Chapter 11 Limits Fits and Tolerances

11.1 Definition
Limit: The maximum and minimum permissible sizes within which the actual size
of a component lies are called Limits.
Tolerance:It is impossible to make anything to an exact size, therefore it is
essential to allow a definite tolerance or permissible variation on every specified
dimension.

11.2 Types of Tolerances

Unilateral Tolerance:
Tolerances on a dimension may either be unilateral or bilateral.
When the two limit dimensions are only on one side of the nominal size,
(either above or below) the tolerances are said to be unilateral.
For unilateral tolerances, a case may occur when one of the limits coincide
with the basic size.

Figure 11.1: Tolerance

Bilateral Tolerance: When the two limit dimensions are above and below nominal
size, (i.e. on either side of the nominal size) the tolerances are said to be
bilateral. Unilateral tolerances, are preferred over bilateral because the operator
can machine to the upper limit of the shaft (or lower limit of a hole) still having
the whole tolerance left for machining to avoid rejection of parts.
 Figure 11.2: Schematic Representation of Tolerances

Tolerance Build up:If a part comprises of several steps, each step having some
tolerance specified over its length, then the overall tolerance on the complete
length will be the sum of tolerances on individual lengths as shown in fig 11.3

Figure 11.3: Tolerance Build up

Compound Tolerances:A compound tolerance is one which is derived by

considering the effect of tolerances on more than one dimension.

Figure 11.4: Compound Tolerances

For ex, the tolerance on the dimension L is dependent on the tolerances on D, H

& .
The dimension L will be maximum when the base dimension is (D+a), the angle
is (+a), and the vertical dimension is (H-d).
The dimension L will be minimum when the base dimension is (D-b), the angle is
(-b), and the vertical dimension is (H+c).

11.3 Terminology of Limit Systems

 Limits of size: The two extreme permissible sizes of a component
between which the actual size should lie including the maximum and
minimum sizes of the component.
Nominal size: It is the size of the component by which it is referred to as
a matter of convenience.
Basic size: It is the size of a part in relation to which all limits of variation
are determined.
Zero Line: It is the line w.r.t which the positions of tolerance zones are
shown
Deviation: It is the algebraic difference between a limit of size and the
corresponding basic size.
UpperDeviation: It is the algebraic difference between the maximum
limit of size and the corresponding basic size. It is denoted by letters ES
for a hole and es for a shaft.
Lower Deviation: It is the algebraic difference between the minimum
limit of size and the corresponding basic size. It is denoted by letters EI
for a hole and ei for a shaft.
Fundamental Deviation: It is the deviation, either upper or lower
deviation, which is nearest to the zero line for either a hole or a shaft. It
fixes the position of the tolerance zone in relation to the zero line.
Allowance: It is the intentional difference between the hole dimensions
and shaft dimension for any type of fit.
Size of tolerance: It is the difference between the maximum and
minimum limits of size.

11.4 Standardization:
Standardization is a process which leads to the establishment of desirable
criteria with respect to size, material and so on to which everyone can adhere to.
If this is done, it is expected that the standard would meet all their requirements
and enable them to manufacture and stock the minimum variety of parts.
It is of economic advantage if designs make use of standard parts such as
screws, splines, gears and so on that have been manufactured with standard
cutting tools, inspected with standard gauges, stored and dispatched using
standard containers. Though, there may be the need to use nonstandard parts
but the cost of such special parts would be more as compared to standard parts.
Standards are available to engineers to cover dimensions, allowances and
tolerances, specification of materials, properties of materials, machines, tools
and gauges, methods of installations of engineering products and inspection. The
application of standards affects quality and if the criteria which have been
established in the standard are desirable, then the quality level should be
enhanced.

11.5 Interchangeability:
Interchangeability is a system which allows any component to be assembled
correctly with any mating part or be substituted for another part both are chosen
randomly. Some finished products, units or sub units of the same type could be
fitted or be replaced without previous selection or without any work done on it.
Interchangeability in production occurs when some standardized components or
parts are used in the assembly of a machine as specified in the drawing. Such a
system makes it possible to assemble a machine or product within the shortest
possible time and is thus economical.
Interchangeability makes mass production of a component feasible and may
reduce set-up time on machines. Instead of producing or manufacturing each
part in a product, such part could be bought outright and assembled.
Interchangeability makes it possible to save cost, as some parts in a product
have shorter life span and as such can be changed instead of buying the whole
product. Imagine what happens if
Interchangeability is nil and one has a faulty bearings in a car.

Terminologies:
Nominal size: The size designation used for general identification. The
nominal size of a shaft and a hole are the same.
Basic size: It is the size whose limit dimensions are specified using the
upper and lower deviations. In case of a fit, the basic size of both
connected elements must be the same.
It may also be stated to be the exact theoretical size of a part. The number
of significant digits implies the accuracy of the dimension.
Design size: The ideal size for each component (shaft and hole) based
upon a selected fit. The difference between the design size of the shaft
and the design size of the hole is equal to the allowance of the fit. The
design size of a part corresponds to the Maximum Material Condition
(MMC). That is, the largest shaft permitted by the limits and the smallest
hole. Emphasis is placed upon the design size in the writing of the actual
limit dimension, so the design size is placed in the top position of the pair.

11.6 Fits and Their Classifications

When two parts are to be assembled, the relation resulting from the difference
between their sizes before assembly is called a fit. A fit may be defined as the
degree of tightness and looseness between two mating parts. The important
terms related to the fit are given below:
Clearance: In a fit, this is the difference between the sizes of the hole and the
shaft, before assembly, when this difference is positive. The clearance may be
maximum clearance and minimum clearance. Minimum clearance in the fit is the
difference between the maximum size of the hole and the minimum size of the
shaft.
Interference: It is the difference between the sizes of the hole and the shaft
before assembly, when the difference is negative. The interference may be
maximum or minimum. Maximum interference is arithmetical difference between
the minimum size of the hole and the maximum size of the shaft before
assembly. Minimum interference is the difference between the maximum size of
the hole and the minimum size of the shaft.
Transition: It is between clearance and interference, where the tolerance zones
of the holes and shaft overlap.
So, you can see that fits depend upon the actual limits of the hole and or shaft
and can be divided into three general classes:
(i) Clearance Fit.
(ii) Interference Fit.
(iii) Transition Fit.

11.6.1 Clearance Fit

In clearance fit, an air space or clearance exists between the shaft and hole as
shown in Figure 11.5. Such fits give loose joint. A clearance fit has positive
allowance, i.e. there is minimum positive clearance between high limit of the
shaft and low limit of the hole.

Figure 11.5: Clearance Fit

Clearance fit can be sub-classified as follows:
Loose Fit:It is used between those mating parts where no precision is
required. It provides minimum allowance and is used on loose pulleys,
agricultural machineries etc.
Running Fit:For a running fit, the dimension of shaft should be smaller
enough to maintain a film of oil for lubrication. It is used in bearing pair
etc. An allowance 0.025 mm per 25 mm of diameter of boaring may be
used.
Slide Fit or Medium Fit:It is used on those mating parts where great
precision is required. It provides medium allowance and is used in tool
slides, slide valve, automobile parts, etc.

11.6.2 Interference Fit

A negative difference between diameter of the hole and the shaft is called
interference. In such cases, the diameter of the shaft is always larger than the
hole diameter. In Figure 11.6. Interference fit has a negative allowance, i.e.
interference exists between the high limit of hole and low limit of the shaft.

Figure 11.6: Interference Fit

In such a fit, the tolerance zone of the hole is always below that of the shaft. The
shaft is assembled by pressure or heat expansion.
The interference fit can be sub-classified as follows:
 Shrink Fit or Heavy Force Fit:It refers to maximum negative allowance.
In assembly of the hole and the shaft, the hole is expanded by heating and
then rapidly cooled in its position. It is used in fitting of rims etc.
Medium Force Fit:These fits have medium negative allowance.
Considerable pressure is required to assemble the hole and the shaft. It is
used in car wheels, armature of dynamos etc.
Tight Fit or Press Fit:One part can be assembled into the other with a
hand hammer or by light pressure. A slight negative allowance exists
between two mating parts (more than wringing fit). It gives a semi-
permanent fit and is used on a keyed pulley and shaft, rocker arm, etc. 30
Metrology and Instrumentation

11.6.3 Transition Fit

It may result in either clearance fit or interference fit depending on the actual
value of the individual tolerances of the mating components. Transition fits are a
compromise between clearance and interference fits. They are used for
applications where accurate location is important but either a small amount of
clearance or interference is permissible. As shown in Figure 11.7, there is
overlapping of tolerance zones of the hole and shaft.

Figure 11.7: Transition Fit

Transition fit can be sub-classified as follows:

Push Fit: It refers to zero allowance and a light pressure (10 cating
dowels, pins, etc.) is required in assembling the hole and the shaft. The
moving parts show least vibration with this type of fit. It is also known as
snug fit.
Force Fit or Shrink Fit: A force fit is used when the two mating parts are
to be rigidly fixed so that one cannot move without the other. It either
requires high pressure to force the shaft into the hole or the hole to be
expanded by heating. It is used in railway wheels, etc.
Wringing Fit:A slight negative allowance exists between two mating
parts in wringing fit. It requires pressure to force the shaft into the hole
and gives a light assembly. It is used in fixing keys, pins, etc.

11.7 Systems of Fit

A fit system is the systems of standard allowance to suit specific range of basic
size. If these standard allowances are selected properly and assigned in mating
parts ensures specific classes of fit. There are two systems of fit for obtaining
clearance, interference or transition fit. These are:
(i) Hole basis system (Figure 11.8)
(ii) Shaft basis system (Figure 11.9)
 Figure 11.8: Hole Basis System

Figure 11.9: Shaft Basis System

11.7.1 Hole Basis System

In the hole basis system, the size of the hole is kept constant and shaft sizes are
varied to obtain various types of fits.
In this system, lower deviation of hole is zero, i.e. the low limit of hole is same as
basic size. The high limit of the hole and the two limits of size for the shaft are
then varied to give desired type of fit. The hole basis system is commonly used
because it is more convenient to make correct holes of fixed sizes, since the
standard drills, taps, reamers and branches etc. are available for producing holes
and their sizes are not adjustable. On the other hand, size of the shaft produced
by turning, grinding, etc. can be very easily varied.
11.7.2 Shaft Basis System
In the shaft basis system, the size of the shaft is kept constant and different fits
are obtained by varying the size of the hole. Shaft basis system is used when the
ground bars or drawn bars are readily available. These bars do not require
further machining and fits are obtained by varying the sizes of the hole.
In this system, the upper deviation (fundamental deviation) of shaft is zero, i.e.
the high limit of the shaft is same as basic size and the various fits are obtained
by varying the low limit of shaft and both the limits of the hole.
1. Deviation: It is the algebraic difference between a size, to its
corresponding basic size. It may be positive, negative or zero.
2. Upper Deviation: It is the algebraic difference between maximum
limit of size and its corresponding basic size.
3. Lower Deviation: It is the algebraic difference between minimum
limit of size and its corresponding basic size.

11.8 Standard system of limit & fit

1. As per the Indian standard IS 919, the present system of limit and fit
comprises of 18 grade of fundamental tolerance & 25 types of
fundamental deviation.
2. The tolerances are denoted by two symbol, a letter symbol (which also
indicate the fundamental deviation from basic size) and number symbol
(which is called grade)
3. Fundamental deviation for holes is represented by capital letter symbol
ranging from A & ZC.
 4. Fundamental deviation for shaft is represented by small letter symbol
ranging from a & zc.
5. These letter represent the degree of looseness of tolerance zone to the
basic size.The I, L, O, Q, W & I, l, o, q and w have been excluded from the
mentioned deviation.

Figure 11.9: Standard system

11.9 International tolerance Grade

11.10 Limit gauges
These are inspection tools for rigid design, without a scale, which serve to check
the dimensions of manufactured parts. Gauges do not indicate the actual value
of the inspected dimension on the work. They can only be used for determining
as to whether the inspection parts are made within the specified limits. These
gauges are made up of suitable wear resisting steel and are normally hardened
to not less than 750 HV and suitably stabilised and ground and lapped.
The Go and No Go gauges may be in the form of separate single ended gauge,
or may be combined on one handle to form a double ended gauge. Progressive
gauge is the single ended gauge with one gauging member having two
diameters to the Go and No Go limits respectively.
A typical limit plug gauge and limit snap gauge are shown in the Fig.

Figure 11.10: Limit Plug Gauge Figure 11.11:

Limit Snap Gauge

11.10.1 Gauge Design Taylors principle:

Every gauge is a copy of the part which mates with the part for which the gauge
is designed. For example, a bush is made which is to mate with a shaft; in this
case, the shaft is the mating part. The bush is check by a plug gauge which in so
far as the form of its surface and its size is concerned, is a copy of the mating
part (shaft).
Taylors principle: According to Taylor, Go and No Go gauges should be
designed to check maximum and minimum material limits which are checked as
below:
Go limit: This is applied to upper limit of a shaft and lower limit of a hole.
No Go limit: This is applied to lower limit of a shaft and the upper limit of a
hole.
Taylors principle states that the Go gauges should check all the possible
elements of dimensions at a time (roundness, size, location, etc.) and the No Go
gauge should check only one element of the dimension at a time.
Based on Taylors principle, Go gauge is designed for maximum material
condition and No Go gauge is designed for minimum material condition.

11.10.2 Types of Limit Gauges:

The various types of limit gauges used for gauging internal diameters of holes
are:

1. Full form cylindrical plug gauge: The gauging surface is in the form of an
external cylinder. Generally a small circumferential groove is cut near the leading
end of the gauge and the remaining short cylindrical surface is slightly reduced
in order to act as a pilot.

Figure 11.12: Full form cylindrical plug gauge

2. Full form spherical plug or disc gauge: The gauging surface is in the
form of a sphere from which two equal segments are cut off by planes normal to
the axis of the handle.

Fig. 2.9 Full form spherical plug gauge

Figure 11.13: Full form spherical plug or disc gauge

3. Segmental cylindrical bar gauge: The gauging surface is in one of the
two forms: one form; external cylindrical form from which two axial segments are
made by lowering down surface at other places. (Fig.11.14) the other form;
external cylindrical form in which segments are formed by removing remaining
material. (Fig. 11.15).
Figure 11.14: Segmental cylindrical bar gauge Figure 11.15:
Segmental cylindrical bar gauge

4. Segmental spherical plug gauge: It is similar to full form spherical plug

gauge but has two equal segments cut off by planes parallel to the axis of the
handle in addition to the segments cut off by planes normal to the axis of the
handle.

Fig. 2.12 Segmental Spherical plug gauge

Figure 11.16: Segmental spherical plug gauge

5. Segmental cylindrical bar gauge with reduced measuring faces: It is
similar to the segmental cylindrical bar gauge but has reduced measuring faces
in a plane parallel to the axis of the handle.

Fig.2.13 Segmental cylindrical bar gauge

Figure 11.17: Segmental cylindrical bar gauge with reduced measuring

faces
6. Rod gauge with spherical ends: It has spherical end surfaces which form
part of one single sphere.

Figure 11.18: Rod gauge with spherical ends

Fig. 2.14 Rod guage with spherical ends

The various types of limit gauges used for gauging external diameters of shaft
are:
1. Full form cylindrical ring gauge: The gauging surface is in the
form of an internal cylinder and whose wall is thick enough to avoid
deformation under normal conditions of use.
2. Gap gauge: It has one flat surface and one cylindrical surface, the
axis of the two surfaces being parallel to the axis of the shaft being
checked. The surfaces constituting the working size may both be
flat or both cylindrical also.

The gauges (for internal taper) are marked with a ring on the gauge planes
another ring to indicate the minimum depth of internal taper. The distance
between the two ring marks Z corresponds to the permissible deviation of the
gauge plane for particular taper. For testing the external taper of the tanged end
shank, the ring gauge is inserted, as far as it goes with light pressure. At the
extreme position, no part of the tang under test should extend beyond the
surfaces A, B and C. The shank surfaces may however, lie flush with these
surfaces.

Review questions
1. Explain the concept of interchangeability with examples
2. Discuss the need of the use of selective assembly by giving a practical
example.
3. Define the terms:
(a) Limits
(b) Tolerance
(c) Basic size
(d) Fundamental Deviation
(e) Fit
(f) Gaugemakers Tolerance
(g) Wear allowance
(h) Go and NO-GO Gauge
4. Explain the need and types of giving the tolerances with examples.
5. Discuss unilateral and bilateral systems of writing tolerances with suitable
examples and explain which system is preferred in interchangeable
manufacture and why.
6. State and explain Taylors principle of limit-gauge design.
7. Write a short note on limit gauges.
8. Define fits and explain in brief the types of fits.
9. Explain with a neat diagram the essential conditions of interference and
clearance.
10.Write down the examples of use of the following types of fits:
(a) Push fit
(b) Press fit
(c) Running clearance fit
(d) Wringing fit
11.Differentiate between
(a) Tolerance and allowance
(b) Interchangeable manufacturing and selective assembly concepts
(c) Hole-base system and shaft-base system
(d) Measuring instrument and gauge
(e) Workshop gauge and inspection gauge
12.Explain with a sketch the allocation of gauge tolerance and wear
allowance for workshop, inspection and general grade conditions.
13.Enumerate the types of plug gauges and draw neat sketches of any three
of them by stating their applications.
14.Discuss the use of taper plug gauges.
15.Draw the sketch of a progressive-type solid plug gauge and discuss the
advantages and limitations of this type of gauging.
16.Explain the use of bore gauge and filler gauge.
17.Discuss the various applications of air plug gauges.