Sridhara T., Asst. Professor, Dept. of Mechanical Engg.

Unit 2

UNIT 2

SYSTEM OF LIMITS, FITS, TOLERANCES AND GAUGING

 Introduction
 Definition of limits
 Need for limit system
 Tolerance
 Tolerance dimensions ( system of writing tolerance)
 Relationship between Tolerance Vs Cost
 Compound tolerance.
 Tolerance accumulation or tolerance “build –up”
 Specifying tolerances in assembly
 Interchangeability
 Selective assembly
 Limits of size
 Indian standard (IS 919-1963)
 Condition for the success of any system of limits and fits.
 Concepts of Limits of size and Tolerance
 Some Definitions
 Definition of Fit
 Types of Fit and their Designation (IS 919-1963)
 Specific types of Fit
 Allowance
 Geometrical Tolerance
 Positional Tolerance
 Symbols and terms used in IS 919-1965
 System of Fits
 Hole Basis System
 Staff Basis System
 Significance of Hole Basis System
 Tolerance Grade
 Numerical Problems
 Plain gauges
 Limit gauging
 Plug gauges
 Ring gauges
 Snap gauges or gap gauges
 Gauge materials : selection of material for gauges
Material used for gauges
 Taylor`s principle of gauge design
 Gauge tolerance
 Method of gauge maker`s tolerance
 First system
 Second system
 Third system
 Wear allowance consideration on gauge maker`s tolerance
 Numerical problems

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Sridhara T., Asst. Professor, Dept. of Mechanical Engg. Unit 2

INTRODUCTION:

 In nature two extremely similar (identical) things are difficult to obtain.

 If at all we come across exactly similar things, it must be only by chance.
 Its holds good for production of component parts in engineering.
 Every process is combination of three elements namely, man, machine and material
 A change in any of these constitutes a change in the process.
 The above said three elements are subjected to inherent and characteristics variations.
Example:
1.Drilling operation is to be performed on castings.
2.Shaft rotating in bearing.

Thus we conclude that:

1. It is not possible to make any part precisely to a given dimension, due to variability of elements of
production process.
2. Even if by chance the part made exactly to a given dimension, it is impossible to measure it accuracy
enough to prove it.
3. If attempts are made to achieve perfect size the cost of production will increase tremendously.
Therefore, the magnitude of permissible variation in dimension has to be allowed to account for the
variability.

******syllabus starts from here******

Limits:
Definition: The maximum and minimum permissible sizes within which the actual size of a component lies
are called limits.
 Limits are fixed with reference to the basic size of that dimension.
 Upper limit (The high limit) for that dimension is the largest size permitted and the low limit is the
smallest size permitted for that dimension.

Need for limit system:

 The correct and prolonged functioning of manufactured products depends upon its correct size
relationship between various components of the assembly.
 This means that the parts must fit together in a certain way.
Example: Valve Assembly
Hence purpose of limit system is to establish the types of fits and recommend the dimensions of the mating
parts

Tolerance:
Definition:
Tolerance can be defined as “the permissible variation in size or dimension “of a part.
Or
Tolerance is the difference between the upper limit and lower limit of a part.

The word Tolerance indicated that a worker is not expected to produce the part to the exact size, but a
definite small size error is permitted.

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Sridhara T., Asst. Professor, Dept. of Mechanical Engg. Unit 2

Tolerance Zone: The difference between upper limit and the lower limit of a dimension represents the
margin for variation in workmanship, and is called a “Tolerance zone”.

Example: a shaft of 25 mm basic size may be written as 25 + 0.02.

Upper limit = 25 + 0.02 = 25.02 mm
Lower limit = 25 – 0.02 = 24.98 mm
Tolerance = upper limit – lower limit
= 25.02 – 24.98 = 0.04 mm
NOTE: The tolerance is always a positive quantitative number.

*** very very imp.

System of writing Tolerance (Toleranced dimensions):
There are two systems of writing tolerance:
1. Unilateral system
2. Bilateral system

1. Unilateral system:
When the two limit dimensions are only above or only below the nominal size (basic size) then the
tolerances are said to be Unilateral.
+0.03 +0.01 -0.00 -0.01
Example:
+0.02 +0.00 , -0.01
25 , 25 25 , 25 -0.02 etc…
Tolerance

Tolerance

Basic size
Tolerance

Tolerance

Figure: unilateral system

2. Bilateral system:
When the limit dimensions are given above and below the nominal size (basic size) then the
tolerances are said to be bilateral.
Example: 25+0.02 , 25 +0.01 etc…
Tolerance
Tolerance

Basic size

Figure: Bilateral Tolerance

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Sridhara T., Asst. Professor, Dept. of Mechanical Engg. Unit 2

Unilateral tolerance is preferred over bilateral tolerances because the operator can machine to the upper limit
of the shaft (or lower limit of the hole) still having the whole tolerance left for machining before the parts
are rejected.
 It is easy and simpler to determine deviations
 GO gauge end can be standardized as the holes of different tolerance grades have the same lower
limit and all the shafts have same upper limit.

Relationship between Tolerance and Cost:

 The relationship between tolerance and cost of production is shown in figure.

 If the tolerance are made closer and closer, the cost of production goes on increasing, because to
manufacture the component with closer tolerance.

Specifying tolerance in an assembly:

The type of assembly or fit between the mating parts will be decided based on the functional requirements
(i.e., clearance type of fit like in bearing and shaft.)

Accordingly tolerances on the shaft and hole are decided using the following two methods:
1. complete interchangeability
2. Statistical approach.

In complete interchangeability, no risk is taken even for a single non-confirming assembly.

If the fit between shaft and hole is clearance type as shown in figure, then for the complete
interchangeability.

Tolerance on shaft = Tolerance on hole = Half of the maximum clearance – half of the minimum clearance

In Statistical approach:
 Statistical approach bases the permissible tolerance on the normal distribution curve.
 Considering that only 0.3% of the parts would lie outside ±3σ limits.
 This approach, obviously, allow wider tolerances and permits cheaper production methods especially
in mass production.
 It was estimated that about 33% more tolerance may be permitted by statistical approach compared
to complete interchangeability.

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Sridhara T., Asst. Professor, Dept. of Mechanical Engg. Unit 2

Compound Tolerance:
 A compound tolerance one which is derived by considering the effect of tolerance on more than one
dimension.
 For example: in figure the tolerance on dimension L are dependent on tolerances on D, H, and Ө.
 This compound tolerance on L is the combined effect of all the three tolerances.
 The dimension L will be maximum when the base dimension is D+a, θ+α and the vertical dimension
is H-d.
 The dimension L will be minimum when the base dimension is D-b, θ-β and the vertical dimension is
H+c.
L

+c
-d
H +a
-b
q

+a
-b
D

figure: Compound tolerance

Tolerance accumulation or Tolerance “Build-up”:

If a part consists of several steps, each step having some tolerance over its length, then overall tolerance on
complete length will be the sum of the tolerance on individual lengths as shown on figure.

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Sridhara T., Asst. Professor, Dept. of Mechanical Engg. Unit 2

Interchangeability:
Interchangeability occurs when one part in an assembly can be substituted for a similar part which has been
made to the same drawing.
 Suppose there are 100 parts each with a hole, and 100 shafts which have to fit into any of the holes.
 If they is interchangeability then any one of the 100 shafts should fit into any of the holes and the
required kind of fit can be obtained.
 Hence, for interchangeability of holes and shafts, we need a system of limits and fit which gives
standard values for the limits on the hole and shaft, so that particular type of fit can be obtained.

Interchangeability is possible only when certain standard are strictly followed.

 In Universal interchangeability the mating parts are drawn/manufactured from two different
manufacturing sources.
 Universal interchangeability is desirable and which will be an international standard.
 In Local interchangeability the mating parts are manufactured from same manufacturing sources, in
which local standard is followed.
 The required type is obtained in an assembly either by universal or local/full interchangeability or
selective assembly.

Selective Assembly:
 In selective assembly, the parts are graded according to their size by automatic gauging.
 In which only matched grades are assembled.
 This technique is most suitable for where close fit (Interference fit) of two component assembles are
required.
 It results in complete protection against non-confirming assemblies and reduces machining costs,
since close tolerance can be maintained.

Example: practical example of this system is the assembly of piston with cylinder bores. Let the bore size
be mm & the clearance required for the assembly 0.12mm on the diameter. Let the tolerance on bore and the
piston each = 0.04mm. Then,
Dimension of bore diameter is 50+0.02 mm.
Dimension of piston shaft is 49.88+0.02 mm.

By grading and making the bores and the piston they may be selectively assembled to give the clearance of
0.12 mm as given below.
Cylinder bore 49.98, 50.00, 50.02
Piston 49.86, 49.88, 49.90
 Selective assembly is often followed in aircraft, automobiles and other industries where the tolerance
are very narrow and are not possible to manufacturer by an sophisticated machine at reasonable cost.
 Here close tolerances to be achieved without actually being produced.

Limits of Size:
In deciding the limits for a particular dimension it is necessary to consider following.
1. Functional requirements: the intended function that a component should perform
2. Interchangeability: replacements of the component in case of failure/ damage without difficulty
3. Economy in production time and cost.

 Thus degree of tolerance provided on the mating components calls for a compromise.
 Number of standards on limit and fit systems has been published to help the designer in selecting the
uniform limits and fits.

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 Sridhara T., Asst. Professor, Dept. of Mechanical Engg. Unit 2

Indian standard (IS 919 – 1963):

 The Indian standard system of limits and fits comprises suitable combination of 18 grades of
fundamental tolerances or grades of accuracy of manufacturer (IT0 to IT16), and 25 types of
fundamental deviations represented by letter symbols for both holes and shafts (capital letters A to
ZC for holes and lower case letters a to zc for shafts).
 In diameter steps up to 500mm.
 The 25 fundamental deviations of hole are represented BY
A,B,C,D,E,F,G,H,JS,J,K,M,N,P,R,S,T,U,V,X,Y,Z,ZA,ZB,ZC

Maximum and minimum Metal Limits

(Or Maximum and Minimum Metal conditions):

HOLE

LML
MML
MML

LML

SHAFT

Figure: MML & LML of Hole and Shaft

 If the tolerance for the shaft is given as 25+0.05, the upper limit will be 25.05 mm and the lower limit
will be 24.94 mm.
 The shaft is said to be have Maximum Metal Limit (MML) of 25.05mm, since at this limit the shaft
has maximum possible amount of metal.
 The limit of 24.95 will then be the minimum or “Least metal Limit” (LML) because at this the shaft
will have the least possible amount of metal.
 Similarly, for hole is designated as 30+0.05 mm.
 The upper limit will be 30.05 mm and the lower limit will be 29.95 mm.
 Then, the maximum metal limit (MML) of hole will be equal to 29.95 mm, since at this lower limit
the hole has the maximum possible amount of metal.
 While the minimum metal limit (LML) of hole will be equal to 30.05 mm. then, the upper limit of
the hole has the minimum possible amount of metal.

Some Definitions:
(Terminologies used in Limits and Fits)

Shaft: The term shaft refers not only to the diameter of a circular shaft but also to any external dimension of
a component.
Hole: The term shaft not only refers to the diameter of the circular hole but also any internal dimension of a
component.
Tolerance for shaft
Tolerance for hole

Upper deviation
Lower deviation

HOLE

hole
ZERO LINE
Upper deviation
Max dia
Min dia

shaft
Max dia
Min dia

BASICSIZE

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Lower deviation

SHAFT
Sridhara T., Asst. Professor, Dept. of Mechanical Engg. Unit 2

 When an assembly is made of two parts, one is known as male-surface and the other mating part as
female (enveloping) surface.
 The male surface is called as shaft and the female surface is called as hole.

Basic Size or Nominal Size: It is the standard size of a part in relation to which all limits of variation are
determined. the basic size is same for hole and shaft.

Actual size: actual size is the dimension as measured on manufacturing part.

Zero line: it is straight line drawn horizontally to represent the basic size. In the graphical representation of
limits and fits, all the deviations are shown with respect to the zero line (datum line).
 The positive deviations are shown above zero line and negative deviation are shown below zero line
as shown in figure.
Deviation: deviation is the algebraic difference between the size (actual, maximum, etc) and the
corresponding basic size.

Upper deviation: it is the algebraic difference between the upper (maximum) limit of size and the
corresponding basic size.
 It is positive quantity when the upper limit of size is greater than the basic size and negative quantity
when the upper limit of the size less than the basic size as shown in figure.
 It is denoted by „ES‟ for hole and „es‟ for shaft.

Lower deviation: it is it is the algebraic difference between the lower (minimum) limit of size and the
corresponding basic size.
 It is positive quantity when the lower limit of size is greater than the basic size and negative quantity
when the lower limit of the size less than the basic size.
 It is denoted by „EI‟ for hole and „ei‟ for shaft.

Fundamental deviation: either the upper or lower deviation, which is the nearest one to the zero line
for either a hole or a shaft.
 It fixes the position of Tolerance zone in relation to the zero line.
tolerance

tolerance zone
lower deviation

(fundamental
deviation)
zero line
upper limit
lower limit

basic size

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Sridhara T., Asst. Professor, Dept. of Mechanical Engg. Unit 2

zero line

(upper deviation)
tolerance zone

tolerance
fundamnental deviation

lower limit

upper limit
From the figure sit is very clear that when the tolerance zone is above the zero line, then lower deviation is
fundamental deviation. While, the tolerance zone is below zero line , then upper deviation is fundamental
deviation.

Basic shaft: basic shaft is the shaft whose upper deviation is zero. Thus upper limit of the basic shaft is the
same as the basic size. It is denoted by letter „h‟

Basic hole: basic hole is the hole whose lower deviation is zero. Thus lower limit of the basic hole is the
same as the basic size. It is denoted by letter „H‟

Size Tolerance: The relationship of deviation with tolerance is given by,

For shaft, IT = es – ei (upper deviation – lower deviation)
For hole, IT = ES – EI (upper deviation – lower deviation)

Definition of fits, types of fits and their Designation (Is 919 – 1963):
Fit: fit may be defined as a degree of tightness or looseness between two mating parts to perform a definite
function when they are assembled together.

Accordingly, a fit may result either in a moveable joint or a fixed joint.

For example: a shaft running in a bearing can move in relation to it and thus forms a moveable joint,
whereas, a pulley mounted on the shaft forms a fixed joint.

Types of fits (Classification of fits):

On the basis of positive, zero and negative values of clearance, there are three types of fits:
1. Clearance fit
2. Interference fit
3. Transition fit.

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Sridhara T., Asst. Professor, Dept. of Mechanical Engg. Unit 2

1. Clearance fit:
 In this type of fit, the largest permitted shaft diameter is smaller than the diameter of the smallest
hole as shown in figure.
 So that the shaft can rotate or slide through with different degree of freedom according to the
purpose of mating part.
 In this type of fit shaft is always smaller than hole.
clearence

hole hole
hole
shaft Zero line

shaft shaft

Figure: clearance fit

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Sridhara T., Asst. Professor, Dept. of Mechanical Engg. Unit 2

2. Interference fit:
 In this type of fit the minimum permissible diameter of the shaft is larger than the maximum
allowable diameter of the hole.
 Here the shaft and hole members are intended to be attached permanently and used as a solid
component.
Example: bearing bushes, steel rings on a wooden bullock cart wheel etc.,
Interference

shaft
shaft
hole shaft
Zero line
hole hole

3. Transition fit.
 Transition fit lies mid way between clearance and interference fit.
 In this type of fit, the diameter of the largest allowable hole is greater than that of the smallest shaft,
but the smallest hole is smaller than the largest shaft, so that a small positive and negative clearance
exists between the shaft and hole as shown in figure.
Example: Spigot in mating holes, coupling rings.
+ve clearence

-ve clearance

hole
shaft shaft
Zero line
hole

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Sridhara T., Asst. Professor, Dept. of Mechanical Engg. Unit 2

Maximum clearance: it is the difference between the minimum size of shaft and maximum size of hole.

Minimum clearance: it is the difference between the maximum size of shaft and minimum size of hole.

Special types of fit:

1. Slide fit: this type of fit has very small clearance, the minimum clearance being zero.
 Sliding fits are employed when the mating parts required to moving slowly in relation to each other.
 It is clearance type of fit
Example: tailstock spindle of lathe, feed movement of spindle quill in drilling.

2. Driving fit: in this fit, the shaft is made slightly larger than the hole. Such that parts can be assembled by
driving force.
 This is employed when the parts are to remain in a fixed position relative to each other.
 It is an interference type of fit.

3. Push fit or Snug fit: this type of fit represent a close fit which permits assembling of parts by hand.
 It provides a small clearance
 It is transition type of fit
Example: change gears.

4. Force fit or pressed fit: force fit are employed when the mating parts are not required to be disassembled
during their total service life.
 In which assembly is obtained only when high pressure is applied.
 It is interference type of fit.
Example: forging machine.

5. Selective fit or tight fit: it provides less interference than force fit.
 Tight fits are employed for mating parts that may be replaced while overhauling of the machine.
 It is interference type of fit.
Example: cylindrical grinding machine.

6. Shrinkage fit: it refers to maximum negative allowance.

 This fit is obtained by making the shaft larger than the hole. In this pressure is not required for
assembling but instead the hole is heated and expand sufficiently to permit shaft to be inserted easily.
Then hole is cooled to shrink tightly around the shaft.
 It is interference type of fit.

7. Freeze fit: in freeze fit the shaft (internal member) is contracted by cooling and assembled with the hole
(external member).
When the assembled parts are exposed to the atmospheric temperature, the contracted shaft (internal
member) expands and thus fit into the hole (external member).
It is interference type fit.
Example: insertion of valve seat in engine cylinder heads.

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Sridhara T., Asst. Professor, Dept. of Mechanical Engg. Unit 2

Allowance:
 It is the intentional difference between the lower limit of the hole and upper limit of the shaft.
 The allowance may be positive or negative.
 The positive allowance is called clearance and negative allowance is called interference.

Figure: allowance

Difference between tolerance and Allowance:

Tolerance
1. It is the difference between the upper
limit and lower limit of a part
2. It is the permissible difference in
dimension or size of a part.
3.it is absolute value without sign
4. Tolerance provided because operator is
not possible to produce a part to exact size.
Allowance
1.It is the intentional difference between
lower limit of hole to upper limit of shaft
2. It is the prescribed difference between the
dimensions of two mating parts.
3. allowance may be +ve or –ve
4. allowance provided on mating parts to
provide desired type of fit.

Geometrical Tolerance:
 It is necessary to specify and control the geometric features of a component, such as straightness,
flatness, roughness etc., In addition to linear dimensions.
 Geometric tolerances are concerned with the accuracy of the relationship of one component to
another, and it should be specified separately.
 Geometric tolerance may be defined as the maximum permissible overall variation of form, or
position of form, or position of feature.

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Sridhara T., Asst. Professor, Dept. of Mechanical Engg. Unit 2

Symbols and terms used in IS 919-1965:

 The Indian standards are in line with ISO recommendations.
 Basic shaft: is a shaft whose upper deviation is zero., ie, fundamental deviation is zero: shaft “h”.
 Basic hole: is one whose lower deviation is zero, i.e, fundamental deviation is zero: hole “h”.
 The letter symbols for tolerances on shaft and holes as shown in figure. For shaft ‟a‟ to „g‟ the
fundamental deviation is below zero line and for shaft „j‟ to „zc‟ is above the zero line.
 The fundamental deviations for holes „A‟ to „H‟ correspond exactly in value with those for shafts „a‟
to „h‟ but in opposite directions.
 Hole „A‟ and shaft „a‟ have the largest fundamental deviations.
 Hole being positive and shaft being negative.
 The first eight designations represent a clearance fit system.
 The remaining groups „JS‟ to „ZC‟ and „js‟ to „zc‟ do not correspond in their deviations in quite the
same way. They are intended for use in interference and transition fits.
 In the table, formulae are given to determine the fundamental deviation.
 The other deviations are derived directly using the absolute value of tolerance IT by means of
algebraic relationship.
ei = es – IT

es = ei + IT

Formulae for shaft & hole dimensions for sizes from 500 mm upto 3150 mm.

Shafts Holes Formulae for deviation in µ

Type F.D Sign Type F.D Sign For D in mm
0.44
d es - D EI + 16 D
e es - E EI + 11 D0.41
f es - F EI + 5.5 D0.41
g es - G EI + 2.5D0.34
h es - H EI + 0
js ei - JS ES + 0.5 ITn
k ei + K ES - 0
m ei + M ES - 0.024 D + 12.6
n ei + N ES - 0.04 D + 21
p ei + P ES - 0.072 D + 37.8
r ei + R ES - Geometric mean between p and and s
or P and s
s ei + S ES - IT7 +0.4D
t ei + T ES - IT7 + 0.63D
u ei + U ES - IT7 + D

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Sridhara T., Asst. Professor, Dept. of Mechanical Engg. Unit 2

Tolerance grade:

The tolerance grade is an indication of the degree of accuracy of manufacturer.

In IS standard 18 grades of standard tolerance are designated as IT01, IT0, IT1 upto IT16.
Their numerical values have been determined in terms of the standard tolerance unit i, where I in microns is
expressed as

𝟑
𝒊 = 𝟎. 𝟒𝟓 𝑫 + 𝟎. 𝟎𝟎𝟏𝑫 (For basic size upto and including 500 mm)
Where D is in mm and is the geometric mean of the lower and upper diameter of a particular step in which
the diameter lies.

The various diameter steps specified by IS 919 are:

1-3, 3-6, 6-10, 10-14, 14-18, 18-24, 24-30, 30-40, 40-50, 50-65, 65-80, 80-100, 100-120, 120-140, 140-160,
160-180, 180-250, 250-315, 315-400, and 400-500 mm.

For basic size from 500 mm upto including 3150 mm, the standard tolerance unit „i‟ is calculated by,

i = 0.004D + 2.1 where D is in mm

The relative magnitude of each grade is

Tol. grade IT5 IT6 IT7 IT8 IT9 IT10 IT11 IT12 IT13 IT14 IT15 IT16
Values 7i 10i 16i 25i 40i 64i 100i 160i 250i 400i 640i 1000i

Designation of Holes, shafts and fits

A hole or a shaft is completely described if the basic size, followed by the approximate letter and the number
of tolerance grade is given.

Example:
i. a 50mm H-hole, with the tolerance grade of IT7, is written as 50H7.
ii. a 50 mm f-shaft, with the tolerance grade of IT8, is written as 50f8.
iii. A fit is designated by the basic size common to both shaft and hole followed by symbols
corresponding to each elements, the hole is quoted first, thus, if the basic size is 50 mm, the hole
is H7 and shaft is f8, then fit can be indicated as 50H7f8

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Sridhara T., Asst. Professor, Dept. of Mechanical Engg. Unit 2

Geometric characteristics and symbols:

It is of two types
1. Single feature
2. Related feature.

Positional Tolerance:
If A particular hole is to be drilled in a plate.
First axis of the hole will be defined and located. Some tolerance is allowed on this.
Thus center of hole itself can occupy any position within a square at the center depending on the tolerance
specified to locate center
Then some tolerance has to be specified for manufacturing hole. Thus hole obtained will be having
cumulative effect of two tolerances.
This problem is obviated by specifying positional tolerances.

 In conventional method a positional tolerance is given by tolerance coordinates is as shown in figure.

 In case of hole illustrated, it will be seen that the tolerance zone for a hole center is square.
 If the tolerance coordinate are not equal then zone would be rectangle.
 Thus permissible error in position of center varies within the direction of error.
 But, in most of the cases, the designer wishes to restrict the amount by which the hole may vary from
its true position irrespective of direction of error.

 The method of tolerancing as shown in figure a and figure b provides a circular tolerance zone for
the center and consequently permits the same error in any direction.
 A careful study of figure shows how much tolerancing allows a large positional error for a hole
which is not on maximum metal condition.

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