
14 – 18 -0.095 -0.050 -0.016 -0.006 0 0.001 0.012 0.018 0.028 0.033
18 – 24 -0.110 -0.065 -0.020 -0.007 0 0.002 0.015 0.022 0.035 0.041
24 – 30 -0.110 -0.065 -0.020 -0.007 0 0.002 0.015 0.022 0.035 0.048
30 – 40 -0.120 -0.080 -0.025 -0.009 0 0.002 0.017 0.026 0.043 0.060
40 – 50 -0.130 -0.080 -0.025 -0.009 0 0.002 0.017 0.026 0.043 0.070
50 – 65 -0.140 -0.100 -0.030 -0.010 0 0.002 0.020 0.032 0.053 0.087
65 – 80 -0.150 -0.100 -0.030 -0.010 0 0.002 0.020 0.032 0.059 0.102
80 – 100 -0.170 -0.120 -0.036 -0.012 0 0.003 0.023 0.037 0.071 0.124
100 – 120 -0.180 -0.120 -0.036 -0.012 0 0.003 0.023 0.037 0.079 0.144
120 – 140 -0.200 -0.145 -0.043 -0.014 0 0.003 0.027 0.043 0.092 0.170
140 – 160 -0.210 -0.145 -0.043 -0.014 0 0.003 0.027 0.043 0.100 0.190
160 – 180 -0.230 -0.145 -0.043 -0.014 0 0.003 0.027 0.043 0.108 0.210
180 – 200 -0.240 -0.170 -0.050 -0.015 0 0.004 0.031 0.050 0.122 0.136
200 – 225 -0.260 -0.170 -0.050 -0.015 0 0.004 0.031 0.050 0.130 0.258
225 – 250 -0.280 -0.170 -0.050 -0.015 0 0.004 0.031 0.050 0.140 0.284
250 – 280 -0.300 -0.190 -0.056 -0.017 0 0.004 0.034 0.056 0.158 0.315
280 – 315 -0.330 -0.190 -0.056 -0.017 0 0.004 0.034 0.056 0.170 0.350
315 – 355 -0.360 -0.210 -0.062 -0.018 0 0.004 0.037 0.062 0.190 0.390
355 - 400 -0.400 -0.210 -0.062 -0.018 0 0.004 0.037 0.062 0.208 0.435
Source: Preferred metric Limits and Fits Based on ANSI B4.2-1978. See also BSI 4500
 In Table 3, it is important to take note of the following.

 For the shaft letter codes c, d, f, g and h:
o upper deviation = fundamental deviation, that is, 𝛿 = 𝛿
o lower deviation = upper deviation – tolerance grade, 𝛿 = 𝛿 − ∆𝑑
 For the shaft letter codes k, n, p, s and u:
o lower deviation = fundamental deviation, that is, 𝛿 = 𝛿
o upper deviation = lower deviation + tolerance grade, 𝛿 = 𝛿 − ∆𝑑
 For the hole letter code H:
o lower deviation = 0, that is, 𝛿 = 0
o upper deviation = tolerance grade, that is, 𝛿 = ∆𝑑
 Base on the standards for fits, a classification of fits is given as follows:
 Running or Sliding fits
o RC1: close sliding fits
o RC2: sliding fits
o RC3: precision running fits
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o RC4: close running fits
o RC5 and RC6: medium running fits
o RC7: free running fits
o RC8 and RC9: loose running fits
 A graphical representation of these fits depicted in Fig 7 gives an approximate
comparison of the allowances and tolerance.
Figure 7: Graphical Representation of Standard Running or Sliding Fits.
 Locational Fits
o These determine only the location of moving parts.
o Locational clearance (LC) fits are specified in nine classes as shown in Fig 8.
Figure 8: Graphical Representation of Standard Clearance Locational fits.
 Transition Fits
o These are compromise between clearance and interference fits, and they are
specified in seven classes as shown in Fig 9.
Figure 9: Graphical Representation of Standard Transition Fits
 Locational interference Fits

o These are used when accuracy of location is of prime importance as in jigs and
fixtures; they are specified in two classes as shown in Fig 10.
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Figure 10: Graphical Representation of Standard Locational Interference Fits.
 Force or Shrink Fits

o These are shown if Fig 11
o They are interference fits classified as follows:
 FN1: Light drive fits
 FN2: medium drive fits
 FN3: heavy drive fits
 FN4 and FN5: force fits or shrink fits in parts that can be highly stressed
Figure 11: Graphical representation of Standard Force or shrink fits.
 The above classification of fits is also summarized in Table 4, with preferred metric
symbolic specifications based on the basic-hole system and ANSI B4.2-1978.
 Note that, for a fit specification H7/g6, H7 stands for the hole and g6 stands for the
shaft.
 If the basic size is included, the fit specifications appear, for example, as 32H7, for the
hole, and 32g6, for the shaft.
 Thus, for the hole 32 denotes the basic size D = 32 mm, H denotes the fundamental
deviation F = 0.000 mm, and 7 denotes the tolerance grade ΔD or IT7.
 For the shaft, 32 denotes the basic size d = 32 mm, g denotes the fundamental
deviation F, and 6 denotes the tolerance grade Δd or IT6.
 Sample analyses of fit using the metric preferred standard hole-basis system are given
as follows:
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Table 4: Specifications based on Basic-Hole System
Type of Fit Description Symbol

Clearance Loose running fit: for wide commercial tolerances or H1/e11
allowance on external members
Free running fit: not for use where accuracy is essential, H9/d9
but good for large temperature variations, high
running speeds, or heavy journal pressure
Close running fit: for running on accurate machines and H8/f7
for accurate location at moderate speeds and journal
pressures
Sliding fit: used where parts are not intended to run H7/g6
freely, but must move and turn freely, and locate
accurately
Locational clearance fit: provides snug fit for location of H7/h6
stationary parts, but can be freely assembled and
disassembled
Transition Locational Transition fit: for accurate location, a H7/k6
compromise between clearance and interference
Locational Transition fit: for more accurate location H7/n6
where greater interference is permissible
Interference Locational interference fit: for parts requiring rigidity H7/p6
and alignment with prime accuracy of location but
without special bore pressure requirements
Medium drive fit: for ordinary steel parts or shrink fits H7/s6
on light sections, the tightest fit usable with cast iron
Force fit: suitable for parts which can be highly stressed H7/u6
or for shrink fits where the heavy pressing force
required are impractical
Source: Preferred Metric Limits and Fits based on ANSI B4.2-1978.
Page/17
Example 1:
 Determine the free running fit tolerances for a shaft and hole of nominal size and
basic size of 8 mm.
Solution:
 From the Table 4, the specification for the free running fit tolerances is 8H9/8d9.
 Thus:
Hole Shaft
Basic diameter D = 8 mm d = 8 mm
Tolerance Grade ΔD = 0.036 mm (Table 2: IT9) Δd = 0.036 mm (Table 2: IT9)

Fundamental
F = 0.000 mm F = -0.040 mm (Table 3: d)
Deviation
Upper Deviation u = F + ΔD = 0.036 mm u = F = -0.040 mm
Lower Deviation l = F = 0.000 mm l = u - Δd = -0.076 mm

Maximum
Dmax = D + u = 8.036 mm dmax = d + u = 7.960 mm
Diameter
Minimum Diameter Dmin = Dmax – ΔD = 8.000 mm dmin = dmax – Δd = 7.924 mm
Dav = (Dmax + Dmin)/2 = 8.018 dav = (dmax + dmin)/2 = 7.942
Average Diameter
mm mm
Maximum
Cmax = Dmax – dmin = 8.036 – 7.924 = 0.112 mm
Clearance
Minimum
Cmin = Dmin – dmax = 8.000 – 7.960 = 0.040 mm
Clearance
System Tolerance Ts = Cmax – Cmin =0.112 – 0.040 = 0.072 mm
Dimension
Tolerance Shown 8.018 00,.018
018
8.036 00..000
036 7.942 00,.018
018
7.960 00..000
036
on Drawing
Page/18
Example 2:
 Determine the loose running fit tolerances for a shaft and hole that have basic
diameter of 32 mm.
Solution:
 From Table 4, the specification for the loose running fit tolerances is 32H11/32c11.
 Thus:
Hole Shaft

Fundamental
F = 0.000 mm F = -0.120 mm (Table 3: c)
Deviation
Upper Deviation u = F + ΔD = 0.160 mm u = F = -0.120 mm
Lower Deviation l = F = 0.000 mm l = u - Δd = -0.280 mm
Maximum Diameter Dmax = D + u = 32.160 mm dmax = d + u = 31.880 mm
Minimum Diameter Dmin = Dmax – ΔD = 32.000 mm dmin = dmax – Δd = 31.720 mm

Average Diameter
mm mm
Maximum Clearance Cmax = Dmax – dmin = 32.160 – 31.720 = 0.44 mm
Minimum Clearance Cmin = Dmin – dmax = 32.000 – 31.880 = 0.12 mm
System Tolerance Ts = Cmax – Cmin =0.44 – 0.12 = 0.32 mm

Dimension
Tolerance Shown on 32.080 00,.080
080
32.160 00..000
160 31.800 00,.080
080
31.880 00..000
160
Drawing
Page/19
Exercises:
 Determine the force fit tolerances for a shaft and hole that have a basic diameter of
32 mm.
 Determine the dimension and tolerance to be specified on a drawing for a shaft and
hole having a basic size of 50 mm. The fit must allow a snug fit but be freely
assembled and disassembled.
Answer:
 From Table 4, the specification for the force fit tolerances is 32H7/32u6.
 Thus:
Hole Shaft

Fundamental
F = 0.000 mm F = 0.060 mm (Table 3: u)
Deviation
Upper Deviation u = F + ΔD = 0.025 mm u = l +Δd = 0.76 mm
Lower Deviation l = F = 0.000 mm l = F = 0.60 mm

Maximum
Dmax = D + u = 32.025 mm dmax = d + u = 32.076 mm
Diameter
Minimum Diameter Dmin = Dmax – ΔD = 32.000 mm dmin = dmax - Δd = 32.060 mm
Average Diameter
mm mm
Maximum
Cmax = Dmax – dmin = 32.025 – 32.070 = -0.035 mm
Clearance
Minimum
Cmin = Dmin – dmax = 32.000 – 32.076 = -0.076 mm
Clearance
System Tolerance Ts = Cmax – Cmin = -0.035 – (-0.076) = 0.041 mm
Dimension
Tolerance Shown 32.013 00,.013
013
32.025 00..000
025 32.068 00,.013
013
32.076 00..000
016
on Drawing
Page/20

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Lecture Note 01 on Standards, Tolerances, Limits and Fits

MEE 411: Mechanical Engineering Design II

Mechanical Engineering Design II

 Standards are of different categories such as given, and explained as follows:

 Standardization is the process of developing and implementing technical standards.

1.3 Technical standards

1.3.1 Types of technical standards

The primary types of technical standards are:

Technical standard are available in:

1.3.3 Geographical Levels of Technical Standards

 When a geographically defined community needs to solve a community-wide

1.3.4 Usage of Technical Standards

Party Mutual Gain Problem Solution

1.4.1 Definition of Tolerances

 Engineering tolerance may be referred to as the permissible limit, or limits, of

1.4.2 Considerations when Setting Tolerances

1.4.3 Mechanical Component Tolerances

Figure 1: Metric Nomenclature for limits and fits.

d max ) and the basic size ( D or d ).

1.4.4 International Tolerance Grades

 When designing mechanical components, a system of standardized tolerances called

Table 1: International Tolerance Grades

 An analysis of fit by statistical interference is also extremely useful.

1.4.5 Tolerance and Allowance

The terms are often confused, but sometimes a difference is maintained.

1.4.6 Specification of Tolerances

 Ways of expressing tolerances include:

(c) Geometric Tolerance (d) General Tolerance

General Tolerances could be in the form of a

ALL DECIMAL DIMENSIONS TO BE

Means that a dimension such as .500 would

Figure 2: Specification of Tolerances

1.5 Limits and Fits

 Limit refers to the maximum and minimum sizes shown by tolerances.

 Fit refers to the degree of tightness between two parts.

(a) Fit tolerance

(b) Fit of a Bar and Slot

(c) Fit of a Shaft and Hole

Figure 5: Hole-Basis System

 For instance, in Fig 5b:

1.5.3 Standard Fits

Figure 6: Metric Preferred Hole-Basis System of Fit

Table 2: Tolerance Grades Table

Tolerance Grades (D or d)

Table 3: Fundamental Deviation for Shafts

Upper Deviation (  u ) letter Lower Deviation (  l ) letter

 In Table 3, it is important to take note of the following.

Figure 7: Graphical Representation of Standard Running or Sliding Fits.

Figure 8: Graphical Representation of Standard Clearance Locational fits.

Figure 9: Graphical Representation of Standard Transition Fits

 Locational interference Fits

Figure 10: Graphical Representation of Standard Locational Interference Fits.

 Force or Shrink Fits

Figure 11: Graphical representation of Standard Force or shrink fits.

Table 4: Specifications based on Basic-Hole System

Type of Fit Description Symbol

Tolerance Grade ΔD = 0.036 mm (Table 2: IT9) Δd = 0.036 mm (Table 2: IT9)

Lower Deviation l = F = 0.000 mm l = u - Δd = -0.076 mm

Tolerance Grade ΔD = 0.160 mm (Table 2: IT11) Δd = 0.160 mm (Table 2: IT11)

Lower Deviation l = F = 0.000 mm l = u - Δd = -0.280 mm

Maximum Diameter Dmax = D + u = 32.160 mm dmax = d + u = 31.880 mm

Minimum Diameter Dmin = Dmax – ΔD = 32.000 mm dmin = dmax – Δd = 31.720 mm

Minimum Clearance Cmin = Dmin – dmax = 32.000 – 31.880 = 0.12 mm