LIMIT, FIT AND TOLERANCE

The primary aim of any general system of standard fits and limits is to give guidance to the user
for selecting basic fundamental clearances and interferences for a given application; and for a fit,
to deter-mine tolerances and deviations of parts under consideration according to the standard
ISO 286:1988.
SIZE DESIGNATIONS
The following terminologies can be well explained using the conventional diagram shown in
Fig.
1. Shaft: The term ‘shaft’, used in this standard has a wide meaning and serves for specification
of all outer elements of the part, including those elements, which do not have cylindrical shapes.
2. Hole: The term ‘hole’ can be used for specification of all inner elements regardless of their
shape.
When an assembly is made of two parts, one is known as the male (outer element of the part)
sur-face and the other one as the female (inner element of the part) surface. The male surface is
referred as ‘shaft’ and the female surface is referred as ‘hole’.
4. Basic Size: It is the theoretical size from which limits of size are derived by the application of
allowances and tolerances. The basic size or normal size is the standard size for the part and is
the same both for the hole and its shaft.

5. Actual Size: Actual size is the dimension as measured on a manufactured part.

6. Limits of Size: The maximum and minimum permissible sizes within which the actual size of
a component lies are called Limits.
7. Maximum Limit: The maximum limit or high limit is the maximum size permitted for the
part.
8. Minimum Limit: The minimum limit or low limit is the minimum size permitted for the part.
9. Zero Line: In a graphical representation of limits and fits, a zero line is a straight line to
which the deviations are referred to. It is a line of zero deviation and represents the basic size.
When the zero line is drawn horizontally, positive deviations are shown above and negative
deviations are shown below this line.
10. Deviation: It is the algebraic difference between a size (actual, limit of size, etc.) and the
corresponding basic size.
11. Upper Deviation: It is designated as ES (for hole) and es (for shaft). It is the algebraic
difference between the maximum limit of the size and the corresponding basic size. When the
maximum limit of size is greater than the basic size, it is a positive quantity and when the
minimum limit of size is less than the basic size then it is a negative quantity.
12. Lower Deviation: It is designated as EI (for hole) and ei (for shaft). It is the algebraic
difference between the minimum limits of size and the corresponding basic size. When the

Bably Das, Assistant Professor, Department of Mechanical Engineering, CUET

minimum limit of size is greater than the basic size, it is a positive quantity and when the
minimum limit of size is less than the basic size then it is a negative quantity.
13. Fundamental Deviations (FD): This is the deviation, either upper or the lower deviation,
which is the nearest one to the zero line for either a hole or a shaft. It fixes the position of the
tolerance zone in relation to the zero line (refer Fig.).
14. Actual Deviation: It is the algebraic difference between an actual size and the corresponding
basic size.
15. Mean Deviation: It is the arithmetical mean between the upper and lower deviation.

6. Tolerance: It is the difference between the upper limit and the lower limit of a dimension. It is
also the maximum permissible variation in a dimension.
17. Tolerance Zone: It is a function of basic size. It is defined by its magnitude and by its
position in relation to the zero line. It is the zone bounded by the two limits of size of a part in
the graphical presentation of tolerance.
18. Tolerance Grade: It is the degree of accuracy of manufacturing. It is designated by the
letters IT (stands for International Tolerance). Numbers, i.e., IT0, IT01, IT1, follow these letters
up to IT16; the larger the number, the larger the tolerance.
19. Tolerance Class: This term is used for a combination of fundamental deviation and
tolerance grade.
20. Allowance: It is an intentional difference between the maximum material limits of mating
parts. For a shaft, the maximum material limit will be its high limit and for a hole, it will be its
low limit.
21. Fits: The relationship existing between two parts, shaft and hole, which are to be assembled,
with respect to the difference in their sizes is called fit.
22. Basic Shaft and Basic hole: The shafts and holes that have zero fundamental deviations.
The basic hole has zero lower deviation whereas, the basic shaft has zero upper deviation.

TOLERANCE:
It is impossible to make anything to an exact size, therefore it is essential to allow a definite
tolerance or permissible variation on every specified dimension.
Tolerance can be defined as the magnitude of permissible variation of a dimension or other
measured or control criterion from the specified value. Tolerance is always a positive
quantitative number.
The primary purpose of tolerances is to permit variation in dimensions without degradation of
the performance beyond the limits established by the specification of the design.
• For Example a dimension given as 1.625 ± .002 means that the manufactured part may be
1.627” or 1.623”, or anywhere between these limit dimensions.
Why Tolerances are specified?
• Variations in properties of the material being machined introduce errors.
• The production machines themselves may have some inherent inaccuracies.
• It is impossible for an operator to make perfect settings. While setting up the tools
and workpiece on the machine, some errors are likely to creep in.
How tolerance can be specified?
Tolerance can be specified on both the meeting elements, i.e., on the shaft and/or on the hole. For
example, a shaft of 30-mm basic size along with a tolerance value of 0.04 may be written as 30 ±
0.04. Therefore, the maximum permissible size (upper limit) is 30.04 mm and the minimum
permissible size (lower limit) is 29.96 mm. Then the value of the tolerance zone is (upper limit −
lower limit) = 0.08 mm.

Bably Das, Assistant Professor, Department of Mechanical Engineering, CUET

This is because, as closer tolerances are specified, to achieve that practically we have to use very
high-precision machines and tools, trained and highly skilled operators, highly precise and
accurate testing and inspection device.
Tolerances can be specified by two systems:
1. Unilateral Tolerances System: In this type of system, the part dimension is allowed to vary
on one side of the basic size, i.e., either below or above it. This system is preferred in an
interchangeable manufacturing environment. This is because it is easy and simple to determine
deviations. This system helps standardize the GO gauge end. This type of tolerancing method
is helpful for the operator, as he has to machine the upper limit of the shaft and the lower limit
of the hole knowing fully well that still some margin is left for machining before the part is
rejected.
For unilateral tolerances, a case may occur when one of the limits coincide with the
basic size

2. Bilateral Tolerances System: In this system, the dimension of the part is allowed to vary in
both the directions of the basic size. So, limits of the tolerances lie on either side of the basic
size. Using this system, as tolerances are varied, the type of fit gets varied. When a machine
is set for a basic size of the part then for mass production, the part tolerances are specified by
the bilateral system.

Bably Das, Assistant Professor, Department of Mechanical Engineering, CUET

Prob: Determine the dimension and tolerances on flange thickness T in Fig. (Jain: Problem
4.2)
Tight tolerances result in:
 Unnecessary machining and inspection time,
 High rejects,
 Adversary relationship between design, manufacturing and inspection.
Loose tolerances result in:
 Assembly problem,
 Poor product performance.
 What is Optimum tolerance? Describe about the range of optimum tolerance
Optimum tolerances:
A designer must explore information & techniques available as guidance in the establishment of
realistic &, where possible, optimum engineering tolerances.
 It must be remembered that the cost of machining & finishing to tighter tolerances increases
rapidly. One should have fairly good idea of relative cost of producing parts with different
tolerances. The standard products available within the specified tolerances should be considered.
One should have good understanding of tolerances resulting from various production processes.
 The understanding of statistical tools is of great help .It can be assumed that the most of
the most of the manufacturing processes produce parts which are normally distributed.
 The use of quality control charts also enables one to be more realistic in selection of
tolerances. Quality control charts is a powerful tool for the definition of the potential dimensional
accuracy of manufacturing processes. Quality control charts are good guide for the design office
in establishing of realistic specifications.
 It is very important that the designer understands the capability of manufacturing processes
in producing parts to a given tolerance. Computer simulation techniques are used to provide
understanding of the tolerance requirement of product design. Computer simulation provides data
on the probability of parts of a certain tolerance range interfering at assembly.
ISO SYSTEM OF TOLERANCE
The Indian standards are in line with the ISO (international organization for standards)
It consists of 18 grades of fundamental tolerances (or grades of accuracy for manufacture) and 25
types of fundamental deviation.
The 18 grades of fundamental tolerances are IT01,IT0,ITI,IT2……. IT16
The 25 fundamental deviations are A,B,C,D,E,F,G,H,JS,J,K,M,N,P,R,S,T,U,V,X,Y,Z,ZA,ZB,ZC
The above capital letter symbols are used for hole and corresponding small letter symbols are
used for shaft (i.e for shaft a,b,….. za, zb & zc).
For each fundamental deviation there are different grades of tolerances. The tolerance grade
decides the accuracy of manufacture.

The fundamental tolerance unit: The numerical value of standard tolerance are determined in
terms of standard tolerance unit ‘i’ in µm, which is a function of basic size. It is used to express
various IT grades from IT5 to IT16, where the value of i in terms of the diameter D (in mm) can
be calculated as

The diameter ‘D’ (in mm) is the geometric mean of the diameter steps.

Bably Das, Assistant Professor, Department of Mechanical Engineering, CUET

Diameter steps in I.S.I are: 1-3, 3-6, 6-10, 10-18, 18-30, 30-50, 50-80, 80-120, 120-180, 180-
250, 250-315, 315-400 and 400-500 mm

The values of tolerances for tolerance grades IT5 to IT16 are given in following Table

ALLOWANCE
Allowance is the prescribed difference between the dimension of 2 mating parts for any type of
fit. The allowance may be +ve or-ve. The +ve allowance is called clearance and –ve allowance is
called interference.

Bably Das, Assistant Professor, Department of Mechanical Engineering, CUET

 DIFFERENCE BETWEEN TOLERANCE & ALLOWANCE
Tolerance Allowance
1. It is the permissible variation in dimension of 1.It is the prescribed difference between the
a part either a hole or a shaft) dimensions of two mating parts (hole and shaft)
2. It is the difference between higher and lower 2. It is the difference between the maximum
limits of dimension of a part shaft and minimum hole size.
3. Tolerance is provided or a dimension of a part
3. Allowance is provided on the dimension of
as it is not possible to make a part to exact
mating parts to obtain desired type of fit.
specified dimension

FIT
It is the relationship that exists between two mating parts, a hole and shaft with respect to
their dimensional difference before assembly.
Fit is the general term used to signify the degree of tightness or looseness that may result from
the application of a specific combination of allowances and tolerances in mating parts.
• Three types of fit
– Clearance Fit
– Transition Fit
– Interference Fit
A. Clearance Fit: It is a fit which always provides clearance. Here the tolerance zone of the
hole will be above the tolerance zone of the shaft. Maximum clearance is the difference
between the maximum hole and minimum shaft. Minimum clearance is the difference
between the minimum hole and maximum shaft.

B. Transition Fit: In this type of fit, the diameter of the largest allowable hole is greater
than the smallest shaft, but the smallest hole is smaller than the largest shaft, such that a
small positive or negative clearance exists between the shaft & hole.
Ex: Coupling rings, Spigot in mating holes, etc.

Bably Das, Assistant Professor, Department of Mechanical Engineering, CUET

C. Interference Fit:It is defined as the fit established when a negative clearance exists between
the sizes of holes and the shaft. It is a fit which always provides interference. Here the tolerance
zone of the hole will be below the tolerance zone of the shaft. Maximum interference is the
algebraic difference between the minimum hole and maximum shaft. Minimum interference is
the algebraic difference between the maximum hole and minimum shaft. In this type of fit, the
minimum permitted diameter of the shaft is larger than the maximum allowable diameter of
the hole. In case of this type of fit, the members are intended to be permanently attached.
Ex: Bearing bushes, Keys & key ways

SYSTEMS OF FIT
Properties and fields of use of preferred fits are described in the following overview. When
selecting a fit, it is often necessary to take into account not only constructional and technological
but also economic aspects. Selection of a suitable fit is important, particularly in view of those
measuring instruments, gauges and tools which are implemented in production. Therefore, while
selecting a fit, proven plant practices may be followed.

Bably Das, Assistant Professor, Department of Mechanical Engineering, CUET

HOLE-BASIS SYSTEM:
Combinations of various shaft tolerance zones with the hole tolerance zone ‘H’ achieve the
desired clearances and interferences in the fit. In this system, as shown in Fig. 6.13(a) of
tolerances and fits, the lower deviation of the hole is always equal to zero and it is assumed as
the basic size. Hole-basis system is preferred from the manufacturing point of view. This is
because, it is more convenient and economical to use standard tools, e.g., drils, reamers,
broaches, etc. (whose sizes are not adjustable) to produce a hole. It also requires less space to
store the standard tools used to produce shafts of varied dimensions. On the other hand, shaft size
can be varied comparatively easily about the basic size by means of turning and/or grinding
operations. And also, gauging of shafts can be conveniently and quickly done with the help of
adjustable gap gauges.

SHAFT-BASIS SYSTEM:
Combinations of various hole tolerance zones with the shaft tolerance zone h achieve the desired
clear-ances and interferences in the fit. In this system of tolerances and fits, the upper deviation
of the hole is always equal to zero and it is assumed as the basic size. The system shown in Fig.
6.13(b) is not suitable for mass production as it is inconvenient, time-consuming and a costly
affair to produce a shaft of exact size.It also requires a large amount of capital and storage space
to store the tools used to produce holes of different sizes. And it is not convenient and easy to
inspect the produced hole and make it fit the standard sized shaft.

Difference between hole basis & shaft basis system:

Hole basis system Shaft system

1. Size of hole whose lower deviation is zero 1. Size of shaft whose upper deviation is zero (h-
(H.hole) is assumed as the basic size. shaft) assumed as basic size.
2. Limits on the hole are kept constant and those 2. Limits on the shaft are kept constant and those
of shafts are varied to obtain desired type of fit. of holes are varied to have necessary fit.
3. Hole basis system is preferred in mass 3. This system is not suitable for mass production
production because it is convenient and less costly because it is inconvenient time consuming and
to make a hole of correct size due to availability costly to make a hole of any size w.r to field shaft
of standard drills reamers. size so as to obtain required fit.

Bably Das, Assistant Professor, Department of Mechanical Engineering, CUET

 4. It is much more easy to vary the shaft sizes 4. It is rather difficult to vary the hole sizes
according to the fit required. according to the fit required.
5. It required less amount of capital and storage 5. It needs large amount of capital and storage
space for roofs needed to produce shaft of space for large numbers of tools required to
different sizes. produce holes of different sizes.
6. Changing of shafts can be easily and 6. Being internal measurement gauging of holes
conveniently done with suitable gap Gauges can’t be easily and conveniently done.

DESIGNATION OF HOLES AND SHAFTS:

One should always keep in mind that the value of a fundamental deviation is a function of the
range of basic size in which the basic size falls but not the specific basic size. These ranges
(diameter steps up to 500 mm) of basic size have been specified in IS: 919 ( please refer Table
6.3). Holes or shafts can be described completely in the following manner:
1) Hole = 55 H7 means
55 = the basic size of the hole
H = the position of the hole w.r.t zero line. For this case it is on the zero line.
7 = the tolerance grade, i.e., IT7. By knowing this value, the limits for 55-mm size
can be found out.
2) Shaft = 60 m9 means
60 = the basic size of the shaft.
m = the position of the shaft w.r.t zero line. In this case, it is above the zero line.
9 = the tolerance grade, i.e., IT9. By knowing this value, the limits for 60-mm size
can be found out.

ILLUSTRATION FOR DETERMINING TYPE OF FIT:

Determine type of Fit of 55 H7 f8:
1. Determine value of D=√50 × 65 = 57.008 mm
3
2. Determine value of i = 0.45 √𝐷+ 0.001 D = 1.789 microns.
3. Now consider first for Hole H7,
Value for the Tolerance IT7 (From Table of tolerance grade) = 16 (i ) = 16 (1.789) = 0.028 mm
As the H-hole lies on the zero line, its fundamental deviation is zero and lower deviation is zero.
Basic size = 55 mm
∴ Lower limit of size = Basic size + Fundamental deviation = 55 mm
∴ Upper limit =Lower limit + Tolerance = 55 mm + 0.028 =55.028 mm
Hence, hole size varies between 55.00 mm to 55.028 mm.

Bably Das, Assistant Professor, Department of Mechanical Engineering, CUET

4. Now consider for shaft 55f8,
Value for the tolerance IT8 = 25 (i ) = 25 (1.789 microns) = 0.0447 mm
As the f-shaft lies below the zero line, its fundamental deviation is the upper deviation.
Hence, the formula for fundamental deviation from Table 6.5 is
F.D.= [−5.5 D 0 . 41 ] =−5.5 D 0.41 = −5.5 (57.0.08) 0 . 41 = −28.86 microns = −0.0288 mm
∴ Now, upper limit of shaft = Basic size + Fundamental deviation
= 55 mm + (−0.0288) = 54.9712 mm
And, lower limit of shaft = Upper limit of shaft -Value for the Tolerance IT8
= 54.9712 − 0.0447 = 54.9265 mm
Hence, shaft size varies between 54.9265 mm to 54.9712 mm.
5. To check the type of fit we have to calculate
Maximum clearance = 55.028 mm − 54.9265 mm = 0.1015 mm [∴ clearance exists]
Minimum clearance = 54.9712 mm − 55.00 mm = 0.028 mm [∴ clearance exists]
6. Therefore, we can conclude that the type of fit of 55 H7f8 assembly results into ‘Clearance
fit’.
Example 1:
A 50 mm diameter shaft is made to rotate in the bush. The tolerances for both shaft and bush are
0.050 mm. Determine the dimension of the shaft and bush to give a maximum clearance of 0.075
mm with the hole basis system.
Example 2:
Determine the dimensions and tolerances of shaft and hole having size of 30 H7h8 . Also
determine the allowance (i.e. minimum clearance) and maximum clearance
Example 3:
Design a plug gauge for checking the hole of 70H8. Use IT8 = 25i, Diameter step = 50 to 80 mm.
Example 4:
Design and make a drawing of general purpose ‘GO’ and ‘NO-GO’ plug gauge for inspecting a
hole of 22 D8. Data with usual notations: i. Fundamental deviations for hole D = 16 D 0.44.
ii. Value for IT8 = 25i;Use the I.S.I. diameter steps.
Taking gaugemaker’s tolerance equal to 10% of the work tolerance, design a plug gauge to check
the fit. Find whether wear allowance will be provided or not?

Bably Das, Assistant Professor, Department of Mechanical Engineering, CUET

 Table 4.2 (R.K. Jain)

GAUGES:

Gauges are inspection tools of rigid design, without a scale the dimensions of the manufacturing
parts. Gauges do not indicate the actual dimensions of the manufacturing parts but they only used
for determining as to whether the inspected parts are made within the specified limits.
Gauges are classified as:

(1) According to their type:

 Standard & limit gauges,
 Limit Gauges.
(2) According to their purpose:
 Workshop gauges,
 Inspection gauges,
 Reference or master gauges.
(3) According to their purpose:
 Plug gauge for checking holes,
 Snap and ring gauges for checking shafts.
(4) According to their design:
 Single limit and double limit gauges,
 Single ended and double ended gauges,
 Fixed and adjustable gauges.

Bably Das, Assistant Professor, Department of Mechanical Engineering, CUET

 LIMIT GAUGES

Limit gauges are made to the limits of the dimensions of the part to be tested. There are two limit
of dimensions, so we need two limit gauge.
A Go-No GO gauge refers to an inspection tool used to check a workpiece against its
allowed tolerances. It derives its name 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 - No Go 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

DIFFERENCE BETWEEN WORKSHOP & INSPECTION GANGES

workshop gauges Inspection of gauges

(i)Workshop gauges are used by the operator Inspection gauges are used by inspectors for final
during manufacture of parts in the shop. inspection of the manufactured part.
These gauges are mode slightly larger tolerance
(ii) These gauges usually have limits within those than the workshop gauges. This is ensure that the
of the components being inspected. work which passes the workshop gauges will be
accepted by inspection gauges
iii. The tolerance on the workshop gauges is The tolerance on the inspection gauges is
arranged to fall inside the work tolerance. arranged to fall outside the work tolerance zone.
iv. Some of the components which are in work Some components which are not in work
tolerance limits may be rejected under workshop tolerance may be accepted when tested by
gauges inspection gauges

Bably Das, Assistant Professor, Department of Mechanical Engineering, CUET

 DIFFERENCE BETWEEN GAUGES MEASURING INSTRUMENTS
Gauges Measuring instrument
1. Check the dimension a part whether is within a range or 1.It measures the actual dimension of a
not part
2 No adjustment is required while is use 2. Adjustment is required
3 Quick method 3 Time taking Method
4. These are specially meant 4. These are general purpose instruments
5. Less skill is required during use 5. Skill is required during use
Ex. Limit Gauges Ex. Micrometer, Varied calipers etc

GAUGE DESIGN
To a greater or lesser extent, every gauge is a copy of the part which mates with the part for which
the gauge is designed
If a gauge is designed as an exact copy of the opposed part in so far as the dimension to be checked
is concerned it is called a “Standard Gauge
In design of a gauge, simplicity should be the main aim as simple gauges can take measurements
continuously and accurately
TAYLOR’S PRINCIPLE:
According to Taylors Principle:
Go gauges should check all the possible elements of dimensions at a time (roundness, size,
location etc. ) and No Go gauge should check only one element of the dimension at a time.
Limit gauges are designed based on Taylor’s principle
According to Taylor, ‘Go’ and ‘No Go’ gauges should be designed to check maximum and
minimum material limits which are checked as below;
‘GO’ Limit. This designation is applied to that limit of the two limits of size which
corresponds to the maximum material limit considerations, i.e. upper limit of a shaft and lower
limit of a hole.
The GO gauges should be of full form, i.e. they should check shape as well as size.
No Go’ Limit:
This designation is applied to that limit of the two limits of size which corresponds to the
minimum material condition. i.e. the lower limit of a shaft and the upper limit of a hole.
‘No Go’ gauge should check only one part or feature of the component at a time, so that specific
discrepancies in shape or size can be detected. Thus a separate ‘No Go’ gauge is required for
each different individual dimension.

Furthermore the measuring surfaces of ‘GO’ gauges which constantly rub against the surfaces of
parts in inspection are consequently subjected to wear and lose their initial size. Thus due to
wear. the site of “GO” plug gauges is reduced while that of “GO” snap gauges is increased
Therefore a special allowance of metal is added in the direction opposite to the wear, For this

Bably Das, Assistant Professor, Department of Mechanical Engineering, CUET

reason GO plug gauges are made with two positive deviations & GO snap gauges with two
negative deviation form of the nominal size .

Work shop gauge:

1. Used by the operator during manufacture of a part in shop.
2. Usually have limits with in those of components being inspected.
3. The tolerance is arranged to fall inside the work tolerance.
4. Some of the components which are in work tolerance limit may be rejected under these
gauges.

Inspection Gauge:
1. Used by inspector for the final inspection.
2. These gauges are made slightly larger tolerance than the work shop gauges.
3. The tolerance on inspection gauges is arranged to fall outside the work tolerance.
4. Some rejected parts may be accepted.
IT of Inspection Gauge>Work tolerance>W/S Gauge Tolerance.

Gauge Tolerance/ Gauge Maker’s Tolerance/ Manufacturing Tolerance:

In actual practice Gauges can’t be manufactured to the exact size (Due to imperfection in the
process). Some allowance must be provided to the gauge maker known as gauge tolerance.
Gauge tolerance should be kept as small as possible but this will increase the cost of
manufacturing the gauges.
Gauge tolerance of limit gauges (GT)= 1 /10th of Work Tolerance (WT) Or Work shop Gauges
(GO, NOGO Gauges) (10%)
Gauge tolerance for Inspection gauges (GT) = 5% of WT (GO, NOGO Gauges)
Gauge tolerance for Master/Reference gauges (GT) = 10% of WT

Wear Allowance:
The measuring surfaces of GO gauges rub constantly against the surfaces of work piece during
checking. This results in wearing of measuring surfaces of gauges.
The size of GO plug gauges is reduced and that of Ring or Snap Gauges is increased.

Bably Das, Assistant Professor, Department of Mechanical Engineering, CUET