Engineering Measurement-

Limits, Fits and Tolerances

Subject: Industrial Engineering and Measurement
Code:MEC602
Prof. Nilotpal Banerjee
 Limits Fits and Tolerance
• Due to inevitable inaccuracy in manufacturing methods a part can not be
made precisely according to given dimensions.
• Two extreme permissible sizes of a part between which the actual size is
contained are called limits.
• The relationship existing between two parts which are to be assembled
with respect to the difference on their sizes before assembly is called a fit.
• Tolerance is defined as the total permissible variation of a size. It is the
difference between maximum limit and minimum limit of size.
 Limits Fits and Tolerance
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.
Types of Fits: The three types of fits are shown in Fig. 2.1 The disposition of tolerance
zones for the three classes of fit are shown in Fig. 2.2.

Fig. 2.1 Types of fits

 Limits Fits and Tolerance
Fig. 2.2 Disposition of tolerance zones for the three classes of fit
Three general types of fit between the mating parts
1. Clearance fit: A clearance fit is one having limits of size so
prescribed that a clearance always results when mating parts
are assembled.
2. Interference fit: An interference fit is one having limits of size
so prescribed that an interference always results when mating
parts are assembled.
3. Transition fit: A transition fit is one having limits of size so
prescribed that either a clearance or interference may always
result when mating parts are assembled.
Terminology for fits and Tolerances

2.3 Terminology for fits and tolerances

 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 of size: The greater of the two limits of size.
Minimum limit of size: 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.
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
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 fig. 2.4.
 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.

Fig. 2.4 Disposition of fundamental deviation and tolerance zone with respect to the zero line

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: .
Bilateral Tolerance:
.
Limit Tolerance:
.
 Classification of Tolerances
Bilateral Tolerance:
When the tolerance distribution lies on either side of the basic size, it is known as bilater
al tolerance. In other words, the dimension of the part is allowed to vary on both sides of
the basic size but may not be necessarily equally disposed about it.
.
Example: , .
Compound Tolerance: 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.
 Classification of Tolerances
Accumulated Tolerances: Consider the example shown in the figure,
. . .
L A= . , LB= . , LC= .
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 = .
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 beside,
 Standard Tolerances
There are 18 standard grades of tolerances as specified by BIS with
designations ITOI, ITO and IT to IT 16.

The standard tolerances for the various grades are given in

Table 1.1 and tolerance grades for various manufacturing
processes in Table 1.2
Tolerance grade in various manufacturing processes
Table 2.2 Tolerance grade in various manufacturing processes
 Hole Basis and Shaft Basis for Fits
1. Hole basis system: In this system, the different clearances and interferences are
obtained in associating various shafts with a single hole, whose lower deviation is zero.
2. 2. Shaft basis system: In this system, the different clearances and interferences are
obtained in associating various holes with a single shaft, whose upper deviation is zero.
 Selection of Fits
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.
Basic size: This is the size in relation to which all limits of size are derived. Basic or nominal
size is defined as the size based on which the dimensional deviations are given. This is, in
general, the same for both components.
Limits of size: These are the maximum & minimum permissible sizes acceptable for specific
dimension. The operator is expected to manufacture the component within these limits.
The maximum limit of size is the greater of the two, whereas the minimum limit is the
smaller of the two.
Tolerance: This is the total permissible variation in the size of a dimension, that is, the
difference between the maximum and minimum limits of size. It is always positive.
Allowance: It is the intentional difference between the LLH and HLS. An allowance may be
either positive or negative. Allowance = LLH – HLS
 Selection of Fits
Grade: This is an indication of the tolerance magnitude; the lower the grade ,the finer is the
tolerance.
Deviation: It is the algebraic difference between a size and its corresponding basic size. It
may be positive, negative, or zero.
Upper deviation: It is the algebraic difference between the maximum limit of size and its
corresponding basic size. This is designated as ‘ES’ for a hole and as ‘es’ for a shaft.
Lower deviation: It is the algebraic difference between the minimum limit of size and its
corresponding basic size. This is designated as ‘EI’ for a hole and as ‘ei’ for a shaft.
Actual deviation: It is the algebraic difference between the actual size and its corresponding
basic size.
Fundamental deviation: It is the minimum difference between the size of a component and
its basic size. This is identical to the upper deviation for shafts and lower deviation for holes.
 Selection of Fits
Zero line: This line is also known as the line of zero deviation. The convention is to draw the
zero line horizontally with positive deviations represented above and negative deviations
indicated below. The zero line represents the basic size in the graphical representation.
Shaft and hole: These terms are used to designate all the external and internal features of a
ny shape and not necessarily cylindrical.
Fit: It is the relationship that exists between two mating parts, a hole and a shaft, with resp
ect to their dimensional difference before assembly.
Tolerance symbols: These are used to specify the tolerance and fits for 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.
 Selection of Fits
Sketch showing the basic nomenclature
 Fundamental Deviations
The Value for the Hole from "A" to "H" are positive (+), for the Shaft from "a" to "h" are negative (-).
The Value of the Hole from "J" to "K" either positive (+) or negative (-), for Shaft form "j" to "k"
either positive (+) or negative (-).
Commonly used fits
Table : commonly used fits
Commonly used fits
Table : commonly used fits
 Limit Gauges
Limit Gauges
Two sets of limit gauges are necessary for checking the size of various
parts. There are two gauges: Go limit gauge, and Not Go limit gauge.
1. Go Limit: The Go limit applied to that of the two limits of size
corresponds to the maximum material condition, i.e. (1) an upper
limit of a shaft, and (ii) the lower limit of a hole. This is checked by the
Go gauge.
2. No Go Limit: The Not Go limit applied to that of the two limits of
size corresponds to the minimum material condition, i.e. (1) lower
limit of a shaft, and (ii) the upper limit of a hole. This is checked by
the No Go gauge.
According to the type and principle of manufacturing the gauges may be classified as:
(a) Standard gauges,
(b) Limit gauges,
(c) Indicating gauges, and
(d) Combination gauges.
(a) Standard Gauges:
If the Go gauge is an exact model of
the mating member whose dimensions
to be checked, then such a gauge is
termed as the standard gauge.