Chapter5

Limits,Fits,andTolerances

1
 Introduction
Notwopartscanbeproducedwithidenticalmeasurementsby
anymanufacturingprocess.

Inanyproductionprocess,regardlessofhowwellitisdesignedor
howcarefullyitismaintained,acertainamountofnatural
variabilitywillalwaysexist.

Thesenaturalvariationsarerandominnatureandarethe
cumulativeeffectofmanysmall,essentiallyuncontrollablecauses.

Usually,variabilityarisesfromimproperlyadjustedmachines,
operatorerror,toolwear,and/ordefectiverawmaterials.

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 Introduction
Suchcharacteristicvariabilityisgenerallylargewhencomparedto
thenaturalvariability.

Thisvariability,whichisnotapartofrandomorchancecause
pattern,isreferredtoasassignablecauses.

Characteristicvariationscanbeattributedtoassignablecauses
thatcaneasilybeidentifiedandcontrolled.

Iftheprocesscanbekeptundercontrol,thatis,alltheassignable
andcontrollablecausesofvariationshavebeeneliminatedor
controlled,thesizevariationswillbewellwithintheprescribed
limits.

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 Introduction
Somevariabilityindimensionwithincertainlimitsmustbe
toleratedduringmanufacture,howeverprecisetheprocessmaybe.

Thepermissibleleveloftolerancedependsonthefunctional
requirements,whichcannotbecompromised.

Nocomponentcanbemanufacturedpreciselytoagiven
dimension;itcanonlybemadetoliebetweentwolimits,upper
(maximum)andlower(minimum).

Thedesignerhastosuggestthesetolerancelimits,whichare
acceptableforeachofthedimensionsusedtodefineshapeand
form,andensuresatisfactoryoperationinservice.
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 Introduction
Whenthetoleranceallowedissufficientlygreaterthanthe
processvariation,nodifficultyarises.

Thedifferencebetweentheupperandlowerlimitsistermed
permissivetolerance.

Forexample,ashafthastobemanufacturedtoadiameterof40
0.02mm.

Thismeansthattheshaft,whichhasabasicsizeof40mm,will
beacceptableifitsdiameterliesanywherebetweenthelimitsof
sizes,thatis,anupperlimitof40.02 mm andalowerlimitof
39.98mm.Thenpermissivetoleranceisequalto40.0239.98=
0.04.
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 Tolerances
Tolerancecanbedefinedasthemagnitudeofpermissiblevariationof
adimensionorothermeasuredvaluefromthespecifiedvalue.

Itcanalsobedefinedasthetotalvariationpermittedinthesizeofa
dimension,andisthealgebraicdifferencebetweentheupperand
loweracceptabledimensions.Itisanabsolutevalue.

Thebasicpurposeofprovidingtolerancesistopermitdimensional
variationsinthemanufactureofcomponents,adheringtothe
performancecriterionasestablishedbythespecificationanddesign.

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 Tolerances
Ifhighperformanceisthesolecriterion,thenfunctional
requirementsdictatethespecificationoftolerancelimits;otherwise,
thechoiceofsettingtolerance,toalimitedextent,maybeinfluenced
anddeterminedbyfactorssuchasmethodsoftoolingandavailable
manufacturingequipment.

Theindustryfollowscertainapprovedaccuracystandards,suchas
ANSI(AmericanNationalStandardsInstitute)andASME(American
SocietyofMechanicalEngineers),tomanufacturedifferentparts.

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 ManufacturingCostandWorkTolerance

Itisverypertinenttorelatetheproductionofcomponentswithinthespecified
tolerancezonetoitsassociatedmanufacturingcost.

Asthepermissivetolerancegoesondecreasing,themanufacturingcost
incurredtoachieveitgoesonincreasingexponentially.

Whenthepermissivetolerancelimitsarerelaxedwithoutdegradingthe
functionalrequirements,themanufacturingcostdecreases.
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 Tolerances
ClassificationofTolerance
Tolerancecanbeclassifiedunderthefollowingcategories:
1.Unilateraltolerance
2.Bilateraltolerance
3.Compoundtolerance
4.Geometrictolerance

UnilateralTolerance
Whenthetolerancedistributionisonlyononesideofthebasicsize,itis
knownasunilateraltolerance.
Inotherwords,tolerancelimitsliewhollyononesideofthebasicsize,
eitheraboveorbelowit.

Example:+0.02 +0.02 0.01+0.00

40+0.01, 40 0.00,40 0.02,40 0.02
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Tolerances

10
 Tolerances
BilateralTolerance

Whenthetolerancedistributionliesoneithersideofthebasicsize,itisknownas
bilateraltolerance.

Inotherwords,thedimensionofthepartisallowedtovaryonbothsidesofthe
basicsizebutmaynotbenecessarilyequallydisposedaboutit.

Example:+0.02
40 0.02, 40 0.01

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 Tolerances
CompoundTolerance
Whentoleranceisdeterminedbyestablishedtolerancesonmorethanone
dimension,itisknownascompoundtolerance.

Forexample,toleranceforthedimensionRisdeterminedbythecombined
effectsoftoleranceon40mmdimension,on60,andon20mmdimension.
ThetoleranceobtainedfordimensionRisknownascompoundtolerance
(Fig.3.4).Inpractice,compoundtoleranceshouldbeavoidedasfaras
possible.

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 GeometricTolerance
Geometrictolerancesareusedtoindicatetherelationshipofonepart
ofanobjectwithanother.ConsidertheexampleshowninFig.3.5.

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 Tolerances
Formtolerances:Formtolerancesareagroupofgeometric
tolerancesappliedtoindividualfeatures.Theylimittheamountof
errorintheshapeofafeatureandareindependenttolerances.Form
tolerancesassuchdonotrequirelocatingdimensions.Theseinclude
straightness,circularity,flatness,andcylindricity.

Orientationtolerances:Orientationtolerancesareatypeof
geometrictolerancesusedtolimitthedirectionororientationofa
featureinrelationtootherfeatures.Thesearerelatedtolerances.
Perpendicularity,parallelism,andangularityfallintothiscategory.

Positionaltolerances:Positionaltolerancesareagroupofgeometric
tolerancesthatcontrolstheextentofdeviationofthelocationofa
featurefromitstrueposition.Thisisathreedimensionalgeometric
tolerancecomprisingposition,symmetry,andconcentricity.
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Consider the example shown if figure 3.6.
+ 0.02 + 0.02 + 0.02
Let LA = 30 0.01 mm, LB = 20 0.01 mm and LC = 10 0.01 mm

The overall length of the assembly is the sum of the individual length of components
given as

L = LA + LB + LC
L = 30 + 20 + 10 = 60 mm

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Then,cumulativeuppertolerancelimitis0.02+0.02+0.02=0.06mmand
cumulativelowerlimit= 0.01 0.01 0.01= 0.03mm
+0.06
Thereforedimensionoftheassembledlengthwillbe=60 0.03 mm

It is essential to avoid or minimize the cumulative effect of tolerance buildup, as

it leads to a high tolerance on overall length, which is undesirable.
If progressive dimensioning from a common reference line or a baseline
dimensioning is adopted, then tolerance accumulation effect can be minimized.
This is clearly illustrated in Fig. 3.7.

16
MaximumandMinimumMetalConditions
Letusconsiderashafthavingadimensionof40 0.05mm.
Themaximummetallimit(MML)oftheshaftwillhaveadimensionof40.05mm
becauseatthishigherlimit,theshaftwillhavethemaximumpossibleamountof
metal.
Theshaftwillhavetheleastpossibleamountofmetalatalowerlimitof39.95
mm,andthislimitoftheshaftisknownasminimumorleastmetallimit(LML).
Similarly,consideraholehavingadimensionof45 0.05mm.
Theholewillhaveamaximumpossibleamountofmetalatalowerlimitof44.95
mmandthelowerlimitoftheholeisdesignatedasMML.
Forexample,whenaholeisdrilledinacomponent,minimumamountofmaterial
isremovedatthelowerlimitsizeofthehole.Thislowerlimitoftheholeisknown
asMML.
ThehigherlimitoftheholewillbetheLML.Atahighlimitof45.05mm,thehole
willhavetheleastpossibleamountofmetal.
ThemaximumandminimummetalconditionsareshowninFig.3.8 17
 FITS
Fits
Manufacturedpartsarerequired
tomatewithoneanotherduring
assembly.

Therelationshipbetweenthetwo
matingpartsthataretobe
assembled,thatis,theholeand
theshaft,withrespecttothe
differenceintheirdimensions
beforeassemblyiscalledafit.

Anidealfitisrequiredforproper
functioningofthematingparts.
Threebasictypesoffitscanbe
identified,dependingontheactual
limitsoftheholeorshaft:
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 FITS
1. Clearancefit
2.Interferencefit
3. Transitionfit
Clearancefit:Thelargestpermissible
diameteroftheshaftissmallerthanthe
diameterofthesmallesthole.
Thistypeoffitalwaysprovidesclearance.
Smallclearancesareprovidedforaprecise
fitthatcaneasilybeassembledwithoutthe
assistanceoftools.Whenrelativemotions
arerequired,largeclearancescanbe
provided,forexample,ashaftrotatingina
bush.
Incaseofclearancefit,thedifference
betweenthesizesisalwayspositive.The
clearancefitisdescribedinFig.3.9.
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 FITS
Interferencefit:Theminimumpermissiblediameteroftheshaft
exceedsthemaximumallowablediameterofthehole.

Thistypeoffitalwaysprovidesinterference.Interferencefitisa
formofatightfit.Toolsarerequiredforthepreciseassemblyoftwo
partswithaninterferencefit.

Whentwomatingpartsareassembledwithaninterferencefit,it
willbeanalmostpermanentassembly,thatis,thepartswillnot
comeapartormoveduringuse.Toassemblethepartswith
interference,heatingorcoolingmayberequired.

Inaninterferencefit,thedifferencebetweenthesizesisalways
negative.

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 Allowance
Allowance:Anallowanceistheintentionaldifferencebetweenthemaximum
materiallimits,thatis,LLHandHLS(minimumclearanceormaximum
interference)ofthetwomatingparts.Itistheprescribeddifferencebetween
thedimensionsofthematingpartstoobtainthedesiredtypeoffit.
Allowancemaybepositiveornegative.Positiveallowanceindicatesaclearance
fit,andaninterferencefitisindicatedbyanegativeallowance.
Allowance=LLHHLS

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 FitTypes
Type 1: Clearance fit = Occurs when two toleranced mating
parts will always leave a space or clearance when assembled
Type 2: Interference fit = Occurs when two toleranced mating
parts will always interfere when assembled

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OxfordUniversityPress2013.Allrightsreserved.
 FitTypes
Type 3: Transition fit = Occurs when two toleranced mating
parts are sometimes and interference fit and sometimes
clearance fit when assembled.

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OxfordUniversityPress2013.Allrightsreserved.
 GeneralTerminologyinFits
Basicsize:Thisisthesizeinrelationtowhichalllimitsofsizearederived.
Basicornominalsizeisdefinedasthesizebasedonwhichthedimensional
deviationsaregiven.Thisis,ingeneral,thesameforbothcomponents.
Limitsofsize:Thesearethemaximumandminimumpermissiblesizes
acceptableforaspecificdimension.Theoperatorisexpectedto
manufacturethecomponentwithintheselimits.Themaximumlimitofsize
isthegreaterofthetwolimitsofsize,whereastheminimumlimitofsizeis
thesmallerofthetwo.
Tolerance:Thisisthetotalpermissiblevariationinthesizeofadimension,
thatis,thedifferencebetweenthemaximumandminimumlimitsofsize.It
isalwayspositive.
Allowance:ItistheintentionaldifferencebetweentheLLHandHLS.An
allowancemaybeeitherpositiveornegative.
Allowance=LLHHLS
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 GeneralTerminologyinFits
Grade:Thisisanindicationofthetolerancemagnitude;thelowerthegrade,the
finerthetolerance.
Deviation:Itisthealgebraicdifferencebetweenasizeanditscorrespondingbasic
size.Itmaybepositive,negative,orzero.
Upperdeviation:Itisthealgebraicdifferencebetweenthemaximumlimitofsize
anditscorrespondingbasicsize.ThisisdesignatedasESforaholeandases fora
shaft.
Lowerdeviation:Itisthealgebraicdifferencebetweentheminimumlimitofsize
anditscorrespondingbasicsize.ThisisdesignatedasEIforaholeandaseifora
shaft.
Actualdeviation:Itisthealgebraicdifferencebetweentheactualsizeandits
correspondingbasicsize.
Fundamentaldeviation:Itistheminimumdifferencebetweenthesizeofa
componentanditsbasicsize.Thisisidenticaltotheupperdeviationforshaftsand
lowerdeviationforholes. 25
 GeneralTerminologyinFits
Zeroline:Thislineisalsoknownasthelineofzerodeviation.Theconvention
istodrawthezerolinehorizontallywithpositivedeviationsrepresentedabove
andnegativedeviationsindicatedbelow.Thezerolinerepresentsthebasicsize
inthegraphicalrepresentation.
Shaftandhole:Thesetermsareusedtodesignatealltheexternalandinternal
featuresofanyshapeandnotnecessarilycylindrical.
Fit:Itistherelationshipthatexistsbetweentwomatingparts,aholeanda
shaft,withrespecttotheirdimensionaldifferencebeforeassembly.

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GeneralTerminologyinFits

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 GeneralTerminologyinFits
BasicHoleSystem
Thebasicholesystemisusedtoapplytolerances
toaholeandshaftassembly.

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 GeneralTerminologyinFits
Tolerancesymbols:Theseareusedtospecifythetoleranceandfitsfor
matingcomponents.Forexample,in40H8f7,thenumber40indicatesthe
basicsizeinmillimeters;capitalletterHindicatesthefundamental
deviationforthehole;andlowercaseletterfindicatestheshaft.The
numbersfollowingthelettersindicatecorrespondingITgrades.

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GeneralTerminologyinFits

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 GeneralTerminologyinFits
The ISO System of Limits and Fits (referred to as the ISO system) is
covered in national standards throughout the world, as shown by the
following list:

Global ISO 286

USA ANSI B4.2
Japan JIS B0401
Germany DIN 7160//61
France NF E 02-100-122
UK BSI 4500
Italy UNI 6388
Australia AS 1654

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GeneralTerminologyinFits

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ClearanceFit (e.g.:H7/f6)

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ClearanceFit (pl.H7/f6)

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ClearanceFit (pl.H7/f6)

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 TransitionFit

Either a clearance or an interference may result

depending on the exact value of the dimensions
of the machined shaft and hole within the
specified tolerance zones.
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TransitionFit (e.g.:H7/j6)

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TransitionFit (e.g.:H7/j6)

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TransitionFit (e.g.:H7/j6)

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TransitionFit (e.g.:H7/j6)

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 InterferenceFit

The mating parts have such limits that the lowest

shaft diameter is larger than the largest hole
diameter..

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InterferenceFit(H7/n6)

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InterferenceFit (H7/n6)

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InterferenceFit(H7/n6)

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 Example:50H7/f6
OnlinecalculationofFits
http://www.tss.trelleborg.com/global/en/service/fits_tolerance/fits_tolerance_1.html

Hole Shaft

UpperLimit 50.025 49.975

LowerLimit 50 49.959

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 Twowaysofindicatingtolerancesontechnical
drawings
Limits of a dimension or the tolerance values are
specified directly with the dimension.

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 Indicatingtolerances

The dimension is given by:

a shape symbol,
nominal size,
a letter indicating the
position of the tolerance
zone in relation to zero line,
a number indicating the
width of the tolerance zone.

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SpecifyingFitsintechnicalDrawing

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