IPE 301

Limits, Tolerances and Fits

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Basics

Generally in engineering, any component manufactured is

required to fit or match with some other component.
The correct and prolonged functioning of the two components
in match depends upon the correct size relationships between
the two, i.e., the parts must fit with each other in a desired
way.
If a shaft is to rotate in a hole, there must be enough
clearance between the shaft and hole to allow the oil film to be
maintained for lubrication.
If the clearance is too small, excessive force would be required
in rotation of shaft.
If clearance is too wide, there would be vibrations and rapid
wear and ultimate failure

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Basics

Impossible to achieve dimensional perfection

temperature, tool wear, vibrations, human error.

due

to

Lot of time and cost of manufacturing will be high, to maintain

very close degree of accuracy.

Cost

Accuracy

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Terminology

Shaft: Not only the diameter of the circular shaft but also to any
external dimension on a component.
Hole: Not only the diameter of the circular hole but also to any
internal dimension on a component.
Basic Size or Basic dimension: It is the theoretical size from
which limits of size are derived by the application of allowances
and tolerances.
Actual Size: The measured size of the finished part.
Limit of size: Maximum and minimum permissible sizes of part.

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Terminology

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Terminology

Maximum Limit: Maximum limit or high limit is the maximum

size permitted for the part.
Minimum Limit: Minimum limit or low limit is the minimum size
permitted for the part.
Tolerance: Difference between maximum and minimum limit of
size.
Zero line: Line of zero deviation and represents the basic size.
Allowance: It is the intentional difference between the
Maximum Material Limit(MML) of mating parts. For shaft, the
maximum material limit will be its high limit and the for the hole
the maximum material limit will be its low limit

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Terminology

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Terminology

Deviation: It is the algebraic difference between a size and

corresponding basic size
Upper Deviation: The algebraic difference between the
maximum limit of size and the corresponding basic size. Positive
quantity when the maximum limit of size is greater than basic
size and negative for vice versa.
Lower Deviation: The algebraic difference between the
minimum limit of size and the corresponding basic size. Positive
quantity when the minimum limit of size is greater than basic
size and negative for vice versa.
Fundamental Deviation: It is equal to either upper or lower
deviation which is closer to the zero line.

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Terminology

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Terminology

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Terminology

Unilateral limit: both the limits of the size are on the same
side of the zero line. One of the limits may be basic size.
Bilateral limit: One of the limits is one side and the other at
the other side of zero line.
Unilateral system is more satisfactory and realistically applied
where it is common knowledge that dimensions will most
likely to deviate in one direction. Ex: Drilling a standard size
hole, the drill most likely to produce oversize hole, than
undersize hole.

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Terminology

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Fits

Fit is the general term used to signify the range of tightness or

looseness that may result from the application of a specific
combination of allowances and tolerances in mating parts.
Three types of fit
Clearance Fit
Interference Fit
Transition Fit
Movable Joint (Clearance): Shaft running in a bush
Fixed Joint (Interference): Pulley mounted on a shaft

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Fits

In clearance fit shaft is always smaller than hole. Positive

allowance between largest possible shaft and smallest possible
hole.
Minimum clearance: Difference between maximum shaft and
minimum hole.
Maximum clearance: Difference between minimum shaft and
maximum hole.
Types of Clearance Fit:
Slide Fit
Easy Slide Fit
Running Fit
Slack Running Fit
Loose Running Fit

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Fits

In Interference fit shaft always larger than

the hole. Tolerance zone of shaft entirely
above the hole.
Minimum interference: difference between
maximum hole and minimum of shaft.
Maximum interference: difference between
minimum hole and maximum of shaft
In Transition fit tolerance varies between
clearance and interference fits. Tolerance
zone of shaft and hole overlap.

Interference fit

Types of Transition Fit:

Force Fit
Tight Fit
Wringing Fit
Push Fit

Transition fit

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Hole and Shaft System

HOLE BASED SYSTEM
Size of hole is kept constant,
shaft size is varied
to get different fits.
Basic size = Low limit of hole
Hole H

SHAFT BASED SYSTEM

Size of shaft is kept constant,
hole size is varied
to get different fits.
Basic size = High limit of shaft
Shaft h

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Tolerance

Tolerance can be defined as the magnitude of permissible

variation of a dimension or other measured or control criterion
from the specified value.
The primary purpose of providing tolerances is to permit
variation in dimensions of shaft or hole without degradation
of the performance beyond the limits established by the
specification of the design.
For Example a dimension given as 1.625 .002 means that
the manufactured part may be 1.627 or 1.623, or anywhere
between these limit dimensions.

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Tolerance

The amount of tolerance depends on:

The function of the product (the allowance desired in the fit)
Manufacturing process available
Cost of production and assembly.
Cost of production or assembly decrease with increase of
tolerance:

Need for some sophisticated machinery

Higher skill required
Increased attention to inspection and handling
Tolerance assignment balanced between cost and quality.

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Tolerance

Tolerance can be based on the two methods of analysis:

Complete interchangeability
Statistical assembly
Complete interchangeability means that all parts will
assemble even though the parts are at their extreme limits.
There should be no rejected assembly for improper tolerance.
Statistical assembly methods considers the probability that
the dimensions will not occur so frequently at or near the
extreme limits as between or near the centre of these limits.

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Tolerance

Complete Interchangeability:
It is necessary to chose one direction as positive and the other
as negative. The sum of distance is zero.
In order to determine the tolerances of the individual
components, it is necessary to consider the tolerance of entire
assembly.

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Tolerance

Statistical Assembly:
A well controlled machinery operation will not produce many
parts with exactly extreme limits dimension.
Frequency of occurrence follow the normal distribution (Mean
and Standard Deviation)
Symmetrical about its vertical axis
About 99.73% values fall under the curve and only 0.27% are
expected to fall beyond these limits.

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Tolerance

Mean Value of Clearance

X clearance = X bearing - X shafts
Standard Deviation of the Variation Of Clearance

A hole and mating shaft have a nominal assembly size of 38mm.

The assembly is to have a maximum total clearance of 0.15m
and a minimum total clearance of 0.05mm. Determine the
specifications of the parts (a) for 100% interchangeability and (b)
for statistical average interchangeability.

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Tolerance

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Tolerance

100% interchangeability
BD + DE = BE
BD = BE DE
DE = Half of minimum clearance = 0.05/2 = 0.025mm
BE= Half of maximum clearance = 0.15/2 = 0.075mm
BD = Tolerance of shaft = 0.075 0.025 = 0.05 mm
Maximum limit of shaft = 38 0.025 = 37.975mm
Minimum limit of shaft = 37.975 0.05 = 37.925mm
Similarly, FH = HE EF = Tolerance of bearing = 0.075 0.025 =
0.05 mm
Minimum limit of bearing = 38 + 0.025 = 38.025mm
Maximum limit of bearing = 38.025 + 0.05 = 38.075mm

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Tolerance

Statistical interchangeability:
6clearance = Max total clearance Min total clearance = 0.15 0.05 = 0.1mm
clearance = 0.0167mm
bearing = shaft = P = 0.0118mm
tolerance for bearing or shaft = 6P = 0.0707mm
Maximum limit of shaft = 38 0.025 = 37.975mm
Minimum limit of shaft = 37.975 0.0707 = 37.904mm
Minimum limit of bearing = 38 + 0.025 = 38.025mm
Maximum limit of bearing = 38.025 + 0.0707 = 38.0957mm
Almost 41.42% more tolerance than 100% interchangeability and
only 3out of 1000 can be expect not in tolerance zone. So
manufacturing cost will be less, but not suitable for large quantities.

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Tolerance

ISO (International Organization for Standardization):

ISO systems cover holes and shafts from the smallest size up
to 3150 mm.
For different fits, series of tolerance grades available for
different range.
Hole and shaft basis system can be used.
28 different holes and shafts for any basic sizes
28 Holes: A, B, C, D,, Z, Za, Zb, Zc
28 Shafts: a, b, c, d,.., za, zb, zc
18 grades of tolerance IT0, IT01, IT2,.IT15, IT16 tolerance
grades decides the accuracy for manufacture.

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Tolerance

The selection of letter

freezes one limit of hole /
shaft
(how much away from
Basic size)

45 E8/e7
One
can
have
different
possible
combinations;
eg.
45H6g7,
45H8r6,
45E5p7
E.S. upper
deviation
E.I. lower
deviation
H : lower
deviation of hole
is zero
h : upper
deviation of shaft is
zero

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Calculation of Tolerance Grades

Tolerance grades is multiplier of standard tolerance unit i ,

Up to 500 mm

i = 0.004 D + 2.1 (m)

Above 500 mm

Where, D = (Geometric mean diameter steps in mm)

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Calculation of Tolerance Grades

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Calculation of Tolerance Grades

Calculate
Calculate limits
limits of
of tolerance
tolerance and
and allowance
allowance for
for 25H8/d9.
25H8/d9.
Steps:
Steps: 1-3,
1-3, 3-6,
3-6, 6-10,
6-10, 10-18,
10-18, 18-30,
18-30, 30-50,
30-50, 50-80,
50-80, 80-120.
80-120.