S .

I N
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 SYSTEM OF FITS AND TOLERANCES
Limit is the standard permissible variation in
dimension.

Due to the inevitable inaccuracy of manufacturing

methods, a part cannot be made precisely to a given
dimension, the difference between I N maximum and
E S .
minimum limits of size is OTtolerance.
Nthe
KTU
When two parts are to be assembled, the relation
resulting from the difference between their sizes before
assembly is called a fit.

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CONVENTIONAL DIAGRAM OF LIMITS AND FITS

S . I N
T U N OTE
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 Tolerance
• How to decide tolerance?
– Functional requirements of mating parts
– Cost of production
S .
– Available manufacturingTprocess
E I N
U N O
KT
• Choose as coarse tolerance as possible without
compromising functional requirements
• Proper balance between cost and quality of parts

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UNILATERAL TOLERANCE

S . I N
T U N OTE
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BILATERAL TOLERANCE

S . I N
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 HOLE SHAFT

Max Hole size – Basic Size = Upper Deviation Max shaft size – Basic Size = Upper Deviation
Min Hole size – Basic Size = Lower Deviation Min shaft size – Basic Size = Lower Deviation

S . I N
T U N OTE
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 CLEARANCE FIT

S . I N
T U N OTE
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Maximum shaft dimension < Minimum hole dimension

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 INTERFERANCE FIT

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Maximum Hole size < Minimum Shaft size

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 TRANSITION FIT

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Obtained by overlapping of tolerance zones of shaft and hole ……Does not

guarantee neither clearance nor interference fit
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To obtain different types of fits, it is general practice to vary
tolerance zone of one of the mating parts

HOLE BASED SYSTEM-

Size of hole is kept constant,
shaft size is varied
to get different fits.

S . I N
T U N OTE
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SHAFT BASED SYSTEM-
Size of shaft is kept constant,
hole size is varied
to get different fits.

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 HOLE BASIS & SHAFT BASIS SYSTEM

S . I N
T U N OTE
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A fit is indicated by the basic size common to both components, followed by symbol
corresponding to each component, the hole being quoted first.

E.g. 45 H8/g7

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 Gauges

S . I N
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 Gauges
• Gauges are inspection tools with rigid design,
without a scale which serve to check dimension
of a part.
• They do not determine (measure) the actual size
or dimensions of part. . I N
O T E S
• They are only T N
used
U to determine whether the
inspected partK has been made within the
specified limits.
• These gauges consist of two sizes corresponding
to their maximum and minimum limits

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Plain gauges are classified in the following ways :
(1) According to their type :
(a) Standard gauges (b) Limit gauges

(2) According to purposes :

(a) Workshop gauge (b) Inspection gauge
(c) Reference or master gauge.
S . I N
(3) According to theT U
formN OTE
of the tested surface :
K
(a) Plug gauge (b) Snap, Gap or Ring gauge.

(4) According to their design :

(a) Single limit and double limit gauges
(b) Single-ended and double-ended gauges
(c) Fixed and adjustable gauges.
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• Standard Gauges. If a gauge is made as an exact copy of the

mating part of the component to be checked, it is called as

standard gauge. A standard gauge cannot be used to check an

interference fit. It has limited applications.

• Limit Gauges. Limit gauges are very widely used in

N
S . I
T U N OTE
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industries. As there are two permissible limits of the dimension

of a part, high and low, two gauges are needed to check each

dimension of the part, one corresponding the low limit of size

and other to the high limit of size of that dimension. These are

known as GO and NO-GO gauges.

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Limit Plug Gauges
• Gauges used for checking the holes are called
"Plug gauges". The 'GO' plug gauge is the size
of the low limit of the hole while 'NO-GO'
plug gauge is the size of the high limit of hole.
S . I N
T U N OTE
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 Snap, Gap or Ring Gauges
• Snap gauges, Gap gauges or Ring gauges are used
for checking the shafts or male components.
• Snap gauges can be used for both cylindrical as
well as non-cylindrical work or compared to ring
gauges which are conventionally used only for
cylindrical work.
S . I N
Ecorresponding to the
• To Go snap gauge isN O
the T
size
U while the ‘NO GO’ gauge
KTshaft,
high limit of the
corresponds to the low limit.
• Double – ended snap gauges can be conveniently
used for checking sizes from 3 mm to 100mm and
single- ended progressive type snap gauges are
suitable for sizes from 100mm to 250mm.

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 Ring gauges
• Snap gauges, Gap gauges or Ring gauges are used for
checking the shafts or male components.
• Ring gauges are used to test external diameters.

S . I N
T U N OTE
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 Taper Gauges
• Taper gauges are made in both the plug and ring styles
and, in general, follow the same standard construction
as plug and ring gauges. When checking a taper hole,
the taper plug gauge is inserted into the hole and a
slight pressure is exerted against it. If it does not rock
in the hole, it indicates that the taper angle is correct.
• The same procedure is followed E S . I
in Na ring gauge for
N O T
TU
testing tapered spindle.
K

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 Snap Gauges
• These gauges are used for checking external
dimensions. Shafts are mainly checked by
snap gauges. They may be solid and
progressive or adjustable or double-ended.

S . I N
T U N OTE
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Thread Gauges
• Thread gauges are used to check the pitch
diameter of the thread. For checking internal
threads (nut, bushes, etc.), plug thread gauges
are used, while for checking external threads
(screws, bolts, etc.), ring thread gauges are used.

S . I N
T U N OTE
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Template Gauge
• It is made from sheet steel. It is also called
profile gauge. A profile gauge may contain two
outlines that represent the limits within which
a profile must lie as shown in Figure
S . I N
T U N OTE
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Feller Gauges
• Feller gauges are used for checking clearances
between mating surfaces. They are made in
form of a set of steel, precision machined
blade 0.03 to 1.0 mm thick and 100 mm long.

S . I N
T U N OTE
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Plate and Wire Gauges
• The thickness of a sheet metal is checked by
means of plate gauges and wire diameters by
wire gauges.

S . I N
T U N OTE
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Taylor's Principle of Gauge Design
1. It states that GO gauges should be designed to
check the maximum material limit, while the NO-
GO gauges should be designed to check the
minimum material limit.
S . I N
T U N OTE
• Now, the plug K
gauges are used to check the hole,
therefore the size of the GO plug gauge should
correspond to the low limit of hole, while that of
NO-GO plug gauge corresponds to the high limit
of hole.
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• Similarly, the ‘GO Snap gauge’ on the other
hand corresponds to the high limit of shaft,
while ‘NO-GO Snap’ gauge corresponds to the
low limit of shaft.

• The difference in size between . I the

N GO and
O T E S
NOGO plug gauges,
K T U N as well as the difference
in size between GO and NO-GO Snap gauges
is approximately equal to the tolerance of the
tested hole or shaft in case of standard gauges.

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(2) ‘GO’ gauges should check all the related
dimensions (roundness, size, location etc).
Simultaneously whereas ‘NO-GO’ gauge should
check only one element of the dimension at a time.
• According to this rule, GO plus gauge should have a
full circular section and be of full length of the hole
it has to check. E S . I N
U N O T
• This ensures that T
K any lack of straightness, or
roundness of the hole will prevent the entry of full
length GO-plug gauge.
• If this condition is not fulfilled, the inspection of the
part with the gauge may give wrong give wrong
results.
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28/01/2012 lec# 7 & 8 203

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28/01/2012 lec# 7 & 8 204

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OPTICAL FLAT

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• If an optical flat is placed upon another flat reflecting surface (without
pressure) it will not form an intimate contact, but will lie at some
angle making an inclined plane.
• If the optical flat be now illuminated by monochromatic source of
light, the eye if placed in proper position, will observe a number of
bands.
• These are produced by the interference of the light rays reflected from
the lower surface of the top flat and the top surface of the lower flat
S . I N
through the very thin layer of air between the flats.
U N OTE
• S is the source of monochromatic light.
T
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• At point A, the wave of incident beam from S is partially reflected
along AB and is partially transmitted across the air gap along AC.
• At C, again the ray is reflected along CD and passes out towards the
eye along CDE.
• Thus the two reflected components, reflected at A and C are collected
and recombined by the eye, having travelled paths whose lengths
differ by an amount ACD.
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 Optical Flats

• Used with monochromatic light to check

work for flatness, parallelism and size
• Disks of clear fused quartz,
E S . I N
lapped to within
U N O T
KT of an inch of flatness
few millionths
• Used with helium light source
– Produces greenish-yellow light 23.1323 µin.

17-220
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N.P.L. FLATNESS INTERFEROMETER

S . I N
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• This instrument is mainly used for checking the flatness
of flat surfaces.
• The flatness of any surface is judged by comparing with
an optically flat surface which is generally the base
plate of the instrument.
• This instrument essentially consists of a mercury vapour
lamp.
• As we are interested in having single monochromatic
source of light, the radiations of
E S .
the I N
mercury lamp are
passed through aK U
green N O T
filter.
T
• The wavelength of the resulting monochromatic
radiation is of the order or 0.0005 mm.
• This radiation is then brought to focus on pinhole in
order to obtain an intense point source of light.
• A mirror is used in order to deflect the light beam
through 90°.
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• The pinhole is placed in the focal plane of a collimating lens, thus the
radiations out of the lens will be parallel beam of light.
• This beam is directed on the gauge to be tested via an optical flat. The
fringes formed are viewed directly above by means of a thick glass
plate semi-reflector set at 45° to the optical axis.
• The gauge to be tested is wrung on the base plate whose surface is
finished to a degree comparable to that of the highest quality gauge
face.
S . I N
• As the optical flat is placed above it in a little tilted position,
T U N OTE
interference fringes are formed ; one between rays reflected from the
K
under surface of the optical flat and those reflected from the surface of
the gauge, and the other between rays reflected from the under surface
of the optical flat and those reflected from the base plate.
• If the gauge face is flat and parallel to the base plate, then the optical
flat being equally inclined on both the surfaces the fringe pattern from
both the gauge face and the base plate will consist of straight, parallel
and equally spaced fringes
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