Fits and Tolerances
Lecture-01 (part-1)
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CHAPTER ONE : Fits and Tolerances
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CHAPTER ONE : Fits and Tolerances
Why tolerances and fits are required?
Due to the inevitable inaccuracy of manufacturing methods, a part
cannot be made precisely to a given dimension, the difference between
maximum and minimum limits of size of a part is the tolerance.
Tolerance is the total amount that a specific dimension is permitted to vary.
There is no such thing as an "exact size". Tolerance is key to
interchangeable parts.
When two parts are to be assembled, the relation resulting from the
difference between their sizes before assembly is called a fit.
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CHAPTER ONE : Fits and Tolerances
Examples of Interchangeable Manufacture
Bottle caps Rims Tires
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CHAPTER ONE : Fits and Tolerances
Advantages For Interchangeable Manufacture
Replacement: One such part can freely replace another, without
any custom fitting (such as filling).
Easy to Assembly: This interchangeability allows easy assembly of
new devices
Repairing: Easier repair of existing devices.
Minimizing time and cost: Minimizing both the time and skill
required of the person doing the assembly or repair.
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CHAPTER ONE : Fits and Tolerances
How to decide tolerance?
• Functional requirements of mating parts
• Cost of production
• Available manufacturing process
Choose as coarse tolerance as possible without compromising
functional requirements.
Proper balance between cost and quality of parts.
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CHAPTER ONE : Fits and Tolerances
Dimensional Tolerances
Some of the dimensional tolerances terms are defined as follows:
1. Dimension (A dimension is "a numerical value expressed in appropriate units of measure and indicated on a drawing and
in other documents along with lines, symbols, and notes to define the size or geometric characteristic, or both, of a part or part feature")
2. Size (It is a number expressed in a particular unit in the measurement of length)
3. Basic size (the theoretical size used as a starting point for the application of tolerances)
4. Actual size (of a part) (the measured size of the finished part after machining)
5. Design size (The ideal size for each component (shaft and hole) based upon a selected fit)
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CHAPTER ONE : Fits and Tolerances
6. Limits of size (the maximum and minimum sizes shown by the tolerance dimension)
7. Maximum limit of size (Is the maximum size permitted for the part)
8. Minimum limit of size (it is the minimum size permitted for the part limit of size)
9. Maximum material limit (condition) (is the condition of a part when it contains the most
amount of material. The MMC of an external feature (such as a shaft) is the upper limit. The MMC of an internal feature(such as a
hole) is the lower limit)
10. Minimum material limit (condition) (is the condition of a part when it contains the least
amount of material possible. The LMC of an external feature is the lower limit of the part. The LMC of an internal feature is the
upper limit of the part.)
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CHAPTER ONE : Fits and Tolerances
11. Tolerance (Tolerance is the difference between maximum limit of size and minimum limit of size)
12. Zero line (Basic size) (it represents the basic size)
13. Upper deviation (It is the algebraic difference between maximum limit of size and its corresponding basic size)
14. Lower deviation (It is the algebraic difference between minimum limit of size and its corresponding basic size)
15. Tolerance zone (a region representing the difference between the upper and the lower limits)
16. Unilateral tolerance (In this method of presenting the limits, variation is allowed only on one side of the zero line)
17. Bilateral tolerance (Here the limits variation is allowed on either sides of the zero line)
18. Shaft (it refers to any external feature of a part, including any non cylindrical features as well)
19. Hole (the term used for any internal feature of a part including any non cylindrical as well)
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Examples of holes and shafts
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Video link to understand tolerances:
https://www.youtube.com/watch?v=KiXHABfRHfQ
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Basic size
Tolerance
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Unilateral tolerance
Bilateral tolerance
Zero line
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CHAPTER ONE : Fits and Tolerances
20. Basic shaft (the shaft chosen as a basis for the shaft basis system of fit)
21. Basic hole (the hole chosen as a basis for the hole basis system of fit)
22. Fit (Fit is the relationship that exists between two mating parts, a hole and shaft with respect to their dimensional difference )
23. Basic size of a fit (common value of the basic size of the two parts of a fit)
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CHAPTER ONE : Fits and Tolerances
Clearance
24. Clearance fit fit
Hole Shaft
25. Interference fit Tolerance Zone of
Hole
Tolerance Zone of
Shaft
Shaft
Hole
26. Transition fit
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CHAPTER ONE : Fits and Tolerances
27. Minimum clearance
28. Maximum clearance
29. Minimum interference
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CHAPTER ONE : Fits and Tolerances
30. Maximum interference
An interference fit results in an interference between two
mating parts under all tolerance conditions.
A clearance fit results in a clearance between the two
mating parts under all tolerance conditions.
A transition fit results in either a clearance or an
interference condition between two assembled parts.
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31 - Basic Shaft System of fits
In this system the size of the shaft remains the same and the hole size is varied to
get the required fit. Maximum shaft size is taken as the basic size, an allowance is
assigned, and tolerances are applied on both sides of and away from this
allowance.
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32 - Basic Hole System of fits
In this system the size of the hole remains the same and shaft size is varied to get
the required fit. Minimum hole is taken as the basic size, an allowance is
assigned, and tolerances are applied on both sides of and away from this
allowance.
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Some definitions
Basic Size: is the size from which limits or deviations are assigned.
Basic sizes, usually diameters, should be selected from a table of
preferred sizes.
Deviation: is the difference between the basic size and the hole or
shaft size.
Upper Deviation: is the difference between the basic size and the
permitted maximum size of the part.
Lower Deviation: is the difference between the basic size and the
minimum permitted size of the part.
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Or Zero deviation line
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Some Definitions
Fundamental Deviation: is the deviation closest to the basic size. This
is identical to the upper deviation for shafts and the lower deviation
for holes in a clearance fit.
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Some Definitions
The hole-basis system of preferred fits is a system in which the basic
diameter is the minimum size of the hole. For the generally
preferred hole-basis system, the fundamental deviation is specified
by the upper-case letter.
The shaft-basis system of preferred fits is a system in which the basic
diameter is the maximum size of the shaft. The fundamental
deviation is given by the lowercase letter.
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CHAPTER ONE : Fits and Tolerances
1.2 Symbols for Tolerances and Deviation and Symbols for Fits:
1. Tolerance values (The tolerance value is a function of the basic size and is indicated by a number called the grade. )
2. Tolerance zone position
The position of the tolerance zone with respect to the zero line, is indicated by a letter symbol, a capital letter for holes and a small letter for shafts.
The tolerance size thus defined by its basic value followed by a symbol composed of a letter and a number. It is established by a
combination of the fundamental deviation indicated by a letter and the IT grade number. In the dimension 50H8, the H8 specifies the tolerance
zone.
Example for shaft: 45 g7
International Tolerance Grade (IT)
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CHAPTER ONE : Fits and Tolerances
1.2 Symbols for Tolerances and Deviation and Symbols for Fits:
3.A fit (A fit is indicated by the basic size common to both components, followed by symbol corresponding to each component, the
hole being quoted first)
Example: 50 H8 f7
Possibly 50 H8 – f7
Or 50 H8/f7
https://books.google.com.sa/books?id=2ck0AwAAQBAJ&pg=SA6-PA13&lpg=SA6-PA13&dq=fundamental+deviation+selection+fits+IT&source=bl&ots=ZO-
M0zNqbP&sig=ofRGWezbxKzJe9uW9zwxVZRZPdk&hl=en&sa=X&redir_esc=y#v=onepage&q=fundamental%20deviation%20selection%20fits%20IT&f=false
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CHAPTER ONE : Fits and Tolerances
1.3: Grades of tolerances:
Eighteen grades of tolerances are provided IT01, ITO and IT1 to IT16
The Table 1.1 gives the possible degrees of precision or grade of
tolerance, achieved with different machine tools.
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CHAPTER ONE : Fits and Tolerances
Table 1.1: degree of precision or grade of tolerance
Tolerance grade Intended for Applicable to components or machines
I T 01
IT0 Slip blocks, Reference gauges
IT1
Gauges
IT2
IT3 High quality gauges
IT4
IT5 Ball bearing
IT6 Grinding, Honing
IT7 Broaching
IT8 Fits Center lathe turning
IT9 Worn automatic lathe
I T 10 Milling
I T 11 Drilling, Rough turning
I T 12 Light press work
I T 13 Press work
I T 14 Not for fits Die casting
I T 15 Stamping
I T 16 Sand casting
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International Tolerance Grade Selection
Representation of Tolerance Tolerance Grade defines range of dimensions
2) Number or Grade (dimensional variation)
IT01, IT0, IT1,….IT16 There are manufacturing constraints on tolerance
grade chosen
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Position of the various tolerance zones for CHAPTER
a givenONE : Fits and Tolerances
diameter
in the ISO system
Shafts
Holes
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Position of the various tolerance zones for a given diameter in the ISO system
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Metric Preferred Hole Based System of fit
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Metric Preferred Shaft Based System of fit
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deviations for shafts
Table for fundamental
Adapted from: Metrology & Measurement By Bewoor
https://books.google.com.sa/books?id=2ck0AwAAQBAJ&pg=SA6-PA13&lpg=SA6-
PA13&dq=fundamental+deviation+selection+fits+IT&source=bl&ots=ZO-
M0zNqbP&sig=ofRGWezbxKzJe9uW9zwxVZRZPdk&hl=en&sa=X&redir_esc=y#v=onepage&q=fundamental%20devi
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deviations for shafts
Table for fundamental
Lower deviation ei
Adapted from: Metrology & Measurement By Bewoor
https://books.google.com.sa/books?id=2ck0AwAAQBAJ&pg=SA6-PA13&lpg=SA6-
PA13&dq=fundamental+deviation+selection+fits+IT&source=bl&ots=ZO-
M0zNqbP&sig=ofRGWezbxKzJe9uW9zwxVZRZPdk&hl=en&sa=X&redir_esc=y#v=onepage&q=fundamental%20devi
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deviations for holes
Table for fundamental
Adapted from: Metrology & Measurement By Bewoor
https://books.google.com.sa/books?id=2ck0AwAAQBAJ&pg=SA6-PA13&lpg=SA6-
PA13&dq=fundamental+deviation+selection+fits+IT&source=bl&ots=ZO-
M0zNqbP&sig=ofRGWezbxKzJe9uW9zwxVZRZPdk&hl=en&sa=X&redir_esc=y#v=onepage&q=fundamental%20devi
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ation%20selection%20fits%20IT&f=false
deviations for holes
Table for fundamental
Please note that all values in
this table are actually negative
Adapted from: Metrology & Measurement By Bewoor
https://books.google.com.sa/books?id=2ck0AwAAQBAJ&pg=SA6-PA13&lpg=SA6-
PA13&dq=fundamental+deviation+selection+fits+IT&source=bl&ots=ZO-
M0zNqbP&sig=ofRGWezbxKzJe9uW9zwxVZRZPdk&hl=en&sa=X&redir_esc=y#v=onepage&q=fundamental%20devi
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Example
Determine which type of fit is presented by H7/p6? For basic size of 30 mm determine the dimensions of
the hole and the shaft for the given fit. (Fit: 30 H7/p6)
Capital H means basic hole system and
Lower deviation = zero
INTERFERENCE FIT Φ30.035
H7 : Tol Grade 7 for basic size 30 mean 21μ
Φ30.022
variation Φ30.021
Φ30.000
p6 : Tol Grade 6 for basic size 30 means
13μ variation
(p means lower deviation is 22 μ)
Fit: 60 H8/e6
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Example
Creating a Clearance Fit using The Basic Hole System
Given the following fit Φ40 – H11/c11
From table for hole diameter = 40 and H11 we find
Upper deviation = +160 μm & Lower deviation = 0
From table for shaft diameter = 40 and c11 we find
Upper deviation = -120 μm & Lower deviation = -280 μm
Calculations of dimension limits for hole and shaft
- Maximum hole diameter = 40 + 0.16 = 40.16 mm
- Minimum hole diameter = 40 + 0 = 40 mm
- Maximum shaft diameter = 40 +(-120) = 39.88 mm
- Minimum shaft diameter = 40 + (-280) = 39.72 mm
Maximum clearance = Maximum hole diameter – Minimum shaft diameter
= 40.16 – 39.72 = 0.44 mm
Minimum clearance = Minimum hole diameter – Maximum shaft diameter
= 40 – 39.88 = 0.12 mm
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Allowances = minimum clearance = 0.12
Spring 2005 mm = 120 μm
Problems for fits and tolerances
Problem 1: For a given fit of 50 H7/g8, answer the following questions:
• Which fit system it represents?
• Draw sketches to show the fit.
• calculate the shaft and hole dimensions.
• What are the values of the maximum and minimum clearances, and
maximum and minimum interferences?
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Problems for fits and tolerances
Problem 2: For a given fit of 45 G7/h6, answer the following questions:
• Which fit system it represents?
• Draw sketches to show the fit.
• Calculate the shaft and hole dimensions.
• What are the values of the maximum and minimum clearances, and
maximum and minimum interferences?
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Problems for fits and tolerances
Problem 3: For a given fit of 30 H6/p7, answer the following questions:
• Which fit system it represents?
• Draw sketches to show the fit.
• Calculate the shaft and hole dimensions.
• What are the values of the maximum and minimum clearances, and
maximum and minimum interferences?
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Problems for fits and tolerances
Problem 4: For a given fit of 50 H8/f7, answer the following questions:
• Which fit system it represents?
• Draw sketches to show the fit.
• Calculate the shaft and hole dimensions.
• What are the values of the maximum and minimum clearances, and
maximum and minimum interferences?
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Problems for fits and tolerances
Problem 5: For a given fit of 50 F7/h8, answer the following questions:
• Which fit system it represents?
• Draw sketches to show the fit.
• Calculate the shaft and hole dimensions.
• What are the values of the maximum and minimum clearances, and
maximum and minimum interferences?
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