SYSTEM OF LIMITS,

FITS, TOLERANCES AND

GAUGING
TOLERANCES
Tolerance is the total amount that a specific dimension is
permitted to vary in positive or negative side
It is the difference between the maximum and the minimum
limits for the dimension.
 Due to the inevitable inaccuracy of manufacturing methods,
a part cannot be made precisely to a given dimension. So
tolerance is a mandatory thing in designing process of a
component.

TYPES OF TOLERANCES
Unilateral tolerances
Bilateral tolerances
UNILATERAL TOLERANCES
Having variations in only one
directions either upper or lower
Limits are for only the larger or
smaller sizes
BILATERAL TOLERANCES
Having variations in both the upper
and lower directions
The plus and minus limitations
combine to form a single value.
ACCUMALATION TOLERANCES
Tolerances are getting accumulated
in each step of the components
So, the total tolerance is the sum of
the individual tolerance of each
component.
COMPOUND TOLERANCES
Tolerance of one dimension of the
component is dependent on the
tolerance of the other dimension.
That, if tolerance of one component
increases the tolerance of the other
increases or decreases.
 TERMS RELATED TO
METRIC LIMITS & FITS
 Basic Size is the size from which limits or deviations are assigned. Basic sizes,
usually diameters, should be selected from a table of preferred sizes.
 Nominal size is a dimension used to describe the general size
 Actual size is the measured size of the finished part after machining

 Limits is the max and min sizes shown by the toleranced dimension
 Allowance is the min clearance or maximum interference between parts, or the
tightest fit between two mating parts
 Deviation: is the difference between the basic size and the hole or shaft size.
 Upper Deviation: is the difference between the basic size and the permitted maximum
size of the part.
 Lower Deviation: is the difference between the basic size and the minimum permitted
size of the part.
 Fundamental Deviation: is the deviation closest to the basic size.
 Tolerance: is the difference between the permitted minimum and maximum sizes of a
part.
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.
SCHEMATIC REPRESENTATION
OF THE PLACEMENT OF THE
TOLERANCE INTERVAL
 E.S. – upper deviation
 E.I. – lower deviation
 H : lower deviation of hole is zero
 h : upper deviation of shaft is zero
 Formula for Fundamental deviation
will be given separately
DEFINITION OF FITS
 Fit is the general term used to signify the range of tightness or
looseness that may result from the application of a specific
combination of allowances and tolerances in mating parts.
TYPES OF FIT
 CLEARANCE FIT: an internal
member fits in an external member (as
a shaft in a hole) and always leaves a
space or clearance between the parts.
Minimum air space is 0.002”. This is
the allowance and is always positive in
a clearance fit
INTERFERENCE FIT: The internal
member is larger than the external member
such that there is always an actual
interference of material. The smallest shaft is
1.2513” and the largest hole is 1.2506”, so
that there is an actual interference of metal
amounting to at least 0.0007”. Under
maximum material conditions the interference
would be 0.0019”. This interference is the
allowance, and in an interference fit it is
always negative.
TRANSITION FIT: may result in either a
clearance or interference condition. In the
figure below, the smallest shaft 1.2503” will
fit in the largest hole 1.2506”, with 0.003” to
spare. But the largest shaft, 1.2509” will have
to be forced into the smallest hole, 1.2500”
with an interference of metal of 0.009”.
SYSTEM OF FITS
BASIC SHAFT SYSTEM
 the largest diameter of the shaft is assigned the
basic diameter from which all tolerances are
applied.
 The fundamental deviation is given by the
lowercase letter h.
BASIC HOLE SYSTEM
 the smallest hole is assigned the basic
diameter from which the tolerance and
allowance are applied. (more popular than the
basic shaft system because of ease to control
the hole size)
 For the generally preferred hole-basis system,
the fundamental deviation is specified by the
upper-case letter H.
 PLAIN GAUGES
PLAIN PLUG GAUGES
 Used for checking inside diameter of straight hole (generally
"go" and "no-go" variety)
 Consists of handle and plug on each end ground and/or lapped to
specific size
 Small-diameter plug ("go" gage) checks lower limit of hole
 Larger-diameter plug (“no-go” gage) checks upper limit

PLAIN RING GAGES

 Used to check outside diameter of pieces
Ground and lapped internally to desired size
 Size stamped on side of gage
 Outside diameter knurled and "no-go" end identified
by annular groove on knurled surface
 Precautions and procedures similar to those outlined
for a plug gage
 SNAP GAGES
 One of most common types of comparative
measuring instruments
 Faster to use than micrometers
 Limited in their application
 Used to check diameters within certain limits
by comparing part size to preset dimension of
snap gage
 Have C-shaped frame with adjustable gaging
anvils or rolls set to "go" and "no-go" limits
of the part