Dr.

Narendra Kumar_IPE, NITJ 13-02-2023

MECHANICAL MEASUREMENT AND METROLOGY

(IPX-202)

Limit Fit and Tolerances

Instructor: Dr. Narendra Kumar
Assistant Professor, IPE Department
National Institute of Technology Jalandhar
Email: kumarn@nitj.ac.in
Web: https://sites.google.com/view/knarendra/

DR. B. R. AMBEDKAR NATIONAL INSTITUTE

OF TECHNOLOGY JALANDHAR

Is it possible?

50 mm

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Contd…

 Every production process is a combination of three

elements - man, machines and materials.
 A change in any of these 3 elements will change the sizes
of the manufactured parts.
 The incorrect size relationships between the manufactured
parts affect their life and proper functioning.
 In mass production, where number of parts is to be
manufactured, it is not possible to make all parts exactly
alike and to exact dimensions.
 Also, perfect size is not only a difficult, but a costly matter.

Notice the dimensions in drawing

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TERMINOLOGY

Basic size:
 It is the specified standard size of a part, with reference to
which, all the limits of variations of size are determined. It
is same for both hole and its corresponding matting
member i.e. shaft.
 As basic size is specified before the production or
inspection, it is also called as true value.
Actual size:
 It is the actual measured value of manufactured job after
measurement. Therefore, it is also called as measured
value.

Contd…

Zero line:
 Line corresponding to basic size is called as zero line.
 It is the line of zero deviation.

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Contd…

 Hole: It is a term used to specify internal features of part.

 Shaft: It is a term used to specify external features of part.

Contd…

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LIMITS OF SIZE

 The ranges of permissible difference in dimensions have

been standardized under the concept of “limits”.
 Limits of size of a dimension of a part are two extreme
permissible sizes, between which, the actual size of
manufactured part should lie.
 Limits are fixed with reference to the basic size of that
dimension.
 For example, a shaft of 25 mm basic size with tolerance ±
0.02 may be written as 25 ±0.02.
 Higher limit for the dimension is 25.02 mm and lower limit
for the dimension is 24.98 mm.

Contd…

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Contd…

TOLERANCE

 Tolerance is the algebraic difference between the

maximum limit and minimum limit of a hole or shaft.
 It is also defined as ‘difference between upper deviation
and lower deviation'.
 It has an absolute value without algebraic sign. (Neither
plus or minus).
A shaft of dimension
25± 0.02 indicates
that, Upper limit =
25.02 mm and Lower
limit = 24.98 mm.
Therefore, Tolerance
zone = 25.02 – 24.98
= 0.04 mm.

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Need of Tolerance

 In actual practice, it is never possible to make a part or

component exactly same as per the given specified size
(dimension).
 Simultaneously, no measuring instrument or method of
measurement is available, which will show accurate size of
component manufactured.
 Therefore, it is difficult, rather impossible, to produce a
part to an exact size due to,
1. Variations in the properties of raw material being machined.
2. The production machines may themselves have some inherent
inaccuracies.
3. Operator error (how skilled the operator is ?)

Contd…

 An attempt to entirely overcome the above three factors

would result into very high costs.
 Therefore, if some variation to specified size does not
affect the functional requirement of that component, then
some tolerance can be given to basic size.

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SYSTEMS OF TOLERANCE

 Either on one side of basic size or both sides of basic size

 Two systems of specifying the tolerance of a component
Unilateral System:
 If dimension of a part is permitted to vary only on one side
of the basic size
 Tolerance will lie on one side of basic size, either upper or
below it.

Bilateral System:

 If dimension of a part is permitted to vary (change) on both

sides of the basic size, the system of tolerance is said to be
bilateral system.
 It means that, limits of tolerance will lie on either side of
basic size; but it is not necessary to vary tolerance of equal
amounts on both sides of basic size.
 For example, 25+0.02
−0.01 is an example of bilateral tolerance.
Therefore, +0.02 and –0.01 denote permissible higher and
lower deviations respectively.

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DEVIATION

 Deviation is the amount, by which, the actual size of a

manufactured part deviates from its basic size.
 Thus, deviation is the algebraic difference between actual
size and basic size.
 The straight line corresponding to the basic size is called as
zero line (i.e. the line of zero deviation).

Contd…

 Upper deviation is the difference between maximum limit

and basic size.
 Lower deviation is the difference between minimum limit
and basic size.
 Mean deviation is the arithmetic mean (average) of upper
deviation and lower deviation.
 Fundamental deviation is either upper deviation or lower
deviation, which is conventionally chosen to define the
position of tolerance zone in relation to the zero line.
 In fact, it is the upper or lower deviation, which is nearest
to zero line, either for shaft or a hole.

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Contd….

 The minimum difference in size between a component and

the basic size.

Think about the answers

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BASIC SHAFT AND BASIC HOLE

 Basic shaft: It is the shaft, whose fundamental deviation, is

zero or whose maximum limit of size is equal to basic size.
 Basic hole: It is the hole, whose fundamental deviation is
zero or whose minimum limit of size is equal to basic size.

FITS

 In simple words, when two mating parts are to be

assembled, the relation obtained due to the difference
between their sizes before assembly is called as fit.
 Fit is the degree of tightness or looseness between two
mating parts to perform a definite function.
 Various kinds of engagement (fit) between hole and shaft
can be obtained by varying the difference amongst their
average sizes.

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Classification of Fits

 Depending upon the actual sizes of hole or shaft, fits may

be classified as:
(a) Clearance fit, (b) Transition fit, (c) Interference fit.

CLEARANCE FIT

 In this type of fit, diameter of largest shaft is smaller than

diameter of smallest hole, so that, the shaft can rotate or
slide through, with different degrees of freedom according
to the purpose of the mating members.
 For clearance fit : Largest shaft diameter < Smallest hole
diameter

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Contd…

Note:

(a) Slide fit: It has very small clearance between mating parts.
It is employed when the mating parts are required to
move slowly in relation to each other. For example: Tail
stock spindle of lathe.
(b) Running fit: It has a appreciable clearance between
mating parts. It is employed for rotation at moderate
speed. For example: Gearbox bearings, crank shafts in
their main bearings, shaft pulleys etc.
(c) Loose running fit: It is employed for rotation at high
speeds. For example: Idle pulley on shafts, in quick return
mechanism of shaper.

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TRANSITION FIT

 In this type of fit, the sizes of limits of mating parts (shaft

and hole) are so selected that, either clearance or
interference may occur depending upon the actual size of
parts.

INTERFERENCE FIT

 In this type of fit, sizes of mating parts (hole and shaft) are
so selected that, interference or negative allowance will
always occur. Therefore, for Interference fit : Smallest shaft
diameter > Largest hole diameter.

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Interference Classification

 Interference can be classified into following types:

(i) Maximum interference is the negative difference between
the maximum limit size of the shaft and the minimum
limit size of the hole.
(ii) Minimum interference is the negative difference between
minimum limit size of the shaft and the maximum limit
size of the hole.
(iii) Mean interference: Arithmetic mean or Average value of
maximum and minimum interferences.
 For example: Press fit, driving fit, shrink fit etc.
Types: (i) Force fit, (ii) Tight fit, and (iii) Heavy force and
shrink fit.

ALLOWANCE

 Allowance is an intentional difference kept between lower limit

of the hole and higher limit of the shaft.
 Allowance is defined as, "the prescribed difference between the
hole dimension and shaft dimension to obtain desired type of
fit".
 Therefore, an allowance can be either positive (+) or negative
(–), which is decided on the basis of the type of fit required.
 If the limits provided to both mating members are such that,
the shaft diameter will be always smaller than the hole
diameter, we say that, there is positive allowance.
 But, if the shaft diameter is larger than the hole diameter, we
say that, there is negative allowance.
 Positive allowance is called clearance, while negative allowance
is called interference.

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Contd…

 In clearance fit, allowance is the minimum clearance, i.e. difference

between minimum size of hole and maximum size of shaft.
 It is referred as positive allowance. [Ref. Fig. (a)].
 In interference fit, allowance is the maximum interference, i.e.
difference between minimum size of hole and maximum size of shaft.
It is referred as negative allowance. [Ref. Fig. (b)].

DIFFERENCE BETWEEN TOLERANCE AND ALLOWANCE

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Solve

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Solve

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MAXIMUM AND MINIMUM METAL CONDITIONS

 MML-Maximum Metal Limit

 LML- Minimum Metal Limit

Solve

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Solve

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Problem

 Provide suitable words for various dimensions marked as A,

B, C, D, etc.

Solution

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HOLE BASIS AND SHAFT BASIS SYSTEM

 In a general limit system, it is necessary to decide on what

basis, the limits are to be found to give the desired fit.
 Limit and fit system is defined as, "a system of series of
standard allowances and tolerances to suit specific ranges
of basic size, which, when properly selected and assigned
to mating parts ensure specific classes of fit".
 There are two distinct systems for varying the sizes of parts
known as
1. hole basis system
2. shaft basis system

Hole Basis System

 In this system, the design size of hole, whose fundamental

deviation is zero, is assumed as basic size and different
clearances or interferences are obtained by varying the limits of
shaft to have different class of fit.
 In other words, limits of hole are kept constant and limits of
shaft are varied, so as to obtain the necessary type of fit.
 In this system, the hole has constant high and low limits for all
fits of same accuracy grade and for same basic size.

Min

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Shaft Basis System

 In this system, the design size of a shaft, whose fundamental

deviation is zero, is assumed as basic size and different
clearances or interferences are obtained by varying the limits of
hole to have different types of fit.
 In other words, limits of shaft are kept constant and limits of
holes are varied to obtain the necessary type of fit.

Advantages of Hole Basis System:

(i) As hole basis system is very easy, convenient and less

costly to make holes of correct sizes by using drills,
reamers etc., therefore, hole basis system is preferred and
used by almost all industrial companies.
(ii) It is also much easier to vary shaft sizes according to the
fit required, by suitable methods such as turning and
grinding.
(iii) Also, inspection of shafts can be done easily and rapidly
with the help of adjustable gauges. Direct external
measurement (such as shaft) is easier than internal
measurement (such as hole).

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Advantage of Shaft Basis System:

i. It is preferred, when different accessories with different

fits such as pulley, bearings, gears etc. are mounted on a
single large shaft.
 Disadvantages of Shaft Basis System:
(i) In mass production, use of this system will need large
amount of capital and storage space for the large number
of tools (drills, reamers, broaches, punches etc.) required
to produce holes of different sizes.
(ii) So, this method is not preferred in mass production.
(iii) As limits of holes are varied to obtain the necessary type
of it, therefore it becomes compulsory to measure inside
diameter of holes.

Contd…

(i) Internal measurements are always difficult, because of

complex construction of measuring instruments used.
(ii) Internal measurements are time consuming.
(iii) Accuracy is measured value depends upon the skill of
operator. Therefore, cost of inspection increases due to
high wages paid to skilled labours.

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Why hole basis system is preferred over shaft basis

system?

 All modern systems employ the hole basis system, the main
reason being that, it is easier to vary the size of the shaft
than that of the hole.
 The majority of holes in engineering works are produced
with drill and reamer or some similar tool.
 Therefore, it becomes necessary to use very large number
of tools of varying sizes to vary the size of holes.
 However, in some cases, the shaft basis system proves to
be more advantageous than the hole basis system.
For example: Manufacturing of large sized parts.

Problem

 A clearance fit has to be provided for a shaft and bearing

assembly having a diameter of 40 mm. Tolerances on hole
and shaft are 0.006 and 0.004 mm, respectively. The
tolerances are disposed unilaterally. If an allowance of
0.002 mm is provided, find the limits of size for hole and
shaft when (a) hole basis system and (b) shaft basis system
are used.

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Solution (a)

Solution (b)

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Fundamental Deviation

 The fundamental deviation refers to the location of the

tolerance with respect to the zero line (basic/nominal size).
 Capital letters are used for holes and lower case letters are
used for shafts.

(a) Fundamental Deviations – Holes (b) Fundamental Deviations – shafts

SYSTEM OF LIMITS AND FITS

 International Organization for Standardization (ISO) specifies

the internationally accepted system of limits and fits.
 Indian standards are in accordance with the ISO.
 It comprises 18 grades of fundamental tolerances to indicate
the level of accuracy of the manufacture.
 These fundamental tolerances are designated by the letters IT
followed by a number.
 The ISO system provides tolerance grades from IT01, IT0, and
IT1 to IT16 to realize the required accuracy.
 The greater the number, the higher the tolerance limit.
 The choice of tolerance is guided by the functional
requirements of the product and economy of manufacture.

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Contd…

 The degree of accuracy attained depends on the type and

condition of the machine tool used
 Tolerance values corresponding to grades IT5–IT16 are
determined using the standard tolerance unit (i, in μm),
which is a function of basic size.
where D is the diameter of the part in mm.
By using this formula, the value of tolerance unit ‘i’ is obtained for
sizes up to 500 mm.
D is the geometric mean of the lower and upper
diameters of a particular diameter step within
which the given or chosen diameter D lies and is
calculated by using the following equation:

Contd…

 The various steps specified for the diameter steps are as

follows:
1–3, 3–6, 6–10, 10–18, 18–30, 30–50, 50–80, 80–120, 120–
180, 180–250, 250–315, 315–400, 400–500 500–630, 630–
800, and 800–1000 mm.
 The standard tolerances corresponding to IT01, IT0, and IT1
are calculated using the following formulae:

Standard tolerance units

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Contd…

es: Error from zero

line (Basic Size) to
superior size of shaft.

ei: Error from zero

line (Basic Size) to
inferior size of shaft.

ES: Error from zero

line (Basic Size) to
superior size of hole.

EI: Error from zero

line (Basic Size) to
inferior size of hole.

Contd…

• For holes the letters A to G

represent oversize holes,
while the letters N to ZC
represents undersize holes.
• For shafts the letters a to g
represent undersize shafts,
while the letters m to zc are
for oversize shafts.
• It should be noted that H
(holes) and h (shafts) have a
fundamental deviation of
zero and therefore are
commonly used for one or
other of the components of
a fit (hole basis system or
shaft basis system).

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Fundamental Deviation for shafts upto 500 mm

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Clearance Fit (e.g.: H7/f6)

Contd…

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Contd…

Transition Fit (e.g.: H7/j6)

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Contd…

Contd…

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Interference Fit (H7/n6)

Contd…

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Contd…

Two ways of indicating tolerances on technical

drawings

The dimension is given by:

• a shape symbol,
• nominal size,
• a letter indicating the
position of the tolerance
zone in relation to zero line,
• a number indicating the
width of the tolerance zone.

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Applications of different tolerances

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