Fundamentals of

LIMITS, FITS and TOLERANCES

Ability needed to

REPRESENT

INTERPRET

MANUFACTURE

MEASURE
Main applications of Dimensioning and tolerances are
for
Holes & Shafts,

Tapers,

Threads,

Gears,

Splines etc.

± 0.125
59,45
0.025 M 0.025 M
0.015 M
0,45

± 0.125 A
35,95

C0.5(BOTH SIDES)
0.025 A 0.05 M
0.025 M
30°

R0,5(TYP)
0
-1.0
R4 4,15 1,5
0.6(MAX) x 45° R5

DETAIL AT B
-0.2
0.0

SCALE 5:1
+0.1
-0.2
0

Ø25.25

Ø95,68

B
Ø38.0

Ø73,5
Ø40

C1.15 REFER FORGING DRAWING NO RD 040660

03
FOR MATERIAL, HARDNESS & OTHER DETAILS

NOTE : ALL MACHINED SURFACES TO BE

+0.016

M 0.02 M FREE FROM RUST AND DENT MARKS

Ø29.2

-0.350
26,58 CAD REF . : DN NGT_GSL_RD040669-04 PN : TRANSMISSION TOOLS
DO NOT SCALE : IF IN DOUBT. REFER DESIGN OFFICE
± 0.025 MATERIAL
48,3
UNSPECIFIED APPD.
FOR ENGG. REF. 0.030 M MACHINING DEVIATION AS NOTED DGNR
LINEAR DIMENSION ANGULAR DIMN.
BY SIGN DATE
AT ALLOWANCE Above Upto Devn. Short side of ± mm Deg. of
min 1
0.5
6
6
30
±0.1 angle
±0.2 Above Upto SIZE - C
30 120 ±0.3 10 0.1 10
BOSS FACE 0.15 ± 0.075 120
315
315
1000
±0.5 10 50 0.2
±0.8 50 120 0.5
30
20 TO BE USED ON
1000 2000 ±1.2 120 0.8 10

FRONT FACE 0.15 ± 0.075 SCALE 1 :1 PART NAME: TOOL NO : XXXX/Y

FIFTH GEAR - LAYSHAFT
BORE 0.2 TOOL NAME:
SHEET 1 OF 1
BLANK DRAWING(TURNED)
 Different types of tolerances are

1. Dimensional Tolerances
2. Form Tolerances
3. Position Tolerances
4. Surface Roughness values
5. Combination Tolerances
Other details shown on drawing are

Material specification
Special treatments if any
Heat treatments
Assembly condition
Special notes

Tolerance: Tolerance is the total permissible variation

from the specified basic size of the part. It is defined as
the magnitude of permissible variation of a dimension or
measured control criterion from specified value.

Basic size: The basic size is the size on which variation

permitted.

Actual size:
The size of a feature obtained by measurement
 TOL not specified
• Follow general engineering tolerance
• IS 2102 fine, medium, course & very
course
• Unless otherwise specified, it is medium.
• Or else it can be IT 14 VALUE, bilateral
• All drawings need contain conditions on
general tolerance.

1. Open tolerances or General Engineering tolerances

Standards used are
IS 2102 ( Part – 1) – 1993 / ISO 2768 - 1 : 1989

General Tolerances
Part – 1: Tolerances for Linear and Angular
dimensions without individual tolerance indications
Part – 2: Geometrical Tolerances for features
without individual tolerance indications
Ex: 20.0, 20-f, Ø20-f H
 Table 1 – Permissible deviations for linear dimensions except for broken edges
(external radii and chamfer heights, see table 2)
Values in millimeters
Permissible deviations for basic size range
Tolerance Class

0.5 Over Over Over Over Over Over Over

Desig Descripti up to 3 6 30 120 400 1000 2000
nation on 3 up to up to up to up to up to up to up to
6 30 120 120 400 2000 4000

f fine ± 0,05 ± 0,05 ± 0,1 ± 0,15 ± 0,2 ± 0,3 ± 0,5 -

m medium ± ± 0,1 ± 0,2 ± 0,3 ± 0,5 ± 0,8 ± 1,2 ±2

0,1
c coarse ± ± 0,3 ± 0,5 ± 0,8 ± 1,2 ±2 ±3 ±4
0,2
v very - ± 0,5 ±1 ± 1,5 ± 2,5 ±4 ±6 ±8
coarse
1) For nominal sizes below 0,5 mm, the deviations shall be indicated adjacent to the
relevant nominal size (s).

Table 2 – Permissible deviations for broken edges

( external radii and chamfer heights)
Values in millimeters

Permissible deviations for basic

Tolerance Class size range
Designation Descriptio 0.5 up to 3 Over 3 up over 6
n to6
f fine
± 0,2 ± 0,5 ±1
m medium
c coarse
v very ± 0,4 ± 0,1 ±2
coarse
1) For nominal sizes below 0.5 mm, the deviations shall be
indicated adjacent to the relevant nominal size(s).
 Table 3 – Permissible deviations of angular dimensions

Permissible deviations for ranges of lengths, in

millimeters,
Tolerance Class
of the shorter side of the angle concerned
Desig Descript up to 10 over 10 over 50 up over 120 over
nation ion up to 50 to 120 up to 400 400
F fine ± 10 ± 00 30 ± 00 20’ ± 00 10’ ± 00 5
m medium
c coarse ± 10 30’ ± 10 ± 00 30’ ± 00 15’ ± 00 10
v very ± 30 ± 20 ± 10 ± 00 30’ ± 00 20
coarse

Table 1 – General tolerances on straightness and flatness

Values in millimeters

Straightness and flatness tolerances for ranges of nominal lengths

Tolerance
Class
over 10 up over 30 up over 100 over 300 up to Over 1000
up to 10
to 30 to 100 up to 300 1000 up to 3000

H 0,02 0,05 0,1 0,2 0,3 0,4

K 0,05 0,1 0,2 0,4 0,6 0,8

L 0,1 0,2 0,4 0,8 1,2 1,6

 Table-2 General tolerances on perpendicularity
Values in millimeters

Perpendicularity tolerances for ranges of nominal

lengths of the shorter side
Tolerance
Class
over 100 over 300 over 1000
up to 100
up to 300 up to 1000 up to 3000

H 0,2 0,3 0,4 0,5

K 0,4 0,6 0,8 1

L 0,6 1 1,5 2

Table-3 – General tolerances on symmetry

Values in millimeters

Symmetry tolerances for ranges of

nominal lengths
Tolerance
Class
over 100 over 300 over 1000
up to 100
up to 300 up to 1000 up to 3000

H 0,5

K 0,6 0,8 1

L 0,6 1 1,5 2
 Table 4 – General tolerances on circular run-out
Values in mm

Tolerance class Circular run-out tolerances

H 0,1

K 0,2

L 0,5

IS 2102 – PART – 2
• VALUES FOR – Straightness /
perpendicularity / symmetry / Run out
specified
• Circularity - limited to diameter
tolerance or run out value
• Cylindricity – Limited to combined effect
of CIRCULARITY& PARALLELISM.
• Parallelism – Limited to Dimensional
Tolerance & flatness tolerance.
• Coaxiality - Limited to run out tolerance.
ISO 2768 - m
• General Engg. Tole Tolerance class medium

IS 2102 – f
• General Engg. Tole – class fine

ISO 2768 – mK

• General Engg. Tole for dimensions -

Tolerance class. m
• General Engg. Tole for form / position –
tolerance class. K
 IS 2102 – mK - E
• General Engg. Tole for Dimension as per
m
• General Engg Tole for Form / position as
per K
• Enveloping dia limits -E

ISO 2768 - K
• General tol. as dim not considered.
• Form/position as per tol. Class K.
 SPECIFIED TOLERANCE
• VALUE GIVEN
• VALUE AND POSISTIONAL STATUS
GIVEN
• STD.SYMBOLS USED.

2. Specificied tolerances
Standards used
IS 919 (Part – 1) – 1993 / ISO 286 – 1 : 1988
ISO System of Limits and Fits

Part – 1: Bases of tolerances, Deviations and Fits

Part – 2: Tables of standard tolerance Grades and
limit Deviations for Holes and shaft.

Example : 20H7, 20g6, 30 + 0.02

Specific tolerance should be less than open tolerance

 STANDARD SPECIFICATION
Need contain

• HOW MUCH IS THE VALUE OF TOL.

• WHERE IT IS DISPOSED.

HOW MUCH IS THE VALUE

• IS 919 / SP46 OR STD CHARTS SPECIFY.
• 18 GRADES ARE SPECIFIED. VALUE IS
ATTACHED TO A GRADE
• IT=INTERNATIONALTOLERANCE
GRADE.
• AND 18 REPRESENT THE ROUGHFEST
Mfg process
• EVERY MANUFACTURING PROCESS IS
ATTRIBUTED WITH A RANGE OF
ACCURACY GRADE
 HOW MUCH IS THE VALUE
FOR EX;
• TURNING IT7, 8 OR 9
• GRINDING IT 5, OR 7
• MILLING IT 6, 7, OR 8
• LAPPING IT 1, 2, 3, OR 4
• SAND CASTING IT 16, 17, 18
• PRESS WORKING IT 10, 11 OR 12
• INJ. MOULDING IT 12. 123 OR 14

Grades of tolerances obtainable by various

manufacturing processes

According to IS 18 grades of tolerances or accuracy

grades of manufacturing IT1, IT2, IT3….IT18

IT GRADE is generally indicated by numbers from

1 to 18
Manufacturing Processes IT grades

Lapping 1, 2, 3, 4

Honing 3–5

Laser beam machining 5, 6, 7

Super finishing 4–6

Grinding 4–8

Electric Discharge machining 6–7

Boring 5–9
Reaming 5–8
Broaching 5–9
Turning (Diamond tools) 4–7
Turning 7 – 12
Milling 8 – 10
Shaping 10 – 14
Drilling 11 – 14

Extrusion 9 – 12

Blanking 12 – 18

Drawing 10 – 14

Die Casting 12 – 15

Sand casting 14 – 16

HOW MUCH IS THE VALUE.

• EVERY DIM. ALONG WITH A GRADE
RECEIVE A TOL. VALUE.
• FOR EX. DIM 40 & GRADE 8, TOL= ?
• STD. FORMULA APPLIES TO THIS VALUE
• FOR CONVENIENCE, DIMES. ARE
GROUPED. 0 TO 3; 3 TO 6; 6 TO 10 etc.
• SAME VALUE OF TOL. VALID FOR A DIA
GROUP WITH ONE GRADE.
 Table 1 – Numerical values of standard tolerance grades IT for basic sizes up to 3 150 mm

Basic size Standard tolerance grades

mm IT12) IT22) IT32) IT42) IT52) IT6 IT7 IT8 IT9 IT10 IT11 IT12 IT13 IT143) IT153) IT163) IT173) IT183)

Up to
Tolerances
Above and in-
cluding
µm mm
- 33 0,8 1,2 2 3 4 6 10 14 25 40 60 0,1 0,14 0,25 0,4 0,6 1 1,4
3 6 1 1,5 2,5 4 5 8 12 18 30 48 75 0,12 0,18 0,3 0,48 0,75 1,2 1,8
6 10 1 1,5 2,5 4 6 9 15 22 36 58 90 0,15 0,22 0,36 0,58 0,9 1,5 2,2
10 18 1,2 2 3 5 8 11 18 27 43 70 110 0,18 0,27 0,43 0,7 1,1 1,8 2,7
18 30 1,5 2,5 4 6 9 13 21 33 52 84 130 0,21 0,33 0,52 0,84 1,3 2,1 3,3
30 50 1,5 2,5 4 7 11 16 25 39 62 100 160 0,25 0,39 0,62 1 1,6 2,5 3,9
50 80 2 3 5 8 13 19 30 46 74 120 190 0,3 0,46 0,74 1,2 1,9 3 4,6
80 120 2,5 4 6 10 15 22 35 54 87 140 220 0,35 0,54 0,87 1,4 2,2 3,5 5,4
120 180 3,5 5 8 12 18 25 40 63 100 160 250 0,4 0,63 1 1,6 2,5 4 6,3
180 250 4,5 7 10 14 20 29 46 72 115 185 290 0,46 0,72 1,15 1,85 2,9 4,6 7,2
250 315 6 8 12 16 23 32 52 81 130 210 320 0,52 0,81 1,3 2,1 3,2 5,2 8,1
315 400 7 9 13 18 25 36 57 89 140 230 360 0,57 0,89 1,4 2,3 3,6 5,7 8,9
400 500 8 10 15 20 27 40 63 97 155 250 400 0,63 0,97 1,55 2,5 4 6,3 9,7
500 6302 9 11 16 22 32 44 70 110 175 180 440 0,7 1,1 1,75 2,8 4,4 7 11
630 8002 10 13 18 25 36 50 80 125 200 320 500 0,8 1,25 2 3,2 5 8 12,5
800 10002 11 15 21 28 40 56 90 140 230 360 560 0,9 1,4 2,3 3,6 5,6 9 14
1000 12502 13 18 24 33 47 66 105 165 260 420 660 1,05 1,65 2,6 4,2 6,6 10,5 16,5
1250 16002 15 21 29 39 55 78 125 195 310 500 780 1,25 1,95 3,1 5 7,8 12,5 19,5
1600 20002 18 25 35 46 65 92 150 230 370 600 920 1,5 2,3 3,7 6 9,2 15 23
2
2000 2500 22 30 41 55 78 110 175 280 440 700 1100 1,75 2,8 4,4 7 11 17,5 28
2
2500 3150 26 36 50 68 96 135 210 330 540 860 1350 2,1 3,3 5,4 8,6 13,5 21 33

1) Values for standard tolerance grades IT01 and IT0 for basic sizes less than or equal to 500 mm are given in ISO 286 – 1, annex A, table 5.
2) Values for standard tolerance grades IT1 to IT5 (incl.) for basic sizes over 500 mm are included for experimental use.
3) Standard tolerance grades IT14 to IT18 (incl.) shall not be used for basic sizes less than or equal to 1 mm.

Table 1 – Numerical values of standard tolerance grades IT for basic sizes up to 3 150 mm

Basic size Standard tolerance grades

mm IT12) IT22) IT32) IT42) IT52) IT6 IT7 IT8 IT9 IT10 IT11

Up to
Tolerances
Above and
including
µm
- 33 0,8 1,2 2 3 4 6 10 14 25 40 60
3 6 1 1,5 2,5 4 5 8 12 18 30 48 75
6 10 1 1,5 2,5 4 6 9 15 22 36 58 90
10 18 1,2 2 3 5 8 11 18 27 43 70 110
18 30 1,5 2,5 4 6 9 13 21 33 52 84 130
30 50 1,5 2,5 4 7 11 16 25 39 62 100 160
50 80 2 3 5 8 13 19 30 46 74 120 190
80 120 2,5 4 6 10 15 22 35 54 87 140 220
120 180 3,5 5 8 12 18 25 40 63 100 160 250
180 250 4,5 7 10 14 20 29 46 72 115 185 290
250 315 6 8 12 16 23 32 52 81 130 210 320
315 400 7 9 13 18 25 36 57 89 140 230 360
400 500 8 10 15 20 27 40 63 97 155 250 400
500 6302 9 11 16 22 32 44 70 110 175 180 440
630 8002 10 13 18 25 36 50 80 125 200 320 500
800 10002 11 15 21 28 40 56 90 140 230 360 560
1000 12502 13 18 24 33 47 66 105 165 260 420 660
1250 16002 15 21 29 39 55 78 125 195 310 500 780
1600 20002 18 25 35 46 65 92 150 230 370 600 920
2000 25002 22 30 41 55 78 110 175 280 440 700 1100
2500 31502 26 36 50 68 96 135 210 330 540 860 1350

1) Values for standard tolerance grades IT01 and IT0 for basic sizes less than or equal to 500 mm are given in ISO 286 – 1, annex A, table 5.
2) Values for standard tolerance grades IT1 to IT5 (incl.) for basic sizes over 500 mm are included for experimental use.
3) Standard tolerance grades IT14 to IT18 (incl.) shall not be used for basic sizes less than or equal to 1 mm.
 Table 1 – Numerical values of standard tolerance grades IT for basic sizes up to 3 150 mm

Basic size Standard tolerance grades

mm IT12 IT13 IT143) IT153) IT163) IT173) IT183)

Up to and Tolerances
Above
including
mm
- 33 0,1 0,14 0,25 0,4 0,6 1 1,4
3 6 0,12 0,18 0,3 0,48 0,75 1,2 1,8
6 10 0,15 0,22 0,36 0,58 0,9 1,5 2,2
10 18 0,18 0,27 0,43 0,7 1,1 1,8 2,7
18 30 0,21 0,33 0,52 0,84 1,3 2,1 3,3
30 50 0,25 0,39 0,62 1 1,6 2,5 3,9
50 80 0,3 0,46 0,74 1,2 1,9 3 4,6
80 120 0,35 0,54 0,87 1,4 2,2 3,5 5,4
120 180 0,4 0,63 1 1,6 2,5 4 6,3
180 250 0,46 0,72 1,15 1,85 2,9 4,6 7,2
250 315 0,52 0,81 1,3 2,1 3,2 5,2 8,1
315 400 0,57 0,89 1,4 2,3 3,6 5,7 8,9
400 500 0,63 0,97 1,55 2,5 4 6,3 9,7
500 6302 0,7 1,1 1,75 2,8 4,4 7 11
2
630 800 0,8 1,25 2 3,2 5 8 12,5
2
800 1000 0,9 1,4 2,3 3,6 5,6 9 14
1000 12502 1,05 1,65 2,6 4,2 6,6 10,5 16,5
1250 16002 1,25 1,95 3,1 5 7,8 12,5 19,5
1600 20002 1,5 2,3 3,7 6 9,2 15 23
2000 25002 1,75 2,8 4,4 7 11 17,5 28
2
2500 3150 2,1 3,3 5,4 8,6 13,5 21 33

1) Values for standard tolerance grades IT01 and IT0 for basic sizes less than or equal to 500 mm are given in ISO 286 – 1, annex A, table 5.
2) Values for standard tolerance grades IT1 to IT5 (incl.) for basic sizes over 500 mm are included for experimental use.
3) Standard tolerance grades IT14 to IT18 (incl.) shall not be used for basic sizes less than or equal to 1 mm.

HOW MUCH IS THE VALUE

• 60% INCREASE IN TOL. VALUE FOR
EVERY GRADE UP FOR A DIA
GROUP
• EVERY 6TH GRADE GETS 100%
MORE TOL VALUE
WHERE TO DISPOSE TOLE.
• TOL. CAN BE DISPOSED
• ABOVE BASIC DIM.
• BELOW BASIC DIM
• DISTRIBUTED ON EITHER SIDE

WHERE TO POSITION
• POSITIONING IS REPRESENTED BY
CAPITAL LETTERS FOR HOLES A,B,H
• BY SMALL LETTERS FOR SHAFTS a,b,h
• STD DISTANCES ARE KEPT EACH
LETTER & FOR EACH DIA GROUP FROM
BASIC DIM.
• THE DISTANCE TO THE BASIC DIM WITH
LEAST VALUE IS TERMED AS
FUNDEMENTAL DEVIASION;
• FD IS FIXED FOR A DIA-DIM
COMBINATION.
Schematic
representation of the
positions of
fundamental deviations
FITS

When two parts to be assembled, the relation

resulting from the difference between the size
before assembly is called a fit.

A fit is represented by
φ 30 H 7 / g6, φ 30 H 7 / p6, φ 40 H7/h6,
φ 40 H7k6, φ 40 H7p6,
Example of general tolerances on a drawing
INTERPRETATION
FORM TOLERANCES
STRAIGHTNESS
SYMBOL -:

ZONE OF TOLERANCE :- CYLINDER

 5 Tolerance frame
5.1 The tolerance requirements are shown
in a rectangular frame which is divided
into two or more compartments. These
compartments contain, from left to right ,in Figures 3
the following order (see figures 3,4 and 5)
:
_ The symbol for the characteristic to be
toleranced: Figures 4
_ The tolerance value in the unit used for
linear dimensions. This value is preceded
by the sign Φ if the tolerance zone is
circular or cylindrical: Figures 5
_ if appropriate, the letter or letters
identifying the datum feature (see figures
4 and 5)

5 Tolerance frame(contd)
• 5.2 Remarks related to the
tolerance, for example “6
holes”, “4 surfaces” or
“6x” shall be written above
the frame (see figures 6 Figure 6 Figure 7
and 7)
• 5.3 Indications qualifying
the form of the feature
within the tolerance zone
shall be within near the
tolerance frame and may
be connected by a leader Figure 8 Figure 9
line (see figures 8 and 9)
 5 Tolerance frame(contd)
5.4 If it is necessary to specify
more than one tolerance
characteristic for a feature,
the tolerance specifications
are given in tolerance frames
one under the other (see
Figure 10
figure 10)

6 Toleranced features

• The tolerance frame is

connected to the toleranced
feature by a leader line
terminating with an arrow in the
following way: Figure11

• _ on the outline of the feature or

an extention of the outline ( but
clearly separated from the
dimension line) when the
tolerance refers to the line
surface itself (see figures 11 and
12)
Figure12
 6 Toleranced features (contd)

• _ as an extension of a
dimension line when the
tolerance refers to the axis Figure13
or median plane defined by
the feature so dimensioned
(see figures 13 to 15)

Figure14

Figure15

6 Toleranced features(contd)
• _ on the axis when the tolerance
refers to the axis or median plane
of all features common to that
axis or median plane(see figures
16,17 and 18)

Figure16

Figure17 Figure18
 7 Tolerance zones
7.1 The width of the tolerance zone is in the direction of the arrow of the leader
line joining the tolerance frame to the feature which is tolerance, unless the
tolerance value is preceded by the sign Ø (see figures 19&20).

Figure 19 Figure 20

7 Tolerance zones (contd)

• 7.2 In general, the direction of the width of the tolerance zone is
normal to the specified geometry of the part (see figures 21&22)

Figure 21 Figure 22
 7 Tolerance zones (contd)
• 7.3 The direction of the tolerance zone shall be indicated when
desired not normal to the specified geometry of the part (see
figures 23&24)

α
Figure 23 Figure 24

7 Tolerance zones (contd)

7.4 Individual tolerance zones of the same value applied to several separate
features can be specified as shown in figures 25&26.

Figure 25 Figure 26
 7 Tolerance zones (contd)
7.5 Where a common tolerance zone is applied to several separate features,
the requirement is indicated by the words “common zone” above the
tolerance frame (see figures 27&28).

3XA
COMMON ZONE COMMON ZONE

A A A

Figure 27 Figure 28

8 Datums
8.1 When a tolerance feature is related to a datum, this is generally shown by
datum latter which defines the datum is repeated in the tolerance frame.
To identify the datum, a capital letter enclosed in a frame is connected to a solid
or blank datum triangle (see figures 29&30).

Figure 29 Figure 30
 8.2 The Datum triangle with the datum letter is placed:
-On the outline of the feature or an extension of the out line (but clearly
separated from the dimension line), when the datum feature is the line or
surface itself (see figures 31)

Figure 31

- as an extension of the dimension line when the datum feature is the axis or
median plane (see figures 32 to 34).
NOTE - If there is insufficient space for two arrows, one of them may be
replaced by the datum triangle (see figures 33 and 34).

on the axis or median plane when the datum is :

a) the axis or median plane of a single
feature (for example a cylinder);

b) the common axis or plane formed by

two features (see figure 35).
 8.3 If the tolerance frame can be directly connected with the datum feature by
a leader line, the datum letter may be omitted (see figures 36 and 37).

8.4 A single datum is identified by a capital

letter (see figure 38).
A common datum formed by two features is
identified by two datum letter
separated by a hyphen (see figure 39).

If the sequence of two or more datum

features is important the datum letters are
placed in different compartments (see figure
40), where the sequence from left to right
shows the order of priority.

If the sequence of two or more datum features is not important the datum letters
are indicated in the same compartment (see figure 41).

9 Restrictive specifications

9.1 If the tolerance is applied to a restricted length,

lying anywhere, the value of this length shall be
added after the tolerance value and separated from it
by an oblique stroke.

In the case of a surface, the same indication is used.

This means that the tolerance applies to all lines of
the restricted length in any position and any direction
(see figure 42).
 9.2 If a smaller tolerance of the same type is added to
the tolerance on the whole feature, but restricted over a
limited length, the restrictive tolerance shall be indicated
in the lower compartment (see figure 43).
9.3 If the tolerance is applied to a restricted part of
the feature only, this shall be dimensioned as shown
in figure 44.

9.4 If the datum is applied to a restricted part of

the datum feature only, this shall be dimensioned as
shown in figure 45.
•9.5 Restrictions to the form of the feature within
the tolerance zone are shown in 5.3.

Theoretically exact dimensions

If tolerances of position or of profile or of angularity are prescribed for a feature,

the dimensions determining the theoretically exact position, profile or angle
respectively, shall not be toleranced.
These dimensions are enclosed, for example The corresponding actual
dimensions of the part are subject only to the position tolerance, profile
tolerance or angularity tolerance specified within the tolerance frame (see
figures 46 and 47).
Figure 46
Figure 47

.
 • Projected tolerance zone
In some causes the tolerances of
orientation and location shall apply not to
the feature itself but to the external
projection of it. Such projected tolerance
zones are to be indicated by the symbol
(see figure 48).
Maximum material condition

The indication that the tolerance value applies at the Figure 48

maximum material condition is shown by the
symbol placed after:

The tolerance value (see figure 49); Figure 49

The datum letter (see figure 50);

Figure 50
Or both (see figure 51);According to whether
the maximum material principle is to be applied
respectively to the toleranced feature. the datum Figure 51
feature or both.

• Definitions of tolerances
• The various geometrical tolerances are defined with their
tolerance zones in the following pages. In all the illustrations of
the definitions only those deviations are shown with which the
definitions deal.
• Where required for functional reasons, one or more characteristics
will be toleranced to define the geometrical accuracy of a feature.
When the geometrical accuracy of a feature is defined by a certain
type of tolerance, other deviations of this feature in some cases
will be controlled by this tolerance (for example, straightness
deviation is limited by parallelism tolerance). Thus it would
rarely be necessary to symbolize all of these characteristics, since
the other deviations are included on the zone of tolerance defined
by the symbol specified.
FLATNESS
SYMBOL -:

ZONE OF TOLERANCE :- TWO PARALLEL PLANES

CIRCULARITY
SYMBOL -:

ZONE OF TOLERANCE :- TWO COPLANAR

CONCENTRIC CIRCLES
 Circularity
The permissible deviation of the diameter is indicated directly on the drawing; the
general tolerance on circularity is equal to the numerical value of the diameter
tolerance.

EXAMPLE 1

Circularity
The general tolerance in accordance with the indication ISO 2768-mK apply. The
permissible deviations for the diameter of 25mm are ±0.2mm. These deviations lead
to the numerical value of 0.4mm which is greater than the value of 0.2mm given in
table 4; the value of 0.2mm therefore, applies for the circularity tolerance.

EXAMPLE 2
CYLINDRICITY
SYMBOL -:

ZONE OF TOLERANCE :- TWO COAXIAL CYLINDERS

PROFILE OF ANY LINE

SYMBOL -:

ZONE OF TOLERANCE :- TWO PROFILE LINES

PROFILE OF ANY SURFACE
SYMBOL -:

ZONE OF TOLERANCE :- TWO PROFILED PLANES

POSITION TOLERANCES

Other symbols
 PARALLELISM
SYMBOL -:

ZONE OF TOLERANCE :- CYLINDER

Parallelism
Depending on the shapes of the deviations of the features, the parallelism
deviation is limited by the numerical value of the size tolerance (see figure B.3)
or by the numerical value of the straightness or flatness tolerance (see figure B.4)
 PARALLELISM TOLERANCE
PARALLELISM TOLERANCE OF A LINE WITH REFERENCE TO A
DATUM SURFACE
Definition of the tolerance zone Indication and Interpretation

The tolerance zone is limited by

The axis of the hole shall be contained
two parallel planes a distance t
between two planes 0.01 apart and parallel
apart and parallel to the datum
to the datum surface B
surface

PARALLELISM TOLERANCE OF A SURFACE WITH REFERENCE

TO A DATUM LINE
Definition of the tolerance zone Indication and Interpretation

The tolerance zone is limited by

The tolerance surface shall be
two parallel a distance t apart and
contained between two planes 0.1
parallel to the datum line.
apart and parallel to the datum axis
of the hole
 PARALLELISM TOLERANCE OF A SURFACE WITH REFERENCE
TO A DATUM SURFACE

Definition of the tolerance zone Indication and Interpretation

The tolerance zone is limited by The tolerance surface shall be contained

two parallel planes a distance t between two parallel planes 0.01 apart and
apart and parallel to the datum parallel to the datum surface D
surface All the points on tolerance surface in a
length of 100, placed anywhere on this
surface, shall be contained between two
parallel planes 0.01 apart and parallel to the
datum surface A.

PERPENDICULARITY
SYMBOL -:

ZONE OF TOLERANCE :- TWO PARALLEL PLANES

PERPENDICULAR TO DATUM SURFACE
 PERPENDICULARITY TOLERANCE
PERPENDICULARITY TOLERANCE OF A LINE WITH
REFERENCE TO A DATUM LINE
Definition of the tolerance zone Indication and Interpretation

The axis of the inclined hole shall be

The tolerance zone when contained between two parallel planes
projected in a plane is limited by 0.06 apart and perpendicular to the
two parallel straight lines a axis of the horizontal hole A(datum
distance t apart and perpendicular line)
to the datum line

PERPENDICULARITY TOLERANCE OF A LINE WITH

REFERENCE TO A DATUM SURFACE

The tolerance zone is limited by a

The axis of the cylinder shall be
parallelepiped of section t1 xt2 and
contained in a parallelepiped
perpendicular to the datum plane if the
tolerance zone of 0.1x0.2, which is
tolerance is specified in two directions
perpendicular to the datum surface
perpendicular to each other
 PERPENDICULARITY TOLERANCE OF A LINE WITH
REFERENCE TO A DATUM SURFACE

The tolerance is limited by a The axis of the cylinder to which the

cylinder of diameter t perpendicular tolerance frame is connected shall be
to the datum plane if the tolerance contained in a cylindrical zone of
value is preceded by the sign Ø diameter 0.01 perpendicular to the datum
surface A

PERPENDICULARITY TOLERANCE OF A SURFACE

WITH REFERENCE TO A DATUM LINE

DEFINITION OF THE TOLARANCE ZONE INDICATION AND INTERPRETATION

The tolerance zone is limited The tolerance piece of the

by two parallel planes a piece shall be contained
distance t apart and between two parallel
perpendicular to the datum planes 0.08 apart and
line. perpendicular to the axis
A (datum line).
 PERPENDICULARITY TOLERANCE OF A SURFACE
WITH REFERENCE TO A DATUM SURFACE

DEFINITION OF THE TOLARANCE ZONE INDICATION AND INTERPRETATION

The tolerance zone is limited The toleranced surface

by two parallel planes a shall be contained
distance t apart and between two parallel
perpendicular to the datum planes0.08 apart and
surface. perpendicular to the
horizontal datum surface
A.

ANGULARITY
SYMBOL -:
a

ZONE OF TOLERANCE -: TWO PARALLEL PLANES

INCLINED 60 DEGREE TO DATUM SURFACE.
 PERPENDICULARITY TOLERANCE OF A LINE WITH
REFERENCE TO A DATUM SURFACE

The tolerance zone when projected

The axis of the cylinder, to which the
in a plane is limited by two parallel
tolerance frame is connected, shall be
straight lines a distance t apart and
contained between two parallel planes
perpendicular to the datum plane if
0.1 apart, perpendicular to the datum
the tolerance is specified only in one
surface
direction

ANGULARITY TOLERANCE
ANGULARITY TOLERANCE OF A LINE WITH
REFERENCE TO A DATUM LINE
DEFINITION OF THE TOLARANCE ZONE INDICATION AND INTERPRETATION

a) Line and datum line in the The axis of the hole shall
same plane. be contained between
The tolerance zone when two parallel straight
projected in a plane is limited planes 0.08 apart which
by two parallel straight lines a are inclined at 60° to the
distance t apart and inclined at horizontal A-B (datum
the specified angle to the line).
datum line.
DEFINITION OF THE TOLARANCE ZONE INDICATION AND INTERPRETATION

b) Line and datum line in The axis of the hole

different planes projected on a plane
If the considered line and the containing the datum axis
datum line are not in the same shall be contained
plane, the tolerance zone is between two parallel
applied to the projection of straight lines
the considered line on the
plane containing the datum
line and parallel to the
considered line.

ANGULARUTY TOLERANCE OF A LINE WITH

REFERANCE TO A DATUM SURFACE
DEFINITION OF THE TOLERANCE ZONE INDICATION AND INTERPRETATION

The tolerance zone when projected The axis of the hole shall be
in a plane is limited by two contained between two parallel
parallel straight lines a distance t planes 0.08 apart which are
apart and inclined at the specified inclined at 60° to the surface A
angle to the datum surface. (datum surface)
 ANGULARITY TOLERANCE OF A SURFACE WITH
REFERENCE TO A DATUM LINE

DEFINITION OF THE TOLERANCE ZONE INDICATION AND INTERPRETATION

The tolerance zone is limited by The inclined surface shall be

two parallel planes a distance t contained between two parallel
apart and inclined at the specified planes 0.1 apart which are inclined
angle to the datum line. at 75° to the axis A (datum line).

ANGULARITY TOLERANCE OF A SURFACE WITH

REFERENCE TO A DATUM SURFACE

DEFINITION OF THE TOLERANCE ZONE INDICATION AND INTERPRETATION

The tolerance zone is limited by The inclined surface shall be

two parallel planes a distance t contained between two parallel
apart and inclined at the specified planes 0.1 apart which are inclined
angle to the datum surface. at 40° to the surface A (datum
surface).
 POSITION
SYMBOL -:

ZONE OF TOLERANCE :- CYLINDER

POSITIONAL TOLERANCE
POSITIONAL TOLERANCE OF A POINT
DEFINITION OF THE TOLERANCE ZONE INDICATION AND INTERPRETATION

The tolerance zone is limited by a The actual point of intersection shall lie
circle of diameter t, the centre of inside a circle of 0.3 diameter ,the centre
which is in the theoretically exact of which coincides with the theoretically
position of the considered point. exact position of the considered point of
intersection.
Position tolerance of a line
Definition of the tolerance zone Indication and interpretation

The tolerance zone is limited by Each of the lines shall be

two parallel straight lines a contained between two parallel
distance t apart and disposed straight lines 0.05 apart which are
symmetrically with respect to the symmetrically disposed about the
theoretically exact position of the theoretically exact position of the
considered line if the tolerance is considered line, with reference to
specified only in one direction. the surface A (datum plane).

Definition of the tolerance zone Indication and interpretation

The tolerance zone is limited by a Each of the axes of the eight

parallelepiped of section t1x t2 the holes shall be contained within a
axis of which is in the theoretically parallelepipedic zone of width
exact position of the considered 0.05 in the horizontal and 0.2 in
line if the tolerance is specified in the vertical direction and the axis
two directions perpendicular to of which is in the theoretically
each other. exact position of the considered
hole.
Definition of the tolerance zone Indication and interpretation

The tolerance zone is limited by a The axis of the hole shall be

cylinder of diameter ‘t’ the axis of contained within a cylindrical
which is in the theoretically exact zone of diameter 0.08 the axis of
position of the considered line if which is in the theoretically
the tolerance value is preceded by exact position of the considered
the sign ø line, with reference to the
surfaces A and B (datum planes).

Definition of the tolerance zone Indication and interpretation

The tolerance zone is limited by a Each of the axes of the eight

cylinder of diameter ‘t’ the axis of holes shall be contained within a
which is in the theoretically exact cylindrical zone of diameter 0.1
position of the considered line if the axis of which is in the
the tolerance value is preceded by theoretically exact position of the
the sign ø considered hole.
 Position tolerance of a flat surface or a median
plane
Definition of the tolerance zone Indication and interpretation

The tolerance zone is limited by The inclined surface shall be contained

two parallel planes a distance t between two parallel planes which are
apart and disposed 0.05 apart and which are
symmetrically with respect to the symmetrically disposed with respect to
theoretically exact position of the the theoretically exact position of the
considered surface. considered surface with reference to
the surface A(datum plane)and the axis
of the datum cylinder B (datum line)

COAXIALITY
SYMBOL -:

ZONE OF TOLERANCE :- CYLINDER

 Concentricity tolerance of a point

Definition of the tolerance zone Indication and interpretation

The centre of the circle , to which the

The tolerance zone is limited by a tolerance frame is connected, shall be
circle of diameter t the center of contained in a circle of diameter 0.01
which coincides with the datum point concentric with the centre of the
datum circle A.

Coaxiality tolerance of an axis

Definition of the tolerance zone Indication and interpretation

The tolerance zone is limited by a The axis of the cylinder, to which the
cylinder of diameter I, the axis of tolerance frame is connected, shall be
which coincides with the datum axis contained in a cylindrical zone of
if the tolerance value is preceded by diameter 0.08 coaxial with the datum
the sign ø. axis A-B.
 SYMMETRY
SYMBOL -:

ZONE OF TOLERANCE :- TWO PARALLEL PLANES

Symmetry tolerance of a median plane

Definition of the tolerance zone Indication and interpretation

The tolerance zone is limited by two The median plane of the slot, shall be
parallel planes a distance t apart and contained between two parallel
disposed symmetrically to the planes, which are 0.08 apart and
median plane with respect to the symmetrically disposed about the
datum axis or datum plane. median plane with respect to the
datum feature A.
 Symmetry– Examples

For some tolerance zones (for example, for

straightness of a line or axis in one direction
only) there are two possible methods, of
graphical representation:
By two parallel planes a distance ‘t’ apart (see
figure 52);
By two parallel straight lines a distance ‘t’ apart Figure 52
(see figure 53);
Figure 52 shows a three-dimensional
representation, figure 53 its projection in a plane.

There is no difference in the meaning of the

two representations (such a tolerance does not
restrict the deviation in any direction
perpendicular to the arrow). The simpler
method as shown in figure 53 is normally
used in this International Standard.
Figure 53
CIRCULAR RUNOUT
SYMBOL -:

ZONE OF TOLERANCE :- TWO COPLANAR

CONCENTRIC CIRCLES
TOTAL RUNOUT
SYMBOL -:

ZONE OF TOLERANCE :- TWO COAXIAL CYLINDERS

TOTAL RUN-OUT TOLERANCE

TOTAL AXIAL RUN-OUT TOLERANCE INDICATION AND INTERPRETATION

The tolerance zone is limited by

two parallel planes a distance t
apart and perpendicular to the
datum axis.

The total axial run-out shall not be greater than

0.1 at any point on the surface during several
revolutions about the datum axis D and with
relative radial movement between the
measuring instrument and the part. With
relative movement the measuring instrument
or the work piece shall be guided along a line
having the theoretically perfect form of the
contour and being in correct position to the
datum axis.
 MMC, LMC & RFS
MMC - Dimension corresponding to Maximum
Metal Condition
(biggest shaft size or smallest hole size)
LMC - Dimension corresponding to Least Metal
Condition
(smallest shaft or biggest hole size)
RFS - Regardless of feature size

• Actual Dimension vary from MMC limit to

LMC limit
• Worst assembly condition exist when
mating parts at MMC
• Functional assembly requirements can be
related to actual dimension by symbol M
in the drawing
 − Ø0.4 M

M12
Ø12 -0.2
0
Virtual size Virtual size
Tolerance zone Tolerance zone

Ø12.4

Ø12.4
Ø0.4 Ø0.6

Ø12 Ø12 Ø12 Ø11.8 Ø11.8 Ø11.8

Actual Local Sizes Actual Local Sizes

D M

Virtual Condition
normal to Datum Plane D
⊥ Ø0.2 M D
D

Øt
Ø20 -0.1

A2
A1

A3
0

ØG

Datum Plane D

A1 to A3 = actual Local sizes =19.9 ...20

(maximum material size = Ø20)

G = virtual size = Ø20.2

Øt = orientational tolerance zone = 0.2 ..0.3
 Ø0.2
ØG=Ø20.2
Ø20 Ø20 Ø20

Actual Local Sizes

Datum Plane D
Ø0.3

ØG=Ø20.2
Ø19.9 Ø19.9 Ø19.9

Actual Local Sizes

Datum Plane D

Dimensioning of profiles
 0
70
°

25 FOLLWER

120°-
β 0° 20° 40° 60° 80° 100° 230° 260° 280° 300° 320° 340°
210°

a 50 52.5 57 63..5 70 74.5 76 75 70 65 59.5 55 52

0.1
12
0°

12
0°
12
12

0°
0°

0
Ø8

R8 R8

120° 120°

a) Indication on the drawing b) Interpretation

 0.1 A-B
14

14

14

21

28

35

14

14

14

21

28

35
.1
7

7
Ø0

19.5

19.5
21

21
17

17
13

13
10

10
8

8
7

7
A) Indication on the drawing B) Interpretation

0.1

SR
R5 80
80
SR R5
180

230

270 500

A) Indication on the drawing

 R5 80

SR
R5

180
SR

80
230
270
500

B) Interpretation

Packing ring of a pump

0.01/5 NOT CONVEX

0.03
Ø22H7
Ø44H7
 Friction wheel

0.02 A

0.01 A

0.04 A
Ø36 H8

0.01 A

Arbor for milling cutter

+0,18
1520-0
0.05 A 0.01 A
8.2H11

0.01 A
Ø

A
0.1 B

B
A
 0.01
0.005 0.02 AB

0.008 0.01 AB

0.005
0.008 B

Ø11H7

Ø11H7
Ø80

A
A B
FIG. 5

0.025 A

39

Ball bearing inner ring Roller

Bearing housing
25

0.02 A
A
)
58
57

Ø47M6(

30
25
35
34

X 0.03 A

0.03 A
0.1 A
SECTION XX
 CAM

0.03 A

5E9
Ø6H7
A

Ø18 0.02 A

Cam shaft

0.02 AB

0.02 CL OF CAM LOBE

0.02 C
0.08 AB
0.02 AB
R4 R15.75 11°30"

R4
R16 9,015
C
R25.75 9
0.01
A B
 DISC

0.05 A B

40±0.1
3x45°±2° 10
+0.06 X
8 HOLES EQUISPACED Ø11 -0

0.01 A B A
B

11

25,5

+0.02
Ø108

-0.05
Ø142
0

0
160
70
0.02 A B
0.05 A 0.02
8 HOLES
8 HOLES EQUISPACED .M8

Ø9
EQUISPACED M8
X

l 22°10'
0.2 A B
3 0°

19 10
mi
n

SECTION XX

Drilling Jig
0.1

Φ120
Ø120
A

30°

12 HOLES H7

0.02 A
 f A
g

b
Ø

Ød
A

DIM ENSIONS TOLERANCES

PART NO:
b c d e f G
1 15 7 8h8 47 0.005 0.005
2 20 8 10h 8 58 0.01 0.008
3 30 10 15h 9 70 0.02 0.01
4 50 12 25h 9 112 0.05 0.015

Drawing in which dimensions are shown in tabular form

Tolerance Analysis
 Dimension based on functional
Importance
• Dimension ( Series, parallel or progressive )
is done on the basis of functional
importance.

Process Planning ( for the

component shown ) depends
on the way of dimensioning.

PROCESS PLANNING
Oper. No. Operation Sketch

Facing to
1000 55 mm
length

Turning to Ø20
1005 whole length

Turning to Ø8 till
1010 35mm

Same component can be machined another way also

 IMPORTANCE OF
FUNCTIONAL DIMENTIONS

• Do not give ending dimension in the

drawing
• Ending dimension gets cumulative
tolerance, whether add or subtract
• Way of dimensioning will make the
manufacturing process

Examples

35±0.1 and 20±0.05

So 55 will be 55±0.15
T total = Some of individual Tolerances
35±0.1 Tolerance = 0.2
20±0.05 Tolerance = 0.1
55±0.15 Tolerance = 0.3
So T 55 = T 35 + T 20
i.e 0.3 = 02 + 0.1
 Tolerance analysis
c1
c2
C
C

a1 b1
a2 b2
A B
A B

Tolerance analysis Example

8 +0.2and 3 -0.1
+0.1 -0.3
C+c2 = ( A+a2 ) + (B+b2) So 11 ( +0.2 ) + ( -0.1 )
( +0.1) + ( -0.3 )
= 11 +0.1
- 0.2

So c2 = a2 + b2 Now Tol8 = 0.1

Tol3 = 0.2 , Tol11 = 0.3
C2 ( a2 + b2 )
C1
Rule :- C = (A+B) ( a1 + b1 ) ∴ Tol11 = Tol8 + Tol3

-0.2 -0.05
12 +0.1+ 4 ±0.1 + 3 -0.1
( +0.1) + (+0.1) + (+0.1) +0.3
∴ 19 ( -0.2 ) + (- 0.1) + (+ 0.05)
= 19 -0.35

Tol 12 = 0.3 , Tol 4 = 0.2

Tol 3 = 0.15 , Tol 19 = 0.65
 a2
AAa1

EXAMPLE
1
c1 b2 - 0.1 0.00
CCc2 BBb1 12 - 0.3 - 8 ±0.1 = 4 - 0.40

(- 0.1) – (- 0.1 )
i.e. 4(- 0.3) – (+0.1)
∴ Tol 12 = 0.2
( a2 – b1 )
Tol 8 = 0.2
a2 b2
( a1 – b2 ) Tol 4 = 0.4
C = Aa - B b
1 1

+ 0.2 - 0.05 + 0.2

2
±0.1 ±0.1
12 + 0.1 +4 +3 + 0.1 -5 +4 + 0.1
T12 + T4 + T3 + T4 – T5 = T18
+ 0.2 + 0.1 + 0.1 + 0.1 + 0.2 + 0.70
i.e.
∴ 18 + 0.1 – 0.1 – 0.05 – 0.1 + 0.1
= 18 - 0.05
0.1 + 0.2 + 0.15 + 0.1 – 0.2 = 0.75

Series dimensioning not preferred

Parallel dimensions are most preferred , since

Tolerance get added in series dimensioning
 Theory of datum change

Counter bore height

22±0.1 - 18±0.05 = 4±0.15

To get the shank height (reverse)

22±0.1 - 4±0.15 = 18±0.25

So, 18±0.25 , The Tolerance exceeds

Theory of datum change

Check whether Datum change is possible

18±0.05 = 22±0.1 – 4
Datum change is not possible, so redesign the Tolerance
X2
values of 22 and 4 X1
i.e to get 18±0.05 change the change the Tolerance of 22 and 4
Take Tol22 = 0.06 and Tol4 = 0.04
Hence Tol18 = 0.06 + 0.04 = 0.1
∴ Values are 22±0.03 and 4±0.02
 ± 0.1
E
(Ø6H8)
c H8 ⊥ Ø0.1 A

Ø14 H8(25µ)

ØAH8

D- 0.5
Ø20
- 0.1
P
A

± 0.05
B
40
60

± 0.02 ± 0.02
E F

LOCATION

CAN WE CHANGE DATUM ?

 ± 0.1
80

± 0.05
112

- 0.05
20 X1
12 X2

± 0.1
(80 )

0.5 ABC 0.5 ABC

15 15

8x 8x

105 105

R R

SR SR

SØ SØ

CR NONE
*
* NONE
May be filled or not filled
ST NONE

or or