LIMITS, FITS & TOLERANCES

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 WHY TOLERANCES ARE MUST?

Machining a part to absolute dimensional accuracy is impossible in an

average workshop. Because it depends upon the following factors:
* Type of manufacture

* Method of machining

* Condition of machine

* Skill of the machinist

* Time taken

* Geometry of the product

* Condition of measuring tools

* Condition of measuring (METHOD)

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 LIMITS OF SIZE

Limits are the extreme permissible dimensions of a given

part.

There are two extreme permissible sizes for a given

dimension.

The largest permissible size is called upper limit or

maximum limit and the smallest size is known as lower
limit or minimum limit.

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 TOLERANCE

Tolerance is the permissible deviation in the

dimension of a component.

Mathematically,

Tolerance = upper limit size – lower limit size.

(i.e) The difference between upper limit dimension

and lower limit dimension on the basic size of a
component is termed as tolerance .

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 EXAMPLE

Given dimension = 20 ± 0.02

Basic size / Nominal size = 20.00 mm

Maximum limit size = 20.02 mm

Minimum limit size = 19.98 mm

Tolerance = 20.02 – 19.98 = 0.04 mm

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CONSIDERATIONS IN DECIDING THE TOLERANCE
NECESSARY FOR A PARTICULAR DIMENSION:

* Functional requirement:
Function of the component what it is required to do.

* Interchangeability:
Case of replacement in the event of failure.

* Economics:
Minimization of production time and cost.

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Types of tolerances:

Tolerance is basically specified in two forms.

i) Unilateral tolerance.

ii) Bilateral tolerance .

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 UNILATERAL TOLERANCE:
If all the tolerance is allowed on one side of the
nominal dimension or size ,the system is unilateral
tolerance.

Examples: i) 15 0.000
+0.004
ii) 10 + 0.005
0.000
iii) 44 + 0.000
0.005
iv) 20 – 0.01
– 0.02
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 BILATERAL TOLERANCE

If the tolerance is allowed on either sides of the

nominal dimension or size, the system is said
to be bilateral tolerance.

Examples:
i) 15 ± 0.002
ii) 10 ± 0.03
iii) 50 ± 0.2

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TERMINOLOGY OF LIMITS AND FITS

SHAFT :

A term used to designate all external features of a part

including those which are not cylindrical. It is denoted
by lower case alphabets.

A shaft is taken to refer any male component.

E.g. plugs, axles, spindles, locating spigots etc.

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 TERMINOLOGY OF LIMITS AND FITS

HOLE:

A term used to designate all internal features of a part

including those which are not cylindrical. It is denoted
by upper case alphabets.

A hole is taken to refer any female component.

E.g. bore, recess, keyways, etc.

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 TERMINOLOGY OF LIMITS AND FITS

NOMINAL SIZE (BASIC SIZE):

It is the design size of a component from which the

limits are derived by the application of tolerance.

Basic size is same for the hole and shaft.

ACTUAL SIZE:

The size of a finished component which is actually

measurable with any instrument is known as actual
size.

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 TERMINOLOGY OF LIMITS AND FITS
ZERO LINE:

The line which represents the basic size of

component of two mating components in an assembly
on a drawing is known as zero line. In limits and fits,
all deviations are shown with respect to zero line.

DEVIATION:

The algebraic difference between the actual size of a

component and its basic size is known as deviation.

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BASIC SIZE DEVIATIONS AND TOLERANCES

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 TERMINOLOGY OF LIMITS AND FITS

UPPER DEVIATION:

●The algebraic difference between the maximum limit size

and corresponding basic size is called upper deviation.

●It is a positive quantity when maximum limit size is

greater than the basic size and a negative quantity when
maximum size is less than the basic size.

●It is denoted by ‘ES’ (E cart superior) for holes and ‘es’ for
shafts.

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 TERMINOLOGY OF LIMITS AND FITS
LOWER DEVIATION:
●The algebraic difference between minimum limit size and
corresponding basic size is called lower deviation.

●It is a positive quantity when maximum limit size is

greater than the basic size and a negative quantity when
minimum limit size is less than the basic size.

●It is denoted by ‘EI’ (Ecart Inferior) for holes and ‘ei’ for
shafts.

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 FUNDAMENTAL DEVIATION

Fundamental deviation is that one of the two deviations - either

upper or lower - which is the nearest to zero line for either hole
or a shaft.

It fixes the position of tolerance zone with respect to the zero line.
In other words, it locates the tolerance zone w.r.t zero line.

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 FUNDAMENTAL DEVIATION

In total, there are 28 fundamental deviations and are represented

by letter symbols. Upper case letters are used for representing
holes and lower case letters are for shafts.

A, B, C, D, E, F, G, H, J, K, M, N, P, R, S, T, U, V, X, Y, Z, CD, EF,
FG, JS, ZA, ZB, and ZC for HOLES

and

a, b, c, d, e, f, g, h, j, k, m, n, p, r, s, t, u, v, x, y, z , cd, ef, fg, js,

za, zb, zc for SHAFTS.

The letters I,L,O,Q,W are omitted to avoid confusion.

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Fundamental Deviations for HOLES

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Fundamental Deviations for SHAFTS

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 TOLERANCE GRADE

●Tolerance grade is an indication of degree of accuracy of

manufacture and it is denoted by the letters IT followed by a number.
(IT stands for “International Tolerance” grade)

●It represents the magnitude of the tolerance zone or the amount of

variation allowed in the part size.

●In total, there are 20 grades of tolerance and they are denoted as IT0,
IT01, IT1, IT2………IT18.

●As the number gets higher, the tolerance amount increases.

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 TOLERANCE GRADE

Common Applications:

● IT01 to IT6 – is used for gauges and instruments.

● IT5 to IT12 – is used for precision and general engineering

applications.

● IT11 to IT16 – is used for semi finished products.

● IT16 to IT18 – is used for structural engineering applications.

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 TOLERANCE CLASS

Tolerance class is designated by the combination of

fundamental deviation and tolerance grade.
Examples:
I) 25H7 - It is the tolerance size of a hole whose basic size is
25mm. The fundamental deviation is represented by letter
symbol ‘H’ and grade of tolerance is represented by number
symbol 7.
II) 25e8 - It is the tolerance size of a shaft whose basic size is
25mm. The fundamental deviation is represented by letter
symbol ‘e’ and grade of tolerance is represented by number
symbol 8.
III) 40H8 - Basic size = 40 mm; Fundamental deviation = H;
Tolerance grade = 8.
iv) 40g7 - Basic size = 40 mm; Fundamental deviation = g;
Tolerance grade = 7.

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 Procedure for calculating limits

●Find out the value of the tolerance corresponding

to the IT grade

●Find out the fundamental deviation (i.e)

● either ES or EI for holes /

● either es or ei for shafts

●Calculate the other limit from the formulae:

●For Holes, ES = EI + IT or EI = ES – IT

●For shafts, es = ei + IT or ei = es - IT

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 TERMINOLOGY OF LIMITS AND FITS
ALLOWANCE:

The difference between the minimum hole size and maximum

shaft size is known as allowance. An allowance may be either a
positive (+) or a negative (-) according to the type of fit required.

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 FIT
● When two parts are to be assembled ,the relation resulting
from the difference between the sizes before assembly is
called a fit.
● There are three basic types of fits or engagements which
are possible to achieve by varying the amount of allowance
between the size of two mating parts.
They are:

1. Clearance fit.

2. Interference fit.

3. Transition fit.

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 Designation of a FIT

A fit is expressed by writing the following three details in order.

1. The common basic size
2. The tolerance class symbol for the HOLE
3. The tolerance class symbol for the shaft

EXAMPLES:

30H7/g6 20H7/p6

50H6/f5 30H7/m6

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 CLEARANCE FIT

●In clearance fit, the shaft is always smaller than the hole (ie) the
largest permissible shaft diameter is smaller than the diameter of
smallest hole.
●The allowance is always positive in value.
●Assembly/disassembly is possible by hand.
●Applications: For running & sliding assemblies.

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CLEARANCE FIT - SUB TYPES

A) SLACK RUNNING FIT

B) LOOSE RUNNING FIT

C) RUNNING FIT
D) EASY SLIDING FIT
E) PRECISION SLIDING FIT

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 CLEARANCE FIT
A) SLACK RUNNING FIT
It is obtained when there is a considerable
clearance between the mating parts
Eg) shaft of centrifugal pump
B) LOOSE RUNNING FIT
Loose running fit is employed for rotation at very
high speed
Eg) idle pulley on their shaft.
C) RUNNING FIT
Running fit is obtained when there is an
appreciable clearance between the mating parts. It
is employed for rotation at moderate speed.
Eg) gear box bearings , shaft pulleys etc.

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 CLEARANCE FIT
D) EASY SLIDING FIT

This type of fit provides a small guaranteed clearance ,

it serves to ensure alignment between shaft and hole.
Eg) spindle of lathe.

E) PRECISION SLIDING FIT

This type of fit has very small clearance, the maximum
clearance being zero. Sliding fits are required when the
mating parts are required to move slowly in relation to each
other.
Eg) tail stock spindle of lathe, Bush and Pillar for press tool .

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 INTERFERENCE FIT
●In interference fit the shaft is always larger than the hole
(ie) the minimum permissible shaft diameter is larger than
the maximum limit of hole.
●The resulting allowance has always a negative value.
●Assembly/disassembly is possible only by using force.
●Applications: For permanent assemblies.

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 INTERFERENCE FIT SUB TYPES

A) PRESS FIT
B) DRIVE FIT
C) FORCE FIT

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 INTERFERENCE FIT

A) PRESS FIT
It provides less interference and enables easy dismatling
of parts whenever required.
Eg) stepped pulleys on drive shaft of a conveyor
B) DRIVE FIT
It provides medium interference and is employed for
assemblies where dismantling would be difficult.
Eg) gears on the shaft of concrete mixture machine

C) FORCE FIT
Force fits are employed when mating parts are not
required to be disassembled during their total service life.
This type of fit is a permanent type of assembly.
Eg) gears on the shaft of concrete mixture machine

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 TRANSITION FIT
●In transition fit, the resulting fit between the mating parts could be
either a clearance fit or an interference fit depending upon the actual
sizes existing in the hole and shaft.
●The allowance varies from positive to negative corresponding to two
given set of dimensions.
●Assembly/disassembly is possible by light force.
●Applications: For semi permanent assemblies requiring close accuracy
and location.

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 TRANSITION FIT – SUB TYPES

A) PUSH FIT
B) WRINGING FIT

A) PUSH FIT

The fit provides small clearance. It is employed for parts that

must be disassembled during operation of a machine.

B) WRINGING FIT

wringing fit provides either zero interference or a clearance.

These are used where parts can be replaced with out
difficulty during minor repairs.

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 HOLE BASIS SYSTEM

 In this system the Hole diameter is taken as standard

and diameter of shaft is varied to obtain different
types of fits as required for the concerned
application.
 Here the fundamental deviation of hole is zero (ie)
the lower limit of the hole is same as basic size. The
higher limit of hole and the two limit sizes of shaft are
then varied to give desired type of fit
 This is a standard practice followed in all industries.
 Hole “H” is called as basic hole.

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 SHAFT BASIS SYSTEM
 In this system the Shaft diameter is taken as
standard and diameter of holes are varied to obtain
different types of fits as required for the concerned
application.
 Here the fundamental deviation of shaft is zero (ie)
the upper limit of the hole is same as basic size. The
lower limit of shaft and the two limit sizes of holes
are then varied to give desired type of fit
 This is not commonly followed in engineering
applications.
 Shaft “h” is called as basic shaft.

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HOLE-BASIS AND SHAFT-BASIS SYSTEMS

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 Screw thread designation
 Tolerance grades:
– A series of numbers, 3 through 9, were established as
symbols, to reflect the size of the tolerance; the higher
the number the larger the tolerance.
 Fundamental Deviation:
– FOR EXTERNAL THREADS – letters e,g and h
– FOR INTERNAL THREADS – letters G and H

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 Screw thread designation
 Examples:

 FOR INTERNAL THREADS

– M20 x 2—6H
– 6H  tolerance class for the pitch and crest diameters

 FOR EXTERNAL THREADS

– M6 x 0.75—5g—6g
– 5g  tolerance class for the pitch diameter.
– 6g  tolerance class for the crest diameter.

 The crest diameter is the minor diameter in the case of a nut

thread and the major diameter in the case of a bolt thread.

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 Screw thread designation

A fit between a pair of threaded parts is indicated by the

nut thread tolerance designation followed by the bolt
thread tolerance designation separated by a slash.

For example: M12 x 1 - 6H/5g6g

- indicates a tolerance class of 6H for the nut (female)

thread and a 5g tolerance class for the pitch diameter with
a 6g tolerance class for the major diameter.

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 Indian Standards list

 IS 919 : Part 1 : 1993/ISO 286-1 : 1988 ISO systems of limits

and fits: Part 1 Bases of tolerances, deviations and fits
 IS 919 : Part 2 : 1993/ISO 286-2 : 1988 ISO systems of limits
and fits: Part 2 Tables of standard tolerance grades and limit
deviations for holes and shafts
 IS 2102 : Part 1 : 1993/ISO 2768-1 : 1989 General tolerances:
Part 1 Tolerances for linear and angular dimensions without
individual tolerance indications
 IS 2102 : Part 2 : 1993/ISO 2768-2 : 1989 General tolerances:
Part 2 Geometrical tolerances for features without individual
tolerance indications

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 Indian Standards list

 IS 4218 : Part 1 : 2001/ISO 68-1 : 1998 ISO general purpose

metric screw threads: Part 1 Basic profiles
 IS 4218 : Part 2 : 2001/ISO 261 : 1998 ISO general purpose
metric screw threads: Part 2 Diameter pitch combination
 IS 4218 : Part 3 : 1999/ISO 724 : 1993 ISO general purpose
metric screw threads: Part 3 Basic dimensions for design
profile
 IS 4218 : Part 4 : 2001/ISO 262 : 1998 ISO general purpose
metric screw threads: Part 4 Selected sizes for screw, bolts
and nuts
 SP 46 : 2003Engineering Drawing Practice for Schools and
Colleges

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 THANK YOU

2-Mar-10/45

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