LIMITS, FITS, TOLERANCE & SURFACE FINISH

WITH REFERENCE TO BIS (BUREAU OF INDIAN STANDARDS)

INTRODUCTION Because of the inherent limitations in men, material and machines, it will be impossible to manufacture a part accurately to the exact specified size economically. It will be still more difficult to manufacture large number of identical parts exactly to the same sizes. At best even with the greatest care they may be produced to the sizes very close to the basic sizes. Thus the actual machined sizes may be either slightly greater or less than the basic sizes. Therefore it will be inevitable to tolerate variations to the basic sizes so that the actual machined sizes may lie within the specified limits of variations. The extent of variation that can be tolerated for a basic size depends mainly on the functional requirement of the part, its material, type of the force expected on it, machining characteristics and cost. If the tolerable sizes have to be very close to the basic sizes, the cost of the manufacture will be higher since greater skills have to be exercised while machining. The system of specifying the extent of permissible variations for the basic size is called tolerancing. The amount of variation permitted for a basic size is called tolerance. The maximum and minimum permissible sizes within which the actual machined sizes lies are called limits. The functional relationship between the two adjacent parts achieved by the specified tolerances is called fit. ILLUSTRATION OF BASIC SIZE DEVIATIONS, LIMITS & TOLERANCES BASIC SIZE It is defined as the theoretical size of a part, derived from the design after rounding off the nearest whole dimension. The tolerances are always specified to the basic size. In below fig. the dimension 30mm is the basic size.

ACTUAL SIZE It is defined as the size actually obtained by machining. It is founded by actual measurement using measuring instruments. The actual size of the diameter of the shaft is 29.925mm.

LIMITS The two extreme permissible sizes between which the actual size lies are called limits. MAXIMUM LIMITS It is defined as the maximum permissible size for a given basic size. In fig. the maximum limit for the basic size of 30 is = 30 + 0.035 = 30.035mm.

MINIMUM LIMITS It is defined as the minimum permissible size for a given basic size. In fig. the minimum limit for the basic size of 30 is = 30 - 0.215 = 29.785mm.

TOLERANCE It is defined as the amount of variation permitted to a basic size. The difference between maximum and minimum limits of a basic size is called tolerance. In fig. the tolerance is = 30.035 29.785 =0.25mm. DEVIATION It is defined as the difference between the actual size or limit sizes, either maximum or minimum, and the corresponding basic size. ACTUAL DEVIATION It is the algebraic difference between the actual measured size and the corresponding basic size. In fig. actual deviation = 29.925- 30 = -0.075mm. UPPER DEVIATION It is defined as the algebraic difference between the maximum limit of size and the corresponding basic size. In fig. the upper deviation is = 30.035- 30 = 0.035mm. LOWER DEVIATION It is defined as the algebraic difference between the minimum limit of size and the corresponding basic size. In fig. lower deviation is = 29.785- 30 =- 0.215mm.

ZERO LINE In graphical representation of tolerance system, the zero line represents the basic size. The upper deviation and lower deviation are measured from the zero line. The upper deviations and lower deviations are designated as shown in table. DESCRIPTION SHAFT HOLE TOLERANCE ZONE In a graphical representation of a tolerance, the zone bounded by the upper and lower limits of the basic size, shown as hatched in fig. is called tolerance zone. REPRESENTATION OF DIMENSIONAL TOLERANCES ON DRAWINGS I. Unilateral & bilateral tolerance system II. Maximum & Minimum size directly shown III. Basic size with symbol and numeral UPPER DEVIATION es ES LOWER DEVIATION ei EI

UNILATERAL SYSTEM 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. One of the sizes can be the basic size,

BILATERAL SYSTEM 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 & MINIMUM SIZE DIRECTLY SHOWN

BASIC SIZE WITH SYMBOL & NUMERAL

REPRESENTATION OF DIMENSIONAL TOLERANCES The tolerances are specified as shown below: 1. Letter symbol & 2. Number or grade method

1. 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 and shafts are represented by a to z except i, l, o, q and w. 2. NUMBER OF 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 and IT1 to IT16. These grades of tolerances are known as fundamental tolerances. TOLERANCE GRADE IT01, IT0 IT1 TO IT5 IT6 IT7 IT8 IT9 IT10 MANUFACTURING PROCESS AND APPLICATIONS Super finishing process, such as lapping, diamond boring etc. Use :Gauges Grinding Precision turning, broaching, honing Turning, boring and reaming Boring Milling, slotting, planning, rolling and extrusion MACHINE REQUIRED Super finishing machines Grinding machines Boring machine, Honing machine Lathes, capstan and automats Boring machines Milling machine, slotting machine, planning machine and extruders Drilling machine, lathes Presses Die casting machine, hammer machine -

IT11

Drilling, rough turning

IT12,IT13,IT14 Metal forming processes IT15 Die casting, stamping IT16 Sand casting

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.

FITS A machine is built by assembling all its constituting parts. During assembling sometimes a part may be required to be fitted into another part. In such cases and during the working of machine, they may or may not be intended to have a relative motion between them. If there should be relative motion between the two parts, they may be fitted loose or tight otherwise. The fitting of one part into the other, either loose or tight depends on the relationship existing between their mating surfaces which inturn depends on the dimensional differences between the parts. The relationship existing between the mating surfaces of the parts because of the differences in their dimensions is called fit. SHAFT AND HOLE TERMINOLOGY In mechanical engineering practice, generally a rod of circular cross section and a circular hole are termed as shaft and hole respectively. In the system of fits and tolerances, for the sake of simplicity even the non circular sections and also the space containing or contained by the two parallel faces of any part such as, the thickness of a key and the width of a keyway or a slot, are also termed as shaft and hole respectively. CLASSIFICATION OF FITS 1. Clearance fit 2. Interference fit 3. Transition fit

1) CLEARANCE FIT When a smallest hole is larger than the largest shaft, a clearance fit is obtained. Clearance fit always provide a positive clearance between the hole and the shaft over the entire range of tolerances. When relative motions between assembled parts are required a clearance fit is provided. They vary with the shaft speed, shaft bearing load, lubricating oil grade, temperature and the length of the mating surfaces.

2) INTERFERANCE FIT When a largest hole is smaller than the smallest shaft, an interference fit is obtained. E.g. pulley is to be fixed on a shaft. Interference fits are obtained by several methods, for instance, a shaft may be driven into the hole with considerable force, or heating the part having the hole in order to increase the diameter of the hole, or by cooling the shaft and thus decreasing its diameter.

3) TRANSITION FIT This is obtained by overlapping tolerance zones of a shaft and a hole. Consequently, this fit does not guarantee either clearance or interference.

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REPRESENTATION OF HOLES, SHAFTS & FITS A shaft or hole is designated by i. The basic size followed by ii. The appropriate letter and iii. Tolerance grade For example an 50 mm f-shaft with IT7 is indicated as 50f7. Similarly an 50 H-hole with IT8 is expressed as 50 H8. For assembly of above mating parts, the fit is given by 50 H8/f7. Commonly used holes : H7, H8, H9 and H11. Commonly used shafts : c11, d10, e9, f7, h6, k6, n6, p6, s6.

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METHOD OF INDICATING FITS ON DRAWINGS

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SELECTION OF FITS TYPE OF FIT CLEARANCE FIT 1.Precision Sliding fit 2.Close Running fit 3.Normal Running Fit SYMBOL OF FIT H7/h6 H7/g6 H7/f7 EXAMPLES OF APPLICATION Sealing rings, bearing covers, milling cutters on milling mandrels Spline shafts, clutches, movable gears in change gear trains,etc. Sleeve bearings with high revolution, bearings on machine tool spindles. Sleeve bearings with medium revolution, grease lubricated bearings of wheel boxes, gears sliding on shafts, sliding blocks Sleeve bearings with low revolution, plastic material bearings Oil seals (simmering) with metal housing (fit in housing and contact surface on shaft ), multi-spline shafts Large clearance & widely used

4.Easy Running fit

H8/e8

5.Loose Running Fit 6.Slack Running Fit

H8/d9 H8/c11

H11/a11 TRANSITION FIT 1. Light Press Fit 2.Force Fit

H7/n6 H7/m6

3.Push Fit

H7/k6

Gears and bearing bushes, shaft and wheel assembly fixed by feather key Parts of machine tools that must be dismantled without damage e.g. gears, belt pulleys, couplings, fit bolts, inner ring of ball bearings Belt pulleys, brake pulleys, gears and couplings as well as inner rings of ball bearings on shafts for average loading conditions

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4.Easy Push Fit

H7/j6

Parts which are to be frequently dismantled, but are secured by keys e.g. pulleys, hand wheels, bushes, bearing shells, pistons on piston rods, change gear trains

INTERFERENCE FIT 1.Shrink Fit 2.Heavy Drive Fit 3.Press Fit 4.Medium Press Fit

H8/u8 H7/s6 H7/r6 H7/p6

Wheel steel tyres, bronze crowns on worm wheel hubs Couplings, etc. Couplings on shaft ends, bearing bushes in hubs, valve seats Gear wheels

HOLE BASIS & SHAFT BASIS SYSTEM To obtain different types of fits, it is a general practice to vary tolerance zone of one of the mating parts. This has made two systems in use, namely 1. Hole basis system 2. Shaft basis system HOLE BASIS SYSTEM In this system, the different types of fits are obtained by associating shafts of varying limit dimensions with a single hole, whose lower deviation is zero. When the lower deviation of the hole is zero, the minimum limit of the hole will be equal to its basic size, which is taken as the base for computing all the other limit dimensions. SHAFT BASIS SYSTEM In this system, the different types of fits are obtained by associating holes of varying limit dimensions with a single shaft, whose upper deviation is zero. When the upper deviation of the shaft is zero, the

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maximum limit of the shaft will be equal to its basic size, which is taken as the base for computing all the other limit dimensions. WHY THE HOLE BASIS SYSTEM IS PREFERED? The limit dimensions may be specified either by the hole basis system or the shaft basis system. The Bureau of Indian Standards recommended both the systems, but their selection depends on the production methods. Generally holes are produced by drilling, boring, reaming, broaching, etc. where as the shafts are either turned or ground. Suppose the shaft basis system is used to specify the limit dimensions, to obtain various types of fits, numbers of holes of different sizes are required, which in turn requires tools of different types and sizes. If, instead, the hole basis system is used, there will be reduction in the production costs, as only one tool is required to produce the hole and also the shaft can be easily machined to any desired size. Hence, the hole basis system is preferred to the shaft basis system. However, the shaft basis system is preferred when a single shaft has to mate with holes of different sizes to give different kinds of fits, such as in the mating of a gudgeon pin both with the piston and the connecting rod, and the outer rings of antifriction bearings with various bores in housings, etc. ALLOWANCE It is the intentional difference between maximum material limits of the mating parts. Smallest hole minus largest shaft. Allowance= lower limit of hole - upper limit of shaft. The tightest fit between two mating parts. Determines how the two parts will interact with one another. It is a minimum clearance (positive allowance) or maximum interference (negative allowance) between such parts (generally considered worst case).

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LIMIT DEVIATIONS FOR HOLE & SHAFT Here we see limit deviations for Hole A TO Z except I, L, O, Q, W & shaft a to z except i, l, o, q, w with tolerance grade of IT01 to IT18 with different diameters. For example, here we see tables of these for only few holes & shafts.

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MACHINING VARIATIONS FOR DIMENSIONS WITHOUT TOLERANCE INDICATION All dimensions inscribed on a drawing of a machined part should in principle, be associated with the tolerance data which are normally indicated on the dimensioning line after the nominal dimension. However on the drawings of the parts not constituting fits, or without any special accuracy requirement, a general note specifying the value of permissible machining variations for all the untoleranced dimensions may be inscribed in the space provided in the title block. The machining variations permissible for dimensions without tolerance indications may be chosen for linear, angular dimensions & radii, chamfers derived from tables. The values given in these tables are applicable for all machining processes with chips, like turning, milling, etc, and without chips like drawings, embossing, pipe bending etc. And not applicable for production methods like casting, forging, processing, welding, flame cutting, etc. DEVIATIONS FOR LINEAR DIMENSIONS (All dimensions are in mm)
Class of deviation Fine Medium Coarse Extra coarse Above up to 0.5 3 0.05 0.1 3 6 0.05 0.1 0.2 0.5 6 30 0.1 0.2 0.5 1 30 120 0.15 0.3 0.8 1.5 Range of nominal dimensions 120 315 1000 2000 4000 315 1000 2000 4000 8000 0.2 0.3 0.5 0.8 0.5 0.8 1.2 2 3 1.2 2 3 4 5 2 3 4 6 8 8000 12000 4 6 10 12000 16000 5 7 12 16000 20000 6 8 12

DEVIATIONS FOR RADII & CHAMFERS (All dimensions are in mm)

Class of deviation Fine & medium Coarse & extra coarse Above Up to 0.5 3 0.2 0.2 Range of nominal dimensions 3 6 6 30 0.5 1 1 2 30 120 2 4 120 315 4 8

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DEVIATIONS FOR ANGULAR DIMENSIONS (All dimensions are in mm)

Class of deviation Fine & medium Coarse Extra Coarse Permissible variations on length of shorter side of angle Up to 10 Over 10 to 50 Over 50 to 120 Over 120 Degree mm per Degree mm per Degree mm per Degree mm per 100mm 100mm 100mm 100mm 1 1.8 30' 0.9 20' 0.6 10' 0.3 130' 3 2.6 5.1 50' 2 1.5 3.5 25' 1 0.7 1.8 15' 30' 0.4 0.9

SURFACE FINISH OR SURFACE ROUGHNESS OR SURFACE TEXTURE OR SURFACE QUALITY The finish on a metal surface after machining depends mainly on the material, structure of the metal before and after machining, and cutting conditions such as type and degree of sharpness of the cutting tool, depth of the cut, amount of feed, coolant used, working conditions such as hot or cold, vibrations and deflections of the tool or the work piece while cutting etc. A machined surface even with the highest class of finish will not be perfectly smooth, but, instead contains micro irregularities such as valleys and peaks. A surface produced even by super finishing process, when it is observed under microscope, shows micro irregularities. These surface defects may be within hundredth of micron in height which influence the functional qualities of mating parts. These surface irregularities are known as surface finish or surface roughness or surface texture or surface quality.

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TERMINOLOGY FOR SURFACE ROUGHNESS IDEAL SURFACE It is a hypothetical perfect surface without any micro-irregularities. ROUGHNESS It refers to the peaks and valleys which will be observed on the machined surface. a) Roughness height: It represents height of peaks or depth of valleys measured from the mean line for consecutive cycles. b) Mean roughness index: It is the arithmetic mean of absolute values of heights of peaks or depth of valleys and is represented by Ra. c) Surface roughness number: It indicates the average departure of a machined surface over standard sampling length (usually 0.8 to 2.5 mm). It is expressed by micron. WAVINESS This is surface irregularity in the form of waves with larger wave length.

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LAY It is the direction of tool marks or scratches or grains of surface, which are represented on drawing with surface finish symbol as shown in table. It is important to note that the surface roughness is measured at right angle to the direction of lay.

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SAMPLING LENGTH Sampling length is a particular length of the profile decided for the evaluation of the surface irregularities on any chosen portion of the machined surface. This length is also known as cut-off length. The sampling length is selected depending upon the type of machining process as indicated in table below. It is recommended to choose smaller value for the finer grade and larger value for the coarser grade for a given machining process when more than one values are given. SAMPLING LENGTH FOR DIFFERENT MANUFACTURING PROCESS Type of Surfaces Manufacturing process Milling Boring Turning Grinding Planning Shaping Reaming Broaching Diamond Boring Diamond Turning Honing Lapping Super finishing Buffing Polishing Spark Machining Burnishing Drawing Extrusion Moulding Electro polishing Sampling Lengths 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 2.5 2.5 2.5 2.5 2.5 2.5 2.5 8 8 10 10

Machined Surfaces

0.25

8 8

10 10

25

0.25 0.25 0.25 0.25 0.25

2.5 2.5 2.5 2.5 2.5 2.5 2.5

NonMachined Surfaces

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SURFACE ROUGHNESS (Ra) FOR DIFFERENT MANUFACTURING PROCESS Sir. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. Manufacturing Process Sand casting Permanent mould casting Die casting High pressure casting Hot rolling Forging Extrusion Flame cutting, Sawing and Chipping Radial cut off sawing Hand grinding Disc grinding Filling Planning Shaping Drilling Turning & Milling Boring Reaming Broaching Hobbing Surface grinding Cylindrical grinding Honing Lapping Polishing Burnishing Super finishing Surface Roughness Ra in m 5 to 50 0.8 to 6.3 0.8 to 3.2 0.32 to 2 2.5 to 50 1.6 to 25 0.16 to 5 6.3 to 100 1 to 6.3 6.3 to 25 1.6 to 25 0.25 to 25 1.6 to 50 1.6 to 25 1.6 to 20 0.32 to 25 0.4 to 6.3 0.4 to 3.2 0.4 to 3.2 0.4 to 3.2 0.063 to 5 0.063 to 5 0.025 to 0.4 0.012 to 0.16 0.04 to 0.16 0.04 to 0.8 0.016 to 0.32

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REPRESENTATION OF SURFACE ROUGHNESS ON DRAWINGS A blank size of any machine part can be obtained either by casting or forging or stamping or welding. This is used for some surfaces to be machined. These surfaces are clearly indicated on the drawing as shown below: I. The basic symbol is of two unequal legs inclined at approximately 60 to the line representing surface under consideration as shown in fig.

II. If removal of material is not permitted by any production method, then put a circle between two legs of the symbol as shown in fig.

III. If any machining is required on any surface of a part then a bar (horizontal line) is drawn as shown in fig.

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IV. Representation of surface-roughness

SURFACE ROUGHNESS, VALUE GRADES AND SYMBOLS Roughness Values Ra m 50 25 12.5 6.3 3.2 1.6 0.8 0.4 0.2 0.1 0.05 0.025 Roughness Grade Number N12 N11 N10 N9 N8 N7 N6 N5 N4 N3 N2 N1

Roughness Symbols

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