Limits, Fits and Gauges

Introduction:
It is well known fact that no two things in the nature can be identical, they may
be found to be closely similar. This is true of production of component parts in
engineering also. We know that every process is a combination of three
elements, man, machine and material. A change in any one of these will
constitute a change in the process. All these elements are subjected to inherent
and characteristic variations.
Generally, in engineering, any component manufactured is
required to fit or to match with some other component.

If a machine is under control, i.e. no assignable causes of

variation exist, and then the resultant frequency distribution
of dimension produced will be roughly in the form of
normal curve, i.e. 99.7% parts will be within ±3σ limits of
fig 4.1
means setting
The value of σ depends upon the machine used to produce a component.
If value of σ has to be used reduced, then precision machines have to be used
produces the component having less variation in dimensions. It is thus important
to note that the cost of production keeps on increasing tremendously for very
precise tolerance as shown in fig 4.1.as the tolerance approaches zero, the task
of achieving it becomes enormous and finally impossible .in general, tolerance
vs. fabrication cost is hyperbolic curve.
Tolerances:
The primary purpose of tolerances is to permit variation in dimensions without
degradation of the performance beyond the limits established by the
specification of the design.
Functional and non-functional dimensions:
Functional dimensions are those that have to be machined and fit with other
matting components. Non-functional dimensions are those, which need not be
machined to a high degree of accuracy. These have no effect on the quality
performance of the component or assembly.
Why tolerance is specified?
1. Variation in the properties of the material being machined
introduces errors.
2. The production machines themselves have some inherent
inaccuracies built into them and have the limitations to produce perfect
parts.
3. It is impossible for an operator to make perfect settings. In sitting
up the machine, i.e. in adjusting the tools and work piece on the machine,
some errors are likely to creep in.
Design consideration in the selection of engineering tolerances:
Reasons for tendency to select tight tolerance:
The inexperienced designer in order to protect himself specifies significantly
tighter tolerance than necessary for the following reasons:
1. The creed for precision, fear of interface or excessive clearance
between assembled parts.
2. Selection of tolerance from company or vendor standards that tend
to favor tight tolerance or selection from similar previous design that may
have been established on unrealistic tolerance.
3. Practice of considering tight tolerance synonymous with good
quality.

Optimum tolerance:
A good designer must explore information and techniques available as
guidelines in the establishment of realistic and, where possible, optimum
engineering tolerance.
A basic dimension
is the dimension, as worked out by purely design consideration.
If the fit between a shaft and hole is a clearance type, then for complete
interchangeable approach (refer
to fig 4.2) tolerance in shaft
=tolerance in hole =half the
maximum clearance –half the
minimum clearance. fig 4.2
Tolerance accumulation:
The overall tolerance on complete length will be sum of the tolerances on
individual length.
In fig 4.3 g=a+ c+ e and h=b+ d+ f
The affect of an accumulation of tolerances can be minimized by adopting
progressive dimensioning from datum as shown in fig 4.4

fig 4.3 fig 4.4

Compound tolerance:
In fig 4.5, the tolerances on dimension l are dependent on
tolerance on L, h andθ .the minimum tolerance will be
corresponding to L-b, θ +a and h+ c.

fig 4.5
Interchangeability:
An interchangeable part is one, which can be substituted for similar part
manufactured to the same drawing.
Process capability of a machine is defined as
±3σ spread of dimensions of component produced
by it. If a plot is drawn of the actual dimension of
the similar components produced by a machine, it
is found to follow natural law of distribution, i.e.
fig 4.6
having mean of the entire component at central value with a
spread of ±3σ value, σ being known as standard deviation, and ±3σ as the
process capability of machine.

Fig 4.7 below shoes a case in which the process capability of both shaft and hole
producing machines is same but tolerance on parts are desired as one-tenth of
process capability of machine.
Fig 4.8 below shows another case in which the process capability of hole
making machine is much wider than the tolerance of part but shaft-making
machine can produce component to the desired tolerance.
The number of groups depending on the desired tolerance.

No. of groups=process capability/tolerance desired.

 fig 4.7

fig 4.8

fig 4.9

In fig 4.10, the tolerances are shown too much exaggerated.

It is obvious that the sitting of
tolerance value alone is not
sufficient to defined particular

fig 4.10
limits, but position of the tolerance zone relative to the basic size of the feature
must also be specified.

Basic terms:
Nominal size, basic size, zero line, actual size, limits, tolerance.
Fig 4.11 illustrates the concept of basic size and zero line.

Fig 4.12 illustrates the concept of limits of size and tolerances.

Fig 4.13 shows schematic representation of tolerances.

Fig 4.14 for a hole:

Fig 4.15 for a shaft:

 Fig 4.16 shows the fundamental deviation:
Positive and negative allowances are shown in fig 4.17 and 4.18 respectively.

Hole basic system and shaft basic system are defined in fig 4.19(a) and (b) for
clearance fit, transition fit and interference fit.
The fundamental tolerances factor i=0.45 3 D +0.001D
The relative magnitude of each grade is given below for size up to and including
500 mm.

Example 4.1 calculate the limits of tolerances and allowances for a 25 mm shaft
and hole pair designated H8d9.
The disposition of these tolerances and deviations is shown in fig 4.20
Clearance: fig 4.24(a)

Interface: fig2.24 (b)

Showing disposition of maximum interface and minimum interface.

Plain gauges:
Gauges are inspection tools of rigid design, without a scale, which serve to
check the dimension of manufactured parts.
Types of gauges:
The various types of limit plug gauges and limit snap gauges are shown in fig
4.28 below:

Snap gauges:

Fig 4.41

Combined limit gauges: in case of gauging of cylindrical

holes. It is impossible to combine both the 'Go' and 'No Go'
dimensions of plug gauge and thus a single gauge doing
the work of checking both the upper and lower limits.
As shown in fig 4.45

Position gauges:
A simple gauge for checking the location of a recess in relation to a flat surface
is shown in fig 4.46 and another design is shown in fig 4.47.

Taylor's principle
The 'Go' plug gauge (Fig 4.48) is the size of the minimum limit of the hole,
while the 'No Go' plug gauge corresponds to the maximum limit.

The 'Go' snap gauge (Fig 4.49)on the other hand, is of a size corresponding to
the maximum limit of the shaft, while the 'No Go' snap gauge corresponds to
minimum limit.

Gauge maker's tolerance.

 1. first system as shown in fig 4.50
In this method workshop and inspection gauges are made separately and their
tolerance zones are different.

2. second system (revised gauge limits) as shown in fig 4.51

Under this system the disadvantages of inspection gauges are reduced by
reducing the tolerance zone of inspection gauge and the workshop gauge
tolerance remain the same.

Gauges for tapers:

a taper is tested by using taper plug and ring gauges. the important thing in
testing a tapered job is to check the diameter at bigger end and the change of
diameter per unit length.