Engineering Measurement

Limits, Fits and Tolerances

Subject: Industrial Engineering and Measurement

Code:MEC602
Prof. Nilotpal Banerjee
 Limits, Fits and Tolerances
Due to the inevitable inaccuracy of manufacturing
methods, a part cannot be made precisely to a
given dimension. The permissible variation on the
size is called tolerance.

The two extreme permissible sizes on the

actual size are called limits.

When two parts are to be assembled, the relation

resulting from the difference between their sizes
before assembly is called a fit.
1
 General Terminology

I . 1 ·

'
I

.
. .

2
General Terminology
 Cclearance Fit
HOLE HOLE

_·'
.···... .. ·
~
i

· • · •.···.·.....
•. '
,

-. . . .
u . ··.·.·.·•.
..

SHAFT
u L , A· . '

. .
.
·,
.
.
' ' . . ,

SHAFT

Maximum shaft dimension < Minimum hole dimension

 Interference Fit

HOLE HOLE

Maximum Hole size < Minimum Shaft size 5

 TRANSITION FIT
SHAFT

SHAFT

Obtained by overlapping of tolerance zones of

shaft and hole . . . . . . Does not guarantee neither
clearance nor interference fit.
Terminology for fits and tolerances
Basic size: It is the exact theoretical size arrived at by
design. It is also called nominal size.
Actual size: The size of a part as may be found by
measurement.
Maximum limit : The greater of the two limits of size.
Minimum limit : The smaller of the two limits of size.
Allowance: It is an intentional difference between
maximum material limits of mating parts. It is a minimum
clearance or maximum interference between mating parts.
Terminology for fits and tolerances
Deviation: The algebraic difference between a size
(actual, maximum, etc.) and the corresponding basic size.
Actual deviation: The algebraic difference between the
actual size and the corresponding basic size.
Upper deviation: The algebraic difference between the
maximum limit of size and the corresponding basic size.
Upper deviation of hole = ES (Ecart Superior)
Upper deviation of shaft = es
Terminology for fits and tolerances
Lower deviation: The algebraic difference between
the minimum limit of size and the corresponding basic
size.
Lower deviation of hole = EI (Ecart Inferior)
Lower deviation of shaft = ei
Upper deviation= Lower deviation + Tolerance
Terminology for fits and tolerances
Zero line: It is the line of zero deviation and represents the
basic size.
Tolerance zone: It is the zone bounded by the two limits of
size of the parts and defined by its magnitude, i.e. tolerance
and by its position in relation to the zero line.
Fundamental deviation: That one of the two deviations
which is conveniently chosen to define the position of the
tolerance zone in relation to zero line, as shown in figure
Terminology for fits and tolerances
Basic shaft: A shaft whose upper deviation is zero.
Basic hole: A hole whose, lower deviation of zero.
Clearance: It is the positive difference between the hole
size and the shaft size.
Maximum clearance: The positive difference between
the maximum size of a hole and the minimum size of a
shaft.
Minimum clearance: The positive difference between
the minimum size of a hole and the maximum size of a
shaft.
 Classification of Tolerances
Tolerance can be classified under the following categories:
1. Unilateral tolerance
2. Bilateral tolerance
3. Compound tolerance
4. Accumulated tolerance
 Unilateral Tolerance
When the tolerance distribution is only on one side of the
basic size, it is known as unilateral tolerance.
In other words, tolerance limits lie wholly on one side of
the basic size, either above or below it.
Example:

.
Unilateral Tolerance: 2.25 . , can be converted to
Bilateral Tolerance: 2.25 ± 0.004 and also as
.
Limit Tolerance:
.
 Bilateral Tolerance
When the tolerance distribution lies on either side of the b
asic size, it is known as bilateral tolerance.
In other words, the dimension of the part is allowed to var
y on both sides of the basic size but may not be necessaril
y equally disposed about it.
.
Example: 40 ± 0.02, 40 .
 Compound Tolerances
When tolerance is determined by
established tolerances on more
than one dimension, it is known as
compound tolerance.
Example: tolerance for the
dimension R is determined by the
combined effects of tolerance on
40 mm dimension, on 60º, and on
20 mm dimension. The tolerance
obtained for dimension R is known
as compound tolerance. In
practice, compound tolerance
should be avoided as far as
possible.
 Accumulated Tolerances
Example: Consider the example shown in the figure below,

. . .
LA=30 . , LB=20 . , LC=10 .

Cumulative Upper Tolerance is: 0.02+0.02+0.02=0.06

Cumulative Lower Tolerance is:-0.03
Therefore dimension of the assembled length will be
=60 ..
 Accumulated Tolerances
It is essential to avoid or minimize the cumulative effect
of tolerance build‐up, as it leads to a high tolerance on
overall length, which is undesirable. If progressive
dimensioning from a common reference line or base line
is adopted then accumulation effect can be avoided as
shown below,
 Examples on Tolerances
Example 1. A spindle slides freely in a bush. The basic
size of the fit is 50 mm. If the tolerances quoted are 50
for the holes and 50 for the shaft, find the upper limit
and lower limit of the shaft and the minimum clearance.
Solution: Tolerances are given in units of one thousandth
of mm, so the upper limit of the hole will be 50.062 mm
and lower limit for the hole is the same as the basic size of
50.000 mm.
The shaft upper limit will be (50.000 – 0.080) = 49.92 mm
The shaft lower limit will be (50.000 – 0.180) = 49.82 mm
The minimum clearance is (50.000 – 49.920) =0.080 mm.
 Examples on Tolerances
Example 2. A dowel pin is required to be inserted in a base. For
this application H fit for hole and a p fit for the shaft are chosen.
Basic size of the fit is 50 × 10 m. The tolerance quoted are
50 for the hole and 50 for the shaft. Find the upper and
lower limits of the hole and also dowel pin, and the maximum
interference between dowel pin and the hole.
Solution:
The upper limit for the hole = (50.000 + 0.025) = 50.025 mm
The lower limit for the hole = (50.000 + 0) =50.000 mm
The upper limit for dowel pin = (50.000 + 0.042) = 0.042 mm
The lower limit for dowel pin= (50.000 + 0.026) =50.026 mm
The maximum interference between dowel pin and the hole is
= 0.042mm
 Examples on Tolerances
Example 3. For a particular application, a H fit has been selected
for the hole and a k fit for the shaft. The basic size of the fit is
50 × 10 m. The tolerance quoted are 50 for the hole and
50 for the shaft. Find the upper limit and lower limit for the
hole and also for bush.
Solution:
The upper limit for the hole = (50.000 + 0.025) = 50.025 mm
The lower limit for the hole = (50.000 + 0) =50.000 mm
The upper limit for dowel pin = (50.000 + 0.018) = 50.018 mm
The lower limit for dowel pin= (50.000 + 0.012) =50.012 mm
 Examples on Tolerances
Example 4. A 50 mm diameter shaft is made to
rotate in the bush. The tolerances for both
shaft and bush are 0.050 mm. Determine the
dimension of the shaft and bush to give a
maximum clearance of 0.075 mm with the hole
basis system.
Solution:
In the hole basis system, lower deviation of
hole is zero, therefore low limit of hole = 50
mm.
High limit of hole = Low limit + Tolerance =
50.00 + 0.050
= 50.050 mm = 50.050 mm
High limit of shaft = Low limit of hole –
Clearance = 50.00 – 0.075
= 49.925 mm = 49.925 mm
Low limit of the shaft = High limit – Tolerance
= 49.925 – 0.050 = 49.875 mm = 49.875 mm
 Examples on Tolerances
Exercise 5. For each of the following hole and shaft assembly,
find shaft-tolerance, hole-tolerance and state the type of fit,
 Standard Tolerances
There are 18 standard grades of tolerances as specified
by BIS with designations ITO1, IT0 and IT1 to IT 16.
Various grades of tolerances are defined using the
‘standard tolerance unit’, ‘ i ‘ in µm, which is a function
of basic size.
where, D (mm)is the geometric mean of the lower and
upper diameters of a particular diameter step within
which the chosen the diameter D lies.
Diameter steps in BIS are: (a-b, where ‘a’ is above and
‘b’ is up to, Refer Table in the next page) 1-3, 3-6, 6-10,
10-18, 18-30, 30-50, 50-80, 80-120, 120-180, 180-250,
250315,315-400 and 400-500 mm.
 Standard Tolerances
The tolerances have parabolic relationship with the size
of the products. As the size increases, the tolerance
within which a part can be manufactured also increases.
IT01 –0.3 + 0.008D
IT0 –0.5 + 0.012 D
IT1 –0.8 + 0.020D
IT1 –0.8 + 0.020D
IT2 to IT4 –the values of tolerance grades are placed
geometrically between tolerance grades of IT1 and IT5.
Table 2.1 Standard tolerances
Example 6: Evaluate limits and fits for a pair Dia 6 H /g
Solution: The size 6 mm lies in the diametral step of 3-6, therefore, D
is given by, = 3 × 6 = 4.24 mm
The value of fundamental tolerance unit is given by,
= 0.45 +0.001 = 0.45 4.24 +0.001 × 4.24 = 0.7327µm
Limits of tolerance for hole H
The standard tolerance is –16 i = 16 x 0.7327 = 11.72 = 12 µm
The fundamental deviation H hole = 0
Limits of tolerance for g shaft
The standard tolerance is,10 i=10 x 0.7327 = 7.327 = 8 µm
Fundamental deviation for g shaft
= −2.5 . = −2.5 4.24 . = −4.085 = −4µm (Separate table is
provided for FD)
Fit:
Maximum clearance = Maximum size of hole -Minimum
size of shaft
= 6.012 –6.988 = 0.024 mm = 24 µm
Minimum clearance = Minimum size of hole -Maximum
size of shaft
= 6.000 -6.996 = 0.004 mm = 4 µm
The type of fit is Clearance.
Equation Chart to Calculate Fundamental Deviation of Shaft Size Up to 500mm
(Geometric Mean Diameter "mm")
FORMULAE FOR FUNDAMENTAL DEVIATION FOR SHAFTS SIZES UP TO 500 mm

UPPER DEVIATION (es) LOWER DEVIATION (ei)

Shaft Designation In Microns (for D in mm) Shaft Designation In microns (for D in mm)

j5 to j8 No formula
= -(265 + 1.32D) for D ≤ 120 js ITx1/2
;and
a = – 3.52D for D > 120 k4 to k7 =+ 0.6x 3 √D

k for Grade ≤3 and ≥4 =0

= – (140 + 0.852D); for D <160
;And
b = – 1.82D for D > 160 m = + (T7-IT6)

n = + 5D0.34
= – 52D0.2 for D ≤ 40
c = -(95 + 0.82) for D> 40 P = + IT7 + 0 to 5

cd G.M. of values for c and d

= geometric mean of
d =– 16D0.44 r values for p and s

e = -11D0.41
= IT8 + 1 to 4; for D ≤50
ef G.M. of values for e and f s = + 7T7 to + 0.4D; for D > 50

f = -5.5D0.41 t = + IT7 + 0.63D

fg G.M. of values for f and g u = + IT7 + D

g = -2.5D0.34 V = + IT1 + 1.2525D

X = + IT7 + 1.62D

y = + IT7 + 2D

z = + IT7 + 2.52D

za = IT8 + 3 + 3.152D

zb = + IT9 + 4D

h =0 zc = + IT10 + 4D
GENERAL RULE:
Hole limits are identical with the shaft limits of the same symbol (Letter and Grade) but disposed on the
other side of the zero line. EI=- es (EI is equal upper deviation of shaft of the same letter symbol but of
opposite sign.)
Example 7:
Calculate the limits of sizes for Diameter 20 P /h and identify
the fit. The size 20 mm lies in the diametral step of 18-30,
therefore, D is given by, D = 18 × 30 = 20.78 mm
The fundamental tolerance unit ‘i’ is given by –
i = 0.45 D +0.001D = 0.45 20.78 +0.001 × 20.78 =1.258µm
Limits evaluation for *+ Hole:
The fundamental deviation for p shaft =IT7 + 0 to 5
The fundamental deviation P hole =IT6 + 0 to 5
=10i+ 5= 10×1.258 +5=17.58=18µm
For grade 7 the std. tolerance =16 i = 16x1.258 = 20.128 = 21 µm
Limits evaluation for ,- Shaft:
The fundamental deviation for h shaft = 0
For grade 6 the standard tolerance =10 i =10x1.258 = 2.58 =13µm
Fit
Maximum clearance = Maximum size of hole -
Minimum size of shaft
= 19.982 –19.987 = -0.005 = -5 µm
Maximum Interference = Minimum size of hole -
Maximum size of shaft
= 19.961 -20.000 = -0.039 mm = -39 µm
The fit is Interference. But it can become Transition if
some value of FD for p shaft between IT7 + 1 to 5 µm
is selected.
 Standard Tolerances
Table 2.2 Tolerance grade in various manufacturing processes
To obtain different types of fits, it is practice to
vary tolerance zone of one of the mating parts

• HOLE BASED SYSTEM

Size of hole is kept
SHAFT constant, shaft size is
varied to get different fits.
CLEARANCE TRANSITION INTERFERENCE
( i ) HOLE BASIS SYSTEM

SHAFT BASED SYSTEM

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

CLEARANCE TRANSITION INTERFERENCE

(ii) SHAFT BASIS SYSTEM 7
 HoleBasisSystem
Hole basis system is the
most commonly used
system because due to the
fixed character of hole
production tools, it is
difficult to produce holes
with odd sizes. Commonly
used types of fits are given
in Table 1.3. Shafts ‘a’ to
‘h’ produce clearance fit,
‘j’ to ‘n’ transition fit, and
‘p’ onwards interference fit
with hole.
mating components. For example, in 40 H8f7, the number
40 indicates the basic size in millimeters; capital letter H
indicates the fundamental deviation for the hole; and
lower-case letter f indicates the shaft. The numbers
following the letters indicate corresponding IT grades.
 Limit Gauges
Gauging, done in manufacturing processes, refers to the
method by which it is determined quickly whether or not the
dimensions of the checking parts in production, are within
their specified limits. It is done with the help of some tools
called gauges. A gauge does not reveal the actual size of
dimension. A clear distinction between measuring
instruments and gauges is not always observed. High carbon
and alloy steels have been the principal material used for
many years. Limitations to steel gauges are that they are
subjected to some distortion because of the heat-treating
operations and that their surface hardness is limited. These
are largely overcome by the use of chrome plating or
cemented carbides as the surface material. Some gauges are
made entirely of cemented carbides or they have cemented
carbides inserted at certain wear points.
 Limit Gauges
Limit Gauges These are also called „go‟ and „no go‟ gauges. These
are made to the limit sizes of the work to be measured. One of the
sides or ends of the gauge is made to correspond to maximum and the
other end to the minimum permissible size. The function of limit
gauges is to determine whether the actual dimensions of the work are
within or outside the specified limits. A limit gauge may be either
double end or progressive. A double end gauge has the „go‟ member
at one end and „no go‟ member at the other end. The „go‟ member
must pass into or over an acceptable piece but the „no go‟ member
should not. The progressive gauge has „no go‟ members next to each
other and is applied to a workpiece with one movement. Some
gauges are fixed for only one set of limits and are said to be solid
gauges. Others are adjustable for various ranges
 Limit Gauges
✓ The term 'lim it gauges' signif ies the use of gauges
for checking the lim its of the compo nent s.

✓ GO gauge checks Maximum Material Limit {MML)

Tolerance zone$

HLH NOT
LLH Go

GO and NOT GO limits of plug gauge

25
 Marked red

- - - -
NOT
d,o Go GO

Fig. 3.32 Double-ended plug gauges

Handle

NOT
GO GO

IFig. 3.33 Progressive plug gauges

26
✓ Limit gauges ensure that the components lie
within the permissible limits, but they do not
determine the actual size or dimensions.

To l e r a n c e z o n e

HLS NOT
LLS GO

GO and NOT GO limits of snap gauge

27
 Hand grip of non•
4 NOT GO
conducting material
« Marked
red

GO

Fig. 3.34 Double-ended snap gauge Fig. 3.35 Progressive snap gauge

28
 Taylor's Principle
Taylor's principle states that the GO gauge is
designed to check maximum metal
conditions, that is, LLH and HLS.

• GO gauge can be designed to check more

than one dimension at a time.

• NOT GO gauge is designed to check minimum

metal conditions, that is, HLH and LLS.

• NOT GO gauge should check only one

dimension at a time. 29
• Gauge Tolerance: Normal practice is to take gauge
tolerance as 10% of the work tolerance.

• Component that is manufactured outside the limits

should not be accepted by gauges.

• Component rejected by the GO gauge can be

reworked to maintain the limits because GO gauge
checks maximum material limit.

• Component rejected by the NOT GO gauge is

permanently rejected because NOT GO gauge
checks minimum material limit. Hence close gauge
tolerances will be provided on NOT GO gauges.
30