LIMITS FITS & TOLERANCES

Presentation By: Sandeep Kumar

A.P, M.E (GGSCET)
 Objectives
• To understand basics limit’s, fit’s &
of tolerances.
• Calculate basic & gauge tolerances.
• Understand various types of gauges & their
applicability
Terminology of Limit system
 Nominal Size
• Nominal Size is a size “in a name only” which is
used for identification. The nominal size may not
match any dimension of the product, but with in
the domain of that product the nominal size may
correspond to a large number of highly
standardized dimensions and tolerances.
– Example – ½” pipe, 1” pipe etc.
 Basic Size
• It is size of job, in relation to which all limits of
variations are determined. It is same for both
hole and shaft.
 Zero Line
• The line representing basic size is called as zero
line.
 Hole
• Hole is a term used to designate all internal features of
parts including those, which are not cylindrical.
 Shaft
• Shaft is a term used to designate all external features of
parts including those, which are not cylindrical
 Deviation
• It is algebraic difference between actual size of the job
and basic size of the job. Mathematically it is
represented as
• Deviation = Actual Size - Basic Size (Measured
Dimension – Theoretical Dimension)
 Lower Deviation
• It is the difference between minimum limit and basic
size of component.
 Upper Deviation
• It is the difference between maximum limit
and basic size of the component.
 Basic Shaft
• It is shaft whose upper deviation is zero or
where maximum limit size is equal to basic size.
 Basic Hole
• It is hole whose lower deviation is zero or
whose minimum limit size is equal to basic size.
 Tolerance
• It is defined as the difference between maximum
limit and minimum limit of the hole or shaft.
 Limits

• Limit is nothing but two (upper and lower)

extreme permissible sizes between which
the actual size is contained.

Maximum
Tolera
Limit Mam xium
nce
Minimum Tol
Hole Limit M
Linm
m iitium
eran
Lm
i ti
ce Sh
af
t
 Need of Tolerance
 Because of various properties of
material, errors are introduced.
 Change in operator, method, shift etc.
also errors in manufacturing.
 Various machine tools have
inherent inaccuracies while manufacturing.
 Types of Tolerances
• Unilateral Tolerance
• Bilateral Tolerance
 Unilateral Tolerance
• When both limits of size are on the same
side of zero line (either +ve or –ve), this
type of tolerance are called as unilateral
tolerances
 Applications and Advantages
• It is used for requirement of precision fit.
• It is easy and simple as per calculations of
deviations.
• If unilateral system is used, the holes of various
grades are having “same lower limit”. It is easy
to “standardize” hole i.e. GO Gauge.
• It is easy for operator during machining as he
would have machined till upper limit of shaft
(this is also lower limit of hole). He knows that
he still have some margin left for parts to make
it accurate.
 Bilateral Tolerance
• When one of size is at one side of zero line
and other limit of size is at another side of
zero line, the tolerance is called as bilateral
tolerance.
 Difference between unilateral and
bilateral tolerances

Sr. No. Unilateral Tolerance Bilateral Tolerance

1 Both limits are on same side of Both Limits are on different side
zero line of zero line
2 Both limits are having same sign Both limits are having different
(+ or - ) signs (+ and -)
3 Example : 20+0.2 , 20.1−0.2, Example : 10+0.1 , 20.1+0.1, 𝑒𝑡𝑐.
+0.1 −0.1
−0.1 −0.2

20+0.2 etc.
 Tolerance accumulation
The overall tolerance on complete length will be sum of the
tolerances on individual length.
In fig a g=a+ c+ eand h=b+ d+ f
The affect of an accumulation of tolerances can be minimized
by adopting progressive dimensioning from datum as shown
in fig b

Wrong Method Right Method

 Allowance
• The intentional difference kept between hole and shaft
is called allowance or the difference between maximum
material condition of matting part is called as allowance.
• For hole the maximum material condition is minimum
limit. This indicates that the maximum material will
remain with the component, if it is manufactured at
minimum limit size.
• Similarly, for shaft maximum limit is the maximum
material condition.
• If hole size is bigger than the shaft, the allowance is
positive and if hole size is smaller than shaft, the
allowance is negative. Following figure (3.4 (a)) shows
positive allowance and Negative allowance ((3.4(b)).
Fig 3.4 (a) Positive Allowance

Fig. 3.4 (b) Negative Allowance

 Fit
• Degree of looseness or tightness between
two mating parts.
 Types of Fits
• Fit refers to the mating of two mechanical components.
Manufactured parts are very frequently required to mate
with one another. They may be designed to slide freely
against one another or they may be designed to bind
together to form a single unit. The most common fit found
in the machine shop is that of a shaft in a hole.
• There are three general categories of fits: 1) Clearance
fits for when it may be desirable for the shaft to rotate or
slide freely within the hole. 2) Transition fits for when it
is desirable that the shaft to be held precisely, yet not so
tightly that it cannot be disassembled, this is usually
referred to as a Location or Transition fit. and 3)
Interference fits, for when it is desirable for the shaft to
be securely held within the hole and it is acceptable that
some force be necessary for assembly.
 Clearance Fit
• 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.
• The clearance fits may be slide fit, easy sliding fit,
running fit, slack running fit and loose running fit.
 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.
• The interference fits may be shrink fit, heavy
drive fit and light drive fit.
 Transition Fit
• In this type of fit, the size limits for
the mating parts are so selected
clearance
that either
or interference
a may
depending upon the actual occur
mating parts. It may be notedsize thatofin the
a
transition fit, the tolerance zones of hole
and shaft overlap. The transition fits may be
force fit, tight fit and push fit.
 Hole and Shaft basis system
Hole Basis System
• When hole size is kept constant and shaft
size is changed to obtain various types of fit
called as hole basis system.
• Basic size of the hole is taken as the lower
limit of hole. The hole basis system is
indicated by ‘H’, where lower deviation is
zero (as shown in figure)
• Hole basis system is preferable because
holes are produced by standard size of tool
like drills, remares, broach etc. but shafts
are manufactured rolling or casting and
then finished by turning or grinding.
• Hence it is convenient to produce various
sizes of shafts than holes of various sizes.
 Hole Making

Hole Size Constant

If You want any fit then changing hole size is not an good option, so it
is better to adjust the shaft size accordingly.
 Shaft Basis System
• When shaft size is kept constant and hole size is
varied, to get various types of fits called as shaft
basis system.
• Basic size of shaft is taken as maximum limit of
shaft. Shaft basis system is indicated by ‘h’
• Shaft basis system is preferred for long
shafts of full lengths e.g. if shaft is mating
with at least two parts having holes that
need different types of fits example
assembly of piston pin with piston and
connecting rod.
 1.
• Find 1. Maximum Limit 2. Minimum Limit
and Tolerance for
• 0.01
25−0.01

• 0.015
500.000

• 0.025
37.50.014
 2.
& Hole tolerance is
 Numerical - 3
• In a limit system, the following limits are
specified for a hole and shaft assembly:
• Hole = 30+0.02mm and shaft = 30−0.02mm
+0.00
−0.05

• Determine the (a) tolerance and

• (b) allowance.
Tolerance = Max Limit - Min Limit
Allowance => 1. Type - positive
allowance (clearance fit)
2. Value =
 4.
• The following limits are specified in a limit
system, to give a clearance fit between a
• hole and a shaft:
• Hole = 250.03
0.00 𝑚𝑚, Shaft = 25 −0.006
−0.020
• Determine
𝑚𝑚
• (a) Basic
• size
(b) Tolerances on shaft and hole
• (c) Maximum and minimum clearances
3
 Limit Gauges

• Gauging, done in manufacturing processes,

refers to the method by which it is
determined quickly whether or not the
dimensions of the checking parts in
production, are within their specified limits.
• It is done with the help of some tools
called gauges.
 Advantages
 These are free from errors.
 These are portable
 These are independent of power supply
 There is no need of any additional equipment’s with
gauges
 Combined dimensions like length, width,
diameter, and angle can be measured.
 Alignment, location, form also can be checked.
 Provides uniform reference standard.
 Less expensive for mass production
 No need to set using master gauges
 Used by unskilled labor also.
 Classification of Gauges

Gauges

Form of
According to According to According to
Tested
Type Purpose Limits
surface

Standard Worksho
For Holes For Shafts Single Limit
Gauges p
Gagues

Inspection Single End

Limit Gauges Snap Ring Double Limit
Gauges Plug

Master Double End Sing End

Fixed Limit
Plug Snap
Gauges

Progressiv Double End Adujsable Adjustable

e Plug Snap Snap Limit

Hollow End
Plug
 Standard Gauging
• Standard gauges are 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.
• A standard gauge should mate with some
comfort.
 Limit Gauges / Principle of Go – No
Go Gauge
• These are made according to two limits’ i.e.
high and low limit of size.
• The maximum material condition should
cover by ‘Go’ Gauge, which should pass
while gauging.
• Minimum material condition should match
‘No Go’ side of gauge which should not pass
while gauging.
Use of Gauges:
1. GoNo Go.mp4
2. Thread Go No Go.mp4
3. videoplayback.mp4
 Gauge for Hole i.e. internal dimensions
• These gauges are used for checking holes of
many different shapes and sizes.
• There are plug gauges for straight
cylindrical holes, tapered, threaded square
and splined holes.
• Single End Plug Gauge

Go or No Go
Double End Plain Plug Gauge

32.000 32.100

GO NO

GO
Hollow End Plain Plug Gauge

NO
GO
GO
 Progressive Plain Plug gauge
• In this both Go/No-go sides are mounted
one by one so that there is no need of
turning the gauge for checking GO and No
GO.
Gauges for Shaft – Snap Gauges
• A snap gage is a form of Go/no go gauge.
• It is a limit gage with permanently or
temporarily fixed measurement aperture(s)
(gaps) which is used to quickly verify
whether an outside dimension of a part
matches a preset dimension or falls within
predefined tolerances.
• The surfaces which define the edges of the
aperture are the anvils, which may be made
of separate pieces of hard material such as
tungsten carbide for wear resistance.
• Two apertures are frequently used to provide
Go/No-Go testing and are often arranged such
that a part being measured can pass through the
two apertures in sequence; a part that is within
tolerance will pass through the first maximum size
limit aperture but will not be able to pass through
the minimum size limit aperture.
• A snap gauge usually has a "C" shaped frame with
the aperture(s) at the opening of the "C". Snap
gages may be machined and ground out of a
single block of metal or adjustable snap gages,
which have movable anvils that may be adjusted
over a limited range of sizes, may be used. They
may also be of built up construction in which one
or more gage blocks or feeler gauges are
sandwiched between two anvils.
Single End Snap
Double end snap
Adjustable snap
Ring Gauge
 Taylor’s Principle of Gauge Design
• Go Gauge -> Maximum
material condition & Form
• No Go – Minimum material
Condition only

Snap or Ring Gauge

Plug Gauge
Correct gauge according to Taylor's
principle

Right Wrong
 ISO System for Limit’s & Fit’s
• ISO System of limits and fits (IS919-1963)
covers holes and shafts from smallest size to
maximum size.
• For any basic size, 28 types of holes are
available and the series can be obtained by
providing a series of holes which are
oversize and undersize.
• The various hole sizes are A,B,C,……X,Y,Z, ZA,
ZB, ZC. The difference of size of the hole
form basic size and shaft give the needed fit.
• Each of 28 holes have a choice of 18 grades
of tolerances which are IT01, IT0, IT1, IT2,
…..IT15,IT16. These tolerance grades
decides accuracy of manufacturing hole.
• For any basic size of shaft, 28 types of shaft
are available and a series can be obtained by
providing oversize or undersize for getting
required fit.
• The various shaft sizes are a,b,c….x,y,z,
za,zb,zc.
• Each of 28 shafts have choice of 18 grades of
tolerances as IT01, IT0,IT1… as explained
above.
• Following figure shows types of
holes/shafts.
• Following table shows various tolerance
grades according to different machining
processes.
ISO SYSTEM of Limits & Fits
• Where 𝑖 = 0.453 𝐷 + 0.001𝐷 in microns ---
For
Sizes up to 500mm, D is step size in mm i.e 1-3 if component
• size
& 𝑖2mm D=
= 0.04𝐷 + 2.1 1 × 3in= 1.732
microns ---- for
sizes
beyond 500mm to 3150mm.
• As per British standards 1916 for standard
limit’s and fits specified grades IT6 to IT16
only are used and IT6 = 10i & IT16 = 1000IT6.
• IT7 = IT6 x 100.2
• IT8 = IT7 x 100.2 = IT6 x 100.4
• IT9 = IT8 x 100.2 = IT6 x 100.6 & so on
 ISO Nomenclature
• E.g. 35 H8 f7
• 35 - Basic Size
• H – Type of Hole
• 8 - Tolerance grade =
IT8
• f – Type of Shaft
• 7 - Tolerance grade =
IT7
• Fit – Clearance
• System – Hole Basis
 identify type of fits
• 50H7d8
• 25H7f8
• 78M6h8
• Important points for gauge design
– Form of go gauge should exactly coincide with
the form of the opposed (mating) part.
– Go gaugesare complex gauges because
they used for
simultaneously.
– Go gauges must always be put into conditions of

– No gauges only used for checking single element

of feature
 …Contd.
• Important points for gauge design
– No gauge must always be put into conditions of
maximum passability.
 Gauge makers tolerances
• First System

UTL 1 Unit

1 Unit
No Go
Work
tolerance 8 Units 12 Unit
= 10
units
1 Unit

LT 1 Unit Go
L Workshop
Gauges
Inspection gauges

Workshop Gauge - Go – 10% of work tolerance, No Go – 1/10th of work tolerance

Inspection Gauge – 10% beyond work tolerance for both Go & No Go
 Disadvantages
• Some of the components which are in work
tolerance limits may be rejected under
workshop gauges.
• So the are again checked by inspection gauges
and may be accepted after that.
• Some components which are not in work
tolerance limits may be accepted when tested
by inspection gauges.
• The workshop and inspection gauges are to be
made separately as their tolerance zones are
different.
 Second System: Revised gauge limits

UTL
1 Unit
No GO
Work
tolerance 8 Units 11 Unit
= 10
units
1 Unit
Go
LT
L Worksho
p Gauges Inspection gauges
 Present British System
No Go Gauge (H)

Direction of Wear of
ga
Toleranc u ge
e for
Hole
T
Go Gauge (L)
A Gauge
tolerance =
10% work
tolerance
A Go Gauge (H) Wear
T Allowance =
Tolerance 10% Gauge
for Shaft D tolerancce
i rection of Wear of
auge
g
No Go Gauge (L)
 ...Cont
d
• Condition for wear allownce
• Wear Allowance only applicable when work
tolerance is above 0.00875mm
 Numarical
• Calculate dimensions of
plug and ring gauge to 2.Design general type of
control the production of go and no go gagues for
shaft 50H7d8 as per I.S. component having
specification. 25H7f8 fit.
the following Take
assumptions may be 1. i = 0.453 D  0 . 0 0 1 D
made 2. FD = -5.5D0.41
• Step Size => 30 to 50mm 3. Step = 18 to 30mm
• FD = -16D0.44 4.Wear Allowance = 10%
• i = 0.453 D  0 . 0 0 1 D GT
• IT6 = 10i also find type of Fit,
Allowance