Limits, Fits & Tolerances

Types of Geometrical Tolerances

Form of Tolerances
Deviations in flat-surfaces
 Tolerance of straightness

 Tolerances of flatness

Deviations in cylindrical and conical surfaces

 In axial section
 Barrel form

 Concave or convex form

 Curvature of axes

 Taper

 In a transverse section
 Oval form

 Lobed form
Position Tolerances
Deviations in relative location of surfaces
 Radial run out
 Axial run out
 Misalignment

 Non-parallelism of axes
 Incorrect location of intersecting axes
 Non-parallel surfaces
 Non-perpendicular surfaces
Terminology for Geometrical Deviations
Tolerance of straightness
It is determined by the distance between two parallel
lines in plane (say P) right angle with the tested surface.
Tolerance of flatness
It is expressed as the distance between two planes (say
M and N) which enclose the tested surface between
them.
Barrel form, bow form and curvature of axes
They are determined by the difference between the
diameters of cross-sections at the mid-point and ends.
Taper
It is the ratio of difference in the diameters of two cross-
sections at right angle to axis and axial distance between
them.
Oval form and lobed form
These forms are decided by the difference between
major and minor axes of the elliptical shape of a cross-
section.
The lobed form is the one in which the cross-section
contour is made of arcs drawn from different centres.
Radial run out and axial run out
Radial run out is the maximum difference of radial
distance between two concentric circles measured in the
right angle plane to the axis of work-piece for one
complete revolution.
This is due to misalignment of axes, ovality, lobed form
and bending of axes.
Axial run out is the maximum deviation of end surface
from the right angle plane with the axis of the part.
Misalignment
It is the deviation of axes which should normally
coincide with the geometrical axis.
This can be axial misalignment or angular misalignment
Incorrect location of intersecting axes
It is determined as the angular deviation from the
specified angle of intersection and the deviation from the
point of intersection.
Non-perpendicular surfaces
It is the amount of deviation between two orthogonal
surfaces measured by a right angle.
Datum
It is defined as the ideal geometrical references to which
the geometrical tolerance features are related.
It is indicated by a filled inverted triangle and leader line.
It is shown by capital letter enclosed in the triangular
frame.
Representation of Geometrical
Tolerances on drawing
Dimensional Tolerances
The difference between the maximum and minimum
limits of dimension is known as tolerance.
It is always advantageous to select course tolerances
without compromising the functional requirements of
the part.
The system in which deviations are accepted, is known
as limit system.
Terminology for dimensional tolerances
Basic dimension
It is the dimension of the machine part obtained by
design calculations.
The allowable maximum and minimum limits are
decided with reference to the basic size.
Upper deviation
It is the algebraic difference between the maximum size
and basic size.
Upper deviation = maximum limit – basic size
Lower deviation
It is an algebraic difference between the minimum limit
and basic size.
Lower deviation = minimum limit – basic size
Tolerance zone
It is an algebraic difference between the maximum limit
and minimum limit.
Tolerance zone = maximum limit – minimum limit
Actual size
It is the size of component as may be found by actual
measurement.
For a component to be acceptable actual size should be
within maximum limit and minimum limit.
Zero line
In the graphical representation of tolerance system, the
zero line represents the basic size.
The upper deviation and the lower deviation are
measured from the zero line.
Unilateral limits
It is the method of representing limits.
When both the limits of size are on the same side of zero
line, the component dimension has unilateral limits.
Bilateral Limits
Here, one of the limits of the size is on one side of the
zero line and the other limit of size is on the other side
of the zero line.
Maximum material condition
This is defined as the upper limit of the shaft and the
lower limit of the hole.
Minimum material condition
This is defined as the lower limit of shaft and the upper
limit of the hole.
Allowance
It is an intentional difference between the maximum
material limits of mating parts.
Mating surfaces and mating dimensions
When two components are assembled, the contact
surfaces are known as mating surfaces and their
dimensions are termed as mating dimensions.
Basic shaft
A basic shaft is one whose upper deviation is zero.
e.g. shaft h
Basic hole
A basic hole is one whose lower deviation is zero.
e.g. hole H
Selection of tolerances
The amount of tolerance depends upon
The functional requirement of mating components
Manufacturing process available
Cost of manufacturing

Description Limits of tolerances

(microns)
General engineering ± 400
High class engineering ± 250
Extreme precision ± 125
Representation of dimensional
tolerances
Tolerances are specified as
Letter symbol
Number or grade method
Letter symbol
Here the tolerance is designated by selected letters of
alphabet in English language.
Holes are represented by capital letters from A to Z,
except I, L, O, Q and W.
Shafts are represented by a to z except I, l, o, q and w.
Number or grade method
In this method, the tolerance is represented by a
numerical symbol known as the grade.
There are 18 grades of tolerances, designated as IT01,
IT0, IT1 to IT16.
These grades of tolerances are known as fundamental
tolerances.
Standard tolerance unit i can be calculated for
different types of tolerance grade.
 Grade Formulae
IT01 i = 0.3 + 0.008 D
IT0 i = 0.5 + 0.012 D
IT1 to IT4 i = 0.8 + 0.02 D
IT5 to IT16 i = 0.001 D + 0.45 (D^1/3)

Where, D = geometric mean of two diameters in a step

Representation of dimensional
tolerances on drawings
Following are three methods used in practice to show
tolerances on drawings
Maximum and minimum size directly shown
Unilateral and bilateral tolerances system
Basic size with symbols and numerals
Fits
This is the term used to indicate the condition of
tightness or looseness between two mating parts
assembled together.
The nature of fit is determined by the difference
between the hole (internal feature) and the shaft
(external feature) dimensions.
The fits are classified as
Clearance fit
Interference fit
Transition fit
Sliding fit
Clearance fit
When the smallest hole is greater than the largest shaft,
a clearance fit is obtained.
When relative motion between assembled parts is
required, a clearance fit between mating parts is
provided.
Interference fit
When the largest hole is smaller than the smallest shaft,
an interference fit is obtained.
For example, a pulley is t be fixed on a shaft.
Transition fit
This is obtained by overlapping tolerance zones of a
shaft and hole.
Consequently, this fit does not guarantee either
clearance or interference.
Sliding fit
It is special group of transition fit.
It does not guarantee for clearance or interference.
Hole basis system
The nominal size of hole is taken same as the design size.
The tolerance zone of hole is taken as constant, while the
tolerance zone of the shaft is varied above or below the
zero-line according to the required fits.
This system is popular in industries due to availability of
standard tools for producing holes such as drills, reamers
etc.
A shaft of variable tolerance for zone can be easily
manufactured.
The hole basis system is used for locomotive
construction, machine and engine building.
Shaft basis system
A nominal size is taken as a design size.
The tolerance zone of a shaft is adopted as constant
while a tolerance zone of the hole is changed above or
below zero-line according to the fits as required.
Representations of holes, shafts & fits
A shaft or hole is designated by
The basic size followed by
 The appropriate letter and
 Tolerance grade

For example –
 A Φ50 mm f-shaft with IT7 is indicated as Φ50f7.
 Similarly a Φ50 H-hole with IT8 is expressed as Φ50H8.
 For assembly of above mating parts, the fit is given by 50 H8-f7

or 50 H8/f7.