AIN SHAMS UNIVERSITY DESIGN & PROD. ENG. DEPT.

FACULTY OF ENGINEERING Second Year Mechanical

Machine Construction

Fits and Tolerances

By: Tamer Elnady and Ahmed Barakat

Contents
Introduction ............................................................................................................................................ 2
Tolerance and Accuracy .......................................................................................................................... 2
Fits ........................................................................................................................................................... 3
Choice of the appropriate fit and determination of the associated tolerances ..................................... 6
Surface Roughness .................................................................................................................................. 9
Steps to determine a proper fit ............................................................................................................ 11
Step1: Decide the needed fit: Clearance, Interference or Transition ............................................... 11
Step2: Select the tolerance grade and tolerance zone width........................................................... 11
Step3: Indicate the type of fit on the construction drawing ............................................................ 11
Step4: Indicate the tolerances on the working drawings ................................................................. 12
Solved Example: Clearance ................................................................................................................... 13
Solved Example: Interference ............................................................................................................... 14

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AIN SHAMS UNIVERSITY DESIGN & PROD. ENG. DEPT.
FACULTY OF ENGINEERING Second Year Mechanical
Machine Construction

Introduction
When you tell someone in the workshop to turn a certain shaft to a diameter of 70 mm, of course
you dont expect him to give you the shaft exactly 70 mm; because there is nothing exact in
engineering. This diameter is called the Nominal Dimension of the spindle and it will be plus or
minus something, but are you going to accept this something? Your decision will depend on the
accuracy of the spindle. Wait! There is nothing in engineering that is called something!

Therefore, you must specify to him something that is called Tolerance. Tolerance is the allowable
deviation from a nominal value. This depends on the needed accuracy; when accuracy increases, the
deviation (or tolerance) decreases. But, the production cost also increases.

Tolerance and Accuracy

Hence, for each grade of accuracy, there is a certain Tolerance Zone Width. Grades of accuracy are
divided into sixteen grades called Tolerance Grades or IT [IT1 to IT16] according to the field of
application and the production process. Note that the tolerance zone width depends also on the
dimension itself. The Tolerance Limits are the limits within which the dimension is acceptable. The
difference between the upper and lower tolerance limits equals the tolerance zone width. Table 1
shows the bases upon which we choose the tolerance grade, and Table 2 shows the tolerance zone
width for each grade.

Table 1 Choice of tolerance grades.

Tolerance
Production Process Field of Application
Grade
IT1
IT2
Used for gauges
IT3
IT4
Lapping - Very fine grinding - High quality
IT5 Piston pin holes in engines.
boring.
IT6 Fine grinding - Fine honing. Accurate bushes and bearings.
Grinding - High quality turning - honing - Bushes and high quality cylindrical
IT7
Broaching. bores.
IT8 Fine turning - Fine boring - Reaming. Good quality general holes.
IT9 Turning - Fine milling - Boring - Slotting.
IT10 Shaping - Milling - Rolling - Extrusion. Unimportant mating parts.
Rough turning - Drilling - Precision tube
IT11 Very coarse fits e.g. bolts and washers.
drawing.
IT12 Light presswork - Tube drawing.
IT13 General presswork - Tube rolling.
IT14 Die casting.
IT15
Casting - Forging.
IT16

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AIN SHAMS UNIVERSITY DESIGN & PROD. ENG. DEPT.
FACULTY OF ENGINEERING Second Year Mechanical
Machine Construction

Table 2 Choice of tolerance zone width.

Dimension Tolerance Zone Width

More Up
IT1 IT2 IT3 IT4 IT5 IT6 IT7 IT8 IT9 IT10 IT11 IT12 IT13 IT14 IT15 IT16
Than To
3 1.5 2 3 4 5 7 9 14 25 40 60 90 140 250 400 600
3 6 1.5 2 3 4 5 8 12 18 30 48 75 120 180 300 480 750
6 10 1.5 2 3 4 6 9 15 22 36 58 90 150 220 360 580 900
10 18 1.5 2 3 5 8 11 18 27 43 70 110 180 270 430 700 1100
18 30 1.5 2 4 6 9 13 21 33 52 84 130 210 330 520 840 1300
30 50 2 3 4 7 11 16 25 39 62 100 160 250 390 620 1000 1600
50 80 2 3 5 8 13 19 30 46 74 120 190 300 460 740 1200 1900
80 120 3 4 6 10 15 22 35 54 87 140 220 350 540 870 1400 2200
120 180 4 5 8 12 18 25 40 63 100 160 250 400 630 1000 1600 2500
180 250 5 7 10 14 20 29 46 72 115 185 290 460 720 1150 1850 2900
250 315 6 8 12 16 23 32 52 81 130 210 320 520 810 1300 2100 3200
315 400 7 9 13 18 25 36 57 89 140 230 360 570 890 1400 2300 3600
400 8 10 15 20 27 40 63 97 155 250 400 630 970 1550 2500 4000

For the dimensions not related to another part, the tolerance zone width is distributed
symmetrically around the nominal dimension. The diameter is written as follows: 70(half the
tolerance zone width).

Fits
But what happens when the previously mentioned shaft is related to another part? Say a hub of a
gear or pulley. We must first decide the relation between the shaft and the hub (clearance or
interference); this is called Fit. For the clearance case, the shaft diameter must be smaller than the
hub diameter; and for the interference case, the shaft diameter has to be larger than the hub
diameter. As we say smaller and larger, we must set a reference diameter and relate the other to it.
This is what we call Basic Shaft and Basic Hole systems. For example in the basic shaft system, the
shaft diameter is set as reference and the hub diameter determines the type of fit.

Figure 1 Deviations and Tolerances. Ref: Machine Drawing, New Age International Publishers.

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AIN SHAMS UNIVERSITY DESIGN & PROD. ENG. DEPT.
FACULTY OF ENGINEERING Second Year Mechanical
Machine Construction

Figure 2 Clearance Fit. Ref: Machine Drawing, New Age International Publishers.

Figure 3 Transition Fit. Ref: Machine Drawing, New Age International Publishers.

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AIN SHAMS UNIVERSITY DESIGN & PROD. ENG. DEPT.
FACULTY OF ENGINEERING Second Year Mechanical
Machine Construction

Figure 4 Interference Fit. Ref: Machine Drawing, New Age International Publishers.

A
Basic shaft system
B
C
D
E
F
G H
nominal size
h J K
M N P R S T
U
X
Z

Basic hole system z

x
u
s t
p r
m n
H j k
nominal size
deviation g h
f
e
d
c
b

a tolerance zone width

Figure 5 Basic Hole and Basic Shaft Systems

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AIN SHAMS UNIVERSITY DESIGN & PROD. ENG. DEPT.
FACULTY OF ENGINEERING Second Year Mechanical
Machine Construction

Choice of the appropriate fit and determination of the associated

tolerances
With the international ISA-tolerances now in use, two tolerance symbols are necessary along with
nominal size for every fit. One of the symbols specifies the limits for the internal dimension (hole)
and the other for the corresponding external dimension (shaft).

- The alphabetical character specifies the position (deviation) of the tolerance zone with
reference to the zero line (nominal size); small letters for shafts and capital letters for holes,
the hole symbol is written first.
- The numerical character (1 to 16) indicates the quality grade.

Table 3 shows the recommended fits for various applications, and Table 4 shows the deviation of the
tolerance zone from the nominal size for different types of fits. Note that in clearance and
interference cases, the deviation value does not change if we use basic hole or basic shaft systems;
while in the transition case, the deviation value depend on the system followed.

We can summarize in the following points:

- The tolerance is the difference between the maximum and minimum size limits of a
dimension. This is determined by the tolerance zone width.
- The deviation is the difference between the start of tolerance zone and the nominal
diameter. For a negative tolerance zone (below nominal size), the deviation is between the
upper tolerance limit and the nominal size line. For the positive tolerance zone (above
nominal size), the deviation is between the lower tolerance limit and the nominal size line.
This holds for both Basic Shaft and Basic Hole Systems. The deviation is expressed in letters,
a to z for shafts; and A to Z for holes.
- Fits are stated on the assembly drawing, while the tolerances are stated on the working
drawings.
- In most cases, the tolerance grade of the hole is greater than the grade of the shaft.
- Usually, the basic hole system is used in general machine construction; whilst the basic shaft
system is rarely used except in cases of a standard shaft (e.g. of a ball bearing) or hinges.
- Transition fits may be used in selective assembly. Selective assembly serves to give an actual
amount of interference or clearance.

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AIN SHAMS UNIVERSITY DESIGN & PROD. ENG. DEPT.
FACULTY OF ENGINEERING Second Year Mechanical
Machine Construction

Table 3 Recommended fits for different uses.

Type of relation Application Recommended fit

For easily assembled parts with large tolerance

spacer sleeves. H/a
coarse fit hinge pins. H/b
spring and brake holders. H/c
bearings for rollers and guides.
Plenty of play
extra loose
transmission shafts. H/d
running fit
counter shafts.
Considerable play
loose
idler pulleys. H/e
running fit
machine tool shafts in several bearings.
Clearance

Perceptible play
sliding bearings.
running fit H/f
sliding sleeves.
pistons in cylinders.
Can be moved without perceptible play
close
sliding gears and clutches. H/g
running fit
indicator pistons.
For effortlessly axial moving fitting parts
change gears.
spindle sleeve of tail stock. H/h
slide fit
adjustment rings for transmissions. H/g
pins in mechanisms.
centering registers for couplings and pipes.
Using a wooden hammer or by hand All can be
push fit H/j
hubs needing easy removal. used for:
Good for hand hammer couplings
holding fit H/k
keys. clutches
Transition

Difficult with hand hammer gears

drive fit outer rings of ball bearings. belt pulleys H/m
electric motor shafts.
Using press
tight fit inner rings of ball bearings. H/n
armatures on motor shafts.
Ease of dismantle and assembly
medium bronze rims on cast iron hubs. H/p
force fit bearing bushes in housings and connecting rods. H/r
Interference

hubs of couplings, clutches, gears and pulleys.

Heavy drive for permanent assembly
wheels and flywheels. H/s
force fit valve seats. H/t
shaft flanges.
shrink fits. H/u

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 Table 4 Deviations of the tolerance zone from the nominal size for different types of fits.

Deviation of the tolerance zone from the nominal size

Dimension Clearance Transition Interference
j k m n D
More a b c d e f g h BH B Sh BH B Sh B Sh B Sh p r s t u x z
Up To BH BH
Than 5,6 7 8 6 7 8 4-7 othr < 9 >8 <9 <9 >8 3 4 5 6 7 8
0 3 270 140 60 20 14 6 2 0 -2 -4 -6 +2 +4 +6 0 0 0 0 2 -2 4 -4 -4 6 10 14 - 18 20 26
3 6 270 140 70 30 20 10 4 0 -2 -4 - +5 +6 +10 +1 0 -1+D 0 4 -4+D 8 -8+D 0 12 15 19 - 23 28 35 1 2 1 3 4 6
6 10 280 150 80 40 25 13 5 0 -2 -5 - +5 +8 +12 +1 0 -1+D 0 6 -6+D 10 -10+D 0 15 19 23 - 28 34 42 1 2 2 3 6 7
10 14 40 50
290 150 95 50 32 16 6 0 -3 -6 - +6 +10 +15 +1 0 -1+D 0 7 -7+D 12 -12+D 0 18 23 28 - 33 1 2 3 3 7 9
14 18 45 60
18 24 - 41 54 73
300 160 110 65 40 20 7 0 -4 -8 - +8 +12 +20 +2 0 -2+D 0 8 -8+D 15 -15+D 0 22 28 35 2 2 3 4 8 12
24 30 41 48 64 88
30 40 310 170 120 48 60 80 112
80 50 25 9 0 -5 -10 - +10 +14 +24 +2 0 -2+D 0 9 -9+D 17 -17-D 0 26 34 43 2 3 4 5 9 14
40 50 320 180 130 54 70 97 136
50 65 340 190 140 41 53 66 87 122 172
100 60 30 10 0 -7 -12 - +13 +18 +28 +2 0 -2+D 0 11 -11+D 20 -20-D 0 32 2 3 5 6 11 16
65 80 360 200 150 43 59 75 102 146 210
80 100 380 220 170 51 71 91 124 178 258
120 72 36 12 0 -9 -15 - +16 +22 +34 +3 0 -3+D 0 13 -13+D 23 -23+D 0 37 2 4 5 7 13 19
100 120 410 240 180 54 79 104 144 210 310
120 140 460 260 200 63 92 122 170 248 365
140 160 520 280 210 145 85 43 14 0 -11 -18 - +18 +26 +41 +3 0 -3+D 0 15 -15+D 27 -27+D 0 43 65 100 134 190 280 415 3 4 6 7 15 23
160 180 580 310 230 68 108 146 210 310 465
180 200 660 340 240 77 122 166 236 350 520
200 225 740 380 260 170 100 50 15 0 -13 -21 - +22 +30 +47 +4 0 -4+D 0 17 -17+D 31 -31+D 0 50 80 130 180 258 385 575 3 4 6 9 17 26
225 250 820 420 280 84 140 196 284 425 640
250 280 920 480 300 94 158 218 315 475 710
190 110 56 17 0 -16 -26 - +25 +36 +55 +4 0 -4+D 0 20 -20+D 34 -34+D 0 56 4 4 7 9 20 29
280 315 1050 540 330 98 170 240 350 525 790
315 355 1200 600 360 108 190 268 390 590 900
210 125 62 18 0 -18 -28 - +29 +39 +60 +4 0 -4+D 0 21 -21+D 37 -37+D 0 62 4 5 7 11 21 32
355 400 1350 680 400 114 208 294 435 660 1000
400 450 1500 760 440 126 232 330 490 740 1100
230 135 68 20 0 -20 -32 - +33 +43 +66 +5 0 -5+D 0 23 -23+D 40 -40+D 0 68 5 5 7 13 23 34
450 1650 840 480 132 252 360 540 820 1250

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AIN SHAMS UNIVERSITY DESIGN & PROD. ENG. DEPT.
FACULTY OF ENGINEERING Second Year Mechanical
Machine Construction

Surface Roughness
There is no ideally flat surface. There is usually a surface roughness based on the manufacturing
process producing the surface. The surface roughness is characterized by a mean roughness index
(Ra) which is the arithmetic mean of the absolute values of the heights of the profile between the
actual and mean profile.

Table 5 Values of surface roughness for different accuracy grades.

Dimension Values of surface roughness (m)

More Up IT5 IT6 IT7 IT8 IT9 IT10 IT11 IT12 IT13 IT14
Than To
3 0.4 3.2 12.5
0.2 0.8 6.3
3 6 0.4 1.6
3.2 12.5
6 10 0.8
6.3 25
10 18 0.4 1.6
18 30 0.8 12.5
3.2
30 50
1.6 6.3 25
50 80 0.8
80 120 3.2 12.5 50
120 180
1.6
180 250 6.3 25
250 315 1.6 3.2 12.5 50
315 400 6.3 25 100
400 500 3.2 12.5 50

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AIN SHAMS UNIVERSITY DESIGN & PROD. ENG. DEPT.
FACULTY OF ENGINEERING Second Year Mechanical
Machine Construction

Table 5 shows the values of the surface roughness for different accuracy grades. The following gives
some help to the designer in preparing the working drawings and the process sheets. Table 5 shows
RMS values of surface roughness for different accuracy grades.

These are indicated on the working drawings using the following symbols. The x is the maximum
allowed value of the surface roughness of this surface. The symbols in Figure 6 mean:

a) This surface may be obtained by any production method.

b) This surface must be obtained without removal of material.
c) This surface must be obtained by removal of material by machining.
d) A line is added to the longer arm to indicate any special surface characteristics.

Figure 6 Symbols of Surface Roughness

There is a roughness grade number which depends on the roughness values. These are listed in
Table 6.

Table 6 Roughness values according to Ra

Roughness values Ra (m) Roughness grade number

50 N12
25 N11
12.5 N10
6.3 N9
3.2 N8
1.6 N7
0.8 N6
0.4 N5
0.2 N4
0.1 N3
0.05 N2
0.025 N1

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AIN SHAMS UNIVERSITY DESIGN & PROD. ENG. DEPT.
FACULTY OF ENGINEERING Second Year Mechanical
Machine Construction

Steps to determine a proper fit

Step1: Decide the needed fit: Clearance, Interference or Transition

Clearance means that all the probable sizes of the shaft (within the tolerance zone limits) are smaller
than all probable sizes of the hole (within its tolerance zone limits). If the whole tolerance zone of
the shaft is smaller than the whole tolerance zone of the hole, then this is a clearance condition. This
is designated by: h/A or h/B or h/C ------ or h/G for basic shaft system, and H/a or H/b or H/c ------- or
H/g for basic hole system.

Interference means that all the probable sizes of the shaft (within the tolerance zone limits) are
larger than all probable sizes of the hole (within its tolerance zone limits). If the whole tolerance
zone of the shaft is larger than the whole tolerance zone of the hole, then this is an interference
condition. This is designated by: h/P or h/R or h/S ------ or h/Z for basic shaft system, and H/p or H/r
or H/s ------- or H/z for basic hole system.

Transition means that there is a probability for the fit to be clearance or interference. This is
because the shaft tolerance zone intersects with the hole tolerance zone. The upper limit of the
shaft is larger than the lower limit of the hole. This is designated by: h/J or h/K or h/M or h/N for
basic shaft system, and H/j or H/k or H/m or H/n for basic hole system.

The different deviations for each grade of fit are shown in Table 4, and the recommended fit
condition for different applications is shown in Table 3.

Step2: Select the tolerance grade and tolerance zone width

The tolerance grade can be chosen from Table 1 based on the manufacturing process and the
application. Next, the tolerance zone width is shown in Table 2

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AIN SHAMS UNIVERSITY DESIGN & PROD. ENG. DEPT.
FACULTY OF ENGINEERING Second Year Mechanical
Machine Construction

Table 2 as a function of the tolerance grade selected in Table 1, and the dimension to be tolerated.

If the dimension is not related to another part, then it does not matter if this dimension is slightly
bigger or smaller. In this case, the tolerance zone width is divided by 2, and the dimension is written
as . For example, a dimension of 30 mm, IT7, has a tolerance zone width of 0.025 mm. In this case,
the tolerated dimension is written 30 0.012.

If this part is fitted to another part, we need to design a proper fit of the connection. Usually, the
hole dimension takes one IT grade higher than the shaft dimension. For example, if a shaft is 30 mm
in diameter and we need it to be IT7, then the hole in this case is IT8. For the shaft, the tolerance
zone width is 0.025 mm and the tolerance zone width for the hole is 0.039 mm.

Step3: Indicate the type of fit on the construction drawing

The type of fit is indicated only on the construction. We have selected the type of fit and the
tolerance grade. The type of fit and the tolerance grade are indicated on any fitted connection in the
construction drawing as follows

30H8/c7

This is a clearance fit, basic hole system, the tolerance grade of the hole is IT8 and the tolerance
grade of the shaft is IT7.

Step4: Indicate the tolerances on the working drawings

The last step is to calculate the proper tolerances for the hole and shaft sides. This is based on the
type of fit, and the tolerance zone width for each side. These tolerances are indicated only on the
working drawing. In step 3, we chose a fit of H8/c7.

The hole tolerance should be 300.039

0 . The deviation of H is zero and the tolerance zone width of IT8
is 0.039 mm.

The shaft tolerance should be 300.110

0.035 . The deviation of c is -0.110 mm and the tolerance zone
width of IT7 is 0.025 mm.

For the basic hole system, the deviations for the clearance (a to g) are all negative (the shaft should
be smaller), whereas all other deviations are positive (the shaft should be larger). For the basic shaft
system, the deviations for the clearance (A to G) are all positive (the hole should be larger), whereas
all other deviations are negative (the hole should be smaller). This is shown in Figure 1.

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AIN SHAMS UNIVERSITY DESIGN & PROD. ENG. DEPT.
FACULTY OF ENGINEERING Second Year Mechanical
Machine Construction

Solved Example: Clearance

An idler pulley is required to rotate on a shaft of diameter 55 mm, design the fit between the pulley
and the shaft. Indicate the tolerances and calculate the maximum and minimum clearance and
interference.

Step1: Since the pulley is required to rotate on the shaft, the fit should be clearance. According to
Table 3, we choose H/e (Basic Hole). Note that usually pulleys can be considered a standard item
that you buy on-shelf. This mandates that we have a Basic Hole system.

Step2: Assume that the pulley manufacturer has chosen IT8 for the pulley hub dimension. The shaft
will be machined by fine turning and therefore, IT7 is an adequate choice for the tolerance grade of
the shaft. From Table 2, the tolerance zone width for 55 mm IT8 is 0.046 mm and for 55 IT7 is 0.03
mm.

Step3: On the construction drawing, the dimension will be written as 55H8/e7

Step4: In order to calculate the tolerances on each part, we have to get the deviation for each fit
type beside the tolerance zone width. The deviation for H is zero and the deviation of e is -0.06 mm.

+0.046 = deviation of H (0) + tolerance zone width of IT8 (0.046)

Tolerance zone width of IT8 H8
+0 = deviation of H (0)

-0.060 = deviation of e (-0.06)

Tolerance zone width of IT7 e7
-0.090 = deviation of e (-0.06) - tolerance zone width of IT7 (0.03)

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AIN SHAMS UNIVERSITY DESIGN & PROD. ENG. DEPT.
FACULTY OF ENGINEERING Second Year Mechanical
Machine Construction

For this assembly, interference is not possible.

Minimum Clearance = minimum possible hole (0) maximum possible shaft (-0.06) = 0.06 mm

Maximum Clearance = maximum possible hole (0.046) minimum possible shaft (-0.09) = 0.136 mm

Solved Example: Interference

A bearing bush is required to be inserted in a housing of inner diameter 74mm, design the fit
between the pulley and the shaft. Indicate the tolerances and calculate the maximum and minimum
clearance and interference.

Step1: Since the bush-housing assembly should be regarded as one unit, and no relative motion is
allowed between the two parts, the fit should be interference. According to Table 3, we choose H/r
(Basic Hole).

Step2: The housing hole is manufactured using a drilling process and then finished by a reamer. This
gives a possible tolerance grade of IT8. The outer surface of the bush is machined by turning, and IT8
can be used here. From Table 2, the tolerance zone width for 74 mm IT8 is 0.046 mm.

Step3: On the construction drawing, the dimension will be written as 74H8/r8.

Step4: In order to calculate the tolerances on each part, we have to get the deviation for each fit
type beside the tolerance zone width. The deviation for H is zero and the deviation of r is -0.043 mm.

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AIN SHAMS UNIVERSITY DESIGN & PROD. ENG. DEPT.
FACULTY OF ENGINEERING Second Year Mechanical
Machine Construction

+0.089 = deviation of r (+0.043) + tolerance zone width of IT8 (0.046)

Tolerance zone width of IT8 r8
+0.043 = deviation of r (+0.043)
Tolerance zone width of IT8 H8 +0.046 = deviation of H (0) + tolerance zone width of IT8 (0.046)
+0 = deviation of H (0)

Minimum Clearance = minimum possible hole (0) maximum possible shaft (+0.043) = 0 mm

Maximum Clearance = maximum possible hole (0.046) minimum possible shaft (0.043) = 0.003 mm

Minimum Interference = minimum possible shaft (0.043) maximum possible hole (0.046) = 0 mm

Maximum Interference = maximum possible shaft (0.089) minimum possible hole (0) = 0.089 mm

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