Chaptr -2 Limit, Fit,

Tolerance
 Co

C505.2
Know the system of limits, fits, tolerances and
correlate it with machine drawing.
 LIMITS, FITS & TOLERANCE
 Terminology:- The terms related to limit system as
per BIS are as below;
 Size:- It is a number expressed
in a particular unit in the
measurement of length.
Hole
 Basic Size:- It is the size based
Size
Basic

Shaft on which the dimensional

deviations are given.

 Actual Size:- It is the size of the component by actual

measurement after it is manufactured. It should lie
between the two limits of size.
 Limits of size:- These are the extreme permissible
sizes within which the operator is expected to make
the component. Maximum limit of size is the greater
of the two limit size, whereas the Minimum limit of
size is the smaller of the two limit of size.
 Hole:- In the B.I.S. system of limits
and fits, all internal features of a
Hole component including those which
Basic size

Shaft are not cylindrical are designated

as ‘Hole’.
 Shaft:- In the B.I.S. system of limits and fits, all
external features of a component including those
which are not cylindrical are designated as ‘Shaft’.
  Tolerance:- It is the
Lower Deviation

Upper Deviation

difference between
Tolerance

maximum limit of size and

the minimum limit of size.
Hole It is always positive and is
expressed only as a number
[Link].

[Link].

Shaft without a sign.

 Zero line:- In graphical representation of the above

terms, the zero line represents the basic size. This line
is also called as the line of zero deviation.
 Upper Deviation  Fundamental deviation:-
Lower Deviation

There are 25 fundamental

Tolerance

Tolerance
deviations in the B.I.S.
system represented by letter,
Hole
symbols (Capital letters for
[Link].

Holes and small letters for

[Link].

[Link].
[Link].

Shaft Shaft)
  Fundamental Tolerance:-
Lower Deviation

Upper Deviation

This is also called as

Tolerance

‘grade of tolerance’. In the

Indian Standard System,
there are 18 grades
Hole
represented by number
[Link].

[Link].

symbols, both for hole and

[Link].
[Link].

Shaft shaft denoted as IT01, IT0,

IT1, IT2.....IT16. A high
number
 FIT:- It is the relationship that exists between two
mating parts, a hole and shaft with respect to their
dimensional difference before assembly. Three types of
fit are given hereunder;
 Clearance fit:- It is a fit which
always provides clearance. Here
Clearanc
e fit the tolerance zone of the hole will
be above the tolerance zone of the
Hole Shaft
shaft. Maximum clearance is the
difference between the maximum
hole and minimum shaft.
Minimum clearance is the
difference between the minimum
hole and maximum shaft.
  Interference fit:- It is a fit
which always provides
Tolerance Zone of Tolerance Zone of
interference. Here the tolerance
Hole Shaft
zone of the hole will be below
the tolerance zone of the shaft.
Shaft
Maximum interference is the
Hole
algebraic difference between
the minimum hole and
maximum shaft. Minimum
interference is the algebraic
difference between the
maximum hole and minimum
shaft.
  Transition fit:- It is a fit which
Shaft
may sometimes provides
Hole Hole clearance and sometimes
interference. When this class of
Hole fit is represented graphically,
Shaft
Shaft
the tolerance zone of the hole
and shaft will overlap each
other.

Mass Production :- Mass production means

production of a unit, component or part in large
numbers.
Advantages:- [Link] for the manufacture of
components is reduced
[Link] cost of pieces is reduced. 3.
Spare parts can be quickly made
available. Disadvantages:-1. Special
purpose machines are necessary.
[Link] and Fixtures are
needed. 3. Gauges are to be used
instead of conventional precision
instruments. 4. Initial expenditure will be
very high.
 Interchangeability:- When components are mass
produced, unless they are interchangeable, the purpose of
mass production is not fulfilled. By interchangeability, we
mean that identical components, manufactured by
different personnel under different environments, can be
assembled and replaced without any further rectification
during the assembly stage, without affecting the
functioning of the component when assembled.
 Hole Basis System:- Where the
size of the hole is kept constant
and the size of the shaft is varied
to get the different class of fits,
then it is known as the hole basis
system.

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MQAR
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Metrol ogy, Qual ityAssurance&Reliabili ty

Text Books: Engg. MetrologybyR. K. Jain


Ref erenceBooks: 1. Statist ical Quali tyControl byM. Mahajan,

2. ReliabityEngg. byL. Srinath.

1. Needof Inspection

2. Standards of Measurement

3. AngleMeasurement

4. Inspectionof Screw-threadel ements

5. S. Q.C.

6. Reliabili tyDataAnalysi s

TOPICSTOBECOVERED








fromgreek“met ron”(measure)and–logy.

metrol ogyi sthescienceof measurement sandthat tomeasureist o

comparewit hsomethi ng(aunit )whichist akenasthebasi sfor

comparison. (Measurement st andard)

includesall theoretical andpractical aspects of measurement.

Quality:

aproduct’sfi tnessforuse.

thetotalityof featuresthat bearonaproduct’sabili tytosatisfyagiven

need.

theabil ityof asystemorcomponent t operformits requi redf unct ions

underst atedconditionsfor aspecifiedperiodof time.

–Fai lure: theinabilityof anequi pment toperformi tsrequired

function

–Rel iabi lity: theprobabili tyof nofai lurethroughout aprescribed

operati ngperiod.

Metrol ogy:

Rel iabi lity




Thi sist heset of actionstakentodevel opprimaryst andardsof

measurement forthebaseunits andthederivedunit sof theInt ernational

Systemof Units (SI).

Legal metrology

Sci enti ficmetrology

It i sthat part of metrologywhichtreatsunitsof measurement, methodsof

measurement andthemeasuringinst rument, inrelationtot hest atutory,

technical andlegal requirements.

It assuressecuri tyandappropri ateaccuracyof measurement .

Industrial metrology

Thefunctionof industrial metrologyismainl ythepropercal ibration, cont rol

andmai ntenanceof all measuri ngequipment usedi nproducti on,

inspect ionandtesting. Thepurposeis toguaranteet hat

theproducts will complywi thqualitystandards.

For convenience, adist inct ioni softenmadebetweentheseveral fi eldsof

applicationof metrol ogy

Process of Measurement

set of operat ions havingtheobjectiveof determini ngavalueof aquantit y

Measurand: part icularquantit ysubj ect t omeasurement

Ref erence/Standardof Measurement :

Comparator: FixedGauges/MeasuringInstrument :

Needsof Inspect ion

Toensurethat part andcomponentsareconf irmedto

requiredstandards.

Tomeet theneedof Interchangeabilit yof parts.

Tomaintaingoodcustomer relationshipbyensuringthat No

faultyproduct reaches thecustomer.

Theresult of inspectionareforwardedtothemanufacturi ng

department , thushelpsini mprovingthequali ty.

It helps topurchasegoodqualityrawmaterial, tool and

equipment.

It l edtodevelopment of precisi onmeasuringi nstruments.








Hi ghQualit yProduct

performsit sfunctionsrel iabl y

performsit sfunctionsfor alongtime

performsit sfunctionsconveni ently



LowQual ityProduct

doesnot perf ormitsfuncti onreliabl y

fai lsor breaksaf tershort t imeof use

isdiffi cult touse

GOAL

ContinuousQuali tyImprovement

(functi onal ity, reliabili ty, durabi lity, …)

Inspect ion(Measurement )

What?When?How?




Inspect ionspeci fictoPRODUCTS

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Electronicparts (circuits, chi ps, et c. )

Machineelements(engines, brakes, gears, et c. )

Heat andthermodynamiccomponent s(engines, fuel inj ectors, etc. )

Medical andBio-relat edproducts(implants, dent al devices, surgical

parts, etc. )

…
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
Inspect ionspeci fictoPROCESSES


Chi premoval processes(turning, mi lling, drilli ng, et c. )

Chi plessmanufacturi ng(casti ng, moldi ng, f orgi ng, et c. )

Non-tradit ional met hods (EDM, ECM, ul trasonics, etc. )

…
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Inspect ionAFTERproduction

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costlyproductionstepsalreadycomplete

highcost of rejectionorrework

dif ficult totest foral l possibl edefects

dif ficult toidentifyresponsibilityfordefect


Inspect ionDURINGproduction


def ects foundearly, at eachproductionstep

reducedcost of rejecti onor rework

facilit ates cont inuousprocess improvement
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Measurement of DIMENSIONS

Linearmeasurements (length, thickness, etc. )

Angular measurement s(taper, angle, etc. )

Measurement of surfacetexture(roughness, waviness, etc. )

Measurement of geometri cshape(roundness, flat ness,

squareness, etc. )

Measurement of screwthreadsandgears
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Inspect ionf orDIMENSIONALACCURACY

post-process(traditi onal )

in-process(moderntrend)
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DIMENSIONALTOLERANCES

permissibl evariationindimensions

directl yaff ects product qualit yandcost
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SOURCESOFERRORS

anerror isdefinedasreal (untrue, wrong, f alse, nogo)val ueat theoutput

of ameasurement syst emminusideal (true, good, right , go) value.

Error=Ŧ(MV–TV)


Classif icat ionof errors:

1. Absol uteError:-It i sthealgebraicdiff erencebetweentheresul t of

measurement andthevalueof comparison.

(a) Trueabsoluteerror: algebraicdif ferencebetweenresult of

measurement andconventi onal truevalue.

(b) Apparent absoluteerror: if aseriesof measurements aremade, the

dif ferencebetweenoneof themeasurement andthearithmeti cmean.

1. Relat iveError:-It i stherati oof absoluteerrorandthevalueof

comparisionusedformeasurement.


Rel ativeerror=(Absol uteerror/Truevalue)
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TYPESOFERRORS

StaticError
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ReadingError

Environmental Error

Charact eristicError
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Dynami cError
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SystematicError
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RandomError

Instrument al loadingError

1. Stati cError: t heseresul t fromthephysical natureof t hevarious

components of themeasuri ngsystemasthesystemrespondst oa

fixedMeasurandinput .

Duetointrinsici mperfect ions inthehardwareandapparatus

comparedtothei deal i nstrument.

(a) ReadingError:

i. Paral laxError: Possibil ityof Errorduetoparall ax(Readout). Useof

mi rror behi ndthereadout orpoi ntervirtuallyeliminat essuchtypeof

error.

ii. Interpol ationError: It canbetackledbyincreasingOptical

resolut ionbyusi ngamagni fier orusi ngdi gital readout devices.

(a) Envi ronment al Error: Thiserrori sduetotheeff ect of surrounding

temperature, pressureandhumidityonmeasuringsystem. External

inf luencesalsoi ncludeMagnet icorelect ricf ields, nuclear radi ation,

vibrati onor shocketc… thesefactors affectsbothmeasuringsyst em

andmeasurand.

(b) Characterist icError: Thedeviati onof theoutput of themeasuring

systemunderconstant envi ronmental conditi onsf romt hetheoretical

predict edperformanceorf romnomi nal performancespecif icat ion.

2. Instrumental loadi ngError: Thisresul t fromthechangeinmeasurand

itself wheni t isbeingmeasured. It is thus thedifferencebetweent he

val ueof themeasurandbeforeandafterthemeasurement syst emhas

measured.

1. DynamicError: (Rel atedwithtime)

Thi serrorcausedbytimevariat ioninthemeasurandandresul tsfrom

theinabilit yof ameasuringsystemt orespondfait hfull ytoatime

varyingmeasurand. Usual lydynami cresponseisl imit edbyinertia,

damping, fricti onorother physical const raintsinthesensing, readout

ordispl aysystem.


SystematicErrors

Comefromt hemeasuringi nstruments.

Somethingi swrongwit hthe

instrument orit sdatahandlingsystem,

ori nstrument is wronglyusedbythe

Experiment er.

Theerrorsintemperat ure

measurementsbecauseof poor

thermal contact betweenthe

thermomet erandthesubst ance.

Errorsi nmeasurementsof solar

radiati onastreesorbuildi ngsshade

theradi ometer.



RandomErrors

Causedbyunknownand

unpredi ctablechanges inthe

experiment .

Mayoccurinthemeasuring

instrument sori nthe

environmental condit ions

(humidity, temperat ure, etc. )

Theerrorsinvolt age

measurementsbecauseof an

electronicnoiseinthe

circuit of el ectrical i nstrument.

irregul archangesintheheat

lossrat efromasolarcollector

duetothewind.

Athermometert hat al ways

Reads3ºcolderthanthe

act ual t emperat ure

Athermometert hat gi ves

randomvalueswi thin3ºeit her

sideof t heactual temperat ure
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SystematicErrors
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Reproducibl ebet ween

measurements.

Inprinciple, theycanbe

eli minatedpart iallyor

completely. (Control labl eerror)

Accuracyisoftenreducedby

systematicerrors, whichare

dif ficult todetect evenfor

experiencedresearchers.

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Wemust def inet heirsize

Toestimatewhat confi dence

Wehaveinourmeasured

val ue.

RandomErrors

Not reproducibl e, but fluctuat ein

magnit udeandsi gnbet ween

measurements.

Wecanonlyknowt heprobabl e

rangeoverwhicharandomerror

lies.

Precisi onis limitedbythe

randomerrors. It mayusuallybe

det erminedbyrepeati ngthe

measurements.

Theycanbeestimatedso

that themeasuredvalue

canbeadjust edtoallow

for them.

AccuracyandPrecision

Precisi onis defi nedas therepeatabil ityof themeasuring

instrument . It showshowcl oset hemeasuredvalues areto

eachother.

Theprecisionof ameasurement isthesizeof theuni t you

usetomakeameasurement . Ex: 12sand12day

Thenumberof decimal placesinameasurement alsoaffects

precisi on. 10, 10. 1, 10. 12, 10. 1237…. .


Accuracyishowcl oseameasuredvalueistotheactual

(true)value. Theaccuracyof ameasurement is the

dif ferencebetweenyourmeasurement andtheaccepted

correct answer. Thebiggert hedi fference, thel essaccurate

yourmeasurement.

Mi stakeof 5cmi nmeasurement of 100cmor1000cm…


Dif ferencebetweenAccuracyandPreci sion



LowAccuracy

Hi ghPrecision


Hi ghAccuracy

LowPrecision

Hi ghAccuracy

Hi ghPrecision

applya

systematic

adj ustment

needtochangethe

equipment or

methodologyused

If t heinstrument measuresin"1"sthen

anyvaluebet ween6½and7½is

measuredas "7"

If t heinstrument measuresin"2"sthen

anyvaluebet ween7and9is

measuredas "8"

Degreeof Accuracy


Accuracydepends onthe

instrument youare

measuringwith. But as a

general rule: Thedegreeof

accuracyishalf aunit each

sideof t heunit of measure

Factors affectingAccuracy:


1. Standard: ambient i nfluence, stabilit ywit htime, el asti cproperty,

Positionof use……

2. Workpiece: ambient inf luence, cl eanl iness, surfacecondition,

Elasticity, support arrangement, defini ngdatum.

3. Instrument: hysteresis, backlash, fri ction, zerodri ft, error in

Amplif icat ion, calibrati onerroret c…. .

4. Personal: Improper trai ningforhandli nginstrument , ski ll, senseof

Precisi onandaccuracy, att itude……

5. Environmental: temperature, vibrati on, l ight ing, pressure….

SENSITIVITYOFMEASUREMENT

Smallest di fferencei nadi mensiont hat aninstrument candi stinguishor

det ect. It maybedefinedas therateof displacement of theindicat ing

deviceof ani nstrument, w. r. t t hemeasuredquanti ty.

Inother words, sensiti vityof aninstrument is theratioof thescal e

spacingtothescaledivisionval ue.

For example, if onadial indicat or, thescalespacingis1. 0cmandt he

scaledi visi onvalueis 0. 01cm, thensensi tivi tyis 100.

It i salsocal ledasamplifi cati onfactororgearingratio.

Environmental changesaff ect i nstrumentsintwomainways, knownas

zerodri ft andsensitivitydrift .

Zerodri ft descri bestheeff ect wheret hezeroreadingof aninst rument is

modifi edbyachangeinambient condi tions.

Sensiti vitydrif t (alsoknownas scalefact ordrift) definestheamount by

whi chaninst rument'ssensi tivi tyof measurement variesasambi ent

conditi onschange.

CALIBRATION

Cal ibrationistheset of operati onsthat establ ish, under specified

conditi ons, therelati onshipbetweenthevaluesof quanti ties indi catedby

ameasuringinst rument andthecorrespondingvaluesrealizedby

standards.

Cal ibrationistheprocessof est ablishingtherelat ionshipbetweena

measuringdeviceandt heunitsof measure. Thi sisdonebycompari nga

deviceortheoutput of aninstrument t oast andardhavingknown

measurement charact eristics.

Whentheinstrument i smadetogiveanull indi cati oncorrespondi ngtoa

nul l val ueof thequanti tytobemeasured, t heset of operat ioni scal led

zeroadj ustment .

Cal ibrationcanbecall edfor:

wit hanewinstrument

whenaspecif iedt imeperiodiselapsed

whenaspecif iedusage(operatinghours)haselapsed

whenani nstrument has hadashockorvi brat ionwhichpotential ly

mayhaveput it out of calibration

wheneverobservations appearquestionabl e


Cal ibration

Adj usti ngor sett ingof aninstrument to

obt ainaccuratereadingswi thina

ref erencest andard.

Readabi lity

Suscept ibil ityof aninstrument forhaving

its indi cati onsconvertedt oameaningful

number.

Precisi on

Degreeof agreement inthe

measurementsof thesamequantity.

Repeatabili ty

Abi litytodothesamet hingover &over.

Errorbetweenanumber of successive

Att emptstomoveamachinetot hesame

position.


Terminology

Accuracy

Degreeof agreement of the

measureddi mensionwithi tstrue

magnit ude.

Sensiti vity

Smallest di fferencei nadi mension

that ani nstrument candist inguish

ordetect.

Resolut ion

Smallest di mensiont hat canbe

readonaninstrument.

Reproducibi lity

Degreeof agreement inthe

individual resul tsusi ngthesame

methodandt hesametest

substance, but adifferent set of

laborat orycondi tions.

175

235

350

485

595

692

745

856

986

1071

Mean69. 0

174

273

372

464

565

666

769

868

970

1069

Mean69. 0

StandardDeviati on

Ameasureof thespreadof aprobabilit ydistribution, randomvari able, or

multiset of values.

Moreformally, it ist heroot meansquaredevi ationof values fromthei r

ari thmeticmean.

Inpract ice, it is oftenassumed

that thedataaref rom

anapproximatel y

Normallydistributed

populat ion.

Accordi ngtothis,

confidencei ntervalsare:

σ: 68. 26894921371%4σ:99. 99366575163%

2σ: 95. 44997361036%5σ:99. 99994266969%

3σ: 99. 73002039367%6σ:99. 99999980268%

Int erchangeabil ity

Ani nterchangeablepart isonewhichcanbesubst itut edfor similar part

manufacturedtothesamedrawi ng.








Therequiredfit assemblycanbeobtai nedi nTwoways.

a)Universal orf ull interchangeabil ity

b)Selectiveassembly

Ful l int erchangeabili tymeans anycomponent will mat withanyot her

matingcomponent wit hout classifyi ngManuf acturedcomponent sintosub

groupsorWi thout carryingout minor alterati onformat ingPurpose. It

requiresprecisemachines orprocesseswhoseProcessCapabil ityi sequal

orl esst hant hemanufacturingTolerances

all owedfort hat part. Soeverycomponent

producedwil l bewithindesi redt olerances

andcapableof mating(Fitt ing) withany

othermatingcomponentst ogivethe

requiredFit .

Process capabili tyof amachineis

def inedasit s±3σspreadof

dimensions of components produced

byi t.

Advantagesof Int erchangeabili ty


1. Assemblytimeisreducedconsiderably.

2. Thereisanincreasedoutput wi threducedproducti oncost.

3. It facilit ates productionof matingcomponents at dif ferent pl aces

bydifferent operator.

1. Thereplacement of wornout or defectivepart sandrepai rbecomes

veryeasy.

2. Thecost of mai ntenanceandshutdownperiodi salsoreducedt o

mi nimum.

Sel ecti veAssembly:

Inselectiveassemblycomponentsproducedareclassifi edintogroups

accordi ngtothei rsizesbyautomaticgauging. This isdonefor bothHoles

andShaf tsandthencorrespondingpart swil l bematchedproperly.

It reduceschanceof def ecti veassemblyandalsothecost of assemblyas

partsmaybeproducedi nwidertolerances.

Ex: Assembl yof pistonwithcyli nderbores.

Boresize=50mm

clearancerequiredfor assembl y=0. 12mm

Tol eranceinbothboreandpi ston=0. 04mm

Dimensionof borediameter=50

±0. 02

mm

Dimensionof piston=49. 88

±0. 02

mm


Bygradi ngandmarkingthebores andpi stons, theycanbeselect ivel y

assembledasfol lows…


Cyl inderBore=49. 98mm50mm50. 02mm

Piston=49. 86mm49. 88mm49. 90mm

Limits, Fit sandTolerances:

1. It isnot possibletomakeanypart preciselyt oagi vendi mensiondueto

variabi lityof el ementsof productionprocesses.

ManMachineMaterial

2. If bychancethepart i sexactlytoagi vendimension, it i simpossiblet o

measureit accuratelyenoughtoproveit.

3. If att emptsaremadetoachieveperfect size, thecost of product ionwi ll

increase.

For agivensystemof Li mit sandfitst obesuccessful foll owingconditions

aretobesati sfied:

It must bebasedonsamestandardsothat everybodyalike

andagivendi mensionhasthesamemeaningat all pl aces.

Therangeof sizes coveredbythesystemsshouldbesuffici ent

for most purposes.

Eachbasicsi zeof holeandshaft must havearangeof t olerance

val uesf oreachof thedi fferent f its.

Bot huni lateral andbi l ateral methodsof t olerancesandhole

basisor shaf t basissystemshouldbeacceptabl e.

Thefundamental deviationrequiredt ogiveaparticularf it must

increasewit hthebasicsize.

SizeDesignations

Shaft: It ref ersnot onl ytot he

diamet erof acircular shaf t but Also

toanyexternal di mensionof a

component. (Malesurface)

Hole: It ref ersnot onl ytot hedi amet erof acircularHol ebut also

toanyinternal di mensionof acomponent. (Femalesurface)

BasicSi zeor Basi cdimensi on: It isthetheoret ical sizeworked

out bypurelydesi gnconsiderati on, fromwhichlimitsof sizeare

derivedbytheapplicat ionof all owancesandtol erances.

Act ual Size: isthemeasuredsizeof thefinishedpart.

Zeroline: It isthestraight linedrawnhori zont allytorepresent

thebasi csize. Al l thedimensionsareshownw.r. t theZeroline.



SomeDefini tions

Limit: Duet oinevitableinaccuracyof manufacturingmethods, i t is

not possibletomakeapart preci selyt oagi vendimensionand

mayonl ybemadetoliebetweent oextremelypermi ssibl esizes

cal ledt heli mit sfort heactual size.

Upper/Lowerlimit: Largest/Lowest sizepermitt ed

Tol erance: Thepermissibl evariationinsizeordimensi onof apart

iscalledTol erance. It isthedif ferencebetweenU. LandL. Lof

dimension.

It i stheamount bywhichthejobi sallowedt ogoawayf rom

accuracy, wi thout causinganyfunctional t rouble.

Tol eranceis always+ve.

Unilat eral Tolerance: Int his, thedi mension

isallowedtovaryonlyi nonedirectionof

BasicSi ze, eitheraboveorbellowit.

Bil ateral Tolerance: Inthi sthedimensionof part i sallowedt ovaryinboth

thesidesof t hebasicsi ze.



Deviati on: It ist healgebraicdi fferencebetweentheactual

sizeandthecorrespondingbasicsize.

UpperDeviation: It is thealgebraicdifferencebet weent he

upper(Max) limit andthecorrespondingbasicsize.

Denotedby“ES”forHol eand“es” forshaft.

+vewhenUL>Basi csize&-vewhenUL<Basicsize.

LowerDeviat ion: It ist heal gebraicdi fferencebetweenlower

limit andcorrespondi ngBasicsize.

Denotedby“EI”forHol eand“ei” forshaft.

+vewhenLL>Basicsize&-vewhenLL<Basicsi ze.


So, Tolerance=IT

For Shaf t: IT=es–ei For Hol e: IT=ES-EI



Fundamental Deviation: (FD)


It i soneof thetwodeviations(Ei therUDor LD)whichis

convent ionallychoosentodefinetheposit ionof tol erance

Zoneinrelat iont othezerol ine.

It i soneof thetwodeviations(Ei therUDor LD)whichis

Nearest tot hezerolinefor eitherhol eorshaft .

Whentolerancezoneis abovethezerol ine, LDis theFD.

Whentolerancezoneis bell owthezerolineUDi stheFD.


MaximumMetal Limit (MML): At t hisl imi t thepart has

maximumpossi bleamount of metal .

ULforShaft andLLforHole.

Least Metal Limit (LML): At thislimit t hepart hasminimum

possibl eamount of metal.

LLf orShaft andULof Hole.



BasicShaft (h)

It i stheshaf t whoseupperdeviat ionis Zero. UL=basicsize.

BasicHole(H)

It i stheholewhoselowerdeviati onisZero. LL=basicsize

Tol eranceZone: It isthezoneboundedbytwolimitsof size

of apart .

Tol erancegrade(IT):

It i sthedegreeof accuracymanufactureandisdesignated

byt heletter ITfollowedbyanumber.

Thereare18gradesof tolerances –IT01, IT0, IT1 toIT16

Largert henumber, greater will bethetolerance.

IT01toIT4-Forproduct ionof gauges, measuringinstruments

IT5toIT7-Forfit sinprecisionengineeringapplications

IT8toIT11–ForGeneral Engi neering

IT12toIT14–ForSheet metal workingorpressworking

IT12toIT14–ForSheet metal workingorpressworking

IT15toIT16–Forprocessesl ikecasting, general cut tingwork



StandardTol eranceUnit (i )

Aunit, whichisaf uncti onof Basi csizeandwhichiscommon

Tot heformuladefiningthediff erent gradesof tolerances.

It i sdenotedbyletter“i”andexpressedinMicrons.

It servesasabasi sfordeterminingthestandardtol erance(IT)

Oft hesystem. (Micron)


where, D(mm)is thegeometricmeanof thelowerandupperdiamet ersof

aparticular diameter stepwithinwhi chthechosent hediamet erDl ies.

Clearance:

Thi sist hedi fferencebetweenthesizesof t heHoleandshaft

bef oreassemblywhent hisdifferenceispositi ve.

Maximumsizeof Hol e-Minimumsizeof shaft=Max. clearance

Mi nimumsizeof Hol e-Maximumsizeof shaft=Min. Clearance.

Size:

Anumberexpressingthenumeri cal valueof alengthina

particularunit.

All owance:

It i stheprescribeddif ferencebetweenthedimensi onof t wo

matingpart s(HoleandShaft)

It i stheintentional di fferencebetweenlowerl imi t of holeand

Hi gher limit of shaft .

All owance=LLH-HLS

It maybe+veor–ve. +veallowance=clearance

-veallowance=Interference




Tol eranceAl lowance

•Permissibl evariationin

dimensionof apart.

•Tol erance=UL–LL

•It i sprovidedtot hedimension

of apart .

•It hasAbsolutevaluewi thout

sign.


•Prescri beddifferencebetween

thedimensi onof twomating

parts.

•All owance=LLH- ULS

•Providedont hedi mensionof

matingpart stoobtainthe

desiredtypeof fi t.

•It maybe+ve. or–ve.

“Go” limit and“NOGO”l imi t:

“GO” limit refers toULof shaft andLLof Hole.

Thusit correspondstoMML.

“NOGO”l imi t ref erstotheLLof ashaft andULof ahol e.

Thusit correspondstoLML.







Fit s:

It i sthedegreeof tight ness orloosenessbetweentwomati ng

Partstoperf ormadefi nitefunctionwhent heyareassembled

Together.

Afi t mayresult either inamovablejoint orafi xedj oint.

Ex: Shaf t inBeari ng, PulleyonaShaft.

Classif icat ion

Clearancefi t

a)SlideFit

b)EasySlidefit

c)Runni ngfi t

d)Slackrunningf it

e)Looserunningf it

Transit ionf it

a)PushFit

b)Wringingfit


Int erferencefit

a)ForceFit

b)Tight fit

c)Shrinkfit


Clearancefi t:



Int hist ypeof fit Shaft isal ways smal lert hant heHolei. e. ULof shaft i s

smallerthanLLof Hol e.

Clearancefi t exi stswhentheshaft andtheholeareat their MML.

TheTolerancezoneof holewi ll beabovetheshaft tolerance.

All owanceis +ve.


Ex: Shaf t canrotateorslideinabearingwit hdif ferent DOFaccordingto

purposeof matingpart .


a)SlideFit: Tail stockspindleof Lathe

b)EasySlidefit: Spindleof lathe&dividinghead, Pi stons &

Sli deValves, Spi gotsetc.

c)Runni ngfi t: GearBoxBearings, Shaf t Pul leys

d)Slackrunningf it: ArmShaft of ICEngine, Shaft of CF

Pump

e)Looserunningf it: IdlePulleyontheirshaft (QuickReturn

Mechanism)

Int erferencefit

Int hist ypeof fit , LLof shaf t isl arger thanULof Hole.

Thus, theshaft andholesareattachedpermanentlyandusedasasoli d

Component.

Elasticstrainsaredevelopedduringt heprocessof assembly.

All owanceis –ve. (Interference)


Ex: Bearingbush, Smal l endinconnect ingrod, Geari nintermediat e

shaftsi ntrucks.


a)ForceFit: Gearsontheshaft

b)Tight fit: Steppedpulleyondriveshaft of aconveyor,

Cyl indrical GrindingM/C.

A)Shrinkfit /

HeavyForcefit: Metallicrimonthewheelsof acart.

Transit ionf it:

It l iesmidwaybetweentheclearanceandinterf erencefit .

Int his, tolerancezoneof holeandshaf t overlapcompletelyor

inpart.

ULof hole>LLof shaft but LLof hole<ULof shaft .


Ex: Spigot inMat ingparts, Couplingrings etc.


a)PushFit: Changegears, Sl ipbushings

b)Wringingfit: Parts whichcanbereplacedwit hout diffi cult y

duringminorrepairs.

HoleBasisSystem:

Thesizeof holeis kept const ant andshaft si zesarevariedt o

Givevarious typesof fi ts.

Int his, lowerdeviationof t heholeisZeroi . e. LL=Basicsi ze.

Holebasissystemiscommonl yusedasit isconvenient t o

makeaholeof correct sizeduetoavail abil ityof standarddril ls,

Reamers, wi thlesscost.


Shaft BasisSystem:

Thesizeof theshaft iskept const ant andsizesof holeare

variedt oget therequiredtypeof fit.

Int his, UpperDeviati onof theshaft i szeroi. e. UL=Basi csize.

Thi ssystemisnot suit ableformassproductionbecausei t is

Timeconsumingandcostlytomakeashaft of correct size.

Recommendationforl imi tsandfits forEngineeri ng:

For universal Int erchangeabili tyit i sessenti al tofollowa

uni formstandardThroughout theworl d.

Indianstandards (IS)areinlinewithISOrecommendations.

It consi stsof 25Holes desi gnat edbycapit al letter

A, B, C, D, E, F, G, H, JS, J, K, M, N, P, R, S, T, U, V, X, Y, Z,

ZA, ZB, ZC

It consi stsof 25shafts desi gnat edbysmal l let ter

a, b, c, d, e, f , g, h, js, j , k, m, n, p, r, s, t, u, v, x, y, z, za, zb, zc

Eachof holes andshafts hasachoi ceof 18Gradesof

Tol erancesDesignatedas:

IT01, IT0, IT1, IT2, IT3, ………IT15, IT16.

IT01–0. 3+0. 008DIT0–0. 5+0. 012DIT1–0. 8+0. 020D

IT2–2. 7i; IT3-3. 7i; IT4–5i ; IT5–7i;

IT6–10i ; IT7–16i ; IT8–25i; IT9–40i;

IT10–64i; IT11–100i; IT12–160i ;

IT13–250i; IT14–400i; IT15–640i;

IT16–1000i.

Thevalueof ITfor Holeandshaft

Usingt hevalueof “i”as


WhereD=Geomet ricMeanDiameterof thelowerandupper diametersof

AParticular diameter stepinwhichdi ameterl iesi nmm.

ThesevenTol erancegradesIT01, IT0, IT1, IT2, IT3, IT4, IT5coversdiameter

Sizesupto500mmandrest elevengradesi. e. IT06–IT16covers diameter

Sizesupto3150mm.

Fundamental Deviationareobtainedf romEmpirical Formul a(Table/Givenin

Question)forshaft andholerespectivelyupto500mm.

FDf orHoleA–Haresameas that of Shaft a–hbut oppositei ndirecti on.

Theyprovideclearancefit.

FDf orhole“H”andshaf t “h” areZero.

NowIT=ES–EI(Hole)

IT=es–ei (Shaft)


Basicsi zefollowedbysymbol Φ30H7/h8

Holewi thtoleranceGradeIT7=16i

Shaft wi thtolerancegradeIT8=25i.

If Holebasi ssystemFDfor hole=0

FDf orshaft canbefoundout f romthetableorgiveninthequesti on.

Exampl e#1

Evaluat elimits andfi tsforapairof –Diameter6H7/g6. The

size6mmli esinthedi ametral stepof 3-6. Standard

tol eranceforhol eH7i s16i andshaft g6is10i. Fundament al

deviati onforgshaft is µ.

Cal culatethelimitsof sizesforφ25S8/h7andi dent ifythefit .

Thesize25mmli esint hedi ametral stepof 24-30. The

fundamental deviationS8hole–IT7+0. 4D. Forgrade8and

7thestandardtol eranceis25i and16i respectively.

Cal culatethelimitsof sizesforφ60H8/m6andidentifythe

fit . Thesize60mmliesint hedi amet ral stepof 50-80mm.

Thefundamental deviationformisIT7–IT6. Forgrade6

and7themul tipl iersare10and16respecti vely.

Cal culatethelimitsof sizesforφ32S7/h6andi dent ifythe

fit . Thesize32mmliesint hedi amet ral stepof 30-50mm.

Thefundamental deviationSisIT7+0. 4D.Forgrade6and7

themul tipl iers are10and16respecti vely.

GAUGES

Gaugesarescalel essinspectiontools at ri giddesignwhichareusedto

checkthedimensionsof manufacturedparts. Measurement bygaugesis

Easyandrapi d. Sotheyaresuitableinmass producti on. Insteadof

measuringactual dimensi onof eachpart whichisti meconsumingand

Costly, theconformanceof part witht olerancespecificationcanbe

checkedbygauges.

MeasuringInstrument Gauges

1. Theycarrycali bratedscales. 1. Wi thout scales.

Theyaregeneral purposeinstrument.


Theyaremadefor apart icul arcomponent.

Measuresactual dimensionof part.


Checkswhetherthedimensi onsof part sare

wit hint hespecif iedtolerancel imit ornot.

Timeconsumingandnot sui tabl eformass

product ion.

Easyandrapi d, suitabl efor massproducti on.

Ski lledlabourtohandl e. Noneedof skilledlabour.

Increasedcost. Reducedcost.

Adj ustment isrequired. Noadj ustment

PLAINGAUGES

Plaingauges areusedtocheckplain, i. e. unthreadedholes andshaft s.

Classif icat ion:

1. AccordingtoType

(a)StandardGauge: If agaugeismadeasanexact copyof themat ingpart

Ofcomponent tobechecked, it is calledstandardgauge.

Ast andardgaugecan’t beusedtocheckinterf erencefi t.

It hasli mit edapplication.

(a)Limit Gauge: Twogauges areusedtocheckeachdimensi onof the

Part i. e. upperandlowerlimit. Theseare“GO”and“NO-GO”gauges.

GOgaugescheckMMLandNOGOgaugescheckLML.

Thesearewidelyusedindust ries.

Apart is consideredtobegoodif t heGOgaugepass throughtheworkand

theNOGOgaugefailstopass undertheactionof i tsownweight. This

Confirmstheact ual di mensionof part wit hint hespecifi edtolerances.

If botht hegauges fail, it indicatesthat holeis undersizeandshaft is

Oversize.


1. AccordingtoPurpose:

a)Workshopgauge

b)Inspectiongauge

c)Referenceormaster gauge

d)Purchasei nspectiongauge

2. Accordingtotheformof t hetestedsurface:

a)Pluggaugesfor checkingholes

b)SnaporRingorGapgaugesf orcheckingtheshaf t

3. Accordingtotheirdesign:

a)Singl elimit ordoubleli mit gauges

b)Singl eendedor doubl eendedgauges

c)Fixedandadjustablegauges


Dif ferencebetweenworkshopgaugeandInspecti on

gauge?

Workshopgauge:

1. Usedbytheoperator duri ngmanufactureof apart inshop.

2. Usuallyhavel imit swit hint hoseof components being

inspect ed.

3. Thetolerancei sarrangedtofall insidet heworktolerance.

4. Someof thecomponentswhichareinworktolerancelimit

mayberejectedundert hesegauges.

Inspect ionGauge:

1. Usedbyinspectorforthefinal inspecti on.

2. Thesegaugesaremadesli ghtl ylargertolerancet hanthe

workshopgauges.

3. Thetoleranceoninspecti ongaugesi sarrangedtof all

out sidetheworkt olerance.

4. Somerejectedparts maybeaccepted.

ITof Inspect ionGauge>Worktol erance>W/SGaugeTolerance.

GaugeTolerance/GaugeMaker’sTolerance/

ManufacturingTolerance:

Inactual practiceGaugescan’t bemanufact uredtotheexact size(Dueto

imperf ecti onintheprocess). Someallowancemust beprovidedtothe

gaugemaker knownasgauget olerance.

Gaugetoleranceshouldbekept as smal l aspossi blebut thi swil l increase

thecost of manuf acturingt hegauges.

Gaugetoleranceof limit gauges (GT)=1/10thof WorkTolerance(WT)

OrWorkshopGauges(GO, NOGOGauges) (10%)

Gaugetolerancef orInspect iongauges (GT) =5% of WT

(GO, NOGOGauges)

Gaugetolerancef orMaster/Ref erencegauges(GT)=10%of WT




WearAl lowance:

Themeasuri ngsurfacesof GOgaugesrubconstantlyagainst

thesurf aces of workpieceduringchecking. This resultsin

wearingof measuringsurfacesof gauges.

Thesizeof GOpluggaugesisreducedandthat of Ri ngor

SnapGaugesi sincreased.

Wearal lowancei sprovidedtothegaugesinthedirection

Opposit etot hat of thewear.

WAisnot providedforNOGOgaugesast heyarenot

Subject edtomuchwear comparedtoGOgauges.

GOpluggauges=>WAisadded.

GOsnaporringgauges=>WAi ssubtract ed.

WA=5% of WTor10%of GT.

WAmaybeavoidedincl earancef it.

WAisappliedtoW/SGOgaugesnot toInspectionGO

gauges.

Pr
 Basic Shaft System

Shaft
Zero line
 Shaft Basis System:- Where the
size of the shaft is kept constant
and the variations given to the
hole to get the different class of
fits, then it is known as the shaft
basis system.
 GAUGES

Gauges are scale less inspection tools at rigid design

which are used to
check the dimensions of manufactured parts.
Measurement by gauges is
Easy and rapid. So they are suitable in mass production.
Instead of
measuring actual dimension of each part which is time
consuming and
Costly, the conformance of part with tolerance
specification can be
checked by gauges.
 Types of Gauges

Plain gauges are used to check plain, i.e. unthreaded holes and shafts.
 Classification:
 [Link] to Type
 (a)Standard Gauge: If a gauge is made as an exact copy of the mating part
 Of component to be checked, it is called standard gauge.
 A standard gauge can’t be used to check interference fit.
 It has limited application.
 (a)Limit Gauge: Two gauges are used to check each dimension of the
 Part i.e. upper and lower limit. These are “GO” and “NO-GO” gauges.
 GO gauges check MML and NO GO gauges check LML.
 These are widely used industries.
 A part is considered to be good if the GO gauge pass through the work and
 the NO GO gauge fails to pass under the action of its own weight. This
 Confirms the actual dimension of part with in the specified tolerances.
 If both the gauges fail, it indicates that hole is under size and shaft is
 Oversize.
According to Purpose:
a) Workshop gauge
b) Inspection gauge
c) Reference or master gauge
d) Purchase inspection gauge
2. According to the form of the tested surface:
a) Plug gauges for checking holes
b) Snap or Ring or Gap gauges for checking the
shaft
3. According to their design:
a) Single limit or double limit gauges
b) Single ended or double ended gauges
c) Fixed and adjustable gauges
 Taylor’s Principle of Gauge Design:
 It states that
 1. “Go gauges should be designed to check the Maximum Metal
Limit
 (MML) while the NO GO gauge should be designed to check the
Least Metal Limit (LML).”
 GO plug gauge should correspond to LL of Hole.
 NOGO plug gauge should correspond to UL of Hole.
 GO snap gauge should correspond to UL of shaft.
 NOGO snap gauge should correspond to LL of shaft.
 The difference between the GO and NOGO plug gauge as well as
the difference in size between GO and NOGO snap Gauge is
approximately equal to the work tolerance.
 2. “GO gauges should check all the related dimensions
(Roundness, size, location, straightness etc).
 NOGO gauges should check only one element of the dimension at
a time.”
For universal Interchangeability it is essential to follow a
uniform standard Through out the world.
Indian standards (IS) are in line with ISO recommendations.
It consists of 25 Holes designated by capital letter
A, B, C, D, E, F, G, H, JS, J, K, M,N, P, R, S, T, U, V, X, Y, Z,
ZA, ZB, ZC
It consists of 25 shafts designated by small letter Recommendation for
limits and fits for Engineering:
For universal Interchangeability it is essential to follow a
uniform standard Through out the world.
Indian standards (IS) are in line with ISO recommendations.
It consists of 25 Holes designated by capital letter
A, B, C, D, E, F, G, H, JS, J, K, M,N, P, R, S, T, U, V, X, Y, Z,
ZA,, ZC
It consists of 25 shafts designated by smal letter
a, b, c, d, e, f, g, h, js, j, k, m, n, p, r, s, t, u, v, x, y, z, za, zb, zc
Each of holes and shafts has a choice of 18 Grades of
Tolerances Designated as:
IT01, IT0, IT1, IT2, IT3, ……… IT15, IT16.
IT01 – 0.3 + 0.008D IT0 – 0.5 + 0.012 D IT1 – 0.8 + 0.020D
IT2 – 2.7i; IT3 - 3.7i; IT4 – 5i; IT5 – 7i;
IT6 – 10 i; IT7 – 16i; IT8 – 25i; IT9 – 40i;
IT10 – 64i; IT11 – 100i; IT12 –160i;
IT13 – 250i; IT14 – 400i; IT15 – 640i;
IT16 – 1000i.
 Selective Assembly

In selective assembly components produced are

classified into groups according to their sizes by
automatic gauging. This is done for both Holes
and Shafts and then corresponding parts will be
matched properly.
It reduces chance of defective assembly and also the
cost of assembly as parts may be produced in wider
tolerances.
Ex: Assembly of piston with cylinder bores.