LIMITS, FITS & CALCULATIONS

ILLUSTRATION OF BASIC SIZE DEVIATIONS,

LIMITS AND TOLERANCES

Fig. 1.1 Graphical Illustration of Fits and Tolerances

LIMITS
Actual machine size - between the maximum
and minimum limits
MAXIMUM LIMIT

Maximum permissible machine size corresponding to basic

size.
Fig. 1.1, Ø 30 mm is = Ø 30 + 0.035 = Ø 30. 035 mm.

Basic size Maximum limit

MINIMUM LIMIT

Minimum allowable machine size corresponding to basic

size.
In Fig. 1.1, Ø 30 mm is = Ø 30 - 0.215 = Ø 29. 785 mm.

Basic size Minimum limit

TOLERANCE
The difference between the maximum and minimum limits
of a size is tolerance.

In Fig. 1.1 the tolerance is = Ø 30.035 - Ø 29.785 = 0.25m.

Max. limit Min. limit Tolerance

DEVIATION
(Actual, or maximum, or minimum) – (Basic size).

UPPER DEVIATION - (Maximum limit) – (Basic size)

In Fig.1.1, the upper deviation is = Ø 30.035 - Ø 30
= 0.035 mm.
LOWER DEVIATION - (Minimum limit) – (Basic size)

In Fig. 1.1, the lower deviation is = Ø 29.785 - Ø 30

= - 0.215 mm.
ACTUAL DEVIATION - (Actual measured size) – (Basic size)

In Fig. 1.1, the actual deviation = Ø 29.925 - Ø 30

= - 0.075 mm.
ZERO LINE
• A straight line drawn for the basic size is called zero line.

• Upper and lower deviation are referred to zero line.

• Zero line is drawn horizontally.

• Above zero line - positive deviations.

• Below zero line - negative deviations.
TOLERANCE ZONE
The zone bounded by the upper and lower limits of the
basic size.

In Fig. 1.1, tolerance zone is shown by hatched line.

FITS

• The relationship between the mating surfaces of

the parts,because of the difference in dimensions
is
called fit.

• Thus fit has a characteristic effect on the

performance of mating parts.

• Example: width of the slot & the thickness of the

key.
CLEARANCE

 (Hole dimension) – (Dimension of shaft that fit to it).

Maximum - hole size is maximum and the shaft size is

minimum.

Minimum - shaft size is maximum and the hole size is

minimum.

CLASSIFICATION OF FITS
Clearance fit

Interference fit

Transition fit
CLEARANCE FIT
Fit with positive clearance between the hole and the shaft.

B
A
Min hole – Max Shaft = + ve – clearance fit.

Fig. 1.2 Clearance Fit

INTERFERENCE FIT
Fit with negative clearance between the hole and the shaft.

Max hole – Min Shaft = - ve – interferance fit

Fig. 1.3 Interference Fit

TRANSITION FIT
Fit established when the dimensions of the hole are
such that there exists either a positive clearance or a
negative clearance when the shaft is fitted into the hole.

B
Fig 1.4 Transition Fit
 TRANSITION FITS AND INTERFERENCE FITS
Combination of
Quality of Fit Typical uses
Hole and Shaft
H6 j5 fine
Clearance Very small clearance is obtained - used for fits where a
H7 j6 normal transition slight interference is permissible - coupling spigots and
recesses, gear rings clamped to steel hubs.
H8 j7 coarse

H6 k5 fine
True Fits averaging no clearance where slight interference can be
H7 k6 normal transition tolerated , with the object of eliminating vibration - ball
bearings races of light duty.
H8 k7 coarse

H6 m5 fine
Interference
Fits averaging slight interference - used for ball bearing
H7 m6 normal transition
races of medium duty.
H8 m7 coarse

H6 p5 fine Light press fit for nonferrous parts which can be dismantled
Press fit
when required-bearing bushes-press fit for steel, cast iron
H7 p6 normal or brass to steel assemblies- bush in a gear.
H6 r5 fine
Drive fit Medium drive fit for ferrous parts and light drive fit for
H7 r6 normal non-ferrous parts that can be dismantled.
Permanent or semi permanent assemblies of steel and cast
H6 s5 fine
Drive fit iron with considerable gripping force- collars pressed on to
H7 s6 normal shafts, valve seatings etc. For light alloys this gives a press
fit.
H6 u5 fine
Force or High interference fit a thorough investigation into the
H7 u6 normal shrink fit degree of grip and the stresses in the part must be made.
SYSTEMS OF FITS

HOLE BASIS SYSTEM: the hole is constant in

diameter and various types of fits are obtained by
suitably varying the limits of the shaft.

SHAFT BASIS SYSTEM: the shaft is constant in

diameter and various types of fits are obtained by
suitably varying the limits of the hole.
HOLE BASIS SYSTEM

Single hole, whose lower deviation is zero.

Minimum limit of the hole will be equal to its basic size.

Clearance Fit Interference Fit

B C
Fig. 1.5 Hole Basis System
Grades of
MANUFACTURING PROCESS USED
Holes

H5 Fine Boring, Fine Grinding, Honing

H6 Fine Boring, Honing, Hand Reaming

H7 Int. Grinding, Broaching, Reaming

H8 Boring, Machine Reaming

H9 Boring & Reaming

Not for diameter fits; used for milled widths,

H10
drilled holes

Not used in fits; punching, coarse drilling drawn

H11
recesses
 HOLE BASIS SYSTEM - Design Example
Requirement

Hole basic size - 20 mm diameter.

Clearance of - 0.100 mm.
Hole tolerance - 0.025 mm.
Shaft tolerance - 0.050 mm.

Design

Minimum limit of the hole is Ø 20 mm.

Maximum limit of the shaft = Lower limit of the hole –
Minimum clearance

= Ø 19.900 mm
Minimum limit of the shaft = Maximum limit of the shaft –
Tolerance on the shaft.

= Ø 19. 850 mm.

Maximum limit of the hole = Maximum limit of the hole +

Tolerance on the hole.

= Ø 20. 025 mm.

Shaft Hole

Max. limit = Ø 19.900 mm. Max. limit = Ø 20.025 m.

Min. limit = Ø 19. 850 mm. Min. limit = Ø 20. 000 mm.
Why the Hole Basis System is Preferred?

Holes are produced by drilling, boring, reaming,

broaching, etc.,
Shafts are either turned or ground.

Shaft basis system - Holes of different sizes are required,

(requires tools of different types and
sizes).

Hole basis system - Only one tool is required, to

produce the hole and the shaft can
be machined to any desired size.
SYSTEMS OF TOLERANCING

1. UNILATERAL SYSTEM
• Deviations are allowed in only one direction from the
basic size.
• The deviation in the other direction is zero.
• Hence, either the maximum limit or the minimum
limit will be equal to the basic size.
2. BILATERAL SYSTEM
• Deviations are allowed in both the directions from
the basic size.
• The deviations are allowed in both the directions.
• One of the limits - above the basic size.
• Other limits - below the basic size.
FUNDAMENTAL TOLERANCES OF GRADES
MACHINING SYMBOL
MACHINIG PROCESS AND THEIR Ra VALUES
 ATTAINABLE SIZE TOLERANCE

Sl. Machining IT Tolerance value

No. Process Value (for a size of
20 mm)
1 Drilling IT12 0.21
2 Milling IT10 0.084
3 Turning/ Boring IT8 0.013
4 Grinding IT6 0.006
5 Lapping IT4 0.006
6 Broaching IT7 0.021
7 Shaping IT12 0.210
8 Reaming IT8 0.033
9 Hobbing IT7 0.021
10 Surface grinding IT4 0.006
11 Honing IT7 0.021
GEOMETRIC TOLERANCE
What machining process should be adopted to each
step of the following components. Also give step
drawing details ?

(a)
(b) (c)
REFERENCE

1. Gopalakrishna K R, “Machine Drawing”, Tenth

Edition, Bangalore, 1996.

2. Faculty of Mechanical Engineering, PSG College of

Technology, “Design Data Book”, Coimbatore, 1993.

3. ASME Y 14.5M- 1994, “Dimensioning and

Tolerancing”, ASME, New York, 1995.
THANK YOU