Manufacture of machinery such as machine tools, automobiles, I.

C engines, aircrafts,
etc., requires thousands of components which are identical. In such large scale
production, each component should fit in its place exactly during assembly, without using
any hand finishing operation. Further, any component in a machine should be replaceable
by another one, designed to do the same job. Parts which satisfy these requirements are
called interchangeable parts. The manufacture of interchangeable parts requires precision.
Precision is the degree of accuracy, to ensure proper functioning of a part. However,
experience shows that is impossible to make parts economically to the exact dimensions.
This may be due to:
 Inaccuracies of machines and tools,
 Inaccuracies in setting the work to the tool, and
 Error in measuring.
The workman therefore has to be given some allowable margin so that he can produce a
part, the dimensions of which will be between the acceptable limits, a maximum and a
minimum. The system in which a variation is accepted is called the limit system and the
allowable deviations are called tolerances. The relationships between the mating parts
are called fits.

Limit system
The following are some of the terms used in limit system:
 Tolerance: The permissible variation of a size is called tolerance. It is the difference
between the maximum and minimum permissible limits of the given size.
 Limits: The two extreme permissible sizes between which are actual size is contained
are called limits. The maximum size is called the upper limit and the minimum size,
the lower limit.
 Allowance: It is the dimensional difference between the maximum material limits of
the mating parts, intentionally provided to obtain the desired class of fit.
 Actual size: is the measured size.

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 Norminal size: is the size by which a component is referred to as a matter of
convenience.
 Deviation: It is the algebraic difference between a size (actual, maximum, etc.) and
the corresponding basic size. The algebraic difference between the maximum limit of
the size and the corresponding basic size is called the upper deviation and the
difference between the minimum limit of the size and the corresponding basic size is
called the lower deviation. The algebraic difference between the actual size and the
corresponding basic size is called the actual deviation.
 Basic size: The size in relation to which all limits of size are fixed, and will be the
same for both male and female parts of the fit. It is determined solely from design
calculation. If the strength and stiffness requirement need a 50 mm diameter shaft,
then 50 mm is the basic shaft size. The limit corresponding to the basic size is called
the zero line or line of fundamental deviation.
 Design size: It is that size, from which the limits of size are derived by the application
of tolerances. If there is no allowance, the design size is the same as the basic size. If
an allowance of 0.05 mm for clearance is applied say, to a shaft of 50 mm diameter,
then its design size is (50 – 0.05) = 49.95 mm. a tolerance is then applied to this
dimension. The actual size is the size obtained after manufacture.

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 Maximum metal condition (MMC): This is the maximum limit of an external feature;
for example a shaft manufactured to its high limits would contain the maximum
amount of metal. It is also the minimum limit on an internal feature; e.g. a component
which has a hole bored in its lower limit of size would have had the minimum of
metal removed and remain in maximum metal condition.

TOLERANCES

Tolerance is the magnitude of permissible variation of a dimension from the specified

value. In order to maintain economic production and facilitate the assembly of
components it is necessary to allow a limited deviation from the design size. The primary
purpose of tolerances is to permit variation in dimensions without degradation of the
performance beyond the limits established by the specification of the design. Ideal
conditions would call for parts without any dimensional variation, but in actual practice it
is impossible due to errors measurements.

Fundamental tolerances
Tolerance is denoted by two symbols, a letter symbol and a number symbol called the
grade. The fundamental tolerance is a function of the nominal size and its unit is given by
the empirical relation,
Standard tolerance unit, i = 0.45 X √3 D + 0.001D

Thus the fundamental tolerance values for different grades (IT) can be calculated as
illustrated below

Example: To calculate the tolerance for grade 8 for the size range 80 to 120 mm
For the step 80 to 120 mm, the geometric mean is given, by,
D = √(80 X 120) = 98

Grade IT5 IT6 IT7 IT8 IT9 IT10 IT11 IT12 IT13 IT14 IT15 IT16
Multiple 7i 10i 16i 25i 40i 64i 100i 10i 250i 400i 640i 1000i
of units

Where, IT is the fundamental tolerance of grade obtained from Table 4.1.

i = (0.45 X (98)1/3) + (0.001 X 98) = 2.172 microns

For grade 8 as per table the value of tolerance is:

25i = 25*2.172
= 54microns

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 The symbols used for the fundamental deviations for the shaft and the hole are as
follows

Hole Shaft
Upper deviation (E' cart superior) ES es
Lower deviation (E' cart inferior) EI ei

Thus: Shaft, ei = -IT

Holes, EI = ES-IT

Method of placing limit dimensions

There are three methods used in industries for placing the limit dimensions or tolerance
individual dimensions.
Method 1
 In this method, the tolerance dimension is given by its basic value, followed by a
symbol, comprising of both a letter and a numeral

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 Method 2
In this method, the basic size and the tolerance values are indicated above the dimension
line, the tolerance values being in a size smaller than that of the basic size and the lower
deviation value being indicated in line with the basic size

 Method 3
When assembled parts are dimensioned, the fit is indicated by the basic size common to
both the components followed by the hole tolerance symbol first and then by the shaft
tolerance symbol.

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Fit Types and categories

There are thee categories of fits namely clearance, transition and interference.

Clearance fits can be subdivided into running or sliding fits. Running applies to a shaft
rotating at a speed within a journal whereas sliding can be represented by slow
translation, typically of a spool valve. Running and sliding fits are intended to provide a
similar running performance with a suitable lubrication allowance throughout a range of
sizes.

Transition fits are used for location purposes. Because of the difference in sizes they
will either be low clearance fits or low interference fits. They are intended to provide
only the location of mating parts they may provide rigid or accurate location as with
interference fits or provide some measure of freedom in location as in small clearance
fits.

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Interference fits are normally divided into force or shrink fits. If the difference between
the hole and the shaft sizes is negative before assembly, an interference fit is obtained.
The idea of interference is to create an internal stress that is constant through a range of
sizes because the interference varies with diameter. The resulting residual stress caused
by the interference will be dictated by the functional performance situation.

Hole basis and shaft basis system

In working out the limit dimensions for the three classes of fits, two systems are in use,
viz., the hole basis system and shaft basis system.

Hole basis system: In this system, the size of the shaft is obtained by subtracting the
allowance from the basic size of the hole. This gives the design size of the hole.
Tolerances are the applied to each part separately. The lower deviation of the shaft is
zero. The letter symbol for this situation is H.

 With the hole basis system, the lower limit of the hole is equal to its basic size.
e.g. Lower limit of the hole = 40.00 mm
Obtain the maximum limit of the shaft, by subtracting the minimum clearance, from
the lower limit of the hole.
Upper limit of the shaft = 40.00 – 0.10 = 39.90 mm

To obtain the lower limit of the shaft, subtract the tolerance on the shaft from the
upper limit of the shaft.

Lower limit of the shaft = 39.90 – 0.05 = 39.85 mm. Thus, the limits of the shaft are
39.90 and 39.85 mm
Upper limit of the hole = 30.00 + 0.025 = 30.025 mm

Proof
The tolerance on the hole and the shaft together should be equal to the difference between
the maximum and minimum clearances.

Aggregate tolerance = 0.025 + 0.050 = 0.075 mm

Maximum clearance = upper limit of hole – lower limit of the shaft
= 40.025 – 39.850 = 0.175 mm
Minimum clearance = min.size of the hole-max of the shaft
= 40.00 – 39.90 = 0.10 mm
Max clearance-Min clearance = 0.175-0.10
= 0.075mm

Shaft basis system : this is a system whereby the size of the hole is obtained by adding
the allowance to the basic size of the shaft. This gives the design size of the hole.
Tolerances are then applied to each part. The upper deviation of the shaft is zero. The
letter symbol for this situation is h.

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In the shaft basis system, the upper limit of the shaft is equal to the basic size of the shaft.
Upper limit of the shaft = 40.00 mm
The lower limit of the hole may be obtained by adding the minimum clearance to the
basic size of the shaft.
Lower limit of the hole = 40.00 + 0.10 = 40.10 mm. To obtain the maximum limit of the
hole add the tolerance on the minimum limit of the hole.

Upper limit of the Hole = 40.100 + 0.025 =40/125mm.

Thus the limits of the hole are 40.125 and 40.100mm. To obtain a lower limit of the shaft,
subtract the on the shaft from the basic size.

Lower limit of the shaft = 40.00-0.05 = 39.95mm

Thus, the limits on the shaft are 40.00 and 39.95mm

Proof
Maximum clearance = upper limit of hole-lower limit of the shaft
= 40.125-39.950=0.175mm
Minimum clearance = lower limit of the hole- upper limit the shaft
=40.10-40.00=0.10mm
Maximum clearance – minimum clearance = 0.175-0.001=0.075( the aggregate
tolerance)

Tolerance grades- hole basis system

 The hole basis system is preferred in most of the cases, since standard tools like drills,
reamers, broachers, etc., are used for making a hole.
 The method of obtaining and the use of various grades of the unilateral hole H from
H5 to lH11 are given below :

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Tolerance grades- hole basis system

H5 - by precision boring, fine internal grinding or honing.

H6 - by precision boring, fine internal grinding or honing or by hand reaming
H7 - by grinding, broaching or careful reaming
H8 - by boring or machine reaming
H9 - by boring and reaming and is used mostly for non-circular fits.
H10 - This grade is not used for cylindrical fits. It is only used for milled widths and
Unimportant holes of drilled parts.
H11 - This grade is not used in fits. It is used for coarse drilled or punched holes.

Type of fit Symbol Example of application

of fit
Interference fit
Shrink fit H8/u8 Wheel sets, tyres, bronze crowns on worm wheel
Heavy drive fit H7/s6 bubs, couplings under certain conditions, etc.
Press fit H7/r6 Coupling on shaft ends, bearing bushes in hubs,
Medium press fit H7/p6 valve seats, gear wheels.
Transition fit
Light press fit H7/n6 Gears and worm wheels, bearing bushes, shaft and
Force fit H7/m6 wheel assembly with feather key.
Push fit H7/k6 Parts on machine tools that must be changed
Easy push fit H7/j6 without damage, e.g., gears, belt pulleys,
couplings, fit bolts, inner ring of ball bearings.
Belt pulleys, brake pulleys, gears, and couplings as
well as inner rings of ball bearings on shafts for
average loading conditions.
Parts which are to be frequently dismantled but are
secured by keys, e.g., pulleys, hand-wheels,
bushes, bearing shells, pistons on piston rods,
change gear trains.
Clearance fit
Precision sliding fit H7/h6 Sealing rings, bearing covers, milling cutters on
Close running fit H7/g6 milling mandrels, other easily removable parts.
Normal running fit H7/f7 Spine shafts, clutches, movable gears in change
Easy running fit H8/e8 gear trains, etc.
Loose running fit H8/d9 Sleeve bearings with high revolution, bearings on
Slack running fit H8/c11 machine tool spindles, etc.Sleeve bearings with
medium revolution, grease lubricated bearings of
wheel boxes, gears sliding on shafts, sliding blocks.
Sleeve bearings with low revolution, plastic
material bearings.
Oil seals (Simmering) with metal housing (fit in
housing and contact surface on shaft), spline shafts.