LIMITS, FITS & CALCULATIONS

ILLUSTRATION OF BASIC SIZE DEVIATIONS,

LIMITS AND TOLERANCES

Fig. 1.1 Graphical Illustration of Fits and Tolerances

LIMITS
Actual machine size

between the maximum

and minimum limits

MAXIMUM LIMIT

Maximum permissible machine size corresponding to basic

size.
Fig. 1.1, 30 mm is = 30 + 0.035 = 30. 035 mm.
Basic size

Maximum limit

MINIMUM LIMIT
Minimum allowable machine size corresponding to basic
size.
In Fig. 1.1, 30 mm is = 30 - 0.215 = 29. 785 mm.
Basic size

Minimum limit

TOLERANCE

The difference between the maximum and minimum limits

of a size is tolerance.
In Fig. 1.1 the tolerance is = 30.035 - 29.785 = 0.25m.
Max. limit

Min. limit

Tolerance

DEVIATION
(Actual, or maximum, or minimum) (Basic size).

UPPER DEVIATION

(Maximum limit) (Basic size)

In Fig.1.1, the upper deviation is = 30.035 - 30

= 0.035 mm.

LOWER DEVIATION

(Minimum limit) (Basic size)

In Fig. 1.1, the lower deviation is = 29.785 - 30

= - 0.215 mm.
ACTUAL DEVIATION - (Actual measured size) (Basic size)
In Fig. 1.1, the actual deviation = 29.925 - 30
= - 0.075 mm.
ZERO LINE
A straight line drawn for the basic size is called zero line.

Upper and lower deviation are referred to zero line.

Zero line is drawn horizontally.

Above zero line - positive deviations.

Below zero line - negative deviations.

TOLERANCE ZONE
The zone bounded by the upper and lower limits of the
basic size.

In Fig. 1.1, tolerance zone is shown by hatched line.

FITS
The relationship between the mating surfaces of
the parts,because of the difference in dimensions is
called fit.
Thus fit has a characteristic effect on the
performance of mating parts.

Example: width of the slot & the thickness of the

key.

CLEARANCE

(Hole dimension) (Dimension of shaft that fit to it).

Maximum - hole size is maximum and the shaft size is

minimum.
Minimum - shaft size is maximum and the hole size is
minimum.
CLASSIFICATION OF FITS
Clearance fit

Interference fit
Transition fit

CLEARANCE FIT

Fit with positive clearance between the hole and the shaft.

B
A

Min hole Max Shaft = + ve clearance fit.

Fig. 1.2 Clearance Fit

INTERFERENCE FIT

Fit with negative clearance between the hole and the shaft.

Max hole Min Shaft = - ve interferance fit

Fig. 1.3 Interference Fit

TRANSITION FIT

Fit established when the dimensions of the hole are

such that there exists either a positive clearance or a
negative clearance when the shaft is fitted into the hole.

Fig 1.4 Transition Fit

TRANSITION FITS AND INTERFERENCE FITS

Combination of
Hole and Shaft
H6 j5 fine
H7 j6 normal

Quality of Fit
Clearance
transition

Very small clearance is obtained - used for fits where a

slight interference is permissible - coupling spigots and
recesses, gear rings clamped to steel hubs.

True
transition

Fits averaging no clearance where slight interference can

be tolerated , with the object of eliminating vibration - ball
bearings races of light duty.

H8 j7 coarse
H6 k5 fine
H7 k6 normal
H8 k7 coarse
H6 m5 fine
H7 m6 normal

Typical uses

Interference
transition

Fits averaging slight interference - used for ball bearing

races of medium duty.

H8 m7 coarse
H6 p5 fine

Press fit

H7 p6 normal
H6 r5 fine

Drive fit

H7 r6 normal
H6 s5 fine

Drive fit

H7 s6 normal
H6 u5 fine
H7 u6 normal

Force or
shrink fit

Light press fit for nonferrous parts which can be dismantled

when required-bearing bushes-press fit for steel, cast iron
or brass to steel assemblies- bush in a gear.
Medium drive fit for ferrous parts and light drive fit for
non-ferrous parts that can be dismantled.
Permanent or semi permanent assemblies of steel and cast
iron with considerable gripping force- collars pressed on to
shafts, valve seatings etc. For light alloys this gives a press
fit.
High interference fit a thorough investigation into the
degree of grip and the stresses in the part must be made.

SYSTEMS OF FITS

HOLE BASIS SYSTEM: the hole is constant in diameter

and various types of fits are obtained by suitably
varying the limits of the shaft.
SHAFT BASIS SYSTEM: the shaft is constant in
diameter and various types of fits are obtained by
suitably varying the limits of the hole.

HOLE BASIS SYSTEM

Single hole, whose lower deviation is zero.

Minimum limit of the hole will be equal to its basic size.

Clearance Fit
B

Interference Fit
C

Fig. 1.5 Hole Basis System

Grades of
Holes

MANUFACTURING PROCESS USED

H5

Fine Boring, Fine Grinding, Honing

H6

Fine Boring, Honing, Hand Reaming

H7

Int. Grinding, Broaching, Reaming

H8

Boring, Machine Reaming

H9

Boring & Reaming

H10

Not for diameter fits; used for milled widths,

drilled holes

H11

Not used in fits; punching, coarse drilling

drawn recesses

HOLE BASIS SYSTEM - Design Example

Requirement
Hole basic size

20 mm diameter.

Clearance of

0.100 mm.

Hole tolerance

0.025 mm.

Shaft tolerance

0.050 mm.

Design
Minimum limit of the hole is
Maximum limit of the shaft

20 mm.
= Lower limit of the hole
Minimum clearance
= 19.900 mm

Minimum limit of the shaft = Maximum limit of the shaft

Tolerance on the shaft.
= 19. 850 mm.
Maximum limit of the hole = Maximum limit of the hole +
Tolerance on the hole.
= 20. 025 mm.
Shaft

Hole

Max. limit = 19.900 mm.

Min. limit = 19. 850 mm.

Max. limit = 20.025 m.

Min. limit
= 20. 000 mm.

Why the Hole Basis System is Preferred?

Holes are produced by drilling, boring, reaming,
broaching, etc.,
Shafts are either turned or ground.
Shaft basis system - Holes of different sizes are required,
(requires tools of different types and
sizes).
Hole basis system - Only one tool is required, to
produce the hole and the shaft can
be machined to any desired size.

SYSTEMS OF TOLERANCING
1. UNILATERAL SYSTEM
Deviations are allowed in only one direction from the
basic size.
The deviation in the other direction is zero.
Hence, either the maximum limit or the minimum
limit will be equal to the basic size.
2. BILATERAL SYSTEM

Deviations are allowed in both the directions from

the basic size.
The deviations are allowed in both the directions.
One of the limits

above the basic size.

Other limits

below the basic size.

FUNDAMENTAL TOLERANCES OF GRADES

Values of Tolerances in Microns (1 micron = 0.001 mm)
Tolerance Grades
Diameter steps in mm
To and inc 3
Over 3
To and inc 6
Over 6
To and inc 10
Over 10
To and inc 18
Over 18
To and inc 30
Over 30
To and inc 50
Over 50
To and inc 80
Over 80
To and inc 120
Over 120
To and inc 180
Over 180
To and inc 250
Over 250
To and inc 315
Over 315
To and inc 400
Over 400
To and inc 500

01

10

11

12

13

14*

15*

16*

0.3

0.5

0.8

1.2

10

14

25

40

60

100

140

250

400

600

0.4

0.6

1.5

2.5

12

18

30

48

75

120

180

300

480

750

0.4

0.6

1.5

2.5

15

22

36

58

90

150

220

360

580

900

0.5

0.8

1.2

11

18

27

43

70

110

180

270

430

700

1100

0.6

1.5

2.5

13

21

33

52

84

130

210

330

520

840

1300

0.6

1.5

2.5

11

16

25

39

62

100

160

250

390

620

1000

1600

0.8

1.2

13

19

30

46

74

120

190

300

460

740

1200

1900

1.5

2.5

10

15

22

35

54

87

140

220

350

540

870

1400

2200

1.2

3.5

12

18

25

40

63

100

160

250

400

630

1000

1600

2500

4.5

10

14

20

29

46

72

115

185

290

460

720

1150

1850

2900

2.5

12

16

23

32

52

81

130

210

320

520

810

1300

2100

3200

13

18

25

36

57

89

140

230

360

570

890

1400

2300

3600

10

15

20

27

40

63

97

155

250

400

630

970

1550

2500

4000

MACHINING SYMBOL

MACHINIG PROCESS AND THEIR Ra VALUES

Sl.
No.
1
2
3
4
5
6
7
8

Machining Process
Drilling
Planing/ shaping
Turning
Boring
Reaming
Cyclic grinding
Surface grinding
Lapping

Ra
(in microns)
6.3 25
1.6 12.5
1.6 6.3
1.6 6.3
0.8 6.
0.4 3.2
0.4 3.2
0.05 0.4

ATTAINABLE SIZE TOLERANCE

Sl.
No.
1
2
3
4
5
6
7
8
9
10
11

Machining
Process
Drilling
Milling
Turning/ Boring
Grinding
Lapping
Broaching
Shaping
Reaming
Hobbing
Surface grinding
Honing

IT
Value
IT12
IT10
IT8
IT6
IT4
IT7
IT12
IT8
IT7
IT4
IT7

Tolerance value
(for a size of
20 mm)
0.21
0.084
0.013
0.006
0.006
0.021
0.210
0.033
0.021
0.006
0.021

GEOMETRIC TOLERANCE
Sl.
No.

Symbol

Description

Straightness

Flatness

Roundness

Cylindricity

Perpendicularity

Angulaity

Circularity

Profile of a line

Profile of a surface

What machining process should be adopted to each

step of the following components. Also give step
drawing details ?

(a)

(b)

(c)

REFERENCE

1. Gopalakrishna K R, Machine Drawing, Tenth

Edition, Bangalore, 1996.
2. Faculty of Mechanical Engineering, PSG College of
Technology, Design Data Book, Coimbatore, 1993.
3. ASME Y 14.5M- 1994, Dimensioning and
Tolerancing, ASME, New York, 1995.

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