Project Requirements

• Selection of the machine (One week)

• Disassembly of the machine (zero week)
• Measurements of components dimensions
(One week)
• Draw free hand sketches (One week)
• Draw using instruments (assembly and parts
in a separate sheets) (Two week)
• Draw using solid works (Two week)
• Presentations (week number 9)
10/1/2017 2:33:37 AM 1
 Chapter Three
Fits and Tolerances

Prof Dr Tarek Osman

 Three Categories of
Dimensioning

Dimensioning can be divided into three categories:

•General dimensioning,
•Geometric dimensioning, and
•Surface texture.

Prof Dr Tarek Osman

General dimensioning

Prof Dr Tarek Osman

Types of Tolerances

General General Tolerances apply to all

dimensions on a drawing.

Linear Tolerances refer to

Linear specific features that require
more accuracy than general
tolerances provide.

Geometric Tolerances are concerned

Geometric with a feature’s shape or profile, not its
size or dimensions.

Prof Dr Tarek Osman

 General Tolerance General

• Apply to all dimensions on a drawing.

• Often found in the title block of all drawings
intended for manufacturing or as a general
note.
• Normally given in bilateral (‫ )ثنائي‬form, defining
a symmetric limit above and below a
dimension.

Prof Dr Tarek Osman

 Fits and tolerances
• Tolerance :
– Due to the inevitable inaccuracy of manufacturing
methods, a part cannot be made precisely to a
given dimension.
– The difference between maximum and minimum
limits of size is the tolerance.
• Fit:
– When two parts are to be assembled, the relation
resulting from the difference between their sizes
before assembly is called a fit.

9/28/2017 1:29:59 PM 7
Tolerance
Linear

• How to decide tolerance?

– Functional requirements of mating parts
– Cost of production
– Available manufacturing process

• Choose as coarse tolerance as possible without

compromising functional requirements
• Proper balance between cost and quality of parts

Prof Dr Tarek Osman

 Types of Fits
Linear

• A type of fit represents the degree

of tightness between two mating Clearance Fit
parts.
Transition Fit

• Linear tolerances can be classified Interference Fit

in 3 major categories, based on the
interaction between the parts.

Prof Dr Tarek Osman

 Fits and tolerances
• Clearance fit:
Clearance fit is chosen when there is a relative motion between the
two assembled parts, and no power transmission. (e.g. rotating
shaft in a sliding bearing)

Nominal size

Shaft

Hole

9/28/2017 1:29:59 PM 10
 Fits and tolerances
• Transition fit:
Transition fit is a fit lies between the clearance and interference fits, where
there’s no relative motion between the two parts and also no power
transmission. (e.g. Rolling Bearings)

Nominal size

Shaft

Hole
9/28/2017 1:29:59 PM 11
 Fits and tolerances
• Interference fit:
Interference fit is chosen when there’s no relative motion required
between the parts , but there’s a power transmission required.
(e.g. shaft shrink-fitted in a gear)

Nominal size

Shaft

Hole
9/28/2017 1:29:59 PM 12
 Linear

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

Prof Dr Tarek Osman

 Fits and tolerances
• Basics:
• Basic size (nominal size) is the size to which limits or
deviations are assigned and is the same for both
members of the fit. (e.g. φ50 mm)
• Tolerance is the difference between the maximum and
minimum size limits of a part.
• Fundamental deviation is either the upper or the lower
deviation, depending on which is closer to the basic
size.

9/28/2017 1:29:59 PM 14
To obtain different types of fits, it is general practice to
vary tolerance zone of one of the mating parts
Hole H

HOLE BASED SYSTEM-

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

SHAFT BASED SYSTEM-

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

Prof Dr Tarek Osman

 Fits and tolerances
• Hole basis system “H”:
• Hole basis represents a system of fits corresponding to a basic
hole size.

9/28/2017 1:29:59 PM 16
 Fits and tolerances
• Shaft basis system ‘’h’’:
• Shaft basis represents a system of fits corresponding to a basic
shaft size.

• Which system to use? Why?

9/28/2017 1:29:59 PM 17
 Fits

Fits Hole Shaft

Clearance A, B, C, D, E, F, G, H a, b, c, d, e, f, g, h

Transition N, M, K, J n, m, j ,k
Interference P, R, S, U p, r, s, u

Prof Dr Tarek Osman

A fit is indicated by the basic size common
to both components, followed by symbol
corresponding to each component, the
hole being quoted first. Hole/Shaft

e.g. Φ 45 H8/g7

Prof Dr Tarek Osman

 Fits and tolerances
• The standard uses tolerance position letters:
– capital letters for internal dimensions (holes) and
– lowercase letters for external dimensions (shafts).

• The tolerance zones are specified in magnitude in

international tolerance grade numbers, called IT
numbers.
– The smaller grade numbers specify a smaller
tolerance zone.
– These range from IT0 to IT16 (IT0 to IT4 usually for
measuring tools), but only grades IT5 to IT11 are
needed for the preferred fits in machine design.
9/28/2017 1:29:59 PM 20
 Tolerance Grade defines range
Representation of Tolerance
of dimensions (dimensional
2) Number or Grade variation)
IT01, IT0, IT1,….IT16 There are manufacturing
constraints on tolerance grade
chosen

Prof Dr Tarek Osman

FITS APPLICATIONS

Prof Dr Tarek Osman

Prof Dr Tarek Osman
Fits and tolerances

9/30/2017 4:04:39 AM 24
“Forms” of Linear Tolerance
• Unilateral.
Variation in
one direction

• Bilateral.
Variation in
two directions

• Limit.
Max & Min..
largest on top
Cumulative Tolerances

Prof Dr Tarek Osman

Tolerances Related to Machining Processes

Prof Dr Tarek Osman

Prof Dr Tarek Osman
RANGE IN A GIVEN TOLERANCE GRADE

Prof Dr Tarek Osman

Prof Dr Tarek Osman
Prof Dr Tarek Osman
 Fits and tolerances
• Selection of International Tolerance Grades—Metric Series (Size
Ranges Are for Over the Lower Limit and Including the Upper
Limit.

9/28/2017 1:29:59 PM 33
Fits and tolerances IT Grade
Process
4 5 6 7 8 9 10 11
Lapping & Honing
Cylindrical grinding
Surface grinding
Diamond turning
Diamond boring
Broaching
Powder Metal-sizes
Reaming
Turning
Powder metal-Sintered
Boring
Milling
Planing & shaping
Drilling
Punching
Die casting
9/28/2017 1:29:59 PM 34
 Fits and tolerances

IT Grade
Purpose
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Measuring tools

For fits

For materials
For large manufacturing
tolerances

9/28/2017 1:29:59 PM 35
 Fits and tolerances
• Example:
• A fit is chosen between a shaft and a sliding bearing to be:
ɸ60 H9/f7 . What does it mean?
• Solution:
– “ɸ60” is the nominal size (diameter) which is 60 mm.
– “H9” means : It’s a hole basis system with a “IT9” hole tolerance grade
(capital letter).
– “f7” means: the shaft tolerance grade is “IT7” (lower-case letter).
– “H#/f#” means: it’s a clearance fit.

– From tables, we can obtain the hole and shaft sizes with tolerance
deviations:
– Hole: ∅ 𝟔𝟎+𝟎.𝟎𝟕𝟒
+𝟎.𝟎𝟎𝟎 mm & Shaft: ∅ 𝟔𝟎 −𝟎.𝟎𝟑𝟎
−𝟎.𝟎𝟔𝟎 mm

9/28/2017 1:29:59 PM 36
Estimate kind of fit
Linear

Φ30H8/e6
Φ30H7/s6

Prof Dr Tarek Osman

30 H7/s6 (Interference fit)
• Hole • Shaft
• 30 H7 • 30 s6
30 +21 • 30 +48
0 +35
30.021 30.048
30.00 30.035

Prof Dr Tarek Osman

 Φ30H8/e8
30 H8/e8 (clearance fit)
• Hole • Shaft
• 30 H8 • 30 e8
30 +33 30 -40
0 -73
30.033 29.96
30.00 29.927

Prof Dr Tarek Osman

Surface texture

9/28/2017 1:29:59 PM 40
 Surface texture
• Surface finish (texture) is the nature of a surface as
defined by the 3 characteristics of lay, surface
roughness, and waviness.

• It comprises the small local deviations of a surface

from the perfectly flat ideal (a true plane).

• Surface texture is one of the important factors that

control friction and transfer layer formation during
sliding.

9/28/2017 1:29:59 PM 41
Surface texture

9/28/2017 1:29:59 PM 42
 ANALYSIS OF SURFACE ROUGHNESS

• Surface texture is the repetitive or random deviation

from the nominal surface that forms the three-
dimensional topography of the surface.
• Surface texture includes
(1) roughness (nano- and micro roughness),
(2) waviness (macro-roughness),
(3) lay, and
(4) flaws.

Prof Dr Tarek Osman

Prof Dr Tarek Osman
• Nano and microroughness
is formed by fluctuations in
the surface of short
wavelengths, characterized
by hills (asperities) (local
maxima) and valleys (local
minima) of varying
amplitudes and spacing,
and these are large
compared to molecular
dimensions.

Prof Dr Tarek Osman

• Waviness
is the surface irregularity of
longer wavelengths and is
referred to as macro-roughness.
• Waviness may result from
such factors as machine or
workpiece deflections,
vibration, chatter, or heat
treatment.

Prof Dr Tarek Osman

• Lay is the principal direction of the predominant
surface pattern, ordinarily determined by the
production method.

• Flaws are unintentional, unexpected, and

unwanted interruptions in the texture. In
addition, the surface may contain gross deviations
from nominal shape of very long wavelength,
which is known as error of form.

Prof Dr Tarek Osman

 Measurement of roughness
The roughness may be measured, using any of the
following :
1. Straight edge
2. Surface gauge
3. Optical flat
4. Tool marker’s microscope
5. Profilometer
6. Profilograph
7. Talysurf

Prof Dr Tarek Osman

Scanning Laser Microscope
Triangulation
Laser Sensor X/Y

Positioning Tables

Anti-Vibration Table

• 25 μm Spatial Resolution (X & Y)

• 12 μm Vertical Resolution (Z)
Prof Dr Tarek Osman
Prof Dr Tarek Osman
 Surface texture
• How it’s measured:

9/28/2017 1:29:59 PM 51
Prof Dr Tarek Osman
 Surface Roughness
The geometrical characteristics of a surface include,
1. Macro-deviations,
2. Surface waviness, and
3. Micro-irregularities.
The surface roughness is evaluated by the height, Rt
and mean roughness index Ra of the micro-irregularities.
 Surface roughness number
Represents the average departure
of the surface from perfection
over a prescribed sampling
length,
Surface roughness number (Ra) is
expressed in microns.
Ra = (h1+h2+-----+hn)/n
The measurements are usually
made long a line, running at right
angle to the general direction
of tool marks on the surface.

Prof Dr Tarek Osman

• Actual profile, Af
– It is the profile of the actual surface obtained by finishing
operation.

• Reference profile, Rf
– It is the profile to which the irregularities of the surface is
referred to. it passes through the highest point of the actual
profile.

• Datum profile, Df
– It is the profile, parallel to the reference profile. it passes through
the lowest point B of the actual profile
Prof Dr Tarek Osman
• Mean Profile, Mf
– It is that profile, within the sampling length chosen (L) such that the sum of the
material-filled areas enclosed above it by the actual profile is equal to the sum of
the material void area enclosed below it by the profile.

• Peak to valley height, Rt

– It is the distance from the datum profile to the reference profile.

• Mean roughness index, Ra

– It is the arithmetic mean of the absolute value of the highest hi between the actual
x=L
and mean profile.
– Ra = 1/L ∫x=0 |hi| dx , where L is sampling length

Prof Dr Tarek Osman

 Surface texture
Surface roughness (Microns)
Process IT 𝛻𝛻𝛻𝛻 𝛻𝛻𝛻 𝛻𝛻 𝛻
0.025 0.05 0.1 0.2 0.4 0.8 1.6 3.2 6.3 12.5 25 50
Lapping 4-5
Super-finishing
Diamond, precision
boring 5-7
Fine grinding
Honing
Diamond turning
5-6
Gear shaping
Commercial 6-8
grinding
Milling 9-10
Die casting 14
Extruding 12-13
Reaming 6-8
Auto screw m\c 8 58
 Surface texture
Surface roughness (Microns)
Process IT 𝛻𝛻𝛻𝛻 𝛻𝛻𝛻 𝛻𝛻 𝛻
0.025 0.05 0.1 0.2 0.4 0.8 1.6 3.2 6.3 12.5 25 50
Boring 7-11
Broaching 6-8
Finish turning 7-9
Investment casting 15
Drilling 10-13
Powder metallurgy 9
Forging 15
Shell-mold casting 15
Rough grinding 8
Contour sawing 10-13
Rough turning 9-12
Sand casting 16

59
 Surface Roughness expected from manufacturing processes

Tarek Osman
 Surface Roughness expected from manufacturing processes

Tarek Osman
 INDICATION OF SURFACE TEXTURE
The basic symbol consists of two legs of
unequal length inclined at approximately
60o to the line representing the
considered surface
The symbol must be represented by thin
line
If the removal of material by machining is
required, a bar is added to the basic
symbol,(e.g. polishing)
If the removal of material is not permitted, a
circle is added to the basic symbol.(e.g.
coating)
When special surface characteristics have to
be indicated, a line is added to the longer arm
of any of the above symbols, (e.g. milling,
shaping)

Basic symbol : only be used alone when its meaning is explained by a note
Prof Dr Tarek Osman
 Indication of Surface Roughness
The value or values defining the principal criterion
of roughness are added to the symbols

a- surface roughness value

Roughness a obtained by Roughness a obtained by Roughness a shall be

any production process removal of material by obtained without removal
machining of any material

If it is necessary to impose
maximum and minimum limits of
the principal criterion of surface maximum limit (a1) ;minimum
roughness, both values shall be limit (a2).
shown

Prof Dr Tarek Osman

If it is required that the required surface texture be produced by one
particular production method, this method shall be indicated in plain
language on an extension of the longer arm of the symbol

Indication of machining allowance where it is necessary to specify the

value of the machining allowance, this shall be indicated on the left of the
symbols. This value shall be expressed in millimeters.

Prof Dr Tarek Osman

Generally to indicate the surface roughness, the symbol is used instead of value.
The relation is given in following table.

Prof Dr Tarek Osman

 Machining Symbols

This symbol may also be used in a drawing, relating to a production process , to indicate that
a surface is to be left in the state ,resulting from a preceding manufacturing process,
whether this state was achieved by removal of material or otherwise
Position of the Specifications of the Surface Texture in the Symbol - The
specifications Of surface texture shall be placed relative to the symbol
as shown in figure.

Prof Dr Tarek Osman

 Symbols with Additional Indications.

Prof Dr Tarek Osman