Fundamentals of Metrology

Umesh S.
Automotive & Aeronautical Engineering Department
MSRUAS, Bangalore

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 Session 1 break-up
– Fundamentals of metrology
– Terminologies and definitions
– Engineering Tolerances
– Limits & Fits
– Hole and Shaft base systems of tolerances
– Tolerance grades
– Representation of limits, fits and tolerances in
Manufacturing drawings
– Functional gauges

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 Problem of Variation
Drawings

Designer Mfg. Engr.

Concept Sizing x1? x2? r? d? q?

Sizing x1, x2, r, d, q Mfg. Process
Fits
Material Variation
(Mfg. Process)
How much variation can be tolerated? D ± DD(?)
Tolerate it but control it
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Tolerance Economics

“Manufacturing Processes and Materials for Engineers,” Doyle et.al., Prentice-Hall, Inc., 1985

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 Tolerance-need
No feature of a component can be perfect (i.e., no surface flat, no
hole round etc), because of the manufacturing process.

Thus, when dimensioning any feature

• Basic nominal dimension
• Permitted variability (tolerance)
shall be mentioned
Dimensions should be given in as large a tolerances as possible
without interfering with the function of the part to reduce production
costs.
Tolerance is the total amount that a specific dimension is permitted to
vary.
It is the difference between the maximum and the minimum limits for
the dimension.
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 Tolerance
• How to decide tolerance?
– Functional requirements of mating parts
– Cost of production
– Available manufacturing process

• Choose as coarse tolerance as possible without

compromising functional requirements
• Proper balance between cost and quality of parts

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 Types of Tolerance

• Limit tolerance

• Plus minus
Tolerance

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Plus minus-Unilateral Tolerance
The upper and lower deviations are all positive or
all negative. hole  30 0
0.033
shaft  30 0.040
 0.092

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Plus minus-Bilateral Tolerance
The tolerance is split above and below the
basic size shaft  30 0.013
hole  30
0.006
 0.015
 0.008

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 Limits and Fits
When parts are assembled together, engineers have to decide how
they will fit together and the economics associated with it.
• How they will fit together?
– Clearance fit
– Transition fit Standards
– Interference fit
BS4500
• Economics?
ANSI B4.1
– Interchangeability

Fit expresses the relationship between a mating parts with

respect to the amount of clearance or interference which
exists when they are assembled together.
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Limits : Example : Journal bearings are designed to operate at
high rotational speed

• If the clearance between the inner and outer diameter is to small

the bearing will seize
• If the clearance is to big the shaft will vibrate
• Limits on the size of the shaft and hole provide correct operation

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 Limits and
Fits
Definitions

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 Definitions
Nominal size
It is the designation used for the purpose of general identification. It is the
dimension that results from empirical relationships and design
calculations
Basic size
It is the theoretical size from which limits of size are derived by the
application of allowances and tolerances. It is the decimal equivalent of
nominal size. The number of decimal places determines the precision
and the accuracy required.
Actual size
It is the measured size of the finished part. It is the combination of basic
size and its assigned tolerance. It is the size that results from producing
the part, including all manufacturing imperfections. The actual size
must lie within the maximum and minimum allowable values of size;
otherwise the part will be rejected during inspection.

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 Definition of Tolerance
• Tolerance is the total amount that a specific dimension
is permitted to vary.
• It is the difference between the maximum and the
minimum limits for the dimension.
• It is expressed in unilateral and bilateral tolerance
• Unilateral tolerance is a tolerance in which variation is
permitted only on one side of the basic size. For
+.004
example: 1.750 -.000.
• Bilateral tolerance is specified as plus or minus
deviation from the basic size. 1.750 +/- .002

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Allowance
It is the difference between the maximum material
limits of mating parts. it is the minimum clearance
(positive allowance) or maximum interference
(negative allowance) between mating parts. It is also
known as tightest fit between mating parts-the
smallest clearance and larger interference. Allowance
is an algebraic value; it could be a positive or
negative value. Allowance is used to determine the
type of fit
( clearance, transition or interference)

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 Limits and Fits - Definitions
• Limits of size - the maximum and minimum sizes
permitted for a feature.
• Maximum limit of size - the greater of the 2 limits of
size.
• Minimum limit of size - the smaller of the 2 limits of
size.
• Hole - designate all INTERNAL features of a part,
including parts which are not cylindrical.
• Shaft - designate all EXTFRNAL features of a part,
including parts which are not cylindrical.

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 Limits and Fits - Definitions
• Upper deviation - difference between the maximum limit
of size and the corresponding basic size. This is
designated ‘ES' for a hole and 'es' for a shaft.
• Lower deviation - difference between the minimum limit
of size and the corresponding basic size. This is
designated ‘EI' for a hole and 'ei' for a shaft.

• Fundamental Deviation - is the deviation closest to the

basic size

• Allowance – the minimum clearance or maximum

interference between parts - intentional difference
between shaft and hole dimension for achieving
particular type of fit.
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Limits and Fits - Definitions

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 Grades of Tolerances
Group of tolerances with the same level of accuracy for all
basic sizes.

• There are 18 grades of tolerances IT01, IT0, and

IT1 to IT16. (IT - ISO series Tolerances)
• IT01 and IT0 are very fine grades
• IT16 is the most coarse grade reflecting the
precision of the process.
• The degree of error increases with:
– the precision of the process (IT grade), and
– the size of the component.

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 INDIAN STANDARD IS 919-1963

 18 FUNDAMENTAL TOLERANCES or
TOLERANCE GRADES .
 For different grades values of standard
tolerance are determined from diff formulae

Relative magnitude of each grade is

GRADES 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

Where i = 0.45 3 D + 0.001 D

D is the geometric mean of the
group of basic sizes

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Degree of accuracy expected for different
manufacturing processes

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Grades of Tolerances

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Representation of Tolerance
2) Number or Grade
IT01, IT0, IT1,….IT16
Tolerance Grade defines range of
dimensions (dimensional variation)
There are manufacturing constraints
on tolerance grade chosen

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 International Tolerance Grade (IT):

They are a set of tolerances that varies according to the basic

size and provides a uniform level of accuracy within the grade.

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 Limits and Fits Designation
• A hole tolerance with deviation 'H' and tolerance grade IT7 is
designated 'H7'.
• A shaft tolerance with deviation 'p' and tolerance grade IT6 is
designated 'p6'.
• Appropriate tolerance designation for a feature of 45 mm, e.g.
45H7 or 45p6.
• A fit combines the basic size of both features and their
designations. The designation of hole limits should always be
quoted first. E.g. 45H7-p6 or 45H7/p6.

FIT - condition of looseness or tightness between two mating

parts being assembled together

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 FITS

Clearance Fit Transition Fit Interference Fit

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Example - Clearance Fit

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 Clearance Fit

Maximum shaft dimension < Minimum hole dimension

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Example - Transition Fit

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 Transition Fit

Obtained by overlapping of tolerance zones of shaft and hole

……Does not guarantee neither clearance nor interference fit

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Example - Interference Fit

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 Interference Fit

Maximum Hole size < Minimum Shaft size

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 Fits Applications

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 Hole Basis System of Fit
• Associating various shafts with a single hole
• ISO - the lower deviation of the hole is zero

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 Shaft Basis System of Fit
• Associating holes with a single shaft
• ISO - upper deviation of shaft is zero

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To obtain different types of fits, it is general practice to
vary tolerance zone of one of the mating parts

HOLE BASED SYSTEM-

Size of hole is kept constant,
shaft size is varied
to get different fits.

SHAFT BASED SYSTEM-

Size of shaft is kept constant,
hole size is varied
to get different fits.

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 Hole Basis
System of Fit
• More commonly used
• It is easier to manufacture
shaft to the tolerance
values and measure those
values
• Holes are made with
standard tools (drill bits).
Size of the hole drilled is a
function of sizes of drill
bits available
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Shaft Basis
System of Fit
• Less commonly used
• Preferable when a shaft may
have to accommodate a
variety of accessories such
as couplings, bearings,
collars, gears, etc. - constant
shaft diameter with varying
bores of accessories to
obtain different types of fits.
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Representation of Fit Together (Letter & Grade) on
both mating components
decide quality of fit

0.021

Interference
Φ30.035
Fit
Φ30.022
Φ30.021
0.013
0.022
Φ30.000

H7 : Tol Grade 7 mean 21μ variation (H

means upper deviation zero)
p6 : Tol Grade 6 means 13μ variation
(p means upper deviation is 22 μ)
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 Tolerance on
Components

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 ISO Standard "Hole Basis"
Clearance Fits
Type of Fit Hole Shaft
Loose Running Fits. Suitable for loose pulleys H11 c11
and the looser fastener fits where freedom of
assembly is of prime importance
Free Running Fit. Where accuracy is not H9 d10
essential, but good for large temperature
variation, high running speeds, heavy journal
pressures
Close Running Fit. Suitable for lubricated H8 f7
bearing, greater accuracy, accurate location,
where no substantial temperature difference is
encountered.
Sliding Fits. Suitable for precision location fits. H7 g6
Shafts are expensive to manufacture since the
clearances are small and they are not
recommended for running fits except in
precision equipment where the shaft loadings
are very light.
Locational Clearance Fits. Provides snug fit H7 h6
for locating stationary parts; but can be freely
assembled and disassembled.

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 ISO Standard "Hole Basis”
Transition Fits
Type of Fit Hole Shaft
Locational Transition Fits. for accurate H7 k6
location, a compromise between clearance and
interference
Push Fits. Transition fits averaging little or no H7 n6
clearance and are recommended for location fits
where a slight interferance can be tolerated for
the purpose, for example, of eliminating vibration.

ISO Standard "Hole Basis"

Interference Fits
Type of Fit Hole Shaft
Press Fit. Suitable as the standard press fit into H7 p6
ferrous, i.e. steel, cast iron etc., assemblies.
Drive Fit Suitable as press fits in H7 s6
material of low modulus of elasticity such as
light alloys.

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 ISO Clearance Fits

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 Nominal Sizes Tolerance
Over To H7 k6 H7 n6
mm mm 0.001 mm 0.001 mm 0.001 mm 0.001 mm

+10 +6 +10 +10

–– 3 0 +0 0 +4
3 6 +12 +9 +12 +16
0 +1 0 +8
6 10 +15 +10 +15 +19
0 +1 0 +10
10 18 +18 +12 +18 +23
0 +1 0 +12
18 30 +21 +15 +21 +23

ISO
0 +2 0 +15
30 40
+25 +18 25 +33

Transition
40 50 0 +2 0 +17
50 65
+30 +21 +30 +39

Fits
65 80 0 +2 0 +20
80 100
+35 +25 +35 +45
100 120 0 +3 0 +23
120 140
140 160 +40 +28 +40 +52
0 +3 0 +27
160 180
180 200
200 225 +46 +33 +46 +60
0 +4 0 +34
225 250
250 280
+52 -32 +52 +36
280 315 0 - 0 +4
315 355
+57 +40 +57 +73
355 400 0 +4 0 +37
400 450
+63 +45 +63 +80
450 500 0 +5 0 +40

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 Nominal Sizes Tolerance Tolerance
Over To H7 p6 H7 s6
mm mm 0.001 mm 0.001 mm 0.001 mm 0.001 mm

+10 +12 +10 +20

–– 3 0 +6 0 +14
3 6 +12 +20 +12 +27
0 +12 0 +19
6 10 +15 +24 +15 +32
0 +15 0 +23
10 18 +18 +29 +18 +39
0 +18 0 +28
18 30 +21 +35 +21 +48
0 +22 0 +35
30 40
+25 +42 +25 +59
40 50 0 +26 0 +43

ISO 50

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65

80
+30
0
+51
+32
+30
0
+30
+72
+53
+78

Interference
0 +59
80 100 +35 +93
+35 +59 0 +78
100 120 0 +37 +35 +101

Fits
0 +79
120 140 +40 +117
0 +92
140 160 +40 +68 +40 +125
0 +43 0 +100
160 180 +40 +133
0 +108
180 200 +46 +151
0 +122
200 225 +46 +79 +46 +159
0 +50 0 +130
225 250 +46 +169
0 +140
250 280 +52 +198
+52 +88 0 +158
280 315 0 +56 +52 +202
0 +170
315 355 +57 +226
+57 +98 0 +190
355 400 0 +62 +57 +244
0 +208
400 450 +63 +272
+63 +108 0 +232
450 500 0 +68 +63 +292
0 +252

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Limit Gauging

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 Limit Gauging
GO Gauges NO GO Gauges
(NOT GO gauges)
Checks maximum metal condition Checks minimum metal condition
Should assemble (‘go’) with part for Should not assemble (‘Not Go’) with
acceptance part for acceptance

• Gauges are inspection tools used to check the dimensions of parts

• They do not indicate the actual value of dimensions
• Used to determine whether the inspected parts are with in the specified
limits
• Plug gauges for holes and Ring gauges for shaft
• Hole: maximum metal condition-smallest acceptable hole
(Go Limit-lower limit of size)
• Shaft: maximum metal condition-largest acceptable shaft
(Go Limit-upper limit of size)

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 Go-NoGo gauges
• A Go-NoGo gauge) refers to an inspection tool used to check a
workpiece against its allowed tolerances. Its name derives from
its use: the gauge has two tests; the check involves the workpiece
having to pass one test (Go) and fail the other (No Go).
• It is an integral part of the quality process that is used in the
manufacturing industry to ensure interchangeability of parts
between processes, or even between different manufacturers.
• A Go NoGo gauge is a measuring tool that does not return a size
in the conventional sense, but instead returns a state. The state is
either acceptable (the part is within tolerance and may be used) or
it is unacceptable (and must be rejected).
• They are well suited for use in the production area of the factory
as they require little skill or interpretation to use effectively and
have few, if any, moving parts to be damaged in the often hostile
production environment.

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 Plug gauge
These gauges are referred to as plug gauges; they are used in
the manner of a plug. They are generally assembled from
standard parts where the gauge portion is interchangeable with
other gauge pieces (obtained from a set of pin type gauge
blocks) and a body that uses the collet principle to hold the
gauges firmly. To use this style of gauge, one end is inserted
into the part first and depending on the result of that test, the
other end is tried.

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 Plug gauges

Ring gauges

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Snap gauges

Snap gauges are often used when a large quantity of work pieces must be
inspected. The snap gauge has four anvils or jaws, the first one or pair
(outermost) are set using the upper limit (tolerance) of the part and the inner set
adjusted to the lower limit of the part.
A correctly machined part will pass the first set of jaws and stop at the second end
of test. In this manner a part may be checked in one action, unlike the plug gauge
that needs to be used twice and flipped to access the second gauge.

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 Ring gauge
• Ring gauge is a cylindrical ring of steel whose inside diameter is finished to
gauge tolerance and is used for checking the external diameter of a
cylindrical object.
• Ring gauges are used for comparative gauging as well as for checking,
calibrating, or setting of gauges or other standards. Individual ring gauges or
ring gauge sets are made to variety of tolerance grades in metric and English
dimensions for master, setting, or working applications.
• A go ring gauge's dimensions are based on the maximum OD tolerance of
the round bar or part being gauged. A go plug gauge's dimensions are based
on the minimum ID tolerance of the hole or part being gauged.
• No-go gauges consist of a fixed limit gauge with a gauging limit based on
the minimum or maximum tolerances of the inspected part. A no-go ring
gauge's dimensions are based on the minimum OD tolerance of the round
bar or part being gauged

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 (a) Plug gage for holes, with GO and
NOT GO on opposite ends.
(b) Plug gage with GO-NOT GO on one
end.
(c) Plain ring gages for gauging round
rods.
(d) Snap gage with adjustable anvils.

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 Summary
• Basic terms and definitions of limits,
tolerance and fits
• Types and characteristics of fits
• Tolerance grades and significance
have been discussed

Thank You

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