1

Machine Design – I
Code: ME- 216
Credit Hours: 2
Lecture
Limits, Fits and Tolerances

Dr. Muhammad Imran

Mechanical Engineering Program
University of Engineering & Technology
Taxila
 Introduction
 No two parts can be produced with identical measurements by
any manufacturing process.

 In any production process, regardless of how well it is designed or

how carefully it is maintained, a certain amount of natural
variability will always exist.

 These natural variations are random in nature and are the

cumulative effect of many small, essentially uncontrollable causes.

 Usually, variability arises from improperly adjusted machines,

operator error tool wear, and/or defective raw materials.
 Introduction
 Such characteristic variability is generally large when compared to
the natural variability.

 This variability, which is not a part of random or chance cause

pattern, is referred to as ‘assignable causes’.

 Characteristic variations can be attributed to assignable causes

that can easily be identified and controlled.

 If the process can be kept under control, that is, all the assignable
and controllable causes of variations have been eliminated or

controlled, the size variations will be well within the prescribed

limits.
 Introduction
Some variability in dimension within certain limits must be
tolerated during manufacture, however precise the process may be.

The permissible level of tolerance depends on the functional

requirements, which cannot be compromised.

No component can be manufactured precisely to a given

dimension; it can only be made to lie between two limits, upper
(maximum) and low er(minimum).

The designer has to suggest these tolerance limits, which are

acceptable for each of the dimensions used to define shape and
form, and ensure satisfactory operation in service.
 Introduction
 When the tolerance allowed is sufficiently greater than the
process variation, no difficulty arises.

 The difference between the upper and lower limits is termed

permissive tolerance.

 For example, a shaft has to be manufactured to a diameter of 40

± 0.02 mm.

 This means that the shaft, which has a basic size of 40 mm, will
be acceptable if its diameter lies anywhere between the limits of
sizes, that is, an upper limit of 40.02 mm and a lower limit of
39.98 mm. Then permissive tolerance is equal to 40.02 − 39.98 =
0.04.
 Interchangeability
Interchangeability

 The term interchangeability is normally employed for the mass

production of identical items within the prescribed limits of sizes. A
little consideration will show that in order to maintain the sizes of
the part within a close degree of accuracy, a lot of time is required.
But even then there will be small variations. If the variations are
within certain limits, all parts of equivalent size will be equally fit
for operating in machines and mechanisms. Therefore, certain
variations are recognized and allowed in the sizes of the mating
parts to give the required fitting.
 This facilitates to select at random from a large number of parts for
an assembly and results in a considerable saving in the cost of
production. In order to control the size of finished part, with due
allowance for error, for interchangeable parts is called limit system.
 Interchangeability
 This facilitates to select at random from a large number of
parts for an assembly and results in a considerable saving in
the cost of production. In order to control the size of finished
part, with due allowance for error, for interchangeable parts
is called limit system.
Examples of Interchangeable Manufacture

Bottle caps Rims Tires

 Interchangeability

 It may be noted that when an assembly is made of two parts, the

part which enters into the other, is known as enveloped surface
(or shaft for cylindrical part) and the other in which one enters
is called enveloping surface (or hole for cylindrical part).

Notes:
1. The term shaft refers not only to the diameter of a circular shaft,
but it is also used to designate any external dimension of a part.
2. The term hole refers not only to the diameter of a circular hole,
but it is also used to designate any internal dimension of a part.
 Important terms used in Limit System
1. Nominal size. It is the size of a part specified in the drawing as a
matter of convenience.
2. Basic size. It is the size of a part to which all limits of variation (i.e.
tolerances) are applied to arrive at final dimensioning of the mating
parts. The nominal or basic size of a part is often the same.
3. Actual size. It is the actual measured dimension of the part. The
difference between the basic size and the actual size should not
exceed a certain limit, otherwise it will interfere with the
interchangeability of the mating parts.
4. Limits of sizes. There are two extreme permissible sizes for a
dimension of the part as shown in next Fig. The largest permissible
size for a dimension of the part is called upper or high or maximum
limit, whereas the smallest size of the part is known as lower or
minimum limit.
Important terms used in Limit System

Limits of sizes
 Important terms used in Limit System
5. Allowance. It is the difference between the basic dimensions of
the mating parts. The allowance may be positive or negative.
When the shaft size is less than the hole size, then the allowance
is positive and when the shaft size is greater than the hole size,
then the allowance is negative.
6. Tolerance. It is the difference between the upper limit and
lower limit of a dimension. In other words, it is the maximum
permissible variation in a dimension.
 Tolerances
 Tolerance can be defined as the magnitude of permissible variation of a
dimension or other measured value from the specified value.

 It can also be defined as the total variation permitted in the size of a

dimension, and is the algebraic difference between the upper and lower
acceptable dimensions. It is an absolute value.

 The basic purpose of providing tolerances is to permit dimensional

variations in the manufacture of components, adhering to the
performance criterion as established by the specification and
design.
 Tolerances
 If high performance is the sole criterion, then functional requirements dictate
the specification of tolerance limits; otherwise, the choice of setting
tolerance, to a limited extent, may be influenced and determined by factors
such as methods of tooling and available manufacturing equipment.

 The industry follows certain approved accuracy standards, such as ANSI

(American National Standards Institute) and ASME (American Society of
Mechanical Engineers), to manufacture different parts.
 Tolerances
Classification of To lerance
Tolerance can be classified under the following categories:
1. Unilateral tolerance
2. Bilateral tolerance
3. Compound tolerance
4. Geometric tolerance

Unilateral To lerance
When the tolerance distribution is only on one side of the basic size, it is
known as unilateral tolerance.

In other words, tolerance limits lie wholly on one side of the basic size,

either above or be low it.

Example: + 0.02 + 0.02 – 0.01 + 0.00
40 + 0.01, 40 – 0.00, 40 – 0.02, 40 – 0.02
Tolerances
 Tolerances
Bilateral Tolerance

When the tolerance distribution lies on either side of the basic size, it is known as bilateral
tolerance.
In other words, the dimension of the part is allowed to vary on both sides of the basic size
but may not be necessarily equally disposed about it.

Fig. Tolerances (a) unilateral (b) bilateral

 Tolerances
Compound Tolerance
When tolerance is determined by established tolerances on more than one
dimension, it is known as compound tolerance.
For example, tolerance for the dimension R is determined by the combined
effects of tolerance on 40 mm dimension, on 60º, and on 20 mm dimension.
The tolerance obtained for dimension R is known as compound tolerance
(Fig.). In practice, compound tolerance should be avoided as far as possible.

Fig. Compound tolerance

 Geometric Tolerance
Geometric tolerances are used to indicate the relationship of one part of an
object with another. Consider the example given below:

Feature Control Frame

Concentricity Symbol

Fig. Representation of geometric tolerance

 Geometric Tolerance

 Form tolerances: Form tolerances are a group of geometric

tolerances applied to individual features. They limit the amount of
error in the shape of a feature and are independent tolerances. Form
tolerances as such do not require locating dimensions. These include
straightness, circularity, flatness, and cylindricity.

 Orientation tolerances: Orientation tolerances are a type of

geometric tolerances used to limit the direction or orientation of a
feature in relation to other features. These are related tolerances.
Perpendicularity, parallelism, and angularity fall into this category.

 Positional tolerances: Positional tolerances are a group of geometric

tolerances that controls the extent of deviation of the location of a

feature from its true position. This is a three‐dimensional geometric
tolerance comprising position, symmetry, and concentricity.
 Fig. Accumulation of tolerances

Consider the example shown if figure

+ 0.02 + 0.02 + 0.02
Let LA = 30 – 0.01 mm, LB = 20 – 0.01 mm and LC = 10 – 0.01 mm

The overall length of the assembly is the sum of the individual length of components
given as

L = LA + LB + LC
L = 30 + 20 + 10 = 60
mm
Then, cumulative upper tolerance limit is 0.02 + 0.02 + 0.02 =0.06 mm and
cumulative lower limit = – 0.01 – 0.01 – 0.01 = – 0.03 mm
+ 0.06
Therefore dimension of the assembled length will be = 60 – 0.03 mm

It is essential to avoid or minimize the cumulative effect of tolerance build‐up, as

it leads to a high tolerance on overall length, which is undesirable.
If progressive dimensioning from a common reference line or a baseline
dimensioning is adopted, then tolerance accumulation effect can be minimized.
This is clearly illustrated in Fig.

Fig. Progressive dimensioning

Maximum and Minimum Metal Conditions
 Let us consider a shaft having a dimension of 40 ± 0.05 mm.
 The maximum metal limit (MML) of the shaft will have a dimension of 40.05 mm
because at this higher limit, the shaft will have the maximum possible amount of
metal.
 The shaft will have the least possible amount of metal at a lower limit of 39.95
mm, and this limit of the shaft is known as minimum or least metal limit (LML).
 Similarly, consider a hole having a dimension of 45 ± 0.05
mm.

The hole will have a maximum possible amount of metal at a lower limit of 44.95
mm and the lower limit of the hole is designated as MML.

For example, when a hole h is drilled in a component, minimum amount of
as MML.
material
is removed
 The at of
higher limit thethe
lower limitbesize
hole will the of the
LML. Athole.
a highThis
limitlower limit
of 45.05 mm,ofthe
thehole
hole is
known
will have the least possible amount of metal.

 The maximum and minimum metal conditions are shown in Fig.

 FITS
Fits
 Manufactured parts are required
to mate with one another during
assembly.

 The relationship between the two

mating parts that are to be
assembled, that is, the hole and
the shaft, with respect to the
difference in their dimensions
before assembly is called a fit.
Fig. maximum metal limit and
 An ideal fit is required for proper minimum metal limit
functioning of the mating parts.
Three basic types of fits can be
identified, depending on the actual
limits of the hole or shaft:
 FITS
1. Clearance fit
2. Interference fit
3. Transition fit

Clearance fit: The largest permissible

diameter of the shaft is smaller than the
diameter of the smallest hole.

 This type of fit always provides clearance.

Small clearances are provided for a precise
fit that can easily be assembled without the
Fig. Clearance Fit
assistance of tools. When relative motions are
required, large clearances can be provided, for
example, a shaft rotating in a bush.
In case of clearance fit, the difference
 between the sizes is always positive. The
clearance fit is described in Fig.
 FITS
Interference fit: The minimum permissible diameter of the shaft
exceeds the maximum allowable diameter of the hole.

This type of fit always provides interference. Interference fit is a form of
a tight fit. Tools are required for the precise assembly of two parts with an

interference fit.

When two mating parts are assembled with an interference fit, it will be an almost
permanent assembly, that is, the parts will not come apart or move during
use. To assemble the parts with interference, heating or cooling may be
required.
 negative.
In an interference fit, the difference between the sizes is always
 Allowance
 Allowance: An allowance is the intentional difference between the maximum
material limits, that is, LLH and HLS (minimum clearance or maximum
interference) of the two mating parts. It is the prescribed difference between
the dimensions of the mating parts to obtain the desired type of fit.

 Allowance may be positive or negative. Positive allowance indicates a clearance

fit, and an interference fit is indicated by a negative allowance.

Fig. Classification of Fits

 Fit Types
• Type 1: Clearance fit = Occurs when two toleranced mating
parts will always leave a space or clearance when assembled

• Type 2: Interference fit = Occurs when two toleranced mating

parts will always interfere when assembled
 Fit Types
• Type 3: Transition fit = Occurs when two toleranced
mating
parts are sometimes and interference fit and sometimes
clearance fit when assembled.
 General Terminology in Fits
 Basic size: This is the size in relation to which all limits of size are derived.
Basic or nominal size is defined as the size based on which the dimensional
deviations are given. This is, in general, the same for both components.

 Limits of size: These are the maximum and minimum permissible sizes
acceptable for a specific dimension. The operator is expected to
manufacture the component within these limits. The maximum limit of size
is the greater of the two limits of size, whereas the minimum limit of size is
the smaller of the two.

 Tolerance: This is the total

permissible variation in the
is always positive.
size of a dimension,
 that is, the difference
allowance may be either positive or negative.
between the maximum and
minimum limits of size.Allowance
It = LLH − HLS
 General Terminology in Fits
Grade: This is an indication of the tolerance magnitude; the lower the grade, the
finer the tolerance.

Deviation: It is the algebraic difference between a size and its corresponding basic
size. It may be positive, negative, or zero.
Upper deviation: It is the algebraic difference between the maximum limit of size
and its corresponding basic size. This is designated as ‘ES’ for a hole and as ‘es’ for a
shaft.

Lower deviation: It is the algebraic difference between the minimum limit of

size
and its corresponding basic size. This is designated as ‘EI’ for a hole and as ‘ei’ for a
shaft.

Actual deviation: It is the algebraic difference between the actual size and its
corresponding basic size.
Fundamental deviation: It is the minimum difference between the size of a
component and its basic size. This is identical to the upper deviation for shafts and
lower deviation for holes.
 General Terminology in Fits
 Zero line: This line is also known as the line of zero deviation. The convention
is to draw the zero line horizontally with positive deviations represented above
and negative deviations indicated below. The zero line represents the basic size
in the graphical representation.

 Shaft and hole: These terms are used to designate all the external and internal
features of any shape and not necessarily cylindrical.

 Fit: It is the relationship that exists between two mating parts, a hole and a shaft,
with respect to their dimensional difference before assembly.
General Terminology in Fits
 Basis of Limit system
Systems of Fit: There are two systems by which a fits can be accomplished
1. Hole basis system 2. Shaft basis system
When the hole is kept as a constant When the shaft is kept as a constant
member (i.e. when the lower deviation member (i.e. when the upper deviation
of the hole is zero) and different fits of the shaft is zero) and different fits
are obtained by varying the shaft are obtained by varying the hole size,
size, as shown in Fig. then the limit as shown in Fig. then the limit system
system is said to be on a hole basis. is said to be on a shaft basis.
 Basis of Limit system
The hole basis and shaft basis system may also be shown as in Fig.
with respect to the zero line.

Fig. Bases of limit system.

 General Terminology in Fits
The ISO System of Limits and Fits (referred to as the ISO system) is
covered in national standards throughout the world, as shown by the
following list:

Global ISO 286

USA ANSI B4.2
Japan JIS B0401
Germany DIN 7160//61
France NF E 02-100-122
UK BSI 4500 •
Italy UNI 6388
'
Australia AS 1654
Symbols for Tolerances and Deviation and Symbols for
Fits
Symbols for Tolerances and Deviation and Symbols for
Fits
Grades of tolerances
 Degree of precision or grade of tolerance
Tolerance grade Intended for Applicable to components or machines
I T 01
IT0 Slip blocks, Reference gauges
IT1
Gauges
IT2
IT3 High quality gauges
IT4

IT5 Ball bearing

IT6 Grinding, Honing
IT7 Broaching
IT8 Fits Center lathe turning
IT9 Worn automatic lathe
I T 10 Milling
I T 11 Drilling, Rough turning

I T 12 Light press work

I T 13 Press work
I T 14 Not for fits Die casting
I T 15 Stamping
I T 16 Sand casting
International Tolerance Grade Selection
International Tolerance Grade Selection
Example
Metric Preferred Hole Based System of fit
Metric Preferred Shaft Based System of fit
Position of the various tolerance zones for a given diameter in the ISO system
Position of the various tolerance zones for a given diameter in the ISO system
International Tolerance Grade Selection
Table for fundamental deviations for shafts
Table for fundamental deviations for shafts
Table for fundamental deviations for Holes
Table for fundamental deviations for Holes
 Fundamental tolerance unit
Values of standard tolerances:
T = 10 0.2 (G – 1) (0.45 3√D + 0.001D)
G = Tolerance grade IT6 – IT 16
:Fundamental deviations
Shaft deviation:
For each letter symbol defining the position of the tolerance zone, the magnitude and sign of one of
the two deviations which is known as the fundamental deviations (upper deviation) “es” or lower
deviation “ei”
The other deviation is derived from the first one using the magnitude of the standard tolerance
“IT”, by means of the following algebraic relationship:
The fundamental deviation given by the formulae in above tables of deviations is, in principle, that
corresponding to that limit closest to the zero line, in other words, the upper deviation “es” for
shafts (a) to (h), and the lower deviation “ei” for shafts (j) to (Zc).
ei = es - IT
es = ei + IT

It may be noted for shafts a to h, the upper deviations

are considered whereas for shafts j to Zc, the lower )es(
.deviation (ei) is to be considered
Hole deviation:

For each letter symbol, defining the position of the tolerance zone, the magnitude and sign of
the fundamental deviation (lower deviation “EI” for holes (A) to (H) and upper deviation “ES”
for holes (J) to (Zc),
The other deviation is derived from the first one, using the magnitude of the tolerance “IT” by
means of the following relationships.

ES = EI + IT

OR

EI = ES - IT
 Example
Determine which type of fit is presented by H7/p6? For basic size of 30 mm determine the dimensions
of the hole and the shaft for the given fit. (Fit: 30 H7/p6)

Capital H means basic hole system and

upper deviation = zero INTERFERENCE FIT
Φ30.035
H7 : Tol Grade 7 mean 21μ variation
Φ30.022
Φ30.021
Φ30.000
p6 : Tol Grade 6 means 13μ variation
(p means upper deviation is 22 μ)

Fit: 40 H8/e6
 Example

1. The dimensions of the mating parts, according to basic hole system,

are given as follows

Find the hole tolerance, shaft tolerance and allowance?

2. Find the shaft and hole dimensions for a loose running fit with a 34
mm basic size?
3. A journal of basic size of 75 mm rotates in a bearing. The tolerance
for both the shaft and bearing is 0.075 mm and the required allowance
is 0.10 mm. Find the dimensions of the shaft and the bearing bor?

Via online Calculation: https://amesweb.info/fits-tolerances/tolerance-calculator.aspx