ENGINEERING METROLOGY AND

SURFACE ENGINEERING

by K. Shravan Kumar
UNIT-1

by K. Shravan Kumar
 Metrology: The science of measurement. The purpose of this
discipline is to establish means of determining physical quantities, such
as dimensions, temperature, force, etc.

• Derived from the Greek word for Measure.

• It is well-known saying that the knowledge about anything is
complete only when it can be expressed in numbers and something
is known about it.
• For every kind of quantity measured, there must be a unit to
measure it and express it in numbers of that unit.
• There must be a universal standard and the various units for
various parameters of importance must be standardized.
• Most important parameter in metrology (for production engineers)
is the (Length) which can be measured in several ways.
• Other important parameters in Metrology are the Time, Mass,
Force, Temperature, the flow of an electric current, Angle and so
on. or the effects of some of these in combination.

by K. Shravan Kumar
• The results obtained by measurements provide information upon which
decision are made. The purpose of any measurement is to provide a
service to enable a decision to be made. The service will not be complete
unless the measurement is made to an acceptable degree of accuracy, but
it must be realized that no measurement is exact.
• Thus, Metrology is the science of measurement, and measurement is the
language of science. It is language we use to communicate about size,
quantity, position, condition and time.
• The metrologist has to understand the underlying principles to be able to
design and develop new instruments and also to use the available
instruments in the best ways. Metrology is therefore also concerned with
the methods, execution and estimation of accuracy of measurements.
• Thus, it can be said that metrology is mainly concerned with:
• Establishing the units of measurements, reproducing these units in the
form of standards and ensuring the uniformity of measurements.
• Developing methods of measurement.
• Analyzing the accuracy of methods of measurement, establishing
uncertainty of measurement, researching the causes of measuring errors
and eliminating them.

by K. Shravan Kumar
 Types of Metrology
• Scientific Metrology
• Industrial Metrology
• Legal Metrology

by K. Shravan Kumar
 Process of measurement
• The sequence of operations necessary for the
execution of measurement is called process of
measurement.
• There are main three important elements of
measurement,
(1) Measurand: - Measurand is the physical
quantity or property like length, angle, diameter,
thickness etc. to be measured.

by K. Shravan Kumar
(2) Reference: - It is the physical quantity or
property to which quantitative comparisons are
made.
(3) Comparator: - It is the means of comparing
measuring measurand with some reference.
• Suppose a fitter has to measure the length of M.S.
plate- he first lays his rule along the flat. He then
carefully aligns the zero end of his rule with one
end of M.S. flat and finally compares the length of
M.S. flat with the graduations on his rule by his
eyes. In this example, the length of M.S. flat is a
measurand, steel rule is the reference and eye can
be considered as a comparator.
by K. Shravan Kumar
 Methods of Measurement
• Direct Method
• Indirect Method
• Fundamental Method
• Comparative method
• Transposition Method
• Coincidence method
• Deflection method
• Contact Method
• Contactless Method

by K. Shravan Kumar
 Measuring System
• Standard
• Workpiece
• Instrument
• Person
• Environment

by K. Shravan Kumar
Accuracy
Accuracy is defined as the closeness of the
measured value with true value.
OR
Accuracy is defined as the degree to which
the measured value agrees with the true value.

Practically it is very difficult to measure the

true value and therefore a set of observations is
made whose mean value is taken as the true value
of the quantity measured.

by K. Shravan Kumar
Precision
A measure of how close repeated trials are to each
other.
OR
The closeness of repeated measurements.

• Precision is the repeatability of the measuring process. It

refers to the group of measurements for the same
characteristics taken under identical conditions.
• It indicated to what extent the identically performed
measurements agree with each other.
• If the instrument is not precise it will give different results
for the same dimension when measured again and again.

by K. Shravan Kumar
× Low ✓ High × Low ✓ High
Accuracy Accuracy Accuracy Accuracy
× Low × Low ✓ High ✓ High
Precision Precision Precision Precision

by K. Shravan Kumar
Let us consider a weight measuring instrument which
measures the weight of steel cube. Exact weight of the
steel cube is 50 kg.
• Case 1
Trail Weight
1 49.899 kg.
2 49.973 kg.
3 49.935 kg.
4 49.907 kg.

From the above observations, we can conclude that the

instrument has some accuracy since it gives the output
value which is near to the exact value 50 kg. But the
instrument is not precise since it gives different value for
each measurement.
by K. Shravan Kumar
• Case 2
Trail Weight

1 47.819 kg.
2 47.823 kg
3 47.835 kg.
4 47.847 kg.

• From the above observations, we can conclude that

the instrument has some precision since it almost
reproduces same output value 47.8 kg. But the
instrument does not have accuracy since the
measured values are not closer to the actual weight
50 kg.
by K. Shravan Kumar
Factors affecting the accuracy of the
measuring system
The basic components of an accuracy evolution are
the five elements of a measuring system such as:
1. Factors affecting the calibration standards.
2. Factors affecting the work piece.
3. Factors affecting the inherent characteristics of
the instrument.
4. Factors affecting the person, who carries out the
measurements.
5. Factors affecting the environment.

by K. Shravan Kumar
Sensitivity
• Sensitivity may be defined as the rate of
displacement of the indicating device of an
instrument, with respect to the measured
quantity.
• Sensitivity of thermometer means that it is
the length of increase of the liquid per degree
rise in temperature. More sensitive means
more noticeable expansion.

by K. Shravan Kumar
Readability
• Readability refers to the ease with which the
readings of a measuring instrument can be
read.
• Fine and widely spaced graduation lines
improve the readability.
• To make the micrometres more readable they
are provided with Vernier scale or magnifying
devices.

by K. Shravan Kumar
Calibration
• The calibration of any measuring instrument is
necessary to measure the quantity in terms of
standard unit.
• It is carried out by making adjustments such that
the read out device produces zero output for zero
input.
• The process whereby the magnitude of the
output of a measuring instrument is related to
the magnitude of the input force driving the
instrument (i.e. Adjusting a weight scale to zero
when there is nothing on it).

by K. Shravan Kumar
Magnification
• Magnification is the process of enlarging
something only in appearance, not in physical
size so that it is more readable.

by K. Shravan Kumar
Repeatability
It is the ability of the measuring instrument to
repeat the same results for the measurements for the
same quantity, when the measurements are carried out
• by the same observer,
• with the same instrument,
• under the same conditions,
• without any change in location,
• without change in the method of measurement,
• the measurements are carried out in short intervals of
time.

by K. Shravan Kumar
Reproducibility
Reproducibility is the closeness of the
agreement between the results of
measurements of the same quantity, when
individual measurements are carried out
• by different observers,
• by different methods,
• using different instruments,
• under different conditions, locations, times
etc.
by K. Shravan Kumar
 Systems of Limits and Fits
• Basic Size: The size with reference to which the limits of
size are fixed.
• Actual Size: Actual measured dimension of the part.
• Limits of Size: The two extreme permissible sizes of a part
between which the actual size should lie.
• Shaft: A term used by convention to designate all external
features of a part, including those which are not cylindrical.
• Hole: A term used by convention to designate all internal
features of a part, including those which are not cylindrical.
• Zero Line: It is a straight line corresponding to the basic
size. The deviations are measured from this line. The
positive and negative deviations are shown above and
below the zero line respectively

by K. Shravan Kumar
by K. Shravan Kumar
by K. Shravan Kumar
LIMITS:-

Limits can be defined as the permissible variation in dimension

that is permitted to account for variability.
• Manufacturing process is a combination of three elements man,
materials and machine. A change in any one or all of these will
result in changes in sizes of manufactured parts.
• Usually in mass production, large number of components are to be
made by different operators on different machines. So, it is
impossible to make all components with exact dimensions.
• The difference in dimensions vary from machine to machine,
operator to operator and quality of the components.
• The dimension of the manufactured part can thus only be made to
lie between two limits, maximum and minimum.
• The maximum limit is the maximum size permitted for the
component whereas the minimum limit is the minimum size
permitted for the component.

by K. Shravan Kumar
TOLERANCE:-
The permissible variation in size or dimension
is called tolerance. Thus, the word tolerance
indicates that a worker is not expected to produce
the part to the exact size, but a definite small size
error is permitted.
• The difference between the upper limit (high.
limit) and the lower limit of a dimension
represents the margin for variation in'
workmanship, and is called a ‘tolerance Zone'.
• Tolerance can also be defined as the amount by
which the job is allowed to go away from
accuracy and perfectness without causing any
functional trouble, when assembled with its
mating part and put into actual service.
by K. Shravan Kumar
by K. Shravan Kumar
• Tolerance Zone: It is the zone between the
maximum and minimum limit size.
• Upper Deviation: It is the algebraic difference
between the maximum size and the basic size.
The upper deviation of a hole is represented
by a symbol ES (Ecart Superior) and of a shaft,
it is represented by es.
• Lower Deviation: It is the algebraic difference
between the minimum size and the basic size.
The lower deviation of a hole is represented
by a symbol EI (Ecart Inferior) and of a shaft, it
is represented by ei.

by K. Shravan Kumar
by K. Shravan Kumar
by K. Shravan Kumar
 Systems of Writing Tolerances
There are two systems of writing tolerances:
(i) Unilateral system
(ii) Bilateral system

by K. Shravan Kumar
Unilateral System : In this system, the
dimension of a part is allowed to vary only on
one side of the basic size i.e., tolerance lies
wholly on one side of the basic size either above
or below it.

by K. Shravan Kumar
Bilateral system : In this system, the dimension
of the part is allowed to vary on both the sides
of the basic size i.e., the limits of tolerance lie on
either side of the basic size; but may not be
necessarily equally disposed about it.

by K. Shravan Kumar
by K. Shravan Kumar
 TYPE TOLERANCE

Bilateral 0.015

Unilateral 0.005

Unilateral 0.004
by K. Shravan Kumar
Tolerance vs Cost

by K. Shravan Kumar
 Maximum and Minimum metal limits
• Let us consider a shaft having a dimension of 40 ± 0.05 mm.
• The maximum metal limit (MML) of the shaft will have a dimension
of 40.05 mm because at this higher limit, the shaft will have the
maximum possible amount of metal.
• The shaft will have the least possible amount of metal at a lower
limit of 39.95 mm, and this limit of the shaft is known as minimum
or least metal limit (LML).
• Similarly, consider a hole having a dimension of 45 ± 0.05 mm.
• The hole will have a maximum possible amount of metal at a lower
limit of 44.95 mm and the lower limit of the hole is designated as
MML.
• For example, when a hole is drilled in a component, minimum
amount of material is removed at the lower limit size of the hole.
This lower limit of the hole is known as MML.
• The higher limit of the hole will be the LML. At a high limit of 45.05
mm, the hole will have the least possible amount of metal
by K. Shravan Kumar
by K. Shravan Kumar
 HOLE SHAFT

MML LL UL

LML UL LL
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The overall length of the assembly is the sum of the individual length of components
given as
L = LA + LB + LC
L = 30 + 20 + 10 = 60 mm
Then, cumulative upper tolerance limit is 0.02 + 0.02 + 0.02 =0.06 mm and
cumulative lower limit = – 0.01 – 0.01 – 0.01 = – 0.03 mm

Therefore dimension of the assembled length will be =

by K. Shravan Kumar
 Fits
• When two parts are to be assembled the
relation resulting from the difference between
their sizes before assembly is called a fit.
• The fit signifies the range of tightness or
looseness which may result from the
application of a specific combination of
allowances and tolerances in the design of
mating parts.

by K. Shravan Kumar
 Classification of fits

Fits

Clearance Transition Interference

by K. Shravan Kumar
by K. Shravan Kumar
 Clearance Fit
• In clearance fit, an air space or clearance exists between the
shaft and hole.
• Such fits give loose joint.
• A clearance fit has positive allowance, i.e. there is minimum
positive clearance between high limit of the shaft and low
limit of the hole.
• Allows rotation or sliding between the mating parts.

by K. Shravan Kumar
by K. Shravan Kumar
 Types of Clearance Fit
• Loose Fit :It is used between those mating parts
where no precision is required. It provides
minimum allowance and is used on loose pulleys,
agricultural machineries etc.
• Running Fit: For a running fit, the dimension of
shaft should be smaller enough to maintain a film
of oil for lubrication. It is used in bearing pair etc.
• Slide Fit or Medium Fit :It is used on those
mating parts where great precision is required. It
provides medium allowance and is used in tool
slides, slide valve, automobile parts, etc.

by K. Shravan Kumar
by K. Shravan Kumar
 Interference Fit
• A negative difference between diameter of the hole and the
shaft is called interference.
• In such cases, the diameter of the shaft is always larger than
the hole diameter.
• It used for components where motion, power has to be
transmitted.

by K. Shravan Kumar
by K. Shravan Kumar
 Types of Interference Fit
• Shrink Fit or Heavy Force Fit :It refers to maximum negative
allowance. In assembly of the hole and the shaft, the hole
is expanded by heating and then rapidly cooled in its
position. It is used in fitting of rims etc.
• Medium Force Fit :These fits have medium negative
allowance. Considerable pressure is required to assemble
the hole and the shaft. It is used in car wheels, armature of
dynamos etc.
• Tight Fit or Force Fit :One part can be assembled into the
other with a hand hammer or by light pressure. A slight
negative allowance exists between two mating parts (more
than wringing fit). It gives a semi permanent fit and is used
on a keyed pulley and shaft, rocker arm, etc

by K. Shravan Kumar
by K. Shravan Kumar
 Transition Fit
• It may result in either clearance fit or interference fit
depending on the actual value of the individual tolerances of
the mating components.
• Transition fits are a compromise between clearance and
interference fits.
• They are used for applications where accurate location is
important but either a small amount of clearance or
interference is permissible.

by K. Shravan Kumar
by K. Shravan Kumar
 Types of Transition Fit
• Push Fit or Snug Fit: It refers to zero allowance and a light
pressure is required in assembling the hole and the shaft.
The moving parts show least vibration with this type of fit
• Force Fit or Shrink Fit: A force fit is used when the two
mating parts are to be rigidly fixed so that one cannot move
without the other. It either requires high pressure to force
the shaft into the hole or the hole to be expanded by
heating. It is used in railway wheels, etc.
• Wringing Fit :A slight negative allowance exists between
two mating parts in wringing fit. It requires pressure to
force the shaft into the hole and gives a light assembly. It is
used in fixing keys, pins, etc.

by K. Shravan Kumar
by K. Shravan Kumar
by K. Shravan Kumar
 Allowance
• An allowance is the intentional difference
between the maximum material limits, that is,
LLH and HLS (minimum clearance or maximum
interference) of the two mating parts. It is the
prescribed difference between the dimensions of
the mating parts to obtain the desired type of fit.
• Allowance may be positive or negative. Positive
allowance indicates a clearance fit, and an
interference fit is indicated by a negative
allowance.
• Allowance = LLH − HLS

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 Determination of Type of FIT
• ULH-ULS
• ULH-LLS
• LLH-ULS
• LLH-LLS

➢ If all the above values are positive it indicates

Clearance Fit
➢ If all the above values are negative it indicates
Interference Fit
➢ If all the above values are positive and negative it
indicates Transition Fit
by K. Shravan Kumar
Systems of obtaining Different Types of
Fits
• To obtain the desired class of fits, either the size of the
hole or the size of the shaft must vary.
• There are two systems by which a fits can be
accomplished
1. Hole basis system
2. Shaft basis system
Terms & symbols used:
Basic shaft: It is a shaft whose upper deviation is zero. i.e.
the maximum limit of shaft coincides with the nominal
size.(zero line). Eg: shaft ‘h’
Basic hole: It is a hole whose lower deviation is zero. i.e.
the minimum limit of hole coincides with the nominal
size.(zero line). Eg: shaft ‘H’
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 UL
Tolerance
of Hole LL
Hole LD UD
Basic Size
UD LD
UL
LL

Shaft
Tolerance
of Shaft

Basic Hole (or) Hole Basis System Basic Shaft (or) Shaft Basis System

UD=0, i.e. UL of
Shaft = Basic size
LD=0, i.e. LL of
Hole = Basic size Basic Size

by K. Shravan Kumar
 Hole basis System
• In this system, the size of the hole is kept
constant and the shaft size is varied to give
various types of fits.
• In a hole basis system, the fundamental
deviation or lower deviation of the hole is
zero, that is, the lower limit of the hole is the
same as the basic size.
• The two limits of the shaft and the higher
dimension of the hole are then varied to
obtain the desired type of fit.
by K. Shravan Kumar
by K. Shravan Kumar
 Shaft basis System
• The system in which the dimension of the shaft is
kept constant and the hole size is varied to obtain
various types of fits is referred to as shaft basis
system
• In this system, the fundamental deviation or the
upper deviation of the shaft is zero, that is, the
HLH equals the basic size.
• The desired class of fits is obtained by varying the
lower limit of the shaft and both limits of the hole
by K. Shravan Kumar
by K. Shravan Kumar
A 50 mm diameter shaft is made to rotate in the bush. The tolerances for both Bush and
shaft are 0.05mm. Determine the Dimension of Bush and shaft to give a minimum
clearance 0.075mm with the Hole basis system.

0.05mm
Basic size
0.075mm
0.05mm

Hole Shaft

Basic Size = 50mm, As it is a Hole Basis System

LL of Hole = Basic Size i.e. = 50mm,
UL of Hole= Tolerance of Hole+ LL of Hole= 50+0.05=50.05mm
Minimum Clearance = LL of Hole- UL of Shaft LL of Shaft = UL of Shaft – Tolerance
0.075= 50- UL of Shaft =49.925- 0.05= 49.875mm
UL of Shaft = 49.925mm
+0.05 -0.075
Hole 50 +0.00 Shaft 50 -0.125
by K. Shravan Kumar
A clearance fit has to be provided for a shaft and bearing assembly having a diameter of
40mm. Tolerances on hole and shaft are 0.006 and 0.004mm, respectively. The
tolerances are disposed unilaterally. If an allowance of 0.002mm is provided, find the
limits of size for hole and shaft when (a) hole basis system and (b) shaft basis system are
used.
UL
Hole Basis System
0.006 Hole
LLh = 40mm
Basic Size=40mm LL
ULh = Tol of Hole + LLH 0.002
=0.006+40 = 40.006mm UL
ULs = LLh – Allowance 0.004 Shaft
= 40 – 0.002 = 39.998mm LL
LLs = Uls – Tol of Shaft
= 39.998 – 0.004 = 39.994mm
Shaft Basis System
ULs=40mm, LLs= ULs - Tol of Shaft UL
= 40 – 0.004 = 39.996mm
0.006 Hole
LL
LLh = ULs + Allowance 0.002
Basic Size=40mm UL
= 40 + 0.002 = 40.002mm
0.004 Shaft
ULh = LLh + Tol of Hole
LL
= 40.002 + 0.006 = 40.008 mm
by K. Shravan Kumar
A Hole and Shaft are to have a nominal assembly size of 40mm. The assembly is to have a
maximum clearance of 0.15mm and a minimum clearance of 0.05mm. The hole Tolerance
is 1.5 times the Shaft Tolerance. Determine the limits for both hole and shaft. By using
(i) Hole basis System (ii) Shaft Basis System

Basic Size
0.15mm 0.05mm = 40mm

Hole Shaft

Maximum Clearance = Hole Tolerance + Minimum Clearance + Shaft Tolerance

0.15 = 1.5 x Shaft Tolerance + 0.05 + Shaft Tolerance

0.1
Shaft Tolerance = = 0.04 mm
2.5
Hole Tolerance = 0.04 x 1.5 = 0.06 mm
by K. Shravan Kumar
Now Calculate the Dimensions of Shaft
and Hole by using the
(i) Hole basis System
(ii) Shaft Basis System
With the help of Tolerances

Hole Basis System : Hole Dimension , UL= 40.06mm , LL = 40mm

Shaft Dimension, UL = 39.95mm, LL = 39.91mm

Shaft Basis System : Hole Dimension , UL= 40.10mm , LL = 40.05mm

Shaft Dimension, UL = 40mm, LL = 39.96mm

by K. Shravan Kumar
In an Assembly of two parts 50mm nominal Diameter the Lower
Deviation of the Hole is zero and the Higher is 5 microns, while
that of the shaft is -4 and -8 microns respectively, Estimate the
allowance and type of fit of the assembly.

0.005 Hole Basic

Size=50
0.004 mm
0.008
Shaft

by K. Shravan Kumar
 Types of Assemblies
• Trial and Error
• Interchangeable Assembly
• Selective Assembly

by K. Shravan Kumar
Interchangeable Assembly
Interchangeability occurs when one part in an
assembly can be substituted for a similar part
which has been made to the same drawing.
Interchangeability is possible only when certain
standards are strictly followed.
Selective Assembly
In selective assembly, the parts are graded
according to the size and only matched grades
of mating parts are assembled. This technique is
most suitable where close fit of two
components assembled is required.

by K. Shravan Kumar
 Example of Interchangeable Assembly

+0.05 -0.02
Hole 50 +0.00 Shaft 50 -0.04

UL of Hole= 50.05 mm UL of Shaft = 49.98 mm

LL of Hole= 50.00 mm LL of Shaft = 49.96 mm

Clearance FIT

Example of Selective Assembly

Piston and +0.02 +0.02 To get a Minimum
Cylinder -0.02 Clearance of 0.12mm
Cylinder 50 -0.02 Piston 49.88
Assembly
UL of Cylinder = 50.02 mm UL of Piston = 49.90 mm
LL of Cylinder = 49.98 mm LL of Piston = 49.86 mm

Cylinder 49.98 50.00 50.02

Piston 49.86 49.88 49.90

by K. Shravan Kumar
 Standard Limit Systems
Every country has its own standard for
engineering limits and fits. But in order to have
universal interchange ability it is essential to
followed an uniform standard throughout the
world.
Usual standards are
(a) British standard BS- 4500- 1969
(b) The international standard ISO 286- 1988
(c) Indian standard IS-919
by K. Shravan Kumar
All these 3 standards basically make use of the
following
(i) Standard tolerance
(ii) Fundamental deviation
Tolerance Grade (or) Standard tolerance
It is a measure of the magnitude of the tolerance.
Lower the grade the finer the tolerance.
Fundamental deviation
It is the deviation, either upper or lower deviation,
which is nearest to the zero line for either a hole or
a shaft. It fixes the position of the tolerance zone in
relation to the zero line.

by K. Shravan Kumar
Indian standard IS-919
The Indian standards consists of 18 grades of
fundamental tolerances (or grades of accuracy for
manufacture) and 25 types of fundamental
deviation.
• The 18 grades of fundamental tolerances are
IT01,IT0,ITI,IT2……. IT16
• The 25 fundamental deviations are
A,B,C,D,E,F,G,H,Js,J,K,M,N,P,R,S,T,U,V,X,Y,Z,ZA,ZB,ZC
• The above capital letter symbols are used for hole
and corresponding small letter symbols are used
for shaft (i.e for shaft a,b,….. za, zb, zc)
by K. Shravan Kumar
 Standard Tolerance Grade Fundamental Deviation

28
BS- 4500- 1969 (A,B,C,D,E,F,G,H,Js,J,K,M,N,
18 ( IT01,IT0,IT1…..IT16)
P,R,S,T,U,V,X,Y,Z,ZA,ZB,ZC,
CD,EF,FG)

28(A,B,C,D,E,F,G,H,Js,J,K,M,
20 ( IT01,IT0,IT1…..IT18)
ISO 286- 1988 N,P,R,S,T,U,V,X,Y,Z,ZA,ZB,ZC,
CD,EF,FG)

25
IS-919 18 ( IT01,IT0,IT1…..IT16) (A,B,C,D,E,F,G,H,Js,J,K,M,N
,P,R,S,T,U,V,X,Y,Z,ZA,ZB,ZC)
by K. Shravan Kumar
 Fundamental Deviation of Shaft

Basic Size 50 H7 f6

Fundamental Deviation of Hole

Tolerance grade of Hole Tolerance grade of Shaft

by K. Shravan Kumar
 Hole IT Tolerance Grade, i.e. Hole Tolerance

+ Fundamental Deviation
Basic Size
- Fundamental Deviation
IT Tolerance Grade, i.e.
Hole
Hole Tolerance

IT Tolerance Grade, i.e.

Shaft
Shaft Tolerance
+ Fundamental Deviation
Basic Size
- Fundamental Deviation

Shaft IT Tolerance Grade, i.e. Shaft Tolerance

by K. Shravan Kumar
by K. Shravan Kumar
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 C
F
G
H
Basic Size
J
M

j
Basic Size
h
g
f
c
by K. Shravan Kumar
 Tolerance Grade
• Grade is a measure of the magnitude of the tolerance.
Lower the grade the finer the tolerance. There are total
of 18 grades which are allocated the numbers IT01, IT0,
IT1, IT2..... IT16.
• Fine grades are referred to by the first few numbers. As
the numbers get larger, so the tolerance zone becomes
progressively wider. Selection of grade should depend
on the circumstances. As the grades get finer, the cost
of production increases at a sharper rate.

Toleran…

5 6 7 8 10 12 14 16
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 A hole and Shaft has the following dimension 20 H7-f8, the standard
tolerance is given by i=0.45 ∛𝑫 + 0.001D microns, the diameter 20mm falls in
the step of 18-30mm, the fundamental deviation of ‘f’ shaft is -5.5D0.4
Microns. find (i) The Type of Fit (ii) Sketch the fit and show the actual
Dimensions.
D= 18 × 30 = 23.23mm 0.021mm
H7
i=0.45 ∛𝐷 + 0.001D Basic
3
i=0.45 23. 23 + 0.001(23.23) 0.02mm Size=20mm
i= 1.30 microns
Hole tolerance = IT7= 16i= 16x 1.30 = 20.918 microns f8 0.033mm
= 0.021mm
Shaft tolerance = IT8= 25i= 25x 1.30 = 33 microns
= 0.033mm
Fundamental Deviation for shaft = - 5.5D0.14 = - 5.5( 23.23)0.14
= - 20 microns = - 0.02mm
LLh= 20mm,
ULh= 20+0.021= 20.021mm
Clearance FIT
ULs= 20 – 0.02 = 19.98mm,
LLs= 19.98-0.033 = 19.947mm by K. Shravan Kumar
A hole and Shaft has the following dimension 60 H7-m6, the standard tolerance is given
by i=0.45 ∛𝑫 + 0.001D microns, the diameter 60mm falls in the step of 50-80mm, the
fundamental deviation of ‘m’ shaft is (IT7-IT6) Microns. Find the dimensions of hole and
shaft and state the Type of Fit

D= 50 × 80 = 63.2 mm
m6 0.018
i=0.45 ∛𝐷 + 0.001D
3 H7 0.029
0.011
i=0.45 63.2 + 0.001(63.2) 60mm
i= 1.853 microns
Hole tolerance = IT7= 16i= 16x 1.853 Shaft tolerance = IT6= 10i= 10x 1.853
= 29.64 microns = 18.53 microns
= 0.029mm = 0.018mm
Fundamental Deviation for shaft = IT7-IT6 =16i - 10i
= 6i = 6x 1.853=11.11 microns=0.01mm

LLh= 60mm,
ULh= 60+0.029= 60.029mm
Transition FIT
LLs= 60 + 0.011 = 60.011mm,
LLs= 60.011+0.018 = 60.029mm
by K. Shravan Kumar
A hole and Shaft has the following dimension 40 H7-h6, the standard tolerance
is given by i=0.45 ∛𝑫 + 0.001D microns, the diameter 40mm falls in the step of
30-50mm,. Find the dimensions of hole and shaft and state the Type of Fit

H7

h6

by K. Shravan Kumar