Limit, Fit, Tollerance

INTRODUCTION
• No two parts can be produced with identical measurements
by any manufacturing process.

• In any production process, regardless of how well it is

designed or how carefully it is maintained, a certain amount
of variation will always exist.

• It is impossible to produce a part to an exact size or basic

size, some variations, known as tolerances, need to be
allowed.

• The permissible level of tolerance depends on the

functional requirements, which cannot be compromised.
Interchangeability

• Interchangeable parts is one which can be substituted

for similar part manufactured to same drawing
• Any one component selected at random should
assemble with any other arbitrarily chosen mating
component
• Identical components, manufactured by different
operators, using different machine tools and under
different environmental conditions, can be assembled
and replaced without any further modification during
the assembly, without affecting the functioning of the
component when assembled.
Basic Terminology

Shaft
• Term used by convention to designate all external
features of a part, including those which are not
cylindrical.
• Shaft Designation: By lower case letters from a, b, ...
z, za, zb, zc (excluding i, l, o, q, w and adding js, za,
zb, zc) - 25 nos.

Hole
• Term used by convention to designate all internal
features of a part, including those which are not
cylindrical
• Hole Designation: By upper case letters from A, B, ...
Z, ZA, ZB, ZC (excluding I, L, O, Q, W and adding JS,
ZA, ZB, ZC) - 25 nos
Basic size
• Exact theoretical size arrived at by design.
• Basic or nominal size is defined as the size based on which the
dimensional deviations are given
• Same for both hole and shaft.
Actual Size*
• Actual measured dimension of the part.
Limits of Size:
• The two extreme permissible sizes of a part between which the
actual size should lie
Maximum limit of size
• The greater of the two limit of
size
Minimum limit of size
• The smaller of the two limit of
size
Tolerance
• It is the difference between the
upper limit and lower limit of a
dimension.
Tolerance Zone
• It is the zone between maximum
and lower limit size
Deviation
It is the algebraic difference between a size (actual, limit of size,
etc.) and the corresponding basic size.
Upper Deviation
It is designated as ES (for hole) and es (for shaft). It is the
algebraic difference between the maximum limit of the size and the
corresponding basic size. When the maximum limit of size is
greater than the basic size, it is a positive quantity and when the
minimum limit of size is less than the basic size then it is a
negative quantity.
Lower Deviation It is designated as EI (for hole) and ei (for shaft). It
is the algebraic difference between the minimum limits of size and the
corresponding basic size.
When the minimum limit of size is greater than the basic size, it is a
positive quantity and when the minimum limit of size
is less than the basic size then it is a negative quantity.

Zero Line In a graphical representation of limits and fits, a zero line is

a straight line to which the deviations are referred to.
It is a line of zero deviation and represents the basic size. When the
zero line is drawn horizontally, positive deviations are shown above
and negative deviations are shown below this line.
Fundamental Deviations (FD)
This is the deviation, either upper or the lower deviation, which is the
nearest one to the zero line for either a hole or a shaft. It fixes the
position of the tolerance zone in relation to the zero line.

Actual Deviation It is the algebraic difference between an actual size

and the corresponding basic size.

Mean Deviation It is the arithmetical mean between the upper and

lower deviation.
Tolerance Grade It is the degree of accuracy of manufacturing. It
is designated by the letters IT (stands for International Tolerance).
Numbers, i.e., IT0, IT01, IT1, follow these letters up to IT16; the
larger the number, the larger the tolerance.

Allowance It is an intentional difference between the maximum

material limits of mating parts.
For a shaft, the maximum material limit will be its high limit and for
a hole, it will be its low limit.

Fits The relationship existing between two parts, shaft and hole,
which are to be assembled, with respect to the difference in their
sizes is called fit.
Limits
• In mass production environment, producing a perfect size is not
only difficult, but is also, a costly affair.
• Hence, to make the production economical some permissible
variation in dimension has to be allowed to account for
variability.
• Thus, dimensions of manufactured parts, only made to lie
between two extreme dimensional specifications, are called
maximum and minimum limits.
• The maximum limit is the largest size and the minimum limit is
the smallest size permitted for that dimension.
Tolerance
• The inevitable human failings and machine limitations, prevent
achieving ideal production conditions.
• Hence, a purposefully permissible variation in size or dimension
• called tolerance is to be considered for producing a part
dimension.
• And the difference between the upper and lower margins for
variation of workmanship is called tolerance zone.
• To understand tolerance zone, one must know the term basic
size. Basic size is the dimension worked out of purely design
considerations.
• Thus, generally basic dimensions are first specified and then
the value (of tolerance) is indicated as to how much variation in
the basic size can be tolerated without affecting the functioning
of the assembly
• Tolerance can be specified on both the
meeting elements, i.e., on the shaft and/or
on the hole.
• For example, a shaft of 30-mm basic size
along with a tolerance value of 0.04 may be
written as 30 ± 0.04.
• Therefore, the maximum permissible size
(upper limit) is 30.04 mm and the minimum
permissible size ( lower limit) is 29.96 mm.
• Then the value of the tolerance zone is
(upper limit − lower limit) = 0.08 mm.
• The practical meaning of the word tolerance is that the worker
is not expected to produce a part with exact specified size, but
that a definite small size error (variation) is permitted.
• Thus, tolerance is the amount by which the job is allowed to
deviate from the dimensional accuracy without affecting its
functional aspect when assembled with its mating part and put
into actual service.
• If high-performance requirement is the criteria for designing the
assembly then functional requirements will be the dominating
factor in deciding the tolerance value.
Tolerances can be specified by two systems:

1. Unilateral Tolerances System

• In this type of system, the part dimension is allowed to vary on
one side of the basic size, i.e., either below or above it.
• This system is preferred in an interchangeable manufacturing
environment.
• This is because it is easy and simple to determine deviations
2. Bilateral Tolerances System
• In this system, the dimension of the part is allowed to vary in
both the directions of the basic size.
• So, limits of the tolerances lie on either side of the basic size.
Maximum and Minimum Metal Limits

• Consider the tolerance value of a tolerance specified for a shaft

along with a basic dimension given as 30±0. 04 mm.
• Hence, the upper dimension limit will be 30.04 mm and the lower
dimension limit will be 29.96 mm.
• Then, the Maximum Metal Limit (MML) for the shaft is 30.04 mm,
as this limit indicates the maximum allowable amount of metal.
• And the Least (minimum) Metal Limit (LML) of the shaft
dimension is 29.96 mm, as it gives a minimum allowable amount
of metal.
• Similar terminologies are used for a hole.
Fits
• It can be defined as ‘the relationship existing between two parts,
shaft and hole, which are to be assembled, with respect to the
difference in their sizes before the relationship is called fit.
• It is also the degree of tightness or looseness between the two
mating parts.
• Depending on the mutual position of tolerance zones of the
coupled parts, three types of fits can be distinguished:
A. Clearance Fit
B. Transition Fit
C. Interference Fit
Clearance Fit

• It is a fit that always enables a clearance

between the hole and shaft in the coupling.
• The lower limit size of the hole is greater or
at least equal to the upper limit size of the
shaft.
• Always provide positive allowance
• For example,
1. Maximum size of hole—50.1 mm;
Maximum size of shaft— 49.85 mm
2. Minimum size of hole— 49.9 mm;
Minimum size of shaft— 49.65 mm
• Maximum clearance= UL of hole- LL of shaft
• Minimum clearance=LL of hole-UL of shaft
• Eg: Shaft rotating in a bush
Types of Clearance fit

Loose Fit
It is used between those mating parts where no precision is
required. It provides larger clearance and is used on loose pulleys,
agricultural machineries etc.

Running Fit
For a running fit , the dimension of shaft should be smaller enough
to maintain a film of oil for lubrication. It is used in bearing pair etc.

Slide Fit or Medium Fit

It is used on those mating parts where great precision is required. It
has a very small clearance. used in tool slides, automobile parts.
Interference Fit
• It is a fit that always ensures some
interference between the hole and shaft
in the coupling.
• The upper limit size of the hole is smaller
or at least equal to the lower limit size of
the shaft.
For example,
1. Maximum size of hole— 49.85 mm;
Maximum size of shaft—50.1 mm
2. Minimum size of hole— 49.65 mm;
Minimum size of shaft— 49.9 mm
• It is used for components where motion, power has to be
transmitted
• No gap between the faces and intersecting of material will occur.
• Shaft need additional force to fit into the hole
• Max. Interference= LL of hole- UL of shaft
• Min. Interference= UL of hole- LL of shaft
Types of interference fit

Shrink fit or heavy force fit

• It refers to maximum negative allowance.
• In assembly of the hole and shaft, the hole is expanded by heating
and then rapidly cooled in its position
• Used in fitting of rims etc

Medium force fit

• These fits have medium negative allowance.
• Considerable pressure is required to assemble the hole and the
shaft
• It is used in car wheels, armature of dynamos etc.

Tight fit or press fit

• One part can be assembled into the other with a hand hammer or
by light pressure.
• A slight negative allowance exists between two mating parts
• It gives semipermanent fit and is used on a keyed pulley and shaft,
rocker arm etc.
Transition Fit
• It is a fit where (depending on the
actual sizes of the hole and shaft)
both clearance and interference
may occur in the coupling.
• Tolerance zones of the hole and
shaft partly or completely interfere.
• They used for applications where
accurate location is important but
either a small amount of clearance
of interference is permissible
Types of transition fit

Push fit or Snug fit

• It refers to zero allowance and a light pressure is required in
assembling the hole and shaft
• The moving parts show least vibration with this type of fit

Wringing fit
• A slight negative allowance exists between two mating parts
• It requires pressure to force the shaft into the hole and gives a light
assembly
• Used in fixing key, pins etc
Revision
Systems of fit

• Hole Basis and Shaft Basis Systems

• To obtain the desired class of fits. either the size of the hole or the
size of the shaft must vary.
• Two types of systems are used to represent three basic types of fits,
clearance interference, and transition fits
1. Hole basis system
2. Shaft basis system
• Basic hole - Lower deviation is zero
• Basic shaft - Upper deviation is zero
Hole basis system
• The size of the hole is kept constant and the shaft size is varied to
give various types of fits.
• Lower deviation of the hole is zero, i.e. the lower limit of the hole is
same as the basic size.
• The hole basis system is indicated by 'H', this is because lower
deviation of H hole is zero.
• The hole basis system is commonly used because it is more
convenient to make correct holes of fixed sizes, since the standard
drills, taps, reamers and broanches etc. are available for producing
holes and their sizes are not adjustable
• On the other hand, size of the shaft produced by turning grinding etc
can be varied.
(a)Clearnce fit
(b)Transition fit
(c)Interference fit
Shaft basis system
• The size of the shaft is kept constant and the hole size is varied to
obtain various types of fits.
• Fundamental deviation or the upper deviation of the shaft is zero.
• Shaft basis system is indicated by 'h’
• System is not preferred in industries, as it requires more number of
standard size tools, like reamers, broaches, and gauges, increases
manufacturing and inspection costs.
Method of indicating fits
• Fit is designated by its basic size followed by symbols
representing the limits of each of its two components, the
hole being quoted first
• Example: Consider the designation 40 H7/d9
• Basic size of the shaft and hole = 40 mm
• Nature of fit for the hole basis system is designated by H
• Fundamental deviation of the hole is zero.
• Tolerance grade: IT7
• The shaft has a d-type fit, the fundamental deviation has a
negative value.
• IT9 tolerance grade.
Another example
Reminder
Problems
Gauges

• Gauges are inspection tools which serve to check the

dimensions of the manufactured parts.
• According to their type:

Standard gauges
Made to the nominal size of the part to be tested and have
the measuring member equal in size to the mean
permissible dimension of the part to be checked

Limit Gauges
These are made to the limit sizes of the work to be
measured
Limit gauges ensure the size of the component lies within
the specified limits.
These are also called 'go' and 'no go' gauges
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 (2) the lower limit of a hole.
This is checked by the Go gauge
Not 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 (2) the upper limit of a hole
This is checked by the No Go gauge
The types of limit gauges are: 1. Plug Gauge , 2. Snap
Gauge, 3. Ring Gauge
PLUG Gauges
• Plug gauges are the limit gauges used for checking holes
and consist of two cylindrical wear resistant plugs
• The diameter of Go gauge will be equal to the lower limit
of hole and the diameter of NO GO gauge will be equal to
the upper limit of hole.
Snap or Gap Gauges
• A snap gauge consists of a plate or frame with a parallel
faced gap of the required dimension
• Can be used for both cylindrical as well as non cylindrical
work.
Ring Gauges
• Used for gauging shafts
• The diameter of GO gauge will be equal to the upper limit
of shaft and diameter of NOGO gauge will be equal to the
lower lit of shaft
Feeler Gauges
• Feeler gauges are essential precision tools used to
measure the clearance or gap width between two parts
where other measuring instruments may not fit.
• They consist of a set of thin metal blades of various,
precisely marked thicknesses.
Taper Limit Gauges

• Taper gauges are used as plug gauges for checking

tapered holes and taper ring gauges are used for
checking the tapered shaft.
• They are used to check the diameter at the bigger end
and the change in diameter per unit length
Guidelines for Gauge Design
While designing gauges for specific applications, the
following guidelines for gauge design are to be considered.
1. The form of GO gauges should exactly coincide with the
form of the mating part.
2. GO gauges should enable simultaneous checking of
several dimensions. It must always be put in maximum
impassability.
3. NO GO gauges should enable checking of only
dimensions at a time. It must always be put in maximum
passability.
Taylor's principle of gauge design

• The "Go" gauge should always be so designed that it

will cover the maximum metal condition (MMC)
• 'NO - GO" gauge will cover the minimum (least) metal
condition (LMC) of a feature
• The "Go" gauge should always be so designed that it
will cover as many dimensions as possible in a single
operation
• The "NO - GO" gauge will cover only one dimension
• Colour of band at NO GO side of plane gauges is red
Geometric tolerance

• Defines the allowable variations in the form, orientation,

and location of features on a part, beyond just size,
ensuring functional requirements are met.
• It uses a standardized symbolic language with feature
control frames on drawings to communicate precise design
intent, controlling things like flatness, straightness, position,
and parallelism, which is crucial for manufacturing and
assembly
Why it's important:
Clarity: Reduces ambiguity between designers and manufacturers.
Functionality: Ensures parts fit and work together correctly.
Efficiency: Prevents overly tight tolerances, lowering costs and
defects
Importance
Geometric tolerance symbols-14 Symbols
Ways of representations of geometrical tolerance
symbols
Examples of representation of features of geometric tolerances in
engineering drawing of parts
 Design of Tolerances for Various Applications

1. Rotating Shafts and Bearings

Functional Requirement: Smooth rotation with minimal wear
Tolerance Design:
• Small clearance to allow lubrication
• Compensates for thermal expansion
Example:
Bearing bore = 60.000 – 60.025 mm
Shaft diameter = 59.970 – 59.990 mm
2. Machine Tool Components
Functional Requirement: High accuracy and rigidity
Examples: Guideways, Lead screws, Spindles

Tolerance Example: Guideway width = 120 ± 0.01 mm

Reason:
Loose tolerance → vibration and chatter
Tight tolerance → higher machining cost (precision grinding)
3. Automotive and Engine Components
Functional Requirement: Reliability under high temperature and
load
Examples:
Piston–cylinder assembly
Crankshaft journals
Valve guides
Piston–Cylinder Example:
Cylinder bore = 90.00 – 90.03 mm
Piston diameter = 89.95 – 89.97 mm
Reason: Clearance avoids seizure during thermal expansion
4. Electrical and Electronic Assemblies
Functional Requirement: Easy assembly, no component
damage
Examples: PCB holes
Connector pins
Tolerance Example:
PCB hole = 1.00 – 1.05 mm
Pin diameter = 0.95 – 0.98 mm
Reason: Sufficient clearance avoids bending or breakage
5. Precision Instruments and Measuring Devices
Functional Requirement: High accuracy and repeatability
Examples:
Micrometers, Vernier calipers, Dial gauges
Example: Micrometer screw pitch tolerance = ±0.002 mm
Reason: Small dimensional error causes large measurement
error