Limits and fits

Limits, fits, and tolerance

Limits, Fits &Tolerances

describes the total amount a
dimension may vary from a
known or standard
dimension.
Limits, fits, and tolerance

The extreme permissible values of a

dimension are known as limits.
The degree of tightness or looseness
between two mating parts that are
intended to act together is known as
the fit of the parts.
Tolerance on the other hand is the
total amount that a specific
dimension is permitted to vary.
Limits

The extreme permissible values of

a dimension are known as limits. 
Common terms used in limits

1. Nominal size–a dimension used to describe

the general size of a part specified in a
drawing, usually expressed in common
fractions.

2. Basic size-It is the size of a part to which

all limits of variation (i.e. tolerances) are
applied to arrive at final dimensioning of the
mating parts. The nominal or basic size of a
part is often the same.
Common terms used in limits

3. Actual size- It is the actual measured

dimension of the part. The difference between
the basic size and the actual size should not
exceed a certain limit, otherwise it will interfere
with the interchangeability of the mating parts.

4. Limits of sizes- There are two extreme

permissible sizes for a dimension of the part.
The largest permissible size for a dimension of
the part is called upper or high or maximum
limit, whereas the smallest size of the part is
known as lower or minimum limit.
Limits of sizes

Figure 1
Common terms used in limits

5. Allowance- It is the difference between the

basic dimensions of the mating parts. The
allowance may be positive or negative. When
the shaft size is less than the hole size, then
the allowance is positive and when the shaft
size is greater than the hole size, then the
allowance is negative.

6. Tolerance- It is the difference between the

upper limit and lower limit of a dimension.
Tolerance

Since tolerance is the difference

between the upper limit and lower
limit of a dimension; in other words, it
is the maximum permissible variation
in a dimension. The tolerance may be
unilateral or bilateral.

Figure 2
Common terms used in limits

7. Tolerance zone- It is the zone between the

maximum and minimum limit size.

Figure 3

8. Zero line- It is a straight line corresponding

to the basic size. The deviations are measured
from this line.
Common terms used in limits

9. Upper deviation- It is the algebraic

difference between the maximum size and the
basic size. The upper deviation of a hole is
represented by a symbol ES (Ecart Superior)
and of a shaft, it is represented by es.

10. Lower deviation- It is the algebraic

difference between the minimum size and the
basic size. The lower deviation of a hole is
represented by a symbol EI (Ecart Inferior)
and of a shaft, it is represented by ei.
Common terms used in limits

11. Actual deviation- It is the algebraic

difference between an actual size and the
corresponding basic size.

12. Mean deviation- It is the arithmetical mean

between the upper and lower deviations.

13. Fundamental deviation- It is one of the two

deviations which is conventionally chosen to
define the position of the tolerance zone in
relation to zero line.
Fundamental deviation

Figure 4
Common terms used in limits

14. Hole basis- represents a system of fits

corresponding to a basic hole size. The
fundamental deviation is H.

15. Shaft basis represents a system of fits

corresponding to a basic shaft size. The
fundamental deviation is h.
Fits

The clearance is the amount by which the actual size

of the shaft is less than the actual size of the mating
hole in an assembly as shown below.

Figure 5

In other words, the clearance is the difference between

the sizes of the hole and the shaft before assembly.
The difference must be positive.
Types of fits

1. Clearance fit- In this type of fit, the size limits for

mating parts are so selected that clearance between
them always occur. It may be noted that in a
clearance fit, the tolerance zone of the hole is entirely
above the tolerance zone of the shaft.
In a clearance fit, the difference between the
minimum size of the hole and the maximum size of
the shaft is known as minimum clearance whereas the
difference between the maximum size of the
hole and minimum size of the shaft is called maximum
clearance.
Types of fits

2. Interference fit- In this type of fit, the size limits for

the mating parts are so selected that interference
between them always occur. It may be noted that in
an interference fit, the tolerance zone of the hole is
entirely below the tolerance zone of the shaft.

In an interference fit, the difference between the

maximum size of the hole and the minimum size of
the shaft is known as minimum interference, whereas
the difference between the minimum size of the hole
and the maximum size of the shaft is called maximum
interference.
Types of fits

3. Transition fit- In this type of fit, the size limits for

the mating parts are so selected that either a
clearance or interference may occur depending upon
the actual size of the mating parts.
It may be noted that in a transition fit, the tolerance
zones of hole and shaft overlap.
The transition fits may be force fit, tight fit and push
fit.
Fits

The clearance is the amount by which the actual size

of the shaft is less than the actual size of the mating
hole in an assembly as shown below.

Figure 6

In other words, the clearance is the difference between

the sizes of the hole and the shaft before assembly.
The difference must be positive.
Tolerance

When
   all the tolerance is allowed on
one side of the nominal size, e.g
then it is said to be unilateral system
of tolerance.
When do we need tolerances?

In particular, tolerances are assigned

to mating parts in an assembly.
E.g. in case, when the slot in the part
must accommodate another part
interchangeably (interchangeability).
Tolerance expressions

1. Direct limits, or as tolerance value

supplied directly to a dimension.

2. Geometric tolerances, indicated by

special symbols related to part
surfaces.
Tolerance expressions

Figure 7
Standard system of limits, fits and
tolerances

There are 18 standard grades of tolerances as

specified by BIS with designations IT 01, IT 0
and IT 1 to IT 16, and 25 types of fundamental
deviations indicated by letter symbols for both
holes and shafts (capital letter A to ZC for
holes and small letters a to zc for shafts) in
diameter steps ranging from 1 to 500 mm
Standard tolerances

 
The standard tolerances for grades IT 5 to IT 7 are
determined in terms of standard
tolerance unit (i) in microns, where
Standard tolerance unit i= 0.45 + 0.001D
Where I is the standard tolerance unit in
microns and D diameter in mm.
Standard tolerances
Table 1: Standard tolerances
Grade IT5 IT6 IT7 IT8 IT9 IT10 IT11 IT12 IT13 IT14 IT15 IT16

Value 7i 10i 16i 25i 40i 64i 100i 106i 200i 400i 640i 1000i

The values of standard tolerances corresponding to

grades IT 01, IT 0 and IT 1 are as given below:
For IT 01, i (microns) = 0.3 + 0.008 D,
For IT 0, i (microns) = 0.5 + 0.012 D, and
For IT 1, i (microns) = 0.8 + 0.020 D
Standard tolerances

The tolerance values of grades IT 2 to

IT 4 are scaled approximately
geometrically between IT 1 and IT 5.
The fundamental tolerances of grades
IT 01, IT 0 and IT 1 to IT 16 for
diameter steps ranging from 1 to 500
mm are given in the table on the next
slide.
Standard tolerances
Table 2: Fundamental tolerances of grades IT01, IT0 and IT1 to IT16, according t
IS : 919 (Part I) – 1993
Standard tolerances

Table 3: Tolerance grade in various manufacturing processes (ISO)

Tolerance Manufacturing process that can produce

grade
16 Sand casting: flame cutting
15 Stamping
14 Die casting or moulding; rubber moulding
13 Press work, tube rolling
12 Light press work; tube drawing
11 Drilling, rough turning, boring, precision tube drawing
10 Milling, slotting, planning, metal rolling, or extrusion
9 Worm capstan or automatic; horizontal or vertical boring
Centre lather turning and boring, reaming, capstan or automatic
8 in good condition
7 High quality turning, broaching, honing
6 Grinding and fine honing
5 Machine lapping, diamond or fine boring, fine grinding
Standard tolerances
Table 4: Manufacturing processes and IT grades produced (BIS)
Standard tolerances

A fit is designated by its basic size followed by

symbols representing the limits of each of its
two components, the hole being quoted first.
For example, 100 H6/g5 means basic size is 100 mm
and the tolerance grade for the hole is 6 and for the
shaft is 5.
Some of the fits commonly used in engineering
practice, for holes and shafts are shown in the tables
in the next slide which is according to
IS : 2709 – 1982 (Reaffirmed 1993).
Standard tolerances
Table 5: Commonly used fits for holes according to IS : 2709 – 1982
(Reaffirmed 1993).
Standard tolerances
Table 6: Commonly used fits for holes according to IS : 2709 – 1982 (Reaffirmed
1993).
Standard tolerances
Table 7: Commonly used fits for shaft according to IS : 2709 – 1982 (Reaffirmed
1993).
Standard tolerances
Table 8: Commonly used fits for shaft according to IS : 2709 – 1982 (Reaffirmed
1993).
Standard tolerances
Table 9: Descriptions of Preferred Fits Using the Basic Hole System
Source: Preferred Metric Limits and Fits, ANSI B4.2-1978. See also
BS 4500
Hole and shaft basis

Figure 8
Tolerance grades
Table 10: A Selection of International Tolerance Grades—Metric Series (Size
Ranges are for over the Lower Limit and including the Upper Limit. All values are in
mm)
Source: Preferred Metric Limits and Fits, ANSI B4.2-1978. See also BSI 4500.
Tolerance grades
Table 11: Fundamental Deviations for Shafts—Metric Series (Size ranges are for
over the Lower Limit and Including the Upper Limit. All values are in mm)
Source: Preferred Metric Limits and Fits, ANSI B4.2-1978. See also BSI 4500.
Fundamental deviation for shafts

The fundamental deviations for shaft for letter codes

c, d, f, g, and h are:
Upper deviation = fundamental deviation
Lower deviation = upper deviation - tolerance grade
For letter codes k, n, p, s, and u, the deviations for
shafts are
Lower deviation = fundamental deviation
Upper deviation = lower deviation + tolerance grade
Holes and shafts
The lower deviation H (for holes) is zero. For these, the upper deviation equals
the tolerance grade

D=basic size of hole

d=basic size of shaft
δu =upper deviation
δl =upper deviation
δf =fundamental deviation
ΔD =tolerance grade for hole
Δd =tolerance grade for shaft

Note that these quantities are all deterministic.

Thus, for the hole,
Dmax = D + Δd Dmin = D

For shafts with clearance fits c, d, f, g, and h,

dmax = d + δF dmin = d + δF – Δd Figure 9
For shafts with interference fits k, n, p, s, and u,
dmin = d + δF dmax = d + δF + Δd
Selection of fits

Commonly used 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 the table on

the next slide. Shafts ‘a’ to ‘h’ produce clearance fit, ‘j’
to ‘n’ transition fit, and ‘p’ onwards interference fit
with hole.
Commonly used fits
Table 12
Commonly used fits
Dimensioning of Tolerances -Rules

1. The upper deviation should be written above the

lower deviation value irrespective of whether it is a
shaft or a hole.
2. Both deviations are expressed to the same
number of decimal places, except in the cases where
the deviation in one direction is nil.
3. Tolerances should be applied either to individual
dimensions or by a general note, assigning uniform
or graded tolerances.
4. The use of general tolerance not greatly simplifies
the drawing and saves much labour in its
preparation. On the drawing, the limits on a
dimension can be specified in two ways, i.e.
unilateral, and bilateral.
Machining Symbols

Fig 10: Indication of machining allowance

The value of allowance is expressed in mm

Machining Symbols

Fig 11: Basic symbol for indication of surface

roughness

The basic symbol used for indication of

surface roughness consists of two legs of
unequal length inclined at 600 to the line
representing the surface under
consideration,
Machining Symbols
The following guidelines may be used while specifying the
machining symbols:
1. When the surface is produced by any method, it is indicated as
shown in (a) below.
2. When the removal of material by machining is required, a bar is
added to the basic symbol, as shown in Fig. (b).
3. Whenever the removal of material is not permitted In a circle is
added to the basic symbol, as shown n Fig. (c).
4. When some special surface characteristics are to be indicated
(say a milled surface), a line added to the longer leg of the basic
symbol, as shown in d below. 

Figure 12
Indication of Surface Roughness

Table 13: The roughness values Ra (urn) are given

Roughness 50 25 12.5 6.3 3.2 1.6 0.8 0.4 0.2 0.10 0.050 0.025
value, Ra

Value N12 N11 N10 N9 N8 N7 N6 N5 N4 N3 N2 N1

Surface Roughness values
The value defining the roughness value Ra in micron
and roughness grade symbols are given on
production drawings.

Fig 13: Indication of surface roughness in Micrometres or roughness grade symbols

1. When it is necessary to specify the maximum

and minimum limits of the surface roughness, both
the values or grades should be given as shown
below.

Fig 14
Surface values
 2. If it is necessary to indicate the sampling length, it is shown
adjacent to the symbol in (a) below.
 3. If it is necessary to control direction of lay or the direction of
the predominant surface patterns, it is indicated by a
corresponding symbol added to the surface roughness symbol.
4. Whenever, it necessary to specify the value of machining
allowance, it is indicated in the left of the symbol fig (c). This
value is generally expressed in millimetres.

Table 15
Surface values

5. If it is necessary to define surface roughness both before

and after treatment should be explained in a suitable note or
in accordance with the figure shown below.

Fig 16: Use of notes with surface texture symbol

Recap of basic terms
 Size: A number expressing in a particular unit the numerical value of a dimension.
 Actual size: The size of a part as obtained by measurement.
 Limits of size: The maximum and minimum sizes permitted for a feature.
 Maximum limit of size: The greater of the two limits of size.
 Minimum limit of size: The smaller of the two limits of size.
 Basic size: The size by reference to which the limits of size are fixed.
 Deviation: The algebraic difference between a size 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.
 Lower deviation: The algebraic difference between the minimum limit of size and
the corresponding basic size.
 Tolerance: The difference between the maximum limit of size and the minimum
limit of size.
 Shaft: The term used by convention to designate all external features of a part
(including parts that are not cylindrical).
 Hole: The term used by convention to designate all internal features of a part.
Example 1
Find the shaft and hole dimensions for a
loose running fit with a 34-mm basic size.
 From Table 9, the ISO symbol for loose running is 34H11/c11.
From table 10, we find that tolerance grade IT11 is 0.160 mm.
The symbol 34H11/c11, therefore says: ΔD = Δd = 0.160 mm.
Answer: Dmax = D + Δd = 34 + 0.160 = 34.160 mm
Answer: Dmin = D =34.000 mm
So the hole should be give dimensions
The shaft is designated as a 34c11 shaft. From Table 11, the
fundamental deviation is δf = - 0.120 mm. For the shaft
dimensions:
Answer: dmax = d + δf = 34 + (-0.120) = 33.880 mm
Answer: dmin = d + δf - Δd =34 + (-0.120) – 0.160 = 33.720 mm
And the shaft hole should be
Example 2
Find the shaft and hole limits for a medium
drive fit using a basic hole size of 51mm.
From Table 9, the ISO symbol for fit is 51H7/s6. From table 10,
we find that tolerance grade IT7 is 0.030 mm. The symbol
51H7/s6, therefore says: ΔD = 0.030 mm.
Answer: Dmax = D + Δd = 51.000 + 0.030 = 51.030 mm
Answer: Dmin = D =51.000 mm
The shaft is designated as a 51s6 shaft and IT6 tolerance grade
is Δd = 0.019 mm . From Table 11, the IT6 fundamental
deviation is δf = 0.053 mm. For the shaft dimensions:
Answer: dmin = d + δf = 51.000 + 0.053 = 51.053 mm
Answer: dmax = d + δf + Δd =51.000 + 0.053 + 0.0.019 = 51.072
mm
Example 3