Tolerance Limits and Fits

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Tolerance
No two parts are identical.
Variation in size inevitable.
Interchangeability.
Specified by two extreme allowable size called limits.
Difference between the maximum and minimum limit sizes.

Allowance
Provided intentionally.
Gives the required fit (to meet out functional requirement).

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Tolerance Types
Dimensional Tolerance
Geometric Tolerance

What is the difference?

Dimensional tolerances control ____________
Dimensions ?
Geometry ?
Geometric tolerances control Dimensions
__________ & ___________

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Terminology
Standard Size
Used for standard components like bolt, nut, etc..

Basic Size
Size calculated by design.

Actual Size
Size of manufactured component.
Tolerance
Difference between maximum and minimum limit sizes.

Deviation
Difference between the actual size and basic size.

Limits
Two allowable extreme sizes for a component.

Allowance
Dimensional difference between the maximum limit of two mating
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components.

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Types of deviation
Upper deviation
Deviation between maximum deviation limit and its basic size.

Lower deviation
Deviation between minimum deviation limit and its basic size.

Fundamental deviation
It is the upper or lower deviation closest to the basic size.

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Tolerance dependency
Manufacturing process.
Size of the component.

International Tolerance Grade

IT01 to IT7 For measuring tools

IT8 to IT15 For Materials
IT5 to IT11 For fits
IT12 to IT16 Commercial manufacturing
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Tolerances Related to Machining Processes

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Specifying Tolerance - Methods

1) 1.375 0.004

2) 1.371 & 1.379

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3) Fundamental tolerance method

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Bilateral and Unilateral Tolerances

If the deviation is on both sides from basic size bilateral
If the deviation is on one side (one of the deviation zero) - unilateral

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Unilateral

Bilateral

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Fundamental tolerance method

Uses letter and number symbol.
Letters A to Z, ZA, ZB and ZC is specified.
Upper case letters for holes and lower case letters for shafts.
Letters I, L, O, Q and W are not used.
Letter symbol represents the degree of closeness of tolerance zone.
Number symbol represents IT grade.

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Tolerance Zones for holes

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Tolerance Zones for shafts

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Fundamental deviations for holes

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Fundamental deviations for shafts

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Fundamental tolerance Example

50E6 Decode this tolerance symbol.
Basic
size
50

Tol. Zone symbol IT grade

E

E is on the positive side.

So add tolerance to basic size.

Lower deviation = 50+0.050 = 50.050

Upper deviation =
50+0.05+0.016 = 50.066

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Example Contd..
Calculate maximum and minimum sizes of the holes for the given.
a) 80J7

b) 120ZC8
Letter symbol

Basic size

Range

Tol. Zone

Tolerance

Upper/Lower

80

65 80

0.018

Lower

120

100 120

ZC

0.690

Upper

Number symbol

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Basic size

Range

IT Grade

Tolerance

80

50 80

0.030

120

80 120

0.054

Symbol

Minimum size

Maximum size

80J7

80+0.018 = 80.018

80+0.018+0.030 = 80.048

120ZC8

120 0.690 0.054 = 119.256

120 0.690 = 119.310

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Example Contd..
Calculate maximum and minimum sizes of the shaft for the given.

85js10
Letter symbol
Basic size

Range

Tol. Zone

Tolerance

Upper/Lower

85

80 100

js

IT/2

Lower/Upper

Number symbol

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Basic size

Range

IT Grade

Tolerance

85

80 120

10

0.140

Symbol

Minimum size

Maximum size

85js10

85 (0.140/2) = 84.93

85 + (0.140/2) = 85.07

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Example Contd..
A shaft of diameter 30 mm is to be produced in bulk

quantities using capstan lathe. Suggest suitable tolerance.

From table, IT9 is obtainable in a capstan lathe.
Basic size 30
Range 18 30
Tolerance 0.052 (for IT9)
Symmetric tolerance 0.026
So tolerance suggested is 300.026

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Fits
Indicates the tightness or looseness of the mating parts.

Tolerance of B
Part
B

Fit Tolerance:
Clearance,
Interference, or
Transition
Tolerance of A
Part A

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Types of fit
Clearance fit

Hole diameter is always bigger than shaft.

Transition fit Hole diameter is approximately equal to the shaft

diameter.
Interference fit Hole diameter is smaller than shaft diameter.

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Shaft and Hole Clearance and Interference Fits

Clearance

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Interference

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Shaft and Hole Fits Transition Fit

Transition

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System of fits
Hole basis Lower deviation for hole is zero. Basic size is taken
as the minimum hole [H].
Shaft basis Upper deviation for shaft is zero. Basic shaft size is
taken as the maximum shaft diameter [h].

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Basic Hole System

Clearance/Allowance = Hole Shaft
Cmax = Hmax Smin
Cmin = Hmin Smax
Both Cmax and Cmin >0 Clearance fit
Both Cmax and Cmin <0 Interference fit

SMAX
SMIN
HMAX
HMIN

Cmax > 0 Cmin < 0 Transition fit

System Tolerance = Cmax Cmin
Note:
Fix hole size.

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Calculate shaft size from formula.

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Basic Shaft System

Clearance/Allowance = Shaft Hole
Cmax = Hmax Smin
Cmin = Hmin Smax
Both Cmax and Cmin >0 Clearance fit
Both Cmax and Cmin <0 Interference fit
Cmax > 0 Cmin < 0 Transition fit
System Tolerance = Cmax Cmin
Note:
Fix shaft size.
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Calculate hole size from formula

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Specifying a fit
By two fundamental tolerance grades.
Example:
H7 d8 (Hole basis)
D8 h7 (Shaft basis)
First specification is for hole and the second one for shaft.

How to decide on fundamental tolerances?

Based on type of fit suitable for the application.

Knowing application how to select fits?

Use standards. (table)
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Example for fit

A cylinder casing of basic inside diameter 85 mm is to be shrunk

fit with a cylinder liner. Suggest a suitable tolerance for the

cylinder casing and liner.
Solution:
Hole basis Because the basic size is taken as inside diameter (85)
Next select the type of fit. How?
(Use table)

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Summary
Variation in size during production is inevitable.
To control above provide tolerance, while preparing drawings.
Tolerance is provided based on the fit required.
Required fit is selected from standard tables and based on

application.
So a Mechanical engineer
Needs to know about
Tolerance and fits.

Must be capable of interpreting

Tolerance symbols/details

Must be familiar with

Standards related to above and to locate and use standards book.
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