Limits, Fits & Tolerances

Dr. N. VENKAIAH

The wise learn many things from their enemies.

- Aristophanes

What is a tolerance?
Axiom of Manufacturing Imprecision
Generally, all manufacturing processes are inherently imprecise
and produce parts that deviate from nominal size and shape due to
systematic and/or random errors.
The errors may arise from man, material, machine tools,
manufacturing processes etc.
Parts dimensions are allowed to vary to
some extent without interfering with their
performance

= 0.04

20.02
19.98

SHAFT

Tolerance: Permissible variation on a dimension.

Tolerance on a shaft

Case Study
Design of an IC engine
Given: P = 15 kw @ 700 rpm
After design, Dcyl = Dpiston = 50 mm

UL

Piston

LL

During manufacturing:

Dcyl = 50 mm

Dpistion = 49.95 mm

Lower limit (LL) =

50.00

49.85

Upper limit (UL) =

50.05

49.95

Tolerance (UL-LL) =

0.05 mm

0.1 mm

How much to tolerate?

As tolerance

Cost of mfg

As tolerance

Performance

What is Ideal requirement?

Lowest cost & best performance

(Hyperbolic)

That is impossible.
Next alternative?

Tolerance

If cost of manufacturing is more important, give larger tolerance.

If functionality is more important, provide small tolerance.
If both are important, apply medium amount of tolerance.
Overall: A tolerance should be as large as possible without
interfering with the function of the part to minimize production cost.

How much to tolerate?

Examples
1. Piston and cylinder of hydraulic press (pressure range: 500 MPa)
Functionality is important Provide small amount of tolerance
2. Shaft in journal bearing Cost important Provide large tolerance
3. Piston and cylinder of an IC engine Both cost & functionality imp
Provide medium amount of tolerance

Terminology
Nominal size. or

Basic size: Theoretical size (Designers

size) used as a starting point for the application of tolerances.

E.g. Power = 15 kw

@ 750 rpm

Dia. of shaft = 49.2 mm

49.2
Can be written as,
50

(say)

+0.3
0.1

0.6
0.9

Basic size

Standard Preferred Sizes

Unless special conditions exist, the basic size should be

chosen from the lists of preferred basic sizes
7

Terminology
Actual size: Measured size of the finished part.
Limits: Minimum size (lower limit) & maximum size (upper limit)
shown by the toleranced dimension.

Tolerance: Difference between upper and lower limits of size.

MMC (Maximum Material Condition): The condition of a part in
which the part contains the maximum amount of material.
e.g., Biggest shaft or smallest hole.

LMC

(Least or Minimum Material Condition): The condition of a

part in which the part contains the least amount of material.
e.g., Smallest shaft or biggest hole.

Example

0.02
25 + 0.01

25 is nominal size or basic size

Max. size (Max. limit or Upper limit)= 25.02 mm
Min. size (Min. limit or Lower limit) = 24.99 mm
Tolerance = Max. size - Min. size = 25.02 - 24.99 = 0.03 mm
At times, nominal size may lie outside the limiting dimensions
e.g.,

25 0.05
0.10

0.501 Actual measured dimension

0.502 Upper Limit (LMC)

0.498 Lower Limit (MMC)

Engineering dimensioned
drawing

Machined part

10

Two Types of Tolerances

Unilateral Tolerance

30.00

+0.008
-0.000

5.00

+0.008
+0.006

Tolerance lies wholly on one

side of basic size

Bilateral Tolerance

30.00 0.004

5.00 0 .003

Tolerance lies on either side of

basic size.
But need not be equally
disposed about it.
11

Introduction

Fit

Journal bearings are designed to operate at high rotational speed

Too small clearance

- Inadequate lubrication
- Bearing will seize

Too much clearance

- Shaft will vibrate

Proper clearance between the shaft and hole provide correct

operation

Fit describes the working condition (relationship) between mating parts.

Types of Fits
Clearance fit
Shaft is always smaller
Relative movement is present between the mating parts
Clearance is guaranteed under all conditions
E.g.
1. Bearing and shaft
2. Piston and cylinder of an IC engine

13

Types of Fits
Interference fit
Shaft is always larger
Apply heat to hole hole expands insert the
shaft into hole
No relative movement between the mating parts
Interference is guaranteed under all conditions
E.g.
Bearing and bush
Keys and key ways

14

Types of Fits
Transition fit
Tolerance zones overlap
May provide either clearance or interference
Upper limit on the shaft is larger than the lower limit
on the hole and lower limit on the shaft is smaller
than the upper limit on the hole.
Transition fits exist only as a class; any actual hole
and shaft must assemble with either a clearance or
interference fit.
Min. hole & Min shat H > S C

E.g.

Min hole & Max shaft H < S I

Piston and piston rings

Max. hole & Min. shaft H > S C

Shaft and couplings

Max. hole & Max. shaft H > S C

15

Allowance

Intended difference in the sizes of mating parts

Indicates how the two parts will interact with each other

Allowance

Minimum hole size - maximum shaft size

(Diff. between Max. material limits)

In clearance fit, allowance equals the minimum clearance and is a

positive allowance
In interference fit, allowance equals the maximum interference
and is a negative allowance
In short: Allowance is calculated based on the tightest fit
between the mating parts
16

Interference Fit

ALLOWANCE =

17

Interference Fit

0.001

MAX. INTERFERANCE = - 0.004

0.001

1.251
1.250

MIN. INTERFERANCE = - 0.002

1.247
1.248

ALLOWANCE = - 0.004

18

Shaft
Basic size

Tolerance on shaft

Hole

Min. shaft size

Max. shaft size

Min. hole size

Max. hole size

Tolerance Zones
Tolerance on hole
Zero line

19

GATE 2012
In an interchangeable assembly, shafts of size
mate with holes of size 25.000

+0.030
+0.020

25.000

+0.040
0.010

mm

mm

The maximum interference ( in microns) in the assembly is

(A)40

(B) 30

(C) 20

(D) 10

Ans: -(C)
Maximum interference = maximum size of shaft minimum size of hole
= 25.040 - 25.020 = 20 m

20

IES 2011
Interference fit joints are provided for:
(a)
(b)
(c)
(d)

Assembling bush bearing in housing

Mounting heavy duty gears on shafts
Mounting pulley on shafts
Assembly of flywheels on shafts

Ans. (a)

21

GATE 2011
A hole is of dimension
dimension

0.010
0.001

0.015
0

mm. The corresponding shaft is of

mm. The resulting assembly has

(a) loose running fit

(b) close running fit
(c) transition fit
(d) interference fit
Ans. (c)

22

IES 2009
Consider the following joints:
1. Railway carriage wheel and axle
2. IC engine cylinder and liner
Which of the above joints is/are the result(s) of interference fit?
(a)
(b)
(c)
(d)

1 only
2 only
Neither 1 nor 2
Both 1 and 2

Ans. (d)

23

IES 2008
Consider the following statements:
1. The amount of interference needed to create a tight joint varies with
diameter of the shaft.
2. An interference fit creates no stress state in the shaft.
3. The stress state in the hub is similar to a thick walled cylinder with
internal pressure.
Which of the statements given above are correct?
(a)
(b)
(c)
(d)

1, 2 and 3
1 and 2 only
2 and 3 only
1 and 3 only

Ans. (d)
24

Make it compact!
Example:

Medium drive interference fit with nominal size

of 25 mm

aybeforcefit,tightfitandpushfit.

Theinterferencefitsmaybeshrinkfit
lightdrivefit.

Systems of5.BasisofFits
Fit
HoleBasis

Allowance
Basic-Hole System (Preferred Hole System)
Basic size

arance or maximum interference. It is

difference between the basic
Hole The allowance may
mating
gp
parts.
y beZero line
e.

Inthis
diamet
whilet
accord
I

Hole Basis Fits

1. Min. hole size equals basic size

2. Deviation on hole is kept constant

Legends:

Hole
3. Various fits are obtained by varying the limits on shafts.
Shaft
Tolerance

C - Clearance
T - Transition
T
ii
I - Interference

4. Most widely used, as great many holes can be produced using standard
tooling like drills, reamers etc.
5. Uses the symbol H in the tolerance specification

Thi
eco
dril
pro
alte
The
pro
grin
Gen
hole
tem
detr

Systems of Fit
Example: Basic Hole System
Given:

Tolerance for the hole = 0.002

Tolerance for the shaft = 0.03
Allowance = 0.02
Basic dimension =50.00

To determine:
(a) the limits of the shaft
(b) the limits of the hole

Solution:

Systems of Fit
Known:
Allowance=0.02
Tolerance for hole=0.002
Tolerance for shaft=0.03
Because of basic hole system,
Min. hole dimension = Basic dimension = 50
Therefore,
Max. hole dimension = Min. hole + Hole tolerance
= 50 + 0.002 = 50.002
Max. shaft dimension = Min. hole Allowance
= 50 - 0.02 = 49.98
Min. shaft dimension = Max. shaft Shaft tolerance
= 49.98 - 0.03 = 49.95

Systems of Fit
Solution

50.002
50.00

49.98
49.95

Max. I = LL of hole - UL of shaft

Min I = UL of hole - LL of shaft
Min.

Systems of Fit

erferencefitsmaybeshrinkfit,heavydrivefitand
erferencefitsmaybeshrinkfit
heavydrivefitand
ivefit.

BasisofFits
HoleBasis System (Preferred Shaft System)
BasisofFits ShaftBasis
Basic-Shaft

line

This system leads to greater

economy of production, as a single
C
drill or reamer size can be used to
produce a variety of fits by merely
altering the shaft limits
limits.
Hole Basis Fits
The shaft can be accurately
1. Max. shaft produced
size equals
basic
size
to size by
turning
and
grinding.
gends:
2. Deviation on
shaftitisis kept
constant
Generally
usual to
recommend
C - Clearance
Hole
hole-base fits
fits, except where
T - Transition
T 3. i Various
i
Shaft
fitstemperature
are obtained
byavarying the
may have
I - Interference
Tolerance
detrimental effect on large sizes.
T

Here th
produce
basic-siz

Basic size

Shaft

Inthissystem,thebasic
diameteroftheholeisconstant
whiletheshaftsizevaries
Zero
accordingtothetypeoffit.

Shaft Basis Fits

Legends:

limits on

Hole
holes. Shaft
Tolerance

4. Not used often. Used when several parts fit onto one shaft.

C - Clearance
T - Transition
T
ii
I - Interference

Aserie
requir
theref
Itmay
touse
requir
examp
shafts
haveto
variety
coupli
etc.,it
acons
perma
thesh
theacc

5. Uses the symbol h in the tolerance specification

Diameter Ste
DiameterSte

Systems of Fit
Next Example: Basic Shaft System
Tolerance for hole= 0.003
Tolerance for shaft= 0.001
Allowance=0.002
Basic size=50.00

Systems of Fit
Example
Known:
Allowance=0.002
Tolerance for hole= 0.003
Tolerance for shaft= 0.001
Basic size=50.00

Min. hole size:

50.00+0.002=50.002
Max. hole: 50.002+0.003=50.005

Basic shaft system

Max. shaft size=50.00
Min. shaft size:
50.00-0.001=49.999

50.005
50.002

50.000
49.999

IES 2005
Assertion (A): Hole basis system is generally preferred to shaft
basis system in tolerance design for getting the required fits.
Reason (R): Hole has to be given a larger tolerance
(a) Both A and R are individually true and R is the correct
explanation of A
(b) Both A and R are individually true but R is not the correct
explanation of A
(c) A is true but R is false
(d) A is false but R is true
[Ans. (c)]
33

More Terminology !
Deviation. Algebraic difference between the actual size and the basic size.
Upper deviation. Algebraic difference between the upper limit & the basic size.
Lower deviation. Algebraic difference between the lower limit & the basic size.
Fundamental Deviation (F.D)
To define a particular fit, the position of the tolerance zone relative to the
basic size must be specified.
F.D. indicates the position of the tolerance zone relative to basic size.
It is the nearest deviation to the basic size (upper or lower deviation)
F.D. is the difference between basic size and the nearest limit of tolerance

34

Deviations
Indicate all the deviations
Fundamental deviation for hole

Fundamental deviation for shaft

= Lower deviation

= Upper deviation

Upper deviation for shaft

Lower deviation for shaft

Upper deviation for hole

=0

35

Deviations
Indicate all the deviations
Fundamental deviation for shaft
= Lower deviation

Fundamental deviation for hole

Upper deviation for shaft

Lower deviation for shaft

Lower deviation for hole

Upper deviation for hole

= Upper deviation

36

GATE 2001
A shaft has a dimension,

35 0.009
0.025

The respective values of fundamental deviation and tolerance are

(a) 0.025, 0.008
(b) 0.025, 0.016
(c) 0.009, 0.008
(d) 0.009, 0.016
Ans. (d)

37

Todays Quote
Experience is not what happens to the man; it is
what a man does with what happens to him.

- Aldous Huxley

International Tolerance (IT) Grade

(British Standard 4500)
Grade indicates tolerances and the capability of the
machine to be used.
18 grades of tolerances (IT 01, IT 0, IT 1, IT 2, IT 16)
In the increasing order of tolerance
These tolerances are built from fundamental tolerances which
are multiples of fundamental tolerance unit i

For a dimension D,

i = 0.45 3 D + 0.01 D 0.001mm

where D is in mm.

D is not exactly the size under consideration. But is

geometric mean of the range, given in B.S 4500,
which includes the size.

For a 25 mm size, D = 18 30 = 23.24 mm

IT Grade

Grades IT 01, IT 0 and IT 1 to IT 5 are chosen arbitrarily and are

intended for precision manufacturing (Gauge tolerances)

For normal work tolerances: IT6 to IT16

IT 6 = 10 x i
IT 7 = IT 6 x 100.2
IT 8 = IT 6 X 100.4

IT 11 = IT 6 X 10

Note:
Large work piece - Tool is not
stable (deflects during machining)
- Needs more tolerance

IT 16 = IT 6 x 100 and so on.

It may be noted that from IT 6 onwards, every 5th step is 10 times the
respective grade.
i.e. IT 11=10xIT6=10x10i=100 i, IT12=10xIT7=10x16i=160 i, etc. 40

Example
Calculate the limits for 50 H7

For a 50 mm size, D = 30 50 = 38.7 mm

Fundamental tolerance unit i

i = 0.45 3 38.7 + 0.01 38.7 = 1.56 1.6

IT 6 = 10 x i = 16 m
IT 7 = IT 6 x 100.2 = 25 m
0.025

50 H7 = 50 0.000

41

IT Grade
Application of tolerance grades
vIT0 to IT 4

For production of gauges and

measuring instruments

vIT5 to IT 7 -

For precision engineering applications

vIT8 to IT11

For general engineering

vIT12 to IT14

For sheet metal working or press

working

vIT15 to IT16

For processes like casting, general

cutting work
42

Manufacturing Process Associated with ISO IT Tolerance Grade

IT Grade
Lapping
Honing
Super finishing
Cylindrical grinding
Diamond turning
Plan grinding
Broaching
Reaming
Boring, Turning
Sawing
Milling
Planing, Shaping
Extruding
Cold Rolling, Drawing
Drilling
Die Casting
Forging
Sand Casting
Hot rolling, Flame cutting

10

11

12

13

14

15

16

Tolerances for holes and shafts

44

Small letters for shafts

Capital letters for holes

Standard Limit and Fit System

Z
z

Letters indicate the fundamental deviation (relative position of the

tolerances w.r.t basic size).
45

Typical Zones of Fit

Z
z

46

International Tolerance Grade (IT):

47

Workout
A 20 mm nominal diameter journal bearing is to have a clearance, but
close, accurate running fit. Within what size tolerances should the parts
be manufactured? Use the 'basic hole system'.

Solution
A H8/f7 fit is suitable.
From the tables, for a 20 mm diameter nominal size the H8 limits are
+0.033 and -0.000 mm and the f7 limits are -0.020 and -0.041 mm.
Hence the hole diameter should be between 20.000 and 20.033 mm
and the shaft diameter should be between 19.959 and 19.980 mm

48

GATE 2009
What are the upper and lower limits of the shaft represented by 60f8?
Use the following data:
Diameter 60 lies in the diameter step of 5080 mm.
Fundamental tolerance unit, i, in m = 0.45 D1/3 + 0.001D, where D is the
representative size in mm;

Zero line

Tolerance value for lT8 = 25i.

Fundamental deviation for 'f shaft = 5.5D0.41
(a)
(b)
(c)
(d)

UL

Piston

LL

Lower limit = 59.924 mm, Upper Limit = 59.970 mm

Lower limit = 59.954 mm, Upper Limit = 60.000 mm
Lower limit = 59.970 mm, Upper Limit = 60.016 mm
Lower limit = 60.000 mm, Upper Limit = 60.046 mm

[Ans. (a)]

49

IES 2008
Consider the following statements:
A nomenclature 50 H8/p8 denotes that
1. Hole diameter is 50 mm.
2. It is a shaft base system.
3. 8 indicates fundamental deviation.
Which of the statements given above is/are correct?
(a)
(b)
(c)
(d)

1, 2 and 3
1 and 2 only
1 and 3 only
3 only

[Ans. (None)]
50

GATE 2003
The dimensional limits on a shaft of 25h7 are
(a)
(b)
(c)
(d)

Zero line

25.000, 25.021mm
25.000, 24.979 mm
25.000, 25.007mm
25.000, 24.993 mm

UL

Piston

LL

For a 25 mm size, D = 24 30 = 26.8 mm

i = 0.45 3 D + 0.01 D 0.001mm =

IT 6 = 10 x i =
IT 7 = IT 6 x 100.2 =
Ans. (b)
51

IES 2002
In the tolerance specification 25D6, the letter D represents
(a)
(b)
(c)
(d)

Grade of tolerance
Upper deviation
Lower deviation
Type of fit

[Ans. (c)]

52

IES 2000
Which one of the following tolerances set on inner diameter and outer
diameter respectively of headed jig bush for press fit is correct?
(a) G7h6
(c) H 7h 6

(b) F7n6
(d) F7j6

[Ans. (b)]

Z
z

53

GATE 2000
A fit is specified as 25H8/e8. The tolerance value for a nominal diameter of 25
mm in IT8 is 33 microns and fundamental deviation for the shaft is 40
microns. The maximum clearance of the fit in microns is
(a)
(b)
(c)
(d)

7
7
73
106

Ans. (d)

54

GATE 1996
The fit on a holeshaft system is specified as H7 s6.The type of fit is
(a) Clearance fit
(b) Running fit (sliding fit)
(c) Push fit (transition fit)
(d) Force fit (interference fit)
[Ans. (d)]

55

Design
of
Limit Gauges
Depth of friendship does not depend on length of
acquaintance.
~ Rabindranath Tagore
56

Methods of Inspection
1. Inspection by variables
Dimensions of a component are physically measured
If the value of the dimension falls within the limits of the
component, the component is accepted, otherwise
rejected.
This method is suitable in the case of limited
components.
E.g. scale, vernier calliper, micrometer, etc.
2. Inspection by attributes
Dimensions of components are not physically measured
Components are inspected using Go and No Go gauges.
If Go gauge enters the component and No Go gauge
does not enter, the component is accepted.
If both gauges enter or both the gauges do not enter the
component, the component is rejected.
57

Limit Gauges
The gauges used to inspect the limits of a component are
called limit gauges.
Limit gauges are used in mass production
No attempt is made to determine the size of a component.
Gauges are simply used to find whether the part is within
the specified limits of size or not.
It helps in deciding whether the part can be accepted or
rejected.
Quite unskilled person can do this job.
58

Limit Gauges
Typical plug and ring gauges

Checking a Hole using a Plug Gauge

59

Limit Gauges
Go Gauge:

Made to maximum material limit of component

i.e., Minimum hole size or maximum shaft size

Always enters the component, which has material less than

the maximum material limit

Not-Go Gauge:

Made to minimum material limit of component

i.e., Maximum hole size or minimum shaft size

Never enters a component, which has material > max.

material limit.

60

Plug Gauges

Used for checking holes

Cylindrical
resistant plugs.

The plug made to the

lower limit of the hole is
known as GO gauge
and this will enter any
hole which is not
smaller than the lower
limit allowed.

The plug made to the upper limit of the hole is known as NO GO

gauge and this will not enter any hole which is smaller than the upper
limit allowed.

The plugs are arranged on either ends of a common handle.

wear

61

Progressive Plug Gauges

For smaller through holes,

both GO & NO GO gauges are
on the same side separated by
a small distance.

After the full length of GO

portion enters the hole, further
entry is obstructed by the NO
GO portion if the hole is within
the tolerance limits.

62

Ring Gauges

Ring gauges are used for gauging shafts.

They are used in a similar manner to that of GO & NO GO plug

gauges.

A ring gauge consists of a piece of metal in which a hole of required

size is bored.

63

Snap or Gap Gauges

A snap gauge usually consists of a plate or

frame with a parallel faced gap of the required
dimension.

Snap gauges can be used for both cylindrical as

well as non cylindrical work as compared to ring
gauges which are conveniently used only for
cylindrical work.

Double ended snap gauges are used for sizes

ranging from 3 to 100 mm.

For sizes above 100 mm up to 250 mm a single

ended progressive gauge is used.

Taper Gauges

For inspecting tapered hole or shaft, only one gauge is sufficient and
is called taper plug gauge or taper ring gauge respectively.

When checking a taper hole, the taper plug gauge is inserted into the
hole and a slight pressure is exerted against it. If it does not rock in
the hole, it indicates that the taper angle is correct.

The taper diameter is tested for the size by noting how far the gauge
enters the tapered hole or the tapered spindle enters the gauge.

A mark on the gauge shows the correct diameter for the large end of
the taper.

Taper Gauges

To test the correctness of the taper two or three

chalk or pencil lines are drawn on the gauge
about equidistant along a generatrix of the cone.
Then the gauge is inserted into the hole and
slightly turned.
If the lines do not rub off evenly, the taper is
incorrect and the setting in the machine must be
adjusted until the lines are rubbed equally all
along its length.
Instead of making lines on the gauge, a thin
coat of paint (red led, carbon black, Purssian
blue, etc.) can be applied.
The accuracy of a taper hole is tested by a taper
limit gauge. This has two check lines Go and
No Go each at a certain distance from the end
of the face. The Go portion corresponds to the
minimum and No Go to the maximum
dimension.

If top surface of
component lies
between limits
recess, the
component is
accepted.
Taper ring gauge
is always
toleranced at the
small end.

Materials Used for Gauges

High carbon steel: Heat treated Cast steel (0.8-1% carbon) is commonly used
for most gauges.
Mild Steel: Case hardened on the working surface. It is stable and easily
machinable. Case hardened steel: Used for small & medium sized gauges.
Chromium plated & Hard alloys: Chromium plating imparts hardness,
resistance to abrasion & corrosion. Hard alloys of tungsten carbide may also
be used.
Cast Iron: Used for bodies of frames of large gauges whose working surfaces
are hard inserts of tool steel or cemented carbides.
Glass: They are free from corrosive effects due to perspiration from hands.
Also they are not affected by temperature changes.
Invar: It is a nickel-iron alloy (36 % nickel) which has low coefficient of
expansion but not suitable for usage over long periods.

Taylors Theory of Gauging

Go Gauge
1. Go gauge should check maximum material condition (MMC). i.e.,
upper limit of a shaft and lower limit of a hole.
2. GO gauge should be of full form, i.e. it should check shape as well as
size.
3. should check as many dimensions/features as possible at a time.
4. should be geometrical equivalent of the mating part.
5. should be lengthier to check form errors and for easy identification
from NOT GO gauge.

Lengthier GO gauge will NOT enter the

non-straight hole

68

Taylors Theory of Gauging

Not-Go Gauge
1. Not-Go gauge should check minimum (least) material condition
(LMC). i.e. the lower limit of a shaft and the upper limit of a hole.
2.

Not-Go gauge should check only one dimension at a time

(A separate Not-Go gauge is required for each dimension)

69

Taylors Theory of Gauging

A Full form NOT-GO Gauge will NOT reject a bad part

if NOT-GO gauge is made to both dimensions of LMC, a condition

would arise where the width of work is within specified limits whereas
the length is oversize.
Such a gauge will not enter the work, and hence the work will be
accepted although its length is outside the limits.
Thus, a separate NOT-GO gauge is required for each dimension.

70

Taylors Theory of Gauging

For height

For height
For width

For width
Go gauge
71

A small circular area is raised by electro plating, an amount equal to

work Tolerance.
Not-Go gauge conforms to Taylors principle (one dimension at a
time).
72

Example
Find the sizes of Go and No-Go
gauges

+0.3
0.1

25

40

+0.05
0.02

24.9

No Go 1

No Go 2

25.3

40.05

38.98
Go gauge
73

Considerations in Limit Gauge Design

1.

What magnitude of tolerance to be applied to the gauge?

The tolerance of measuring equipment should be 10% of work tolerance.
Which means that for a work tolerance of 0.08 mm, gauge tolerance is
0.008 mm
No hard and fast rule

2.

What allowance shall be made for the gauge to wear?

An allowance for wear is normally applied only to the GOgauge.
Wear allowance is added to increase the service life of gauges
Wear allowance is set from the maximum material limit for the work
The gauge is allowed to wear out until its size coincides with the MMC of
the work

3. How shall the tolerance zones for the gauge be disposed relative to the
work tolerance zones?

B.S 969: 1982 Inspection of Plain Workpieces

74

Disposition of Tolerance Zones for Gauges

(shop floor)
Not Go gauge

PLUG GAUGE TOLERANCE

Go gauge

Wear Allowance for Plug gauge

Wear Allowance for Ring or Gap gauge
Go gauge
RING OR GAP GAUGE TOLERANCE
Not Go gauge

75

Workout
Design the limit gauges for 45 h10 shaft. Assume gauge tolerance and wear
allowance of 10% of work tolerance. Tolerance limits on shaft = 0 and -100
Work tolerance, WT = 100 m
Gauge tolerance, GT = 10% of 100 m = 10 m = 0.01 mm
Wear allowance, WA = 10% of 100 m = 10 m = 0.01 mm

WT = 0.1

WA = 0.01

Zero Line
Go
Not Go

GT = 0.01

GT = 0.01

Gauge

Max. Size

Min. Size

Go

45 0.01 = 44.99 mm

45 (0.01 + 0.01) = 44.98 mm

Not-Go

45 0.1 + 0.01 = 44.91 mm

45 0.1 = 44.9 mm

GATE 2013
+0.020
25+0.010 mm

Cylindrical pins of
diameter are electroplated in a shop. Thickness
of the plating is 302.0 microns . Neglecting gage tolerances, the size of the GO
gage in mm to inspect the plated components is
(A) 25.042

(B) 25.052

(C) 25.074

(D) 25.084

Ans: D
GO gauge always checks MMC.
Hence, size of GO gauge is 25+0.020+2(0.032) = 25.084

77

GATE 2006
A ring gauge is used to measure
(a) Outside diameter but not roundness
(b) Roundness but not out side diameter
(c) Both outside diameter and roundness
(d) Only external threads
[Ans. (a)]

78

GATE 2004
0.05
0.01

GO and NOGO plug gages are to be designed for a hole 20 mm. Gage
tolerances can be taken as 10% of the hole tolerance. Following ISO system of
gage design, sizes of GO and NOGO gage will be respectively
(a)
(b)
(c)
(d)

20.010 mm and 20.050 mm

20.014 mm and 20.046 mm
20.006 mm and 20.054 mm
20.014 mm and 20.054 mm

[Ans. (b)]

No-Go plug gauge

20.046

Go plug gauge

Zero Line

20.014

79

GATE 1995
Checking the diameter of a hole using GONOGO gauges is an, example
of inspection by .....(variables/attributes)
The above statement is
(a) Variables
(b) Attributes
(c) Cant say
(d) Insufficient data
[Ans.(b)]

80

Todays Quote
Be nice to people on your way up because youll meet them on
your way down.

~ Wilson Mizner

Types of Dimensioning
Chained (Relative) dimensioning
Baseline / Absolute / Progressive dimensioning

Chained Dimensioning
Each dimension is specified from the previous one
Tolerances accumulate (stack-up)
3.000
2.985

Tolerance Accumulation
(Stack-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

+a
b
1

+c
d
2

+e
f
3

+g
h

L
+g
h

+a
b
1

+c
d
2

+e
f
3

L =L +L +L

( g = a + c + e,

h = b+d + f

Overall tolerance = g + h = a + b + c + d + e + f
84

Example
+0.1
0.05
1

0.1
2

+0.2
0.1
3

g = 0.1+ 0.1+ 0.2 = 0.4

h = 0.05+ 0.1+ 0.1 = 0.25
Overall tolerance = g + h = 0.4 + 0.25 = 0.65
+0.4
0.25

Tolerance accumulation is dangerous.

Even though individual tolerances are very small, the total
tolerance on a component or assembly will be very large.
85

Effect of Tolerance
on

Dimensioning
Chained (Relative)
Baseline / Absolute / Progressive
Each dimension is specified Each dimension is specified
from the previous one
from a common baseline
Tolerances stack-up
Tolerances do not stack
3.000
2.985

Total tolerance

= 3.000-2.985
= 0.015

Total tolerance

= 3.000-2.995
= 0.005

Tolerance Stack-Up

87

Tolerance Stack-Up
Through Relative Dimensioning

88

Avoid Tolerance Stack-Up

Through Absolute Dimensioning

89

Missed Dimension Calculation

Amax = 65.15 39.85 = 25.3

Amin = 64.85 40.15 = 24.7

A = 25

0.3

or

Note: Reverse calculation need not be true!

90

GATE
GATE1997
1997
Three
blocks
B3toare
1, B
2 and
Three blocks
B1 B
, B2
and
B3 are
be
to
be inserted
in a channel
inserted
in a channel
of width of
S
width
maintaining
maintainingSa minimum
gap of width Ta
= 0.125 mm, asgap
shown
Figure. T =
minimum
ofinwidth
0.125 mm, as shown in Figure.
For
P = 18. 75 0.08;
For P = 18.
18Q 75
0.08;
0 08;
= 25.00
0.12;
28.125 0.1 and
Q = 25.00R= 0.12;
+ X, (where all
R = 28.125S = 72.35
0.1 and
dimensions are in mm), the
S = 72.35
+ XX,is (where all
tolerance
Sol.
dimensions are in mm), the
S = 18.75 + 25 + 28.125 + 0.125
(a) + 0.38 X is (b) 0.38
tolerance
(c) + 0.05

(a) +0.38
[Ans.(d)]
[Ans. (d)]

(d) 0.05

(b) 0.38

= 72.00 + Tol.
(d)0.05
Tol. = 0.08(c)+0.05
+ 0.12 + 0.1 = 0.3
So, S = 72.3
Hence, X = - 0.05
91