LIMITS, FITS & TOLERANCES

Interchangeable Manufacture
( Interchangeability )

Bottle caps Rims

Interchangeable Manufacture

Definition
The interchangeable manufacture implies that,
the parts that are for practical purposes identical.
They are made to specifications by processes that
ensure that they are so nearly identical that they
will fit into any device of the same type
 Advantages For Interchangeable Manufacture

• Replacement: One such part can freely replace

another, without any custom fitting (such
as filling).
• Easy to Assembly: This interchangeability allows
easy assembly of new devices
• Repairing: Easier repair of existing devices.
• Minimizing time and cost :Minimizing both the
time and skill required of the person doing the
assembly or repair.
• Rapid Manufacturing :Machine tool enables the
components to be manufactured more rapidly
 Terminology for LIMITS & FITS

❖ Terminology:- The terms related to limit system are as

below: ❖Standard Size:- Some parts of
machine compo. Like bolt, nuts
standardized for
interchangeability of parts. M10
bolt ( M10.25)
❖Basic Size:- It is the size based
Basic
Size

on which the dimensional

deviations are given.

❖Actual Size:- It is the size of the component by actual

measurement after it is manufactured. It should lie
between the two limits of size.
❖ Limits :- These are the maximum and minimum permissible sizes
of the part.

❖ Maximum limit (Upper Limit ):- Is the maximum size permitted

for the part.
Maximum permissible machine size corresponding to basic size.
Fig. 1.1, Ø 30 mm is = Ø 30 + 0.035 = Ø 30. 035 mm.
Basic size Maximum limit

❖ Minimum limit (Lower Limit):- it is the minimum size permitted

for the part limit of size.

Minimum allowable machine size corresponding to basic size.

In Fig. 1.1, Ø 30 mm is = Ø 30 - 0.215 = Ø 29. 785 mm.

Basic size Minimum limit

•Max material condition (MMC) = the
condition of a part when it contains the
greatest amount of material
• Least material condition (LMC) = the
condition of a part when it contains the
least amount of material possible
•For Shaft-UL,LL
•For Hole-LL,UL
TOLERANCE

The difference between the maximum and minimum limits of a size is tolerance.

In Fig. 1.1 the tolerance is = Ø 30.035 - Ø 29.785 = 0.25m.

Max. limit Min. limit Tolerance

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

• Tolerances are used to control the variation

existing on all manufactured parts.
• Toleranced dimensions control the amount of
variation on each part of an assembly.
• Tolerances allow for interchangeable parts. Parts
made by different companies functionally “fit”
although they may not perfectly fit.
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.
Deviations
❖ Deviation:- It is the algebraic
Lower Deviation

Upper Deviation

difference between a size, to its

corresponding basic size. It may be
positive, negative or zero.
Hole

❖Upper Deviation:- It is the

Max.dia.

Min.dia.

Max.dia.
Min.dia.

Shaft algebraic difference between

maximum limit of size and its
corresponding basic size.
❖Lower Deviation:- It is the algebraic difference between
minimum limit of size and its corresponding basic size.

❖Actual Deviation:- It is the algebraic difference between

actual size and its corresponding basic size.
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.
International tolerance grades ( IT Grades )
(IT01,IT0,IT1 to IT 16)
 Multiplier for tolerance Grades

Grades IT5 IT6 IT7 IT8 IT9 IT10 IT11 IT12 IT13 IT14 IT15 IT16

Multiplier 7i 10i 16i 25i 40i 64i 100i 160i 250i 400i 640i 1000i
of unit i

i= 0.45 D (1/3) + 0.001 D

Letter & Number Symbol for Hole & Shaft
 CLEARANCE FIT
Occurs when two toleranced mating parts will always leave a space or
clearance when assembled

Maximum shaft dimension < Minimum hole dimension

FIT - condition of looseness or tightness between two mating parts being assembled
together
 INTERFERANCE FIT
Occurs when two toleranced mating parts will always interfere when
assembled

Maximum Hole size < Minimum Shaft size

 TRANSITION FIT
Occurs when two toleranced mating parts are sometimes and interference
fit and sometimes clearance fit when assembled.

Obtained by overlapping of tolerance zones of shaft and hole ……Does

not guarantee neither clearance nor interference fit
 HOLE BASIS SYSTEM & SHAFT BASIS SYSTEM
To obtain different types of fits, it is general practice to vary
tolerance zone of one of the mating parts

HOLE BASED SYSTEM-

Size of hole is kept constant,
shaft size is varied
to get different fits.

SHAFT BASED SYSTEM-

Size of shaft is kept constant,
hole size is varied
to get different fits.
A fit is indicated by the basic size common to both components, followed by symbol
corresponding to each component, the hole being quoted first.

E.g. 45 H8/g7