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MODULE 7
Sub Module 7.6
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Contents
DRILLSIZESFORBOLTHOLES4
CLASSESOFFITS5
COMMONSYSTEMOFFITSANDCLEARANCES10
SCHEDULEOFFITSANDCLEARANCESFORAIRCRAFTANDENGINES12
LIMITSFORBOW13
LIMITSFORTWIST13
LIMITSFORWEAR14
STANDARDMETHODSFORCHECKINGSHAFTS,BEARINGSAND
OTHERS16
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For ease of manufacture and replacement, it is essential that For this reason, limits are imposed on the manufacturing
the components of similar mechanisms should be processes, to ensure that, if any two mating parts are
interchangeable. For this reason limits (tolerances and manufactured to the dimensions as stated on the relevant
allowances) are imposed on the manufacturing procedures. drawings, then the parts will assemble without need of further
major adjustments and in the least time possible.
The limits on dimensions ensure that, if any two mating parts
are manufactured to the tolerances and allowances, stated on The limits are based on the allowances and tolerances imposed
the drawing, then they will assemble without the need of further on the dimensions of the manufactured parts. These
hand working or machining to achieve the required standard of dimensions will be given the accuracy required by the designer
fit. of the respective parts.
Because shafts are much easier than holes to machine small ALLOWANCES
diameters, the main systems of Limits and Fits, for engineering
purposes, is usually the hole-based system. The holes are An allowance is a difference in dimension that is necessary to
created to a certain tolerance and the sizes of the shafts are give a particular class of fit between two parts. If, for example
altered to provide the required class of fit between the two (and using a typical limit system), a shaft were required to
items. locate with a corresponding hole in a component. Then, to
assist in the economy of manufacture, either the hole or the
DIMENSIONS shaft is made as accurately as possible to the nominal size and
an allowance is applied to the associated item. The term shaft
Mass production has long been the basis of the approach to the also includes bolts and pins.
most economic methods of manufacturing and the complete
replacement of a defective item is common practice in the If the shaft is constant and the hole varies in size, then the
maintenance of aircraft and aerospace components. system used is said to be shaft-based. If the hole is constant
and the shaft varies in size, then the system is hole based. The
hole-based system is the one in more general use.
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TOLERANCES
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Table 1
TYPES OF TOLERANCES
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Drill sizes (as discussed in the Tools topic) are fixed and can be
found on charts that list each standard drill size, together with
other columns such as clearance and tapping sizes. These
charts may also include equivalent sizes displayed in metric,
fractional, letter and in the number/letter system.
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CLASSES OF FITS
HOLE-BASED SYSTEM
EXAMPLE 1
EXAMPLE 2
The limits shown on a drawing for a mating hole and shaft are:
The limits shown on drawing for a mating hole and shaft are:
Find what type of fit will exist between the hole and shaft.
Find the type of fit that exists between the hole and shaft.
The smallest hole is 10.000 + 0.000 = 10.000 mm.
The largest hole is 40.000 + 0.025 = 40.025 mm
The largest shaft is 10.000 - 0.006 = 9.994 mm.
The smallest shaft is 40.000 + 0.043 = 40.043 mm
Hence the shaft is always smaller than the hole and a clearance
fit will be obtained. The shaft is always larger than the hole and hence we have an
interference fit.
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EXAMPLE 3
The limits shown on a drawing for a mating hole and shaft are:
Find the type of fit that exists between the hole and shaft.
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Newall system
Table 2
Newall System of Fits
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In the Transition Fit, the differences in the upper and lower limits
of both items are negligible so that only light effort is required to
insert the shaft into the hole.
The upper and lower limits of the shaft, in a Clearance Fit, are
always less than those of the hole, so that the shaft moves
easily within the hole.
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COMMON SYSTEM OF FITS AND CLEARANCES Fundamental deviation Fundamental deviation is either the
upper or the lower deviation, depending on which is closer to
Limits the basic size. The fundamental deviation locates the tolerance
zone relative to the basic size.
It is impossible to make anything to an exact size. One way of
getting over this difficulty is to define an acceptable margin Tolerance Tolerance is the difference between the upper and
for every dimension. The extreme permissible values of a lower limit. Where variation either side of the nominal dimension
dimension are known as limits. The larger dimension is called can occur, the tolerance is called bilateral. Where one tolerance
the upper limit and the smaller dimension the lower limit. is zero the tolerance is said to be unilateral.
Nominal size The dimension of an object when variations in International tolerance grade (IT grade) number
size are disregarded International tolerance grade numbers are numbers which for a
particular IT
Basic size Basic Size is the theoretical exact size from which
limits of size are determined by the application of allowances Numbers have the same relative level of accuracy but vary
and tolerances. depending upon the nominal or basic size.
Deviation Deviation is the algebraic difference between a size British Standard Limits and Fits (BS 4500) - Governs limits
and the corresponding basic size. and fits used for holes and shafts in industry.
Upper deviation Upper deviation is the algebraic difference Clearance Clearance is the measured difference in
between the maximum limit and the corresponding basic size. dimensions of two mating parts when the inner member is
smaller than the outer member. Here the reference is to the
Lower deviation Lower deviation is the algebraic difference inner dimensions of the outer part and the outer dimensions of
between the minimum limit and the corresponding basic size. the inner part.
Upper limit - The 'upper limit' is the largest size allowed. Interference Interference is the measured difference
in dimensions of two mating parts when the inner member is
Lower limit - The 'lower limit' is the smallest size allowed. larger than the outer member, where the outer dimensions of
the inner part and the inner dimensions of the outer part is
considered.
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Wear occurs at any time that there is motion between two parts.
This motion can be intentional, such as when a shaft rotates in
a plain (journal) bearing or when a roller moves back and forth
over a track. Wear can also be accidental, where two parts, that
should be immovable, chafe together.
Bow of a shaft
Twist of a shaft.
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When dealing with shafts and tubes, it is vital that not only are Twist is the result of applied torsion on circular or square-
the ends square with each other, but that the centreline of the sectioned shafts. If the twist disappears, as a result of removing
complete shaft or tube is straight. the force, then the shaft will have been loaded below its elastic
limit. If the shaft remains twisted, after removal of the load, then
If the centre line of the shaft is not straight, then the item is it has been loaded above its elastic limit.
bowed. When the shaft or tube is rotating, especially at a high
speed in a bowed state, there is the risk of vibration, which can The action of a shaft (of whatever section), carrying a torque
lead to mechanical failures, loosening of fasteners and (most load is to twist in proportion to the torque applied. The result of
critical of all) fatigue. cyclic loading of shafts is that, at certain times, the shafts have
to be checked for permanent twist. If the shaft has a square
All cylindrical items, both tubular and solid, can be given a limit section, it can be checked for twist on a surface table using a
to the amount of bow permitted. For example a drive shaft, DTI mounted on a surface gauge.
which rotates about 1500 rpm, may have a limit of 0.25 mm
(0.01 in) bow over the length of the shaft. Solid or tubular shafts that have to be checked for twist will
possibly have witness marks or lines engraved or etched at
This ensures that, within the limits of production, the drive shafts each end of the shaft. The shafts can be checked, by mounting
are effectively straight, giving the least possible vibration. the shaft in V blocks and, then, locating these marks in the
horizontal position.
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The designer of the aircraft or equipment will set all limits, with LIMITS FOR WEAR
regards to the distortion of parts and set them down in the
relevant manuals. The methods used to measure the distortion The four dimensions typically covered in wear tables are:
will either be standard procedures, such as using a DTI and
surface table etc., or will have a special procedure included in Dimension New
the manuals.
Permissible Worn Dimension
Clearance New
Dimension New relates to the size of the part when new, and
will show the relevant tolerances.
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Fundamental Deviation forshafts
Basic Size
UpperDeviation Lower Deviation
a b c cd d f g h j k m n p r s t u v x y z za zb zc
3 -270 -140 -60 -34 -20 -6 -2 0 -4 0 +2 +4 +6 +10 +14 - +18 - +20 - +26 +32 +40 +60
3-6 -270 -140 -70 -46 -30 -10 -4 0 -4 +1 +4 +8 +12 +15 +19 - +23 - +28 - +35 +42 +50 +80
6-10 -280 -150 -80 -56 -40 -13 -5 0 -5 +1 +6 +10 +15 +19 +23 - +28 - +34 - +42 +52 +67 +97
10-14 -290 -150 -95 - -50 -16 -6 0 -6 +1 +7 +12 +18 +23 +28 - +33 - +40 - +50 +64 +90 +130
14-18 -290 -150 -95 - -50 -16 -6 0 -6 +1 +7 +12 +18 +23 +28 - +33 +39 +45 - +60 +77 +108 +150
18-24 -300 -160 -110 - -65 -20 -7 0 -8 +2 +8 +15 +22 +28 +35 - +41 +47 +54 +63 +73 +98 +136 +188
24-30 -300 -160 -110 - -65 -20 -7 0 -8 +2 +8 +15 +22 +28 +35 +41 +48 +55 +64 +75 +88 +118 +160 +218
30-40 -310 -170 -120 - -80 -25 -9 0 -10 +2 +9 +17 +26 +34 +43 +48 +60 +68 +80 +94 +112 +148 +200 +274
40-50 -320 -180 -130 - -80 -25 -9 0 -10 +2 +9 +17 +26 +34 +43 +54 +70 +81 +97 +114 +136 +180 +242 +325
50-65 -340 -190 -140 - -100 -30 -10 0 -12 +2 +11 +20 +32 +41 +53 +66 +87 +102 +122 +144 +172 +226 +300 +405
65-80 -360 -200 -150 - -100 -30 -10 0 -12 +2 +11 +20 +32 +43 +59 +75 +102 +120 +146 +174 +210 +274 +360 +480
80-100 -380 -220 -170 - -120 -36 -12 0 -15 +3 +13 +23 +37 +51 +71 91 +124 +146 +178 +214 +258 +335 +445 +585
100-120 -410 -240 -180 - -120 -36 -12 0 -15 +3 +13 +23 +37 +54 +79 +104 +144 +172 +210 +254 +310 +400 +525 +690
120-140 -460 -260 -200 - -145 -43 -14 0 -18 +3 +15 +27 +43 +63 +92 +122 +170 +202 +248 +300 +365 +470 +620 +800
140-160 -520 -280 -210 - -145 -43 -14 0 -18 +3 +15 +27 +43 +65 +100 +134 +190 +228 +280 +340 +415 +535 +700 +900
160-180 -580 -310 -230 - -145 -43 -14 0 -18 +3 +15 +27 +43 +68 +108 +146 +210 +252 +310 +380 +465 +600 +780 +1000
180-200 -660 -340 -240 - -170 -50 -15 0 -21 +4 +17 +31 +50 +77 +122 +166 +236 +284 +350 +425 +520 +670 +880 +1150
200-225 -740 -380 -260 - -170 -50 -15 0 -21 +4 +17 +31 +50 +80 +130 +180 +258 +310 +385 +470 +575 +740 +960 +1250
225-250 -820 -420 -280 - -170 -50 -15 0 -21 +4 +17 +31 +50 +84 +140 +196 +284 +340 +425 +520 +640 +820 +1050 +1350
250-280 -920 -480 -300 - -190 -56 -17 0 -26 +4 +20 +34 +56 +94 +158 +218 +315 +385 +475 +580 +710 +920 +1200 +1550
280-315 -1050 -540 -330 - -190 -56 -17 0 -26 +4 +20 +34 +56 +98 +170 +240 +350 +425 +525 +650 +790 +1000 +1300 +1700
315-355 -1200 -600 -360 - -210 -62 -18 0 -28 +4 +21 +37 +62 +108 +190 +268 +390 +475 +590 +730 +900 +1150 +1500 +1900
355-400 -1350 -680 -400 - -210 -62 -18 0 -28 +4 +21 +37 +62 +114 +208 +294 +435 +530 +660 +820 +1000 +1300 +1650 +2100
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Fig. A
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