METROLOGY

Fits
Definition of fits:
Fits in metrology are the dimensional relation
between the mating parts which are known
as fits.
It indicates the degree of tightness or the
looseness of the mating parts.
 Types of Fits

Examples: Examples:
Examples:
•Piston and cylinder •Shaft key
•Bearing Bush assembly
•Valves •Coupling ring and recess
•Dowel pin in casting assembly
•Nut and bolts •Bearing assembly
•Permanent mounting of the wheel on
•Door hinge assembly •Gear – shaft assembly
a shaft
•Tool slide •Pulley assembly
•Permanent mounting of gear on a
•Tailstock slide of the lathe •Shaft – armature assembly
shaft.
•Plain or taper dowel in a machine
•Pulley mounting on a shaft
assembly
•Gear slip bushing
Types of Fits
 Fits
Clearance Fits: In this type of fit, the mating parts
are so selected that the clearance between them
always occur
Clearance Fits
 Fits
Interference Fits: In this type of fit, the mating
parts are so selected that the interference
between them always occur.
Interference Fits
 Fits
Transition Fits: Transition fits are a compromise
between clearance and interference fits..
Transition Fits
Fits
Q. The following limits are specified in a limit
system, to give a clearance fit between a hole and a
shaft:
Hole = mm and shaft = mm
Determine the following:
(a) Basic size
(b) Tolerances on shaft and hole
(c) Maximum and minimum clearances (IES)
Sol: Hole = 𝟎.𝟎𝟑
mm and shaft = 𝟎.𝟎𝟎𝟔
mm
𝟎.𝟎𝟎 𝟎.𝟎𝟐𝟎
Sol:
(a) Basic size for both shaft and hole = 25mm

(b) Determination of tolerance:

Tolerance on hole = ULH − LLH
= 25.03 − 25.00 = 0.03 mm
Tolerance on sha = ULS − LLS
= 24.994− 24.980 = 0.014 mm
(c ) Determination of clearances:
Maximum clearance = ULH − LLS
= 25.03 − 24.98 = 0.05 mm
Minimum clearance = LLH − ULS
= 25.00 − 24.994 = 0.006 mm
Q. The following limits are specified in a limit
system, to give a transition fit between a hole and a
shaft:
Hole = mm and shaft = mm
Determine the following:
(a) Basic size
(b) Tolerances on shaft and hole
(c) Maximum and minimum allowance
Sol.
Hole = mm and shaft = mm
 Hole Basis and Shaft Basis Systems
Hole Basis system: In this system, the size of the
hole is kept constant and the shaft size is varied
to give various types of fits
 Hole Basis and Shaft Basis Systems

Shaft Basis system: In this system, the size of

the shaft is kept constant and the hole size is
varied to give various types of fits
Q. The hole and shaft assembly of 30 mm nominal
size have tolerances specified as mm for
hole and mm for shaft.
Determine 1. Clearance
2. Allowance
3. Hole and shaft tolerances
4. Fundamental deviation
5. MML for shaft and hole
6. Type of fit.
Solution:
1. Maximum clearance = 0.09 mm Minimum
clearance = 0.04 mm
2. Allowance = Minimum clearance = 0.04 mm
3. Hole tolerances = 0.02 mm Shaft tolerances =
0.03 mm
4. Fundamental deviation of shaft = 0.04 mm
5. Maximum Material Limit for hole = 30.0 mm
Maximum Material Limit for shaft = 29.96 mm
6. Clearance fit.
Q. A hole and shaft have a basic size of 30 mm and
are to have a clearance fit with maximum clearance
of 0.04 mm and a minimum clearance of 0.02 mm.
The hole tolerance is to be 1.5 times the shaft
tolerance. Determine limits for both hole and shaft
using :
1. A hole basis system
2. A Shaft basis system. (IES)
Sol.
Hole basis system
X + 0.02 + 1.5X = 0.04
X = 0.008 mm
1.5 X = 0.012 mm
Hole Max = 30+0.012 = 30.012 mm
Min = 30+ 0.0 = 30.00 mm
Shaft Max = 30- 0.02 = 29.98 mm
Min = 30 – 0.028 = 29.972 mm
Shaft basis system
X + 0.02 + 1.5X = 0.04
X = 0.008 mm
1.5 X = 0.012 mm
Hole Max = 30.032 mm
Min = 30.02 mm
Shaft Max = 30.00 mm
Min = 29.992 mm
Q. A clearance fit has to be provided for a shaft
and bearing assembly having a diameter of 40
mm. Tolerances on hole and shaft are 0.006 and
0.004 mm, respectively. The tolerances are
disposed unilaterally. If an allowance of 0.002
mm is provided, find the limits of size for hole
and shaft when
(a) hole basis system and
(b) shaft basis system are used.
Sol.
(a) When hole basis system is used:
Hole size:
ULH = 40+0.006 = 40.006 mm
LLH = 40+ 0.00 = 40.000 mm

The allowance provided is +0.002 mm.

Therefore, ULS = 40 − Allowance

= 40.000 − 0.002 = 39.998 mm
LLS = ULS − Tolerance
= 39.998 − 0.004 = 39.994 mm
(b) When shaft basis system is used:

Shaft size:
ULS = 40.00 -0.00 = 40.00 mm
LLS = 40.000 − 0.004 = 39.996 mm

Allowance provided: +0.002 mm.

Therefore,
LLH = ULS + allowance
= 40.000 + 0.002 = 40.002 mm
HLH = 40.002 + 0.006 = 40.008 mm
SYSTEM OF LIMITS AND FITS
SYSTEM OF LIMITS AND FITS
SYSTEM OF LIMITS AND FITS
 SYSTEM OF LIMITS AND FITS

The ISO system of limits and fits comprises 18

grades of fundamental tolerances to indicate the
level of accuracy
Tolerance grades: IT01, IT0, and IT1 to IT16

The greater the number, the higher the tolerance

limit.
 Tolerance Grades and their Applications
The ISO and BIS system provides tolerance grades from
IT01, IT0, and IT1 to IT16 to realize the required accuracy
IT01–IT4 For production of gauges, plug gauges, and
measuring instruments
IT5–IT7 For fits in precision engineering applications such
as ball bearings, grinding, fine boring, high-quality
turning, and broaching
IT8–IT11 For general engineering, namely turning, boring,
milling, planning, rolling, extrusion, drilling, and
precision tube drawing
IT12–IT14 For sheet metal working or press working
IT15–IT16 For processes such as casting, stamping, rubber
moulding, general cutting work, and flame cutting
Tolerance values corresponding to grades IT5–IT16 are
determined using the standard tolerance unit (i, in μm),
which is a function of basic size.

i = 0.453 D + 0.001D microns

where, D (mm) is the geometric mean of the

lower and upper diameters of a particular
diameter step within which the chosen the
diameter D lies.
 i = 0.453 D + 0.001D microns
where D is the diameter

The various steps specified for the diameter steps are

as follows:
1–3, 3–6, 6–10, 10–18, 18–30, 30–50, 50–80, 80–120,
120–180, 180–250, 250–315, 315–400, 400–500

D is the geometric mean of the lower and upper

diameters of a particular diameter step within which
the given diameter D lies

D (in mm) = )
The standard tolerances corresponding to IT01, IT0,
and IT1 are calculated using the following formulae:
IT01: 0.3 + 0.008D
IT0: 0.5 + 0.012D
IT1: 0.8 + 0.020D

i i i i i i i i i i i
Designation of Hole and Shaft assembly

25 H7 d8
8 indicates
“IT8”
Basic size
d indicates
H indicates “shaft”
7 indicates
“Hole”
“IT7”
Q. Calculate the fundamental deviation and tolerance and hence
the limits of the size for the shaft and hole for the following fit 64
mm H8f7. The diameter steps are 50 mm and 80 mm. For shaft
designation f, upper deviation is assumed as - 5.5D0.41
Data : For Tolerance
H8 - 25 i
f7 - 16i
Sol. Solution IT 8

Since 64 falls between

diameter range of 50 to 80 so, IT 7
D = √(50 x 80) = 63.24 mm

Fundamental tolerance i = 0.45 ∛D + 0.001 D = 1.856 microns

We should note here that although input D is in mm but i is in microns.
IT 7 = 16 i = 29.69 microns = 0.0296 mm
IT 8 = 25 i = 46.4 microns = 0.046 mm

Fundamental deviation for 'f' type of shaft

• εf = -5.5D0.41 = -5.5(63.24)0.41
•
= -30.11 microns = -0.03 mm

Hole --> Max = 64.046 mm, Min = 64.00 mm

Shaft --> Max = 63.97 mm, Min = 63.941 mm
Allowance = 0.03 mm
Q. Calculate the tolerance, fundamental deviation and
limit of sizes for the shaft designated as 40 H8/f7. where
εf = -5.5D0.41
Design of Limit Gauges
 What are Gauges ?
 Gauges are the scale-less inspection tool used
to check the dimension of the parts.
 It doesn’t determine the actual size or
dimension of part.
 Used to check whether the inspected part
within the specified limit.
 Need for Limit Gauging
 No need of actual size of the part in mass
production
 Inspection to check whether part is within
prescribed limit.
 Speedy inspection with simple tool
 Reduction in production cost
 Classification of Gauges
1. Plain gauges
(a) According to their type:
(i) Standard gauges
(ii) Limit gauges
(b) According to their purpose:
(i) Workshop
(ii) Inspection
(iii) Reference, or master, or control gauges
(c) According to the form of the tested surface:
(i) Plug gauges for checking holes
(ii) Snap and ring gauges for checking shafts
 Classification of Gauges
(d) According to their design:
(i) Single- and double-limit gauges
(ii) Single- and double-ended gauges
(iii) Fixed and adjustable gauges
2. Adjustable-type gap gauges
3. Miscellaneous gauges
(a) Combined-limit gauges
(b) Taper gauges
(c) Position gauges
(d) Receiver gauges
 Gauge Materials
Consideration of selection of material
• Wear resistance
• Dimensional Stability stability and form
• Corrosion resistance
• Easily machinable to get required accuracy and
surface finish
• Low coefficient of expansion
 Gauge Materials
Materials
• High carbon steel
• Mild steel
• Case hardened steel
• Oil hardened steel
• Cast iron
• Glass and ceramic
• Invar
Go gauges and NoGo gauge
Taylor’s Principle for plan limit gauges

1. GO Gauge is designed to check the maximum metal

limit while NO-GO gauge should be designed to
check minimum metal limit.
2. GO gauges should check all related dimension
(roundness, size etc)
3. NO-Go gauge should check only one dimension of
the work piece at a time, for the minimum metal
conditions (indicating the presence of the least
amount of material permitted at a prescribed
surface) size
Taylor’s Principle for plan limit gauges

For Hole
Taylor’s Principle for plan limit gauges

For Shaft
Taylor’s Principle for plan limit gauges
Description of some commonly used gauges
1. Snap Gauges:
 A Snap gauge is used for the inspection of external
dimensions.
 It consist of a U-shaped frame having jaws equipped
with suitable gauging surfaces.
 A plan gauge has two parallel jaws or anvils which
are made to some standard size & cannot be
adjusted
 They may be either single-or double -ended
Snap Or Gap Gauge
 Description of some commonly used
gauges
Double Ended Snap Gauge:
 Description of some commonly used
gauges

Progressive Snap Gauge:

Adjustable-type Snap gauge

lec# 7 & 8
2. Plug Gauges:
 A plain plug gauge is an accurate cylinder used as
an internal gauge for size control of holes
 These gauges may be either single or double ended
Plug Gauge
 Plug Gauge
Single ended GO and NOT- GO Plug Gauges
 Plug Gauge
Double ended Plug Gauges:
Double ended plain gauges have “GO” and “NOT GO”
members assembled on opposite ends
 Plug Gauge
Progressive Plug Gauges:
Progressive gauges have both gauging sections
combined on one side
3. Ring Gauges:
 Used to gauge outside diameters
 Used in Pairs as “Go” & “Not Go”
4. Taper Gauges:
 Taper gauges are not dimensional gauges but
rather a means of checking in terms of degrees
 Their use is a matter more of fitting rather than
measuring
5. Thickness or Feeder Gauge:
 It consist of a number of thin blades & is used in
checking clearances & for gauging in narrow
places
Standard Gauges : These are made to the nominal size of the
parts to be tested.
Limit Gauges : These are „go‟ and „no go‟ gauges.
Plug Gauges : These are used for checking holes of many
different shapes and sizes.
Ring Gauges : External diameter measuring gauges.
Taper Gauges : Taper testing gauges.
Snap Gauges : These are used for checking shafts.
Thread Gauges : These are used for pitch diameter of the
thread.
Form Gauges : These are used to check the contour of a
profile.
Feller Gauges : For checking the clearance between the mating
surfaces.
 Gauges designation

Plug gauges
40 H7

Basic size 7 indicates

H indicates “IT7 Tolerance”
“Gauging a bore”
 Gauges designation
Ring gauges

40 f7
Basic size

f indicates
“Gauging a Shaft”
7 indicates
“IT7 Tolerance”
 Manufacturing Tolerance
• It is economically impractical to attempt to
make “Go” and “Not Go” gauges exactly to the
two limits of work tolerance.

• Limit gauges are made 10 times more accurate

than the tolerances they are going to control
 Wear Allowance
• The surface of “Go” gauge is constantly rub
against the surface of the part in inspection and
loose their initial size.

• The size of plug gauge is reduced but size of

snap gauge is increased.

• 10% wear allowance is provided only for the

“GO” gauge if working tolerance is greater than
0.09 mm.
 Disposition of tolerance and
Allowance
.
 Disposition of tolerance and
Allowance
.
Q. GO and NO GO plug gauges are to be designed for a
hole 𝟎.𝟎𝟓𝟎
𝟎.𝟎𝟏𝟎 .Gauge tolerance can be taken as 10%
the hole tolerance . Find the size of GO and NO GO
design of the plug gauge.

Sol:
Q. Design general type GO and NO GO gauges for
components having 25H8f9 fit. The basic size falls in the
diameter range of 18-30 mm. The fundamental deviation
for ‘f’ shaft = - 5.5D0.41 micron. Fundamental tolerance
unit, i = 0.453 D + 0.001D microns.
Tolerance value for IT8 - 25 i
Tolerance value for IT9 - 40i
 25H8f9 diameter range of 18-30 mm
Sol.
fundamental deviation for ‘f’ shaft = - 5.5D0.41 micron
i = 0.453 ∛D + 0.001D microns.
Tolerance value for IT8 - 25 i
Tolerance value for IT9 - 40i
Sol. Solution
IT 8
Since 25 falls between
diameter range of 18 to 30 so,
D = (10 x 30) = 23.23 mm IT 9

Fundamental tolerance unit, i = 0.45 D + 0.001 D = 1.30 microns

We should note here that although input D is in mm but i is in microns.
Tolerance of Hole
IT 8 = 25 i = 32.68 microns = 0.032 mm
Tolerance of plug gauge = 0.0032 mm (10% of work tolerance)
IT 9 = 40 i = 46.4 microns = 0.052 mm
Tolerance of ring gauge = 0.0052 mm (10% of work tolerance)

Fundamental deviation for 'f' type of shaft

• εf = -5.5D0.41 = -5.5(23.23)0.41
•
= -19.35microns = - 0.019 mm
 Max= 25.0032

GO
Min = 25.0
Plug
Max = 25.0352
NO GO
Min = 25.032
Max= 24.981

GO
Min = 24.9758
Ring
Max = 24.929
NO GO
Min = 24.9238
Q. Design the general type of GO and NOT GO gauges as
per the present British system for a 40 mm shaft and
hole pair designated as 40 H8/d9, given that

(a) i = 0.453 D + 0.001D microns, 40 mm lies in the

diameter range of 30–50 mm
(b) IT8 = 25i
(c) IT9 = 40i
(d) upper deviation of shaft = –16D0.44
(e) wear allowance assumed to be 10% of gauge
tolerance
Since 40 falls between
diameter range of 30 to 50 so,
D = (30 x 50) = 38.72 mm

Fundamental tolerance unit, i = 0.45 D + 0.001 D = 1.571 microns

We should note here that although input D is in mm but i is in
microns.
Tolerance of Hole
IT 8 = 25 i = 39.275 microns = 0.039 mm

IT 9 = 40 i = 62.84 microns = 0.063 mm

Fundamental deviation for 'f' type of shaft

εf = -16D0.44 = -16(38.7298)0.44

= -79.9576microns = - 0.080 mm
Assuming gauge tolerance to be 10% of work tolerance,
gauge tolerance for hole = 10% of 0.039 = 0.0039 mm

Wear allowance for hole = 10% of Gauge tolerance;

Therefore, wear allowance for hole = 10% of 0.0039 = 0.00039
mm
Similarly,
Gauge tolerance for shaft = 10% of 0.063 = 0.0063 mm
Wear allowance for shaft = 10% of 0.0063 = 0.00063 mm

For hole:
The limits of GO Plug gauge are as follows:
Low limit = Basic size + Wear allowance
Low limit = 40.00 + 0.00039 = 40.00039 mm
High limit = Basic size + (Wear allowance + Gauge tolerance)
High limit = 40.00 + (0.00039 + 0.0039) mm
= 40.00 + (0.00429) = 40.00429 mm

𝟎.𝟎𝟎𝟒𝟐𝟗
GO Plug gauge: 𝟎.𝟎𝟎𝟎𝟑𝟗
The limits of NOT GO Plug gauge are as follows:

Low limit = Basic size + Fundamental tolerance for hole

Low limit = 40.00 + 0.039= 40.039 mm

High limit = Basic size + (Fundamental tolerance for hole +

Gauge tolerance)
High limit = 40.00 + (0.039 + 0.0039) mm
= 40.00 + (0.0429) = 40.0429 mm

NOT GO Plug gauge: 𝟎.𝟎𝟒𝟐𝟗

𝟎.𝟎𝟑𝟗𝟎
For shaft:
The limits of GO snap gauge are as follows:

High limit = Basic size − (Fundamental devia on + Wear allowance)

High limit = 40.00 − (0.080 + 0.00063) mm
High limit = 40.00 − (0.08063) = 39.91937 mm

Low limit = Basic size − (Fundamental devia on + Wear allowance

+ Gauge tolerance)
Low limit = 40.00 − (0.080 + 0.00063 + 0.0063) mm
= 40.00 − (0.08693) = 39.91307 mm

GO Snap gauge: −0.08063

−0.08693
Limits of NOT GO snap gauge are as follows:

High limit = Basic size − (Fundamental devia on + Fundamental

tolerance)
High limit = 40.00 − (0.080 + 0.063) mm
High limit = 40.00 − (0.143) = 39.857 mm

Low limit = Basic size − (Fundamental devia on + Fundamental

tolerance + Gauge tolerance)
Low limit = 40.00 − (0.080 + 0.063 + 0.0063) mm
Low limit = 40.00 − (0.1493) = 39.8507 mm

NOT GO Snap gauge: −0.1430

−0.1493
The disposition of gauge tolerances and wear allowance for the GO and NOT
GO plug and snap gauge