TOLERANCES ON PARTS

• It is difficult to manufacture any product or

component to its exact size.
• Tolerance on the parts is therefore the amount of
variation in size tolerated to cover reasonable
imperfections in workmanship and it varies with
different grades of work.
• Tolerance on a dimension can also be specified as
the difference between the maximum limit of size
and the minimum limit of size.
• It is equal to the algebraic difference between the
upper and lower deviations and has an absolute
value without sign.
• There are two basic ways of specifying the working tolerance:
(1) bilateral and
(2) unilateral, tolerances.
• Bilateral tolerances are used where the parts vary in both
directions from the desired or nominal size.
• Unilateral tolerances are used where it is important for the
dimension to vary in only one direction.
• Components produced will fall close to the desired dimension
but can vary in only one direction.
• An example is the drilled hole, as the drill is made close to the
normal hole size, it is seldom possible to drill a hole undersize.
• All drilled holes therefore should carry only a plus tolerance.
Since the tolerance is allowed on one side of the nominal size,
the system is said to be unilateral.
• Closer the tolerance higher is the cost of product.
 LIMITS AND FITS
Allowance
• In a specific type of fit, the difference between hole
size and shaft size is called allowance.
• Allowance is used to explain the difference between
clearance fit and interference fit.
• Positive allowance specifies the clearance fit whereas
negative allowance in a fit specifies the interference
or force fit.
• The relationship existing between two parts, shaft
and hole, which are to be assembled, with respect to
the difference in their sizes before assembly is called
a fit.
• Two parts can fit each other in three ways, viz.
1. Clearance fit
2. Interference fit
3. Transition fit.
 LIMITS AND FITS
Tolerances and Limits
• It is impossible to make anything to an exact size. When working
to a high degree of accuracy, the amount of error that can be
tolerated is stated by placing limits on the drawing.
• Consider a shaft that is to be turned to a diameter of 40 mm. This
is called the nominal diameter.
• The shaft will be satisfactory if its diameter lies between 40.00
+0.05 =40.05 mm and 40.00-0.05 =39.95 mm.
• The dimension 40.05 mm is called the upper limit and the
dimension 39.95 mm is called lower limit.
• The difference between the upper and lower limits is called the
TOLERANCE. Thus, in the case of the 40 mm shaft:
Tolerance =upper limit – lower limit
40.05 -39.95 =0.10 mm
 Tolerances dimensions.

• A tolerance dimension is bilateral [bi meaning

two] if the limits are given above and below
the nominal size, as the case with the above
40mm shaft.
• When the two limits are both above the
nominal size or both below the nominal size
the tolerances are said to be unilateral.
 Maximum and Minimum metal conditions

• The 40mm shaft has an upper limit of 40.05mm and a lower limit of 39.95mm.
• The shaft is said to have a maximum metal limit of 40.05 mm because at this
limit the shaft has the maximum possible amount of metal.
• The limit of 39.95 mm is called the minimum metal limit because at this limit
the shaft has the minimum possible amount of metal.
• Consider a hole with the following specifications; nominal diameter =40 m,
upper limit =40.05 mm, lower limit = 39.95 mm. In this case, when the hole is
at its upper limit the minimum amount of metal is left.
• The limit of 40.05 mm is therefore called the minimum metal limit. When the
hole is at its lower limit the maximum amount of metal is left and hence the
limit of 39.95 mm is called the maximum metal limit.
• To summarize;
 For a shaft: The maximum metal limit is the Upper limit
 The minimum metal limit is the Lower limit
 For a hole: The maximum metal limit is the Lower limit
 The minimum metal limit is the Upper limit
 Definitions
• Basic Hole System- A basic hole system is a
system of fits in which the design size of the
hole is the basic size and the allowance, if any
is applied to the shaft.
• Basic Shaft System- A basic shaft system is a
system of fits in which the design size of the
shaft is the basic size and the allowance, if any,
is applied to the hole
 Types of fits

• When a hole and shaft are fitted together the fit

may be clearance or interference.
• When the shaft is smaller than the hole a
clearance fit result.
• When the shaft is larger than the hole an
interference fit result.
• A clearance fit is obtained if the maximum metal
limit for the shaft is less than the maximum metal
limit for the hole.
• When the maximum metal limit on the shaft is less
than the maximum metal limit on the hole a
clearance fit result.
 Types of fits
• An interference fit is obtained if the minimum metal limit
for the hole is less than the minimum metal limit for the
shaft.
• It is possible to arrange the limits on the hole and the shaft
so that when they are fitted together, either a clearance fit
or an interference fit is obtained, according to the actual
sizes of the hole and shaft, such fits are called Transition fits.
• A Transition fit results when the limits on the hole and shaft
are so arranged that a clearance or interference fit occurs
according to the actual sizes of hole and shaft.
• The allowance is the difference between the maximum
metal limits on the hole and the shaft and it determines the
quality of the fit. The allowance gives the minimum amount
of clearance between the hole and the shaft or maximum
amount of interference.
 Types of fits

• When a hole and shaft are fitted together the fit

may be clearance or interference.
• When the shaft is smaller than the hole a
clearance fit result.
• When the shaft is larger than the hole an
interference fit result.
• A clearance fit is obtained if the maximum metal
limit for the shaft is less than the maximum metal
limit for the hole.
• When the maximum metal limit on the shaft is less
than the maximum metal limit on the hole a
clearance fit result.
 Types of fits
• An interference fit is obtained if the minimum metal limit
for the hole is less than the minimum metal limit for the
shaft.
• It is possible to arrange the limits on the hole and the shaft
so that when they are fitted together, either a clearance fit
or an interference fit is obtained, according to the actual
sizes of the hole and shaft, such fits are called Transition fits.
• A Transition fit results when the limits on the hole and shaft
are so arranged that a clearance or interference fit occurs
according to the actual sizes of hole and shaft.
• The allowance is the difference between the maximum
metal limits on the hole and the shaft and it determines the
quality of the fit. The allowance gives the minimum amount
of clearance between the hole and the shaft or maximum
amount of interference.
 Clearance Fit
• Clearance fit is one in which two assembled parts are
always free to move relative to each other in the assembly.
• In the clearance fit, the largest permitted shaft diameter is
smaller than the diameter of the smallest hole. The
difference between the size of hole and the size of shaft is
defined as clearance.
• Clearance fits have limits of size prescribed so that a
clearance always results in a positive allowance, or air space
is left between mating parts. The parts can be assembled by
hand.
• Clearance fit is of two kinds namely sliding and running fits.
Examples of clearance fit are door hinges, wheel and axle,
shaft and bearing, etc. used in the assembly of parts.
 Interference Fit
• In the interference fit, mating parts in sub assembly or
main assembly are joined tightly together and no relative
motion is possible.
• The minimum permitted diameter of the shaft is larger
than the maximum allowable diameter of the hole.
• In this case, the shaft and the hole member in any sub
assembly or main assembly is to be attached
permanently and used as a solid component but
according to the application of this combination, this type
of fit can be varied. Interference fit is used for permanent
or semi-permanent assembly of parts, which require
rigidity and alignment and no relative motion, such as
dowel pins and bearings in casting.
 Transition Fit
• In this type of fit, the diameter of the largest
allowable hole is greater than that of the smallest
shaft, but the smallest hole is smaller than the
largest shaft, so that small positive or negative
clearance between the shaft and hole member is
employable.
• Thus, transition fit has limits of size of hole and
shaft such that either a clearance or an interference
fit may result when two specific parts from the lot
are assembled.
• That is, sometimes shaft is slightly larger than the
hole and sometimes slightly smaller than the hole.
 Example 1
The limits shown on a drawing for the mating hole and shaft are;
 For the hole; 50.00 +0.46, -0.000 mm
 For the shaft ;50.00 -0.010, -0.028 mm
State the type of fit and find the allowance. What is the greatest
possible amount of clearance or interference?
• Maximum metal limit on the hole =50.00mm
• Maximum metal limit on the shaft =49.990mm
• Since the maximum metal limit on the shaft is less than the
maximum metal limit on the hole we have a clearance fit
• Allowance = 50.00 – 49.990 =0.010mm
• Minimum metal limit on the hole =50.046 mm
• Minimum metal limit on the shaft =49.972 mm
• Greatest possible clearance = 50.046 – 49.972
• =0.074 mm
 Example 2

The limit for a hole and shaft combination are;

• For the hole 80.00+0.035; +0.000mm
• For the shaft 80.00+0.093; +0.071mm
State the type of fit and the allowance
• Minimum metal limit for the shaft = 80.071mm
• Minimum metal limit for the hole =80.035mm
• Since the minimum metal limit for the hole is less
than that for shaft we have an Interference fit
• Maximum metal limit for the shaft =80.093mm
• Maximum metal limit for the hole = 80.000mm
• Allowance = 80.093 – 80.00 = 0.093mm
 Interchangeability
• Interchangeability occurs when one part can be substituted
for a similar part which has been made to the same drawing.
• Suppose we have 50 parts each with a hole and 50 shafts
which have to fit into these holes. If we have
interchangeability then can take any one of the 50 shafts
and fit it into any of the holes and be sure that we obtain
the kind of fit required .
• Hence, for the interchangeability of holes and shafts, we
need a system of limits and fits which gives standard values
for the limits on the hole and shaft so that any particular
type of fit can be obtained.
• If the system is to be really successful it must be provided
for all the possible types of fit needed by engineers. These
are as follows;
 Types of fit needed by engineers.
1. Running fit –This is a clearance fit and as we shall see
later on several grades of running fit may be obtained
which range from an easy fit to a very close fit.
2. Push fit – This is a transition fit. The mating part may be
pushed into the hole by using hand pressure only.
3. Drive fit – This is an interference fit. The shaft can be
fitted into the hole by using a mallet or similar tool. Drive
fits are used when it is necessary to remove the part for
repair or replacement.
4. Force fit –This is also an interference fit but heavy
pressure is needed to fit the shaft in the hole. A permanent
fit is obtained and force fits are used on mating parts which
are never likely to need separating
 The ISO system of limits and fits [BS 4500].
• The limits on a shaft may be specified by means of a deviation from the basic size and
tolerance.
• By varying the deviation different kinds of fit may be obtained.
• The ISO system provided 28 different deviations which allow for every conceivable
type of fit A.
• The deviations for the holes are denoted by the capital letters A ,B , C , CD , D , E ,
EF , FG , G , H , JS , J , K , M , N , P , R, S , T , U , V , X , Y , Z , ZA , ZB , ZC . Holes A to G
are larger than the basic size.
• The deviations on the shafts are denoted by the small letters a, b, c, d etc. Shafts a to
g are smaller than the basic size whilst shafts j to zc are larger than the basic size.
• The amount of tolerance needed depends upon the quality of the work required.
• Sand castings, for instance, will need very large tolerances whilst gauges need very
small tolerances.
• To cover the vast range of work needed in engineering the system uses eighteen
grades of tolerance numbered 01, 0, 1, 2, 3, 4, ….15, 16. The table below gives the
grade of tolerance used for various classes of work:
 Grade of Tolerance for Various Classes of Work

16 Sand casting, flame cutting

15 Stamping
14 Die casting
13 Press work
12 Light press work
11 Drilling, rough turning and boring
10 Milling, slotting and planning
9 Worn capstan horizontal and vertical boring
8 Centre lathe work, reaming and capstan work
7 High quality turning
6 Grinding
5 Ball bearings and fine grinding
4 Gauges
3 Good quality gauges, gap gauges
2 High quality gauges, plug gauges
1 Slip gauges