Tolerances and Fits

Suat Kadıoğlu
September 2009
updated September 2020
 INTRODUCTION -1

• Design of machine elements involves determining their

geometry (shape and size) and material (including
special treatments on the material such as surface
hardening etc.) so that they satisfy 3F requirements
– Form
– Fit
– Function
• Design process has many stages (search and review of
existing designs, standards, rough sketching, design
calculations, material selection, optimization, CAD
modeling etc.) but it typically culminates in preparation of
engineering drawings.
 INTRODUCTION -2

• An engineering drawing in addition to the views of an

element, typically includes
– Various dimensions
– Surface quality
– Material and processing during manufacturing
– Allowable variations from the given dimensions (tolerances)
• In the design of a machine element, one must choose
dimensions, materials and manufacturing processes
which will ensure complete satisfaction of all functional
requirements and failure free operation, and yet keep the
cost as low as possible.
 INTRODUCTION -3

• Machine elements have

– Surfaces which are in physical contact with other elements,
(mating surfaces)
• Strict requirements for surface quality and dimensional accuracy
– Free surfaces, which are not in contact with other elements
• Less strict requirements for surface quality and dimensional
accuracy
• Then the design process also includes the decision on
how much accuracy is required in maintaining a certain
dimension.
• It is (at least from the practical point of view) impossible
to manufacture a machine element to exact dimensions.
 INTRODUCTION -4

• How exact is a dimension?

The answer actually
depends on how precise is
your measurement.
– The intended (exact)
dimension is probably 60.00
mm
– The dimension if measured
with a more sensitive device
Digital caliper with an accuracy of
could have turned out to be
1 hundreth of a mm
60.146 or 60.153 mm
 INTRODUCTION -5

• If the element is to be produced in large numbers the

difficulty in maintaing the exact dimension is more
evident.
• Deviations could be unavoidable but large deviations
(that interfere with intended function of the machine
element) are not permissible.
• Designer must decide how much deviation could be
tolerated.
• This is achieved by prescribing an upper and a lower
(size) limit for certain dimensions of an element.
• Permissible variation on a dimension is called tolerance.
 INTRODUCTION -6
Tolerance is 0.1 mm Tolerance is 0.2 mm

Part of an engineering drawing of a shaft showing certain dimensions with size limits
 INTRODUCTION -7

• It should be kept in mind that tolerance and machining

cost are directly related.
– Closer tolerance requires precision machining and/or multiple
processes such as reaming subsequent to drilling etc.
– Skilled labour might be required.
– Also closer inspection and more careful quality control
procedures might be required.
• When the tolerances (size limits) are not stated on a
drawing, this implies that the average accuracy of the
manufacturing process is sufficient.
– Average accuracies of some manufacturing processes will be
addressed in forthcoming slides.
 INTRODUCTION -8
Tolerances on a dimension can be shown on drawings in different ways
unidirectional Bidirectional unidirectional
Basic size tolerance tolerance tolerance -0.20
14 -0.40
32+0.1 +0.11
36 ±0.2
38 +0.09
 Scope
• In this part of the course ISO system for specifying size
limits and tolerances, particularly for cylindrical parts
(shafts and holes such as those in bushings) will be
introduced.
• ISO: International Standard Organization
• Related ISO standards describe the system of
tolerances in detail.
• In this presentation, basic concepts and definitions will
be explained and some application examples on how to
specify and designate size limits and tolerances will be
given.
• Then Fits (Assemblage of mating shafts and holes) will
be addressed.
Turkish version of ISO Standard

Standard number

European
Norm
Previous (now obsolete) Turkish Standard superceded by TS EN ISO 286-1
British Version of ISO Standard
A Related Turkish Standard
This is an old standard but it is current
as of September 2020.
 PRECISION: The degree of accuracy
BASIC SIZE: The size to which limits
necessary to ensure the functioning of
or deviations are assigned. (Nominal size)
a part as intended.
TOLERANCE: Allowable variation for any
upper dev. du dmax(u.l.) given size and provides a practical means
of achieving the precision required.

shaft Difference between the maximum and

dmin(l.l.) minimum size limits of a part.

DEVIATION: Size - Basic size

lower dev. dl
LOWER DEVIATION:
Basic size, D (d) reference
surface
Minimum Size limit - Basic size
upper dev. Du UPPER DEVIATION:
lower dev. Dl Maximum Size limit- Basic size
FUNDAMENTAL DEVIATION:
hole Upper deviation or lower deviation,
whichever is closer to zero. (Gives
min.size(l.l.) the limit closer to basic size.)
Tells where to apply a given
max. size (u.l.) tolerance w.r.t. basic size.
Dmax
IT NUMBER: (International Tolerance Grade Number) IT designate a
group of tolerances such that for a given IT number, tolerances have
the same relative accuracy for different basic sizes. IT numbers are
integers.

(Closer) 1  IT  16 (Coarse)

IT 6 - IT 11 are preferred.

IT 7: 3510-3mm 5710-3mm
IT 11: 22010-3mm 36010-3mm

100 400
Imply same relative level of accuracy
(Note that we don't multiply by four!) (Basic size)
(Basic size)
 Tolerance Specification:

Holes: A capital letter (indicating fundamental deviation)-followed by IT number.

Examples: H7, P8, etc.

Shafts: A lower case letter (indicating fundamental deviation)-followed by IT number.

Examples: h7, g6, etc.

Note that letters I, L, O, Q, W, i, l, o, q, w are excluded.

For a given basic size the upper deviation, the lower deviation and the tolerance
is given either in tables or by formulas.

Fundamental deviation locates the starting point of the tolerance.

Upper size limit
f.d. f.d.
f.d. Tolerance (zone)

Lower size limit

Basic
size

a-h j k-z

A shaft with various fundamental deviations

Upper size limit

f.d. f.d.
f.d. Tolerance (zone)

Lower size limit

Basic
size

K-Z J A-H

A bushing hole with various fundamental deviations

 Example: Let's have IT 7 tolerance on a shaft with basic size 400.
This corresponds to a range of 5710-3mm.
The question of "where to place this range?" is answered by fundamental deviation.

5710-3
Basic size, 400

Consider three cases f7, h7 and p7.

Let it be given that the fundamental deviation for "f " is -0.062, for "h " 0, and
for " p" +0.062.

Then what are the upper and lower limits of this basic size?

Note that when 2 of the three quantities, (upper deviation, lower deviation and tolerance)
for a basic size are given, the third one can be found.

For shafts a-h are upper deviation letters, k-z are lower deviation letters.
f 7:
0.062 du
0.119 Upper limit: 400.000-0.062=399.938
dl 0.057 Lower limit: 399.938-0.057=399.881
lower Basic size, 400
Note that fundamental deviation
upper is the upper deviation,
limit
limit
du= - 0.062 mm, dl = - 0.119
h 7:
0.057
dl Upper limit: 400.000
0.057
lower
Basic size, 400 Lower limit: 400.000-0.057=399.943
(upper limit) Note that fundamental deviation
limit
is the upper deviation,
du=0.000 mm, dl =-0.057
p 7:
0.057
du
Upper limit: 400.000+0.062+0.057=400.119
0.062 Lower limit: 400.000+0.062=400.062
Note that fundamental deviation
dl Basic size
lower limit Upper limit is the lower deviation,
400
du=0.119 mm, dl =0.062
For a given IT number and dimension range variation of tolerances will be as follows:

HOLES (CAPITAL LETTERS) shafts (lower case letters)

A
(LOWER DEV.) x y z
u v
BC
DE s t
p r
F n
GH km
f.d J f.d
K
.
f.d f.d j
M . g h
N PR e f
S T d
UV
X Y b c
Basic size Z
a
(UPPER DEV.)

Reference line

For holes A-H are lower deviation letters, K-Z are upper deviation letters.
 Fundamental Deviation
• Note that for a given basic size range, a
fundamental deviation letter always
corresponds to the same absolute numerical
value.
• For example,let nominal size be 40-50
• for g3, g5, g6, upper deviation is fund. dev.
and it is -9 microns.
• for G6 and G7, lower deviation is fund. dev.
and it is 9 microns.
 CALCULATION OF A TOLERANCE FOR A GIVEN IT NUMBER
Tolerance  K  i ( IT # -6 )
K  10 1.6 3i  0.45  D  0.001 D
where "i " is in [mm], D which is the nominal size is in [mm].
D  D1D2 , where D1 and D2 are the beginning and end of a size range.
If size ranges are not available, basic size can also be used for D.

D1-D2 i ( 10-3 mm) IT K

1-3 0.60 5 7
3-6 0.75 6 10
6-10 0.90 7 16
10-18 1.10 8 25
18-30 1.30 9 40
30-50 1.60 10 64
50-80 1.90 11 100
80-120 2.20 12 160
120-180 2.50 13 250
180-250 2.90 14 400
250-315 3.20 15 640
315-400 3.60 16 1000
400-500 4.00
 FIT: The desired quality of mating (the range of tightness or looseness)
between two assambled parts is defined as FIT.
Fit results from the combination of allowances and tolerances (i.e. permitted
variation on the dimension). Both members have the same basic size.
ALLOWANCE: Intentional difference between the maximum material limits of
mating parts.
Maximum material limit for a hole: Hole is at its lower limit (smallest)
Maximum material limit for a shaft: Shaft is at its upper limit (largest)
Allowance is therefore either the minimum clearance or the maximum interference.

TYPES OF FITS:
i)Clearance fits: Mating parts have such upper limits and lower limits that there
is always a clearance.
ii)Transition fits:Mating parts have such upper limits and lower limits that there
is either a clearance or an interference depending on the exact
values that result due to manufacturing processes.
iii)Interference fits:Mating parts have such upper limits and lower limits that the
lowest shaft diameter is always larger than the largest hole diameter.
Turkish version of ISO Standard for Fits
Details on TS EN ISO 286-2:2010

Pretty expensive!
 Journal bearing and housing

shaft

There is a clearance (running or sliding) fit

between the shaft and the bearing.
In other words, there is a narrow gap typically
in the order of tens of microns between the
shaft and the bearing. Amount of this gap is very
important for proper lubrication.

Figure from (accessed September 24th, 2020)

https://new.abb.com/mechanical-power-transmission/mounted-bearings/journal-plain-bearings/babbitted-bore
Interference fit parts can be joined by simply forcing them together (press fit) or
by heat shrink assembly (taking advantage of thermal expansion).

There are interference (heat shrink) fits

between the shaft and the gears.
(Uniform tight seating on the shaft and some
torque transmission is accomplished)

Composite gear shaft

«…The only problem is joining the parts to the shaft. One way to do that is with heat-shrink assembly.
As every high-school student learns in physics class, a metal part expands when heated and contracts
to its original size when it cools. Heat-shrink assembly takes advantage of this phenomenon to create
a strong interference fit between two mating parts that otherwise could not be accomplished by simply
forcing them together with an ordinary press-fit.
For example, a gear can be attached to a shaft by heating the gear so that its inner diameter,
which begins slightly smaller than the outer diameter of the shaft, expands.
When the ID has expanded enough, the hot gear is slid over the shaft. As it cools, it shrinks and sticks in place. …»

Figure and the above text are from Assembly Magazine (accessed September 24th, 2020)
(https://www.assemblymag.com/articles/92852-heat-shrink-assembly)
 Transition fits are used in applications where
• Good positioning (none or minimum play, immovably locate),
• And uniform seating of the shaft (it could be a pin)
in its hole is desired
• without requiring a lot force for assembly or dissassembly.

For example, transition fits are used in some rolling element

bearing applications as the fit of choice between outer ring of the
bearing and the housing, and also between the shaft and inner
ring of the bearing.
Outer ring Housing

Inner ring

Figure from (accessed September 24th, 2020)

https://www.amazon.com/Mounted-Diameter-Bearing-Corrosion-Resistance/dp/B07QRZKCZV

Figure from (accessed September 24th, 2020)

https://www.kugellager-express.de/deep-groove-ball-bearing-6415-open-75x190x45-mm
 Clearance Fit Transition Fit Interference Fit:

24.950 25.040 25.040

24.930 25.010 25.020

25.000 25.020 24.980

25.030 25.040 25.010

Tol. on shaft: 24.950-24.930=0.020 Tol. on shaft: 25.040-25.010=0.030 Tol. on shaft: 25.040-25.020=0.020

Tol. on hole : 25.030-25.000=0.030 Tol. on hole: 25.040-25.020=0.020 Tol. on hole: 25.010-24.980=0.030
Basic size: 25 Basic size:25 Basic size:25
Allowance: =25.000-24.950=0.050 Allowance: =25.040-25.020=0.020 Allowance: =25.040-24.980=0.060
(Min. clear.) (Max.Interf.) (Max. Int.)

To specify a fit we need basic size and two complete tolerance specifications,
one for the hole and one for the shaft.
Example: H7/r6, G7/h6 etc.
ISO has adopted an approach such that the nominal size is taken as one limit
dimension and the others are calculated by means of required tolerances.
In practice two systems are used for fits.
A. Basic Hole System:
Minimum hole diameter is taken as the basis and upper limit of the hole is
prescribed according to quality requirement (IT #).
The desired fit is maintained by prescribing the shaft limits.
Lower limit: Basic Hole size
Upper limit: Basic Hole size+tolerance
(Basic size) H --/-- -- Tolerance specification for shaft.
Mostly used in production of single parts.

B. Basic Shaft System:

Maximum shaft diameter is taken as the basis and lower limit of the shaft is
prescribed according to quality requirement (IT #).
The desired fit is maintained by prescribing the hole limits.
Lower limit: Basic shaft size-tolerance
Upper limit: Basic shaft size
(Basic size) -- --/h -- Tolerance specification for hole

Mostly used in mass production.

(Snug fit: H--/h-- )
Example: For a basic size of 60, find upper and lower limits of the hole and the
shaft if a fit of H7/g6 is specified.
(For this size range, g implies a fundamental deviation of -0.010)

Solution:From the tolerance formula; for IT 7 tolerance is 0.030 and for IT

6 tolerance is 0.019 for the given size range (50-80).
Hole: Shaft:
Upper limit: 60.000+0.030=60.030 Upper limit: 60.000-0.010=59.990
Lower limit: 60.000 Lower limit: 60.00-0.010-0.019=59.971

(Clearance Fit), min. clear.: 60-59.99=0.010 and max. clear.: 60.03-59.971=0.059

Usually the problem is reversed, we know the required fit,
(allowance). We choose a fit from the tables.
TOLERANCE ON FIT: Magnitude of possible variation between the maximum and
minimum clearance or interference.

Tf=|Max. Clear.|-|Min. Clear.| Clearance fits

Tf=|Max. Int.|-|Min. Int.| Interference fits
Tf=|Max. Clear.|+|Max. Int.| Transition fits
Tf=TH+TS
TH=Du-Dl ; Tolerance on hole and TS=du-dl; Tolerance on shaft.
Example: For a basic size of 25 and a fit of H7/j5 determine
a) Type of tolerance system
b) Tolerance on hole,TH
c) Tolerance on shaft,TS
d) Upper and lower limits of the hole; Du, Dl
e) Upper and lower limits of the shaft; du, dl Cmax
f) Type of fit +21
g) Tolerance on fit;Tf 5
h) Allowance Imax
T H
TS
Solution
a) BHS 4
b) For IT 7 range (18-30) tolerance is 0.021 Basic size
c) For IT 5 range (18-30) tolerance is 0.009
d) Du= 25.021, Dl=25.000
e) du=25.000+0.005=25.005; dl=25.000-0.004=24.996
f)Transition fit. du> Dl so interf. is possible, dl < Du Clear. is also possible.
g)Tf=TH+TS=0.021+0.009=0.030
h)Allowance is max. interference for transition fits so it is 0.005.
How do we select appropriate tolerance/fit in a particular design problem?

There is not a unique answer for this question but the followings may help.

1) Design calculations: In the design of certain machine elements (such as

journal bearings) , the required fit is obtained as a result of design calculations.

2) Product catalogues: Certain machine elements (such as rolling bearings) can

be selected and ordered from company catalogues. In these catalogues not
only the tolerances of the selected product(for example a ball bearing) but also
the required tolerances for the mating parts (such as the shaft going through the
bearing and the housing) are given.
3) Standards: Standards such as (now withdrawn) TS 2417 (Selection of
tolerance zones for general purposes) and TS 5414 (Tolerance systems: Limits
and fits; selection of tolerance zones for fine mechanics; tolerance zones;
nominal deviations) provide general guidelines. For more standards see course
web site.
4) Company know-how and experience.

5) General engineering literature, hand books, text books etc.

 Tolerances on a Dimension
Precision Fine Medium Coarse

Hole H6 H7 H8 H11
Shaft h5 h6 h8,h9 h11
General precision that can be maintained during mass production for different
manufacturing processes, for a machine element with a basic size of 25-50 mm.
Process Tolerance [mm]
sand casting 0.8-1.5
die casting, plastic molding 0.4
die forging 0.8
drilling 0.1
reaming 0.015
turning 0.2 (rough)
0.1 (finish)
milling 0.1
shaping, planning 0.1
broaching 0.05
grinding 0.01
IT tolerance Application
1 close
2 close gauges
3 close
4 close
5 close, medium
6 close, medium
7 medium
8 medium Machinery

9 medium
10 medium
11 medium, large
12 large
13 large
14 large Coarse work
15 large
16 large
IT qualities associated with different manufacturing processes

Process IT
sand casting 16
forging, drop forging 15, 16
die casting, plastic molding, precision die 14, 10 -12
casting
Press work, tube drawing, extrusion 10-13
drilling 6-12 mm /12-18 mm 11 / 12
shaping, planning 10, 11
milling 8-10
turning 8-10
reaming 7,8
broaching (F<50) 7,8
Honing (F<50) 6
grinding (F<50) 5,6
Lapping (machines) 4-5
Lapping (Gauges, precision work) 1-3
 A suggested youtube video:
https://www.youtube.com/watch?v=wvVMs2BZdeU

Note that there are many videos, pictures and other kinds of digital
resources on the internet, but some of these may contain inaccuarte
information. You are advised to be aware of this.

«To decide about the quality in the parts to be manufactured, choose

• As rough as possible
• As fine as necessary
Considering also, the functions of elements and the cost of the elements.»