Surface Roughness – Limits - Fits - Tolerances

VIT-SMBS KJR CDn SIV

 Objective

• Understand the importance of surface

roughness representation
• To study the different aspects of limit
dimensioning
• To show limit of size and express the fit
• To learn standard systems of limits and fits such
as Hole basis system and Shaft basis system

VIT-SMBS KJR CDn SIV

 Surface Roughness
Surface roughness limits the performance and the properties
of a component

•Roughness increases friction and the wear between

unlubricated surfaces that are in contact with each other.
• In lubricated systems the danger of seizure is reduced due to
smooth surfaces.
• Roughness will tend to reduce the effectiveness of
interference fits.
• Fatigue strength of the component increases with an increase
in smoothness.
• Roughness reduces fluid flow through small sections.

VIT-SMBS KJR CDn SIV

 Surface Roughness and Surface Finish

Surface roughness
– a measurable characteristic based on roughness deviations

Surface finish
- a more subjective term denoting smoothness and general
quality of a surface

• In popular usage, surface finish is often used as a synonym for

surface roughness
• Both terms are within the scope of surface texture

VIT-SMBS KJR CDn SIV

 Machining Symbols

The basic symbol consists of two legs of unequal length inclined

at approximately 60’ to the line representing the considered
surface

If the removal of material by machining is required, a bar is added

to the basic symbol,

If the removal of material is not permitted, a circle is added to

the base symbol.

When special surface characteristics have to be indicated, a

line is added to the longer arm of any of the above symbols,

VIT-SMBS KJR CDn SIV

 Roughness Values,Grades and Symbols

Roughness Grade Number Symbol

Values in μ
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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 Reasons for dimensional variations

•Variations in material properties during machining

•Inaccuracies and errors in manufacturing machines

•Human errors and errors at the time of setting of machine

VIT-SMBS KJR CDn SIV

 Necessity of Limits and Fits

It is necessary to permit the operator, a small deviation

from the exact size, which is not possible in the case of all
components. At the same time, the deviated size should
not affect the quality of the assembly. This sort of
dimensioning is known as limit dimensioning.

VIT-SMBS KJR CDn SIV

 Indian Standard System of Limits and Fits

SIZE: It is a number expressed in a particular unit in the

measurement of length.
BASIC SIZE: It is the size based 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 if the component is to be accepted.
LIMITS OF SIZE: These are the extreme permissible sizes
within which the operator is expected to make the component,
that is, maximum and minimum limits.
MAXIMUM LIMIT OF SIZE: It is the greater of the two limit sizes.
MINIMUM LIMIT OF SIZE: It is the smaller of the two limit sizes.
VIT-SMBS KJR CDn SIV
 Indian Standard System of Limits and Fits (Contd.)

HOLE: In the BIS system of limits and fits all the internal
features of a component, including those which are not
cylindrical, are designated as holes.
DEVIATION: It is the algebraic difference between a size to 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.
LOWER DEVIATION: It is the algebraic difference between the
minimum limit of size and its corresponding basic size.
ACTUAL DEVIATION: It is the algebraic difference between the
actual size and its corresponding basic size.

VIT-SMBS KJR CDn SIV

 Indian Standard System of Limits and Fits (Contd.)

TOLERANCE: It is the difference between the maximum limit

and minimum limit of size. It is always positive and is expressed
only as a number without a sign.
ZERO LINE: In a graphical representation of the above terms,
the zero line represents the basic size. This line is also called as
the line of zero deviation.
FUNDAMENTAL DEVIATION: These are 25 fundamental
deviations in the BIS system which are represented by letter
symbols (capital letters for holes and small letters for shafts).
FUNDAMENTAL TOLERANCE: This is also known as grade of
tolerance. In the BIS system, there are 18 grades of tolerances
represented by number symbols, both for hole and shaft.

VIT-SMBS KJR CDn SIV

 Limits & Fits – Principal Terms

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 FITS

FIT: The relationship between the two mating parts is known as

a fit.

Depending upon the actual limits of the hole or shaft sizes,

fits may be classified as
i) clearance fit
ii) transition fit and
iii) interference fit

VIT-SMBS KJR CDn SIV

 Clearance Fit

It is a fit that gives a clearance between the two mating parts.

Minimum clearance: It is the difference between the minimum

size of the hole and the maximum size of the shaft in a clearance
fit.

Maximum clearance: It is the difference between the maximum

size of the hole and the minimum size of the shaft in a clearance
or transition fit

VIT-SMBS KJR CDn SIV

 Clearance Fit

Minimum clearance value: 29.95 – 29.90 = +0.05 mm

Maximum clearance value: 30.00 – 29.85 = +0.15 mm
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 Transition Fit
This fit may result in either an interference or a clearance,
depending upon the actual values of the tolerance of individual
parts.

Clearance Fit

Shaft dia. 29.95 &

Hole dia. 30.05 (ie. +0.10 mm)

Interference Fit

Shaft dia. 30.00 &

Hole dia. 29.95 (ie. -0.05 mm)

VIT-SMBS KJR CDn SIV

 Interference Fit

If the difference between the hole and the shaft sizes is negative
before assembly; an interference fit is obtained.

Minimum Interference: It is the magnitude of the difference

(negative) between the maximum size of the hole and the
minimum size of the shaft in an interference fit before assembly.

Maximum Interference: It is the magnitude difference between

the minimum size of the hole and the maximum size of the shaft
in an interference or a transition fit before assembly.

VIT-SMBS KJR CDn SIV

 Interference Fit

Minimum Interference value: 30.25 – 30.30 = -0.05 mm

Maximum Interference value: 30.15 – 30.40 = -0.25 mm

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 Basic Shaft System
Basic size applied to shaft
– the type of fit will determine whether the
Fundamental deviation basic size will be the largest shaft or the
for the shaft equals smallest shaft.
the basic size

Fundamental deviation
for the hole equals the Upper deviation
allowance (Minimum clearance /
allowance)

Lower deviation
(Maximum clearance)
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 Basic Hole System
Fundamental Upper deviation
deviation for the (Minimum clearance /
shaft equals the allowance)
allowance

Fundamental
deviation for the Lower deviation
hole equals the (Maximum clearance)
basic size

Basic size applied to hole

– the type of fit will determine whether the basic size
will be the largest hole or the smallest hole.

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 End

VIT-SMBS KJR CDn SIV