LIMITS
FI1S AN) TOLERANCES
249
Classes With holes
Typeof of fit H6 H7 HA Remarhs
Medium drive fit with
easy disrnantling for
Shaft r *r5 ferrns parta amently
Light derive fit with
T eany diarnantling for
E
non-ferrous fit for
R
non-ferrous parts.
Heavy drive for frra
Shaft s *95 *s6 *87
arta, pernanert
R
8erni-perrnanent
asBernbled prese and
E for non-ferrous parta.
N Force fit on ferrOus
C Shaft t *t5 *t6 *7
parts for permanent
assembly.
Shaft u *u5 *u6 *u7 Heavy force it or
shrink fit.
Shaft u, Very large inter
1, y and ference fit. Not
recommended for
use.
Types of Assemblies
There are three ways by which the mating parts can be made to fit
together in the desired manner. These are :
(1) Trial and Error (2) Interchangeable Assembly
(3) Selective Assembly
(1)Trial and Error. When a small number of similar assemblies are
o be made by the same operator the necessary fit can be obtained by trial
and error. This technique simply requires one part to be made to its nominal
1Ze as açcurately as possible, the other part is then machined with a small
amount at a time by trial and error until they fit in the required manner.
This method may be used for "one off jobs", tool room work ete. where both
parts will be replaced at once.
2) Interchangeable Assembly. When alarge number of components
are to be produced then it will not be economical to produce both the mating
components by the 8ame operator. In addition to economy it is also essential
wproduce the components within the minimum possible time. This is only
possible by mass production system. In mass production system there is a
division of labour. The components are produced in one or more batches by
250
machines. METROLOGY
Under such conditions
different operators on different in order
to assemble the mating components with a desired fit, a strict
exercised andthe parts are manufactured with specified tolerancecontrol is
When a system of this kind is used any one component
imits.
random will assemble correctly with any other mating component that
selected at
selected at random, the system is called interchangeable
manufacture of components under such conditions is cailed
assembiy. tTheoo,
able manufacture. Production on an interchangeable basis results interchange-
in in-
ereased output with a corresponding reduction in manufacturing cost
Example : Suppose a clearance it is required between the
+0.04 mating
0.00 mm
parts with hole, specified as 25
-0.02
0.04 mm
and shaft 25
In this case the maximum permissible size of the hole will
= 25.04 mm and the minimum permissible ize 25.00 mm. The dime
sions of the number of holes produced will lie between these two limite
Similarly, the maximum permiss1ble shaft size 24.98 mm and the mini.
mum permissible size of shaf 24.96. The diumensions of all the shat
produced will lie between these two limuts Therefore,even if we select any
hole at random and similarly any shaft at randon with these permissible
tolerances they will assemble with each other and give the deaired
clearance fit.
Interchangeable assembly requir es precise machines or processes
whose process capability is equal to or less than the manufacturing
tolerance allowed for that part. Only then every component produced will
be within desired tolerance and capable cf nating with any other mating
component to give the required fit
Advantages of Interchangeability
1. The operator is not required to waste his skill in fitting the
mating components by trial and error and thus assembly time is
reduced considerably.
2. There is an increased output with reduced production cost.
3. There is a division of labour, the operator has to perform same
limited operations again and again thus he becomes specialized
in that particular work, which helps to improve quality and
reduce the time for operations.
4. It facilitates production of mating components at differett piaces
by ifferent operatars.
5. The replacemeat of worn-out or defective parts and repar
becomes very easy.
6. The cost of maintenance and shutdown period isalso reduced
minmum
LIMITS.
FITS AND TOLERANCES 251
(3 Sclcetive. Assembly. It is sometimds found that it is not economi-
calto manufacture parts to the requircd high degree of accuracy s0 as to
make them interchangeable. The consumer not only wants quality and
trrouble-free products but also he wants them at
precision
Oen special cases of accuracy and uniformity arise which economical prices.
might not be
by certainty at the fits given under fally
For example, if a part of its low limit is assembledinterchangeable
with the matingsystem.
satisfied
part at
limit, the ft so obtained may not fully satisfy the
higfhe assembly(Complete interchangeability in the functional require-
above cascs
beobtained I at some extra cost in inspection and material handling can
by using
selective assembly(whereby parts are manufactured to rather wider toler-
ances.
In selective assembly the components produced are classified
into
gTOups according to their sizes by automatic gauging This is done for both
mating parts, holes and shafts, and only matched groups of mating parts
bcsembled. It results in complete protection against defective assem
blies and reduces matching costs since the parts may be produced with
wider tolerances.
A practical example of this system is the assembly of pistons with
awlinder bores. Let the bore size be 50 mm and the clearance required for
the assembly is 0.12 mm on the diameter. Let the tolerarnce on bore and the
piston each = 0.044 mm. Then,
Dimension of bore diameter is 500.02 mm.
Dimension of piston shaft is 49.880.02 mm
By grading and marking the bores and the pistons they may be
selectively assembled to give the clearance of 0.12 mm as given below:
Cylinder bore 49.98 50.00 50.02
Piston 49.86 49.88 49.90
Gavgesand Gauge Design
(Manufactured parts must be checked to determinewhether they are
according to the specifications or not, and also to control their dimensions.
There are several methods available for the control of dimensions of the
manufactured parts. The dimensions of the component can be checked with
the various precision measuring instruments, which measure the actual
dimension of the part.The measured dimension is then comnpared with the
standard specified dimension todecide whether the components are accept
able or not.In mass production, where large number of similar components
are produced. to measure the dimensions of each part will be a time
Consuming and costly process. Therefore, in mass production instead of
measuring actual dimension of each part the conformance of the part with
toleranco specification can be checked by gauges.
Gauges are scaleless inspection tools at rigid design. which are used
0 eheck the dimensions of manufactured parts. They also check the form
252
of parts. They do not
METROLOoGY
and relative positions of the surfaces of part. detused
ermintoe
(measure) the actual size or
dimensions They are only
determine whether the inspected part
has been made within the
speciñed
limits. These gauges consist of two sizes corresponding to their maximum
limits plug gauges and for gauging
and minimum limitsFor gauging hole
shafts snap gauges are used.
(Gauges are easytoemploy and can be used in many cases by unskilled
operatorsTor checking the component with a gauge it is not necessary to
make anycalculations or to determine the actual dimension of the part, the
time involved for checkinginspection is thus considerably reduced Por
these reasons they find wide application in engineering particularly for
mass production)
Gauges differ from measuring instruments in the following respects :
i) No adjustment is required in their use
(ü) They are not general purpose instruments but are specially maA.
for some particular component, which is to be produced in suffi-
ciently large quantities.
(ii) They give quick results about the conformance or non-conßor.
mance of the part with the specified tolerances.
Plain Gauges
Plain gauges are used for checking plain, that is,unthreaded holes and
shafts. They are classified in the following ways
(1) According to their type:
(a) Standard gauges (6) Limit gauges
(2) According to purposes :
(a) Workshop gauge (b) Inspection gauge
(c) Reference or master gauge.
(3) According to the form of the tested surface
(a)Plug gauge (b) Snap, Gap or Ring gauge
(4) According totheir design:
(a) Single limit and double limit gauges,
(6) Single-ended and double-ended gauges
(c) Fixed and adjustable gauges.
Standard Gauges. If a gauge is made as an exact copy of the mating
part of the component to be checked, it is called as standard gauge Por
example, ifa bushing is to be made which is to mate with a shaft Shat s
the mat1ng part Then, the bushing is checked by a gauge which is acp
of the mating part in form of its surface and size. Astandard gauge anos
be used to check an interference it. It has limited applications
Limut Gauges. Limit gauges are very wadely used in industries As
therè are two pernissible limits of the dimension of a part, high and o
twogauges are needed to check each dimension of tbe part, one correspu
ing the low limit of size and other to the bigh limit of size of tha: c
These are known as GO andNO-GO gauges
MITS)FTS AND TOLERANCES
he. di•ferenc between tho size8 of these two
the workpiece. GO gauges check the gauges is equal to the
tolerance on
Maximum
(MML) and NO-GO gauge checks the Minimum Metal Metal In
Limit (LML). Limít
the
case of ahole, maximum metal limit iis when the hole is as srnall as possible,
that is, it is the low limit of size. In ca_e of hole, therefore, G0 gauge
to the low limit
of size, while NO-GOgauge
corresponds
corresponds
limit of'size(For ashaft, the maximum metal limit is when the shafttoishigh
on
the highlimit of size. Thus, in case of a shaft GO gauge corresponds to the
high limit of size and NO-GO gauge corresponds to the low limit size,
While checking, each of these two gauges is offered in turn to the work.
Apart is considered| to be good, if the GO gauge passes through or over the
work and NO-GO gauge fails to pass under the action of its own weight.
This indicates that the actual dimension of the part is within the specified
tolerance)If both the gauges fail to pass, it indicates that hole is under size
ar shalt is over sizeT both the gauges pass, it means that the hole is over
size or the shaft is under size.
deronce
Tolerance
NOT
GO
Go
(a)For Hole (b) For Shaft
Fig. 9.16. Limit Gauges
Limit Plug Gauges
Gauges used for checking the holes are called "Plug gauges". The GO'
plug gauge is the sizeof the low limit of the hole while NO-GO plug gauge
Is the size of the high limit of hole.
Types of Plug Gauges
1. Solid type. For sizes up to 10 mm. (Refer Fig. 9.17)
d I0 H7. +0.015
Fig. 9,17 S..liui tvne danbleudcd t:un plug tlge
