IPE 301 - Measurement and Instrumentation and

Control
Lecture Sheet-2
Prepared by
Imran Ahmed
Assistant Professor, Department of IPE
MIST, Dhaka, Bangladesh

Tolerance, Fits and Limits

1 Basic concept of Fits and Tolerance
Once the product design is made and specifications are fixed and part drawings are prepared,
all the requirements are built into the drawing of the various parts and it is supplied to the
manufacturing department. So in the drawing the sizes of various parts are mentioned. Now
we know that it is always very difficult to produce the parts to an exact size. So when we
try to produce the parts to exact size we have to use more precise manufacturing processes
like grinding process or lapping process or super finishing process. So thereby the cost of
the product will increase, so we should always see what is the functional aspect the product
and manufacturing aspect of the product and then we should fix - what is the allowable
deviation. So in order to produce the part more economically, some variation in dimension
is allowed, by the design engineer, which will satisfy the functional requirement. So the
tolerances on mating parts decides the type of fit. For example, the design engineer has
made some calculations and the design shows that the size of the shaft is 10 mm. Now we
know that it is very difficult to produce that shaft exactly to 10 mm. So he will allow some
variation in the dimension, then the shaft can vary within its size, say 0.1 mm. That means
the shaft can have the lower limit of 9.9 mm. and the upper limit can go up to 10.1 mm.
So these are limits of the work piece. If the work piece that is produced is having any size
between this 10.1 mm and 9.9 mm then it will be acceptable.

Now while specifying the tolerances, we should see what is the functional need of the work
piece. This is very important. For example say we have a hydraulic cylinder like this, where
in there is some pressurized fluid is there and it is acting some pressure. And now because
of this we get a force here which can be used to move some load. Now the design engineer
should see what is the functionality of this particular product and accordingly he should
decide about the tolerance on the shaft, as well as tolerance on the hole. If the clearance

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 Figure 1.1: Tolerance and fits.

Figure 1.2: Tolerance and fits.

between these two is more, then the fluid will leak and then the required amount of force
we may not get. If it is too tight, then the piston may get jammed in the cylinder, so such
suspects we should see before assigning the tolerance values. And then the tolerance that
is allowed will definitely affect the manufacturing processes and sequences. We can see this
picture this is the work piece tolerance. It will have some effects on manufacturing aspects,
it will affect the cost of the precision (production) and (if) tolerance is very very tight.

2 Interchangeability
Tolerance gives concept of interchangeability. The word can be split into 2 words inter and
changeability. This concept of interchangeability has given manufacturing industry a big
break through. Modern production technique require that a complete product be broken
into various component parts. So, that the production of each part becomes an independent
process leading to specialization . Product is made of number of parts. So, number of parts

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can be again classified into parts which are bought out and parts which are manufactured.
Bought out items means that we buy it from the market which can be used to produce a
product and certain parts are manufactured.

It is essential that the parts are manufactured in bulk to the desired accuracy and at the
same time adhere to the limits of accuracy specified. The manufacturing of a component
under such conditions is called as interchangeability or interchangeable manufacturing.

This gave a big revolution, when interchangeability of manufacturing is adopted, any one
component selected at random should assemble with another with any other arbitrary chosen
mating component. So, if we have a box of nut and we pick one nut randomly that is M 6
nut. Now if we pick a bolt from a a big box of 1000s bolt and that is M 6 then nut and bolt
should be assembled. So, that is the interchangeability in manufacturing.

By interchangeable assembly we means that identical components manufactured by differ-

ent operators can be assembled and replaced without any further modification during the
assembly stage. When components are produced in bulk unless they are interchangeable the
process of mass production is not fulfilled.

In order to achieve the interchangeability several standards need to be followed. Suppose if we

say interchangeability within Bangladesh then it is not accepted because how long can it be
only a Bangladeshi supplier. We have to get into the global market and whatever we produce
those should be matched with international standard. These certain standard need to be
followed based on the interchangeability concept and that can be categorized as universal
interchangeability and local interchangeability. Local interchangeability means when we talk
about only Bangladeshi market. But when we want to supply to other countries like USA,
Europe and China then we have to follow the standards based on universal interchangeability.
when the parts are to be manufactured at different locations are randomly chosen for assemble
then it is called as universal interchangeability. On the other hand, when the parts are
manufactured at the same manufacturing unit and are randomly drawn into the assembly
then it is called as local interchangeability. For example, MAN is an industry, Hyundai is an
industry, they can have their own standards and their standards meet out only within the
assembly.It cannot be generalized to other producer.

3 Selective Assembly Approach

Selective assembly is the cost effective, cost effective approach to reduce the overall variation
thus improving the quality of the assembly product. In this process components of the
mating pair are measured and grouped into several classes as they are manufacture. For
example in to produce a shaft with mentioning tolerance as 50.00+0.046 −0.025 mm which means
that the maximum size is 50.046 mm and minimum size is 49.975 mm. Therefore any shaft
manufactured in-between these limit is accepted. The final product is assembled by selecting
the component of each pair from appropriate classes to meet the required specification as
close as possible.

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4 Tolerance vs Manufacturing Cost
Figure 4.1 indicates the relation between manufacturing cost and tolerance. As the per-
missible tolerance goes on increasing, the manufacturing cost goes on decreasing since more
ease appears in manufacturing. Because As the permissible tolerance increases accuracy de-
creases. Similarly, As the permissible tolerance decreases, the manufacturing cost increases
since accuracy increases.
max

min

min Cost max

Figure 4.1: Manufacturing cost vs tolerance.

5 Reasons for Dimensional Variation

ideal conditions demand for parts without any kind of dimensional variation. But in actual
practice, we know that it is very impossible to get parts without dimensional variation due
to the following reasons.

1. Variations in the properties of the material being machined introduces dimensional

variation. For example the metallurgical property may vary from one place to another
place in the raw material.

2. Dimensional variation may occur due to inherent errors in instruments.

3. Dimensional variation may occur due to human errors during manufacturing process.

4. Deflection of the work piece also introduces inaccuracy in the work piece.

5. Dimensional variation may occur due to friction between different work pieces during
manufacturing process.

6. Dimensional variation may occur due to environmental effects such as temperature

change, moisture etc.

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6 Functional and Non-functional Dimension
Functional Dimension: Functional dimensions are those which have to be mated with
other components.

Non-functional Dimension: Non-functional dimensions are those which need not to be

mated with other components to a high degree of accuracy. this does not have any effect on
the performance of component or assembly.

Let consider the figure 6.1 where datum has not to be mated with other components. Hence
its dimension is non functional dimension (NF). On the other hand, the bore has to be mated
with shaft; hence its dimension is functional dimension (F).

Figure 6.1: Different type of dimensions.

7 Terminologies in Limits fits and Tolerances

The terminologies used in fits, limits and Tolerance are described below.
• Basic Size of Shaft and Basic hole: Basic size is the theoretical size from which
limits of size are derived by the application of allowances and tolerances. It is same
for both hole and shaft. This is the size which is obtained by calculation for strength
[? ] [? ]. If the strength and stiffness requirements need a 50 mm diameter shaft, then
50 mm is the basic shaft size. If it has to fit into a hole, then 50 mm is the basic size
of the hole [? ]. Basic size of machine parts are determined applying machine design
concept. For example if a shaft is required to work under 45 MPa torsional shear stress
then diameter of shaft is determined by following equation.
Mc
τ=
I
• Actual Size: Actual size is the size, when manufacturing the dimensions are obtained
only after completing the product. It may be per standard required dimensions or per

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 basic required dimensions. The size of the manufactured component is called actual
size.

• Zero line: Zero lines can be defined as the graphical representation of Zero in limits
and fits. The line of zero deviation represents the basic size.

• Limits of size: The term limits of size referred to the two extreme permissible sizes for
a dimension of a part, between which the actual size should lie. The largest permissible
size for a dimension is called upper or high or maximum limit, whereas the smallest
size is called lower or minimum limit.

• Maximum limit of size: The term maximum limit of size referred to the maximum
or greatest permissible size of a feature.

• Minimum limit of size: The term minimum limit of size referred to the minimum
or smallest permissible size of a feature.

Figure 7.1: Terminologies in fits, tolerances and limits [? ].

• Tolerance: The term tolerance refers to the difference between the upper (maximum)
limit and lower (minimum) limit of a dimension. In other words, tolerance is the
maximum permissible variation in a dimension. The tolerance may be of two types i.e.
unilateral or bilateral.

• Upper deviation: The algebraic difference between the maximum limit of size (of
either hole or shaft) and the corresponding basic size, like ES (for hole), es (for shaft)

• Lower Deviation: The algebraic difference between the minimum limit of size (of
either hole or shaft) and the corresponding basic size, like EI (for hole), ei (for shaft)

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• Fundamental Deviation: It is one of the two deviations (which is nearest to zero
line for either a hole or a shaft) which is chosen to define the position of the tolerance
zone [? ]. This is identical to the upper deviation for shafts and the lower deviation
for holes in a clearance fit.

Figure 7.2: Terminologies in fits, tolerances and limits [? ].

• Hole Designation: By upper case letters from A, B, . . . Z, Za, Zb, Zc (excluding I, L,

O, Q, W and adding Js, Za, Zb, Zc ) - 25 numbers (28 in ISO)

• Shaft Designation: By lower case letters from a, b, . . . z, za, zb, zc (excluding i, l, o, q, w

and adding js, za, zb, zc ) - 25 numbers

• Maximum Material Condition (MMC): Minimum diameter of a hole and maxi-

mum diameter of a shaft

• Least Material Condition (LMC): Maximum diameter of a hole and minimum

diameter of a shaft.

• 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. Allowance is also defined as the minimum clearance
or maximum interference between parts, or the tightest fit between two mating parts.
The loosest fit is the difference between the smallest shaft and the largest hole. The
tightest fit is the difference between the largest shaft and the smallest hole.

Allowance = Maximum Material Limits of hole − Maximum Material Limits of shaft

Allowance can be positive or negative. If allowance is positive then it means that

clearance fit. If allowance is negative then it means that interference fit. i

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 Figure 7.3: Allowance.

• Grade : It is the indication of tolerance magnitude. The lower the grade, the finer
the tolerance.

• International Tolerance Grade (IT): international tolerance grades are indicated

of the degree of accuracy of manufacturing to be used throughout the globe. Standard
tolerance grades are designated by letter IT followed by a number. For example IT 7.
Here 7 is the grade. And IT 7 are set of tolerances that varies according to basic size
and provide a uniform level of accuracy within grades.

• Tolerance class : It is designated by the letters representing the fundamental de-

viation followed by the number representing it is standard tolerance grade. When the
tolerance grade is associated with letter representing a fundamental deviation to form
a tolerance class, the letters IT are omitted and we directly write H8 and f 7.

• Tolerance symbols : These are used to specify the tolerance and fits for mating
components. For example 40 H8f 6 here 40 indicates the basic size, H indicates the
fundamental deviation of hole and f indicates the fundamental deviation of a shaft
and 8 and 6 are the international tolerance grades.

8 Systems of Tolerances
Before going to discuss about tolerance we will discuss about limits. There are two systems
of tolerances: one is called unilateral tolerance and the other one is called bilateral tolerance.
1. Unilateral Tolerance: In the case of unilateral tolerance, it is specified on one side
of the basic size. For example 25 + 0.02 mm, 25 + 0.01 mm.
−0.02
25+0.02 +0.02 +0.0
+0.01 , 25−0.01 , 25−0 , 25−0.02

the unilateral tolerance system has great advantages . It is easy and simple to deter-
mine the deviations and go gauge (A go/no-go gauge refers to an inspection tool used
to check a workpiece against its allowed tolerances via a go/no-go test) ends can be

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 max. size=24.99
max. size=25.02
Zero

min. size=24.98
min. size=25.01
line

Basic size

Basic size
+0.02
25+0.01
-0.02
25-0.01
min. size=25.00

max. size=25.02
Zero

min. size=24.98

max. size=25
line
Basic size

Basic size
+0.02 +0
25-0 25-0.02

Figure 8.1: Unilateral tolerance.

standardized as the holes of different tolerance grades have the same lower limit and
all the shafts have same upper limit. this type of tolerance greatly assist the operator
when machining of mating parts. The operator machines to the upper limit of the
shaft or lower limit of the hole knowing fully well that he still has some margin left for
machining before the parts get rejected.
2. Bilateral Tolerance: In this type of tolerance, tolerance is provided on both side of
the basic size as upper limit and lower limit. The deviation is allowed on both sides of
the basic size The expression of bilateral are following.
±0.02
25+0.02
−0.01 , 25

0.01 Zero 0.01

basic size=25
basic size=25

line 0.01
0.02

+0.01 + 0.01
25-0.02 25 -

Figure 8.2: Bilateral tolerance.

Another type of tolerance is compound tolerance. Compound tolerance is defined as

when the tolerance is determined by established tolerances on more than one dimension, it

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is known as compound tolerance.

For example, consider the figure 8.3 tolerance for the dimension R is determined by the
combined effects of tolerance on 40 mm dimension, on 60◦ ± 2◦ , and on 20 mm dimension.
The tolerance obtained for dimension R is known as compound tolerance. In practice,
compound tolerance should be avoided as far as possible.

Figure 8.3: Compound tolerance [? ].

Another type of tolerance is geometric tolerance. Geometric tolerance is defined as the

total amount that the dimension of a manufacture part can vary. The geometric tolerance
underlines the importance of shape of a feature and not the size. Geometric tolerance gener-
ally indicates the shape of component. For example figure 8.4 shows the geometric tolerance

Figure 8.4: Geometric tolerance [? ].

of a shaft by showing symbols of different shapes. Therefore The geometric dimensioning

and the tolerance is a method of defining part based on how they functions by using standard
symbols. The geometric tolerance can be further classified into 3 parts.
1. Form tolerances: They are a group of geometric tolerance applied to individual
features. They limit the amount of error in the shape of a feature and are independent
tolerances. Form tolerances talks about individual feature as such do not require
locating dimensions. These include straightness, circularity, flatness, and cylindricity.

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 2. Orientation tolerances: Orientation tolerances are a type of geometric tolerances
used to limit the direction or orientation of a feature in relation to other features.
These are related tolerances. Perpendicularity, parallelism, and angularity fall into
this category.
3. Positional tolerances: Positional tolerances are a group of geometric tolerances that
controls the extent of deviation of the location of a feature from its true position or
datum. This is a three-dimensional geometric tolerance comprising position, symmetry,
and concentricity.

8.1 Standards Related to Tolerances

Following standards are used in limits, fits and tolerance.
• American system ANSI B4.1.
• American system ANSI B4.2.
• ISO system of tolerances.
• American gauge design standard.
• Indian standard IS 919.

9 Maximum and Least (Minimum) Material Limits

(Conditions)
Maximum Material Limits (Conditions) (MMC) or Maximum Material Limit (MML) is the
condition of a feature which contains the maximum amount of material. Least (Minimum)
Material Conditions (LMC) or Least (Minimum) Material Limit (LML) is the condition of
a feature which contains the least amount of material.
Shaft
40 ± 0.1 mm
40.01 mm −→ Maximum Material Limit (MML)
39.90 mm −→ Least (Minimum) Material Limit (LML)
The maximum metal limit (MML) of the shaft will have a dimension of 40.05 mm because
at this higher limit, the shaft will have the maximum possible amount of metal. The shaft
will have the least possible amount of metal at a lower limit of 39.95 mm, and this limit of
the shaft is known as minimum or least metal limit (LML).
Hole
40 ± 0.1 mm
40.01 mm −→ Minimum Material Limit (MML)
39.90 mm −→ Least (Minimum) Material Limit (MML)

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 Figure 9.1: MML and LML.

The hole will have a maximum possible amount of metal at a lower limit of 44.95 mm and
the lower limit of the hole is designated as MML. For example, when a hole is drilled in a
component, minimum amount of material is removed at the lower limit size of the hole. This
lower limit of the hole is known as MML. The higher limit of the hole will be the LML. At a
high limit of 45.05 mm, the hole will have the least possible amount of metal. The maximum
and minimum metal conditions are shown in figure 9.1.

10 Definition of Fits
It is the relationship between two parts that are assembled resulting from the difference
between any two mating parts such as hole and shaft. It also refers to the mating of two
mechanical components manufacturer. All manufactured parts are very frequently required
to mate with one other. they may be designed to slide freely against one another ot may be
designed to bind together to form a single unit. The most common fit found in the machine
shop is that shaft in the hole.

10.1 Types of Fits

Fits are categorized into three types.

1. Clearance fits: The largest permissible diameter of the shaft is smaller than the
diameter of the smallest hole. This type of fit always provides clearance. Small clear-
ances are provided for a precise fit that can easily be assembled without the assistance
of tools. When relative motions are required, large clearances can be provided, for
example, a shaft rotating in a bush. In case of clearance fit, the difference between the
sizes is always positive [? ]. This is usually referred to as a ”sliding fit.” means the
hole size is bigger than the shaft size so that the shaft can freely move inside the hole.
The clearance fit is described in figure 10.1. For example,

(a) Maximum size of hole=50.1 mm; Maximum size of shaft= 49.85 mm.
(b) Minimum size of hole= 49.9 mm; Minimum size of shaft= 49.65 mm.

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 Figure 10.1: Clearance fit.

Now
Maximum clearance = Minimum size of hole − Maximum size of shaft
= (50.1 − 49.65) mm = 0.45 mm

Minimum clearance = Minimum size of hole − Maximum size of shaft

= (49.9 − 49.85) mm = 0.05 mm

2. Interference fits: These fits are used when it is desirable for the shaft to be securely
held within the hole. The minimum permissible diameter of the shaft exceeds the
maximum allowable diameter of the hole. This type of fit always provides interference.
Interference fit is a form of a tight fit. Tools are required for the precise assembly
of two parts with an interference fit. When two mating parts are assembled with an
interference fit, it will be an almost permanent assembly, that is, the parts will not
come apart or move during use. To assemble the parts with interference, heating or
cooling may be required. In an interference fit, the difference between the sizes is always
negative. Interference fits are used when accurate location is of utmost importance and
also where such location relative to another part is critical, for example, alignment of
dowel pins. The interference fit is illustrated in figure 10.2. For example,
(a) Maximum size of hole= 49.85 mm; Maximum size of shaft= 50.1 mm
(b) Minimum size of hole= 49.65 mm; Minimum size of shaft= 49.9 mm
Now
Maximum interference = Minimum size of hole − Maximum size of shaft
= (49.65 − 50.1) mm = −0.45 mm

Minimum interference = Maximum size of hole − Minimum size of shaft

= (49.85 − 49.9) mm = −0.05 mm

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 Figure 10.2: Interference fit.

3. Transition fits: A fit which may provide either a clearance or interference is called
a transition fit. Here, the tolerance zones of the hole and shaft overlap. This type
of fit lies between clearance and interference fit. These types include clearance or
interference fits designed for demountable unmovable couplings where precision of fits
of the coupled parts is the main requirement. The part must be fixed mechanically
to prevent one moving against the other during assembly [? ]. The diameter of the

Figure 10.3: Transition fit.

largest permissible hole is greater than the diameter of the smallest shaft and the
diameter of the smallest hole is smaller than the diameter of the largest shaft. In other
words, the combination of maximum diameter of the shaft and minimum diameter of
the hole results in an interference fit, while that of minimum diameter of the shaft
and maximum diameter of the hole yields a clearance fit. Since the tolerance zones
overlap, this type of fit may sometimes provide clearance and sometimes interference,

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 as depicted in figure 10.3. These fits are used when it is desirable that the shaft is to
be held securely, yet not so securely that it cannot be disassembled. This is also known
as a location fit.
Thus, in order to find out the type of fit, one needs to determine the following.
Maximum size of hole − Minimum size of shaft
Minimum size of hole − Maximum size of shaft
If both the differences are positive, the fit obtained is a clearance fit, and if negative, it is an
interference fit. If one difference is positive and the other is negative, then it is a transition fit.

The three basic types of fits, clearance, transition, and interference, can be further classified,
as shown in figure 10.4.

Figure 10.4: Detailed classification of fits.

11 Different Types of Fit System

There are two types of fit systems available. One is hole based system and another one is
shaft based system.
1. Hole based system: In hole based system, size of hole is kept constant and size of
shaft is varied to obtain different fits as shown in figure ??. In a hole based system the
fundamental deviation or lower deviation of the hole is zero, hence the lower limit of
the hole is the same as the basic size.
2. Shaft based system: In shaft based system, size of shaft is kept constant and size of
hole is varied to obtain different fits as shown in figure ??. In a shaft based system, the
fundamental deviation or upper deviation of the shaft is zero, hence the upper limit of
the shaft is the same as the basic size.

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 Figure 11.1: Fit system.

Problem-1: The limits shown on a drawing for the mating hole and shaft are given as

For the hole 50.00+0.046

−0.000 mm
−0.010
For the shaft 50.00−0.029 mm

Find the type of fit and allowance and also find the greatest possible amount of clearance or
interference. Solution: Given that
hole
min size=49..971
max size=50.046

shat
max size=49..99
basic size=50

+ 0.046 - 0.01
50 - 0.000 50 - 0.029

Figure 11.2: Problem.

Basic size = 50.00 mm

Maximum size of hole = 50.046 mm
Minimum size of hole or maximum metal limit of hole = 50.00 mm
Maximum size of shaft or maximum metal limit of shft = 49.99 mm
Minimum size of shaft = 49.971 mm

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Since minimum size of hole is greater than maximum size of shaft; hence this is clearance
fit.

Now allowance = maximum metal limit of hole- maximum metal limit of shaft
= 50.0 − 49.99 = 0.01 mm

Now

Greatest clearnce = maximum size of hole- minimum size of shaft

= 50.046 − 49.971 = 0.075 mm

Problem-2: The limits shown on a drawing for the mating hole and shaft are given as

For the hole 80.00+0.035

−0.000 mm
For the shaft 80.00+0.071
+0.093 mm

Find the type of fit and allowance and also find the greatest possible amount of clearance or
interference.
shaft

hole

max size=80.093
max. size=80.035

min. size=80.071
min. size=80

+ 0.035 +0.093
80 - 0.000 80 +0.071

Figure 11.3: Problem.

Solution: Given that

Basic size = 80.00 mm

Maximum size of hole or minimum metal limit for hole = 80.035 mm
Minimum size of hole = 80.00 mm
Maximum size of shaft or maximum metal limit of shft = 80.093 mm
Minimum size of shaft or minimum metal limit for shaft = 49.971 mm

Now allowance = maximum metal limit of hole- maximum metal limit of shaft
= 80.0 − 80.093 = −0.093 mm

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Since allowance is negative hence interference fit. The maximum amount of possible inter-
ference is 0.093 mm.

Problem-3: A shaft with 50 mm diameter is made to rotate inside a bush. The tolerance
is for both shaft and bush are 0.050 mm. Determine the dimension of the shaft and bush to
give an allowance of 0.075 mm with a hole basis system.

Solution: Since this is a hole based system; hence the lower deviation of hole is zero. Then

Basic size = 50.00 mm

Minimum size of hole = 50.00 mm
Maximum size of hole or minimum metal limit for hole = 50.050 mm

We know that

Allowance = Maximum Material Limits of hole − Maximum Material Limits of shaft

Therefore
0.075 mm = 50.00 mm − Maximum Material Limits of shaft
Maximum Material Limits of shaft = 50.00 mm − 0.075 mm
Maximum size of shaft = 49.925 mm
Now
Minimum size of shaft = Maximum size of shaft − Tolerance
Minimum size of shaft = 49.925 mm − 0.050 mm = 49.875 mm
Problem-4: The diemension of the hole and shaft are given below.
hole
allowance= 0.075 mm

shat
max size=50.05

0.05 mm
max size=49.925
min size=50

min size=49.875

Figure 11.4: Size of bush and shaft for 0.075 mm allowance.

Maximum Material limits for the shaft is = 100.026 mm

Maximum Material limits for the hole is = 100.000 mm
Minimum Material limits for the shaft is = 100.003 mm
Minimum Material limits for the hole is = 100.036 mm

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Determine the type of fit and allowance.
Solution: Given that

Maximum Material limits for the shaft is = 100.026 mm

Maximum Material limits for the hole is = 100.000 mm

If shaft and hole are made to maximum material limit then interference fit. Again

Minimum Material limits for the shaft is = 100.003 mm

Minimum Material limits for the hole is = 100.036 mm

If shaft and hole are made to minimum material limit then clearance fit.

Allowance =Maximum Material limits for the hole

− Maximum Material limits for the shaft
= (100.000 − 100.026) mm = −0.026 mm

11.1 Expression of Systems of Limits and Fits

The rapid growing of national and international trade necessitates the development of a
formal system of limits and fits at the national and international level. Parts and products
sub-assemblies are moving from one country to another country and assembly happens at
some different country. So, if that is the case then we need standard expression of limits
and fits system. In these perspective, the international organization of standardization (ISO)
specifies the internationally accepted system of limits and fits [? ] by providing the deviations
and fundamental tolerances. The limits of tolerance for holes or shafts are designated by the
appropriate letter indicating the fundamental deviation. And Tolerance grade is dominated
by followed by a suffix number. For example, if the hole deviation ”H” and tolerance grade
IT7,; designation would be H7, if Shaft deviation ”k” and tolerance grade IT6; designation
would be k6.If the basic size 50 mm, tolerance designation would be 50H7 and 50k6 [? ].
• The ISO system of limits and fits comprises 18 grades of fundamental tolerance to
indicate the level of accuracy of the manufacturer. The ISO system provides toler-
ance created from International Tolerance (IT). IT tolerance International Tolerance
of IT 01, IT 0 and IT 1 to IT 16 to realize that required accuracy. IT grades indicate
the limits and tolerance of parts. Instead of writing limit (+0.05, −0.04) to define
the tolerance, IT grades are used. The tolerance for different IT grades can be be
determined from the following table. The table is for both hole and shaft.
• The tolerance value corresponding to the grade IT 5 to IT 16 are determined using a
standard tolerance unit i ( which is expressed in µm), which is function of basic size.
The empirical equation of i is
√
3
i = 0.453 D + 0.001Dµm
Where D is the diameter of the part in millimeters and 0.001D is linear factor which
counteracts the effect of inaccuracy in measurements. By using the above formula for

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 Tolerance grades Basic size: 0-500 Basic size: 501-3150
IT1 2I
IT2 2.7I
IT3 3.7I
IT4 5I
IT5 7i 7I
IT6 10i 10I
IT7 16i 16I
IT8 25i 25I
IT9 40i 40I
IT10 64i 64I
IT11 100i 100I
IT12 160i 160I
IT13 250i 250I
IT14 400i 400I
IT15 640i 640I
IT16 1000i 1000I
IT17 1600i 1600I
IT18 2500i 2500I

grades IT 5 to IT 16, the value of tolerance unit ‘i’ is obtained for basic sizes up to
500 mm.

• When the size of the components to be manufactured exceeds 500 mm, the tolerance
grades IT01–IT4 are not provided, as they are considered to be too small. The funda-
mental tolerance unit I in case of sizes exceeding 500 and up to 3150 mm is determined
as follows: where

I = 0.004D + 2.1

• D is the geometric mean of lower and upper diameter of a particular diameter step
within which the given or the chosen D lies and is calculated by using the formula
Dmax × Dmin by root.
p
Dmax × Dmin

• The various steps specified for the diameter 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, 500 − 630, 630 − 800, and 800 − 1000 mm.

• The tolerance have a parabolic relationship with a size of a product. The tolerance
within which a part can be manufactured also increases as the size increases.

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• The standard tolerance corresponding to IT 01, IT 0 and IT 1 are calculated using the
formula.
IT 01 : 0.3 + 0.008D
IT 0 : 0.5 + 0.012D
IT 1 : 0.8 + 0.020D

• After getting tolerance by using IT grades, we need deviation of tolerance zone from
basic of size or zero line to define the fit system completely. The tolerance zone is
governed by two limits: the size of the component and its position related to the basic
size. The position of the tolerance zone, from the zero line (basic size), is determined
by fundamental deviation.
• The ISO system defining 28 classes of basic deviation for hole base system and for shaft
base system as shown in which are marked by capital letter A, B, C to Z (with the
exception of I, L, O, Q and W) are the smallest letter a, b, c to z c (with the exception
of i, l, o, q) respectively as shown figure 11.5. The upper thick black line indicates the

Figure 11.5: Hole and shaft designations and fundamental deviation diagram.

basic size for the hole and the lower thick black line indicates the basic size for the
shaft and the y axis is fundamental deviation in microns. Now consider the particular
position where hole is designated by H where the upper deviation of the hole is zero
so this is taken as the basic hole. Similarly at the same point on the lower thick black
line, the shaft is designated by h where the lower deviation of the shaft is zero so this
is taken as the basic shaft. When we have to choose a clearance fit or an interference
fit or a transition fit, we first choose the hole and then corresponding shaft.

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• The first eight designations from A (a) to H (h) for holes (shafts) are intended to be
used in clearance fit, whereas the remaining designations, JS (js) to ZC (zc) for holes
(shafts), are used in interference or transition fits.

• Depending on the application, numerous fits ranging from extreme clearance to extreme
interference can be selected using a suitable combination of fundamental deviations and
fundamental tolerances. From figure 11.5, it can be seen that the lower deviation for
the holes ‘A’ to ‘G’ is above the zero line and that for ‘K’ to ‘ZC’ is below the zero
line. In addition, it can be observed that for shafts ‘a’ to ‘g’, the upper deviation falls
below the zero line, and for ‘k’ to ‘zc’ it is above the zero line.

• The Upper and Lower deviations for Shaft are donated by ”es” and ”ei”. The Upper
and Lower deviations for Hole are donated by ”ES” and ”EI”. It can be seen from figure
11.5 that ‘EI’ is above the zero line for holes ‘A’ to ‘G’, indicating positive fundamental
deviation. In contrast, figure 11.5 shows that ‘ei’ is below the zero line for the shafts
‘a’ to ‘g’ and therefore the fundamental deviation is negative. In addition, from Figs
3.17 and 3.18, it can be observed that for holes ‘K’ to ‘ZC’, the fundamental deviation
is negative (‘EI’ below the zero line), whereas for shafts ‘k’ to ‘zc’, it is positive (‘ei’
above the zero line).

• It follows from that the values of ‘ES’ and ‘EI’ for the holes and ‘es’ and ‘ei’ for
the shafts can be determined by adding and subtracting the fundamental tolerances,
respectively as follows.

1. For holes A to G, EI is a positive fundamental deviation and EI = ES − IT.

2. For holes K to Zi, the fundamental deviation ES is negative and ES = EI − IT.
3. For shafts ‘a’ to ‘g’, the fundamental deviation es is negative and es = ei − IT.
4. For shafts ‘k’ to ‘Zi’, the fundamental deviation ei is positive, and ei = es − IT.

• Magnitude and sign of fundamental deviations for the shafts, either upper deviation
‘es’ or lower deviation ‘ei’ for each symbol, can be determined from the empirical
relationships listed in the table shown in figure 11.6. Hole limits are identical with the
shaft limits of the same symbol (letter and grade) but disposed on the other side of
the zero line EI = upper deviation es of shaft of the same letter symbol but of opposite
sign.

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 Figure 11.6: Fundamental deviation formula for shafts of sizes up to 500 mm.

• When the size of the components to be manufactured exceeds 500 mm, the fundamental
deviations for holes and shafts are given in figure 11.7.

11.2 Selection of Engineering Fits

When two parts are going to be assembled then the difference or relationship between their
sizes before assembly is always a matter of concern. That relationship is called engineering
fit. We have already discussed the fundamental deviation diagram for hole and shaft where
capital letter indicates the deviation of hole and small letter indicates the deviation of shaft.
The thickness of box is defined as tolerance and the difference between zero lie and lower line

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Figure 11.7: Fundamental deviation for shafts and holes of sizes from above 500 to 3150 mm.

of tolerance box is called lower deviation and the difference between zero lie and upper line
of tolerance box is called upper deviation . The lower deviation is named as fundamental
deviation. Now let do an example to understand the deviation diagram, IT grade, tolerance
class and tolerance symbols.

25H7g6
Now since capital letter means hole and small letter means shaft. Symbol H indicates that
it is hole based system since there is no lower deviation for hole. The 25 indicates basic size
of hole and shaft. The numerical values followed by letters are called IT grade. The basic
size and IT grade in combination is going to give the tolerance. The figure 11.9 shows the
meaning of the different parts of 25H7g6.
Now for IT grade IT 7, tolerance factor is 16i. Now 25 is in-between 18 and 30; hence

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 A hole tolerance

D upper deviation hole

lower or fundamental
deviation hole G
H
J
S
U
Z
u z
s
d
lower or fundamental
h
deviation shaft g
d upper deviation shaft

a shaft tolerance

Figure 11.8: Hole and shaft designations and fundamental deviation diagram.

25 H7g6

Basic size Hole Hole IT Shaft Shaft IT

fundamental grade fundamental grade
deviation deviation
Figure 11.9: 25H7g6.

Dmax = 30 mm
Dmin = 18 mm

Now let calculate for hole: √

D= 30 × 18 = 23.24 mm
Then √
3
i = 0.45 23.24 + 0.001 × 23.24 = 1.307 µm
Then total IT grade

IT 7 = 16 × 1.307 = 20.92 µm = 0.021 mm

Now tolerance for hole is 0.021 mm. We can also find the tolerance form IT grade table for
shaft as shown in figure 11.10. Basic size 25 mm is in-between 18 − 30 and corresponding
tolerance for IT grade 6 is 0.021 mm which is similar as we have calculated.

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 Figure 11.10: IT grade for shaft: ISO part 919 or part 286.

Since hole is designated by H; hence fundamental deviation of hole is zero. Then

Lower limit = Basic size + Fundamental deviation

LT = 25 + 0 = 25 mm

And

Upper limit = Basic size + Fundamental deviation + Tolerance

U L = 25 + 0 + 0.021 = 25.021 mm

Now let calculate for shaft: √

D= 30 × 18 = 23.24 mm
Then √
3
i = 0.45 23.24 + 0.001 × 23.24 = 1.307 µm
Then total IT grade

IT 6 = 10 × 1.307 = 13.07 µm = 0.0131 mm

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This tolerance for shaft can also be found from IT grade chart. Now let find out the funda-
mental deviation of shaft from chart. Grom figure 11.6 we get that fundamental deviation
for g is

FD = −2.5D0.34 = −2.5(23.24)0.34 = 7.286 µm = −0.007286 mm

Then

Upper limit = Basic size − Fundamental deviation

U T = 25 − 0.007286 = 24.992714 mm = 24.993 mm

And

Lower limit = Basic size − Fundamental deviation − Tolerance

LT = 25 − 0.007 − 0.0131 = 24.98 mm

UT=0.021 mm

IT7 H tolerance=0.021 mm
25
LT=00 mm
FD

UT=-0.007 mm
IT6 g tolerance
LT=-0.20 mm

Figure 11.11: 25H7g6.

11.3 Clearance Fit

Let consider figure 11.12 for details of clearance fit. The figure shows a hole with the
minimum size the maximum size of the hole and algebraic difference between these two
gives the tolerance for the hole. That means the hole size can be anywhere between the
minimum hole and maximum. Similarly we have a shaft with the maximum size and the
minimum size. Now when the shaft size is maximum and the hole size is minimum then
algebraic difference gives the minimum clearance. And when the shaft size is minimum and
the hole size is maximum then the algebraic difference gives the maximum clearance. The
application of clearance fit is shown in figure 11.12 where a shaft has to rotate inside a hole
on bush bearing. there are different grades of clearance fits as per the American standard
b4.1. Clearance fit has following types.

1. Loose Fit: It is used between those mating parts where no precision is required. It
provides minimum allowance and is used on loose pulleys, agricultural machinery etc.

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 Figure 11.12: Clarence fit.

2. Running Fit: For a running fit,the dimension of shaft should be smaller enough to
maintain a film of oil for lubrication. It is used in bearing pair etc.
3. Slide Fit or Medium Fit: It is used on those mating parts where great precision is
required. It provides medium allowance and is used in tool slides, slide valve, automo-
bile parts, etc.

11.4 Interference Fit

This type of interference is used when the minimum permitted diameter of the shaft is larger
than the maximum diameter of the hole. Let consider a bearing housing where any relative

Figure 11.13: Interference fit.

motion between bearing and housing is not allowed. In such a case, interference fit is used.
The diameter of bearing is larger than diameter of housing. Interference fit has following
types
1. Shrink Fit or Heavy Force Fit: It refers to maximum negative allowance. In
assembly of the hole and the shaft, the hole is expanded by heating and then rapidly
cooled in its position. It is used in fitting of rims etc.

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 2. Medium Force Fit: These fits have medium negative allowance. Considerable pres-
sure is required to assemble the hole and the shaft. It is used in car wheels, armature
of dynamos etc.

3. Tight Fit or Force Fit: One part can be assembled into the other with a hand
hammer or by light pressure. A slight negative allowance exists between two mating
parts (more than wringing fit). It gives a semi-permanent fit and is used on a keyed
pulley and shaft, rocker arm, etc.

11.5 Transition 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 that means in this case the tolerance zone of the
shaft and the tolerance zone for the hole overlap each other completely or partly as shown in
figure 11.14. They are used for applications where accurate location is important but either

Figure 11.14: Transition fit.

a small amount of clearance or interference is permissible. Transition fit has following types.

1. Push Fit or Snug Fit: It refers to zero allowance and a light pressure is required in
assembling the hole and the shaft. The moving parts show least vibration with this
type of fit.

2. Force Fit or Shrink Fit: A force fit is used when the two mating parts are to be
rigidly fixed so that one cannot move without the other. It either requires high pressure
to force the shaft into the hole or the hole to be expanded by heating. It is used in
railway wheels, etc.

3. Wringing Fit: A slight negative allowance exists between two mating parts in wring-
ing fit. It requires pressure to force the shaft into the hole and gives a light assembly.
It is used in fixing keys, pins, etc.

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12 Steps in Assessment of Limits and Fits
In assessments of limits and fits, following steps are conducted.

1. To identify the functional needs of limits and fits: At first , we have to identify
the applications of parts to be used so that we can determine the types of fits and
limits are required.

2. To select the type of hole and shaft: After selecting, type of fits and clearance
then we need to select the type of hole such as B hole, C hole, G hole etc and the type
of shaft such as m hole, l hole, g hole.

3. To select the grade of clearance for hole and shaft: Then clearance grades have
to be selected for hole and shaft.

4. To calculate the standard tolerance for hole and shaft combination: Then
we have to calculate the standard tolerance for hole and shaft combination.

5. To calculate the limits on hole and shaft: After finding out clearance grades and
standards limits for hole and shaft then we have to calculate the upper limits and lower
limits of hole and shaft.

6. To calculate the amount of clearance or interference:

After finding out all of these numerical values we have to prepare the drawing of parts.

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