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LIMIT, FIT & TOLERANCE

Topic contents :
1. Introduction
2. Limits and their classification

3. Fits and their classification

4. Systems of Fits

5. Tolerance and their classification

KEY WORDS :
LIMIT

Permissible size

FIT

The degree of tightness or looseness between

two mating parts

Allowance

The amount of designed (intentional) deviation

between two mating dimensions in a fit, which, in
combination with their respective tolerances,
results into a maximum and minimum clearance
or interference

CLEARANCE

The positive difference between the sizes of the

hole and shaft before assembly

Interference

The negative difference between the sizes of the

hole and shaft before assembly

Transition

It is tolerance zone where the hole and shaft

overlap

Tolerance

The permissible variation in size or dimension

Introduction:
No feature of a component can be perfect (i.e., no
surface flat, no hole round etc), because of the
manufacturing process.
It is principally impossible to produce machine parts with
absolute dimensional accuracy.
It is quite sufficient that the actual dimension of the part
is found between two limit dimensions and a permissible
deviation is kept with production to ensure correct
functioning of engineering products.

Introduction:
It is necessary that the dimensions, shape and mutual
position of surfaces of individual parts of mechanical
engineering products are kept within a certain accuracy
to achieve their correct and reliable functioning.

Deviations of actual surfaces are divided into four groups

to enable assessment, prescription and checking of the
permitted inaccuracy during production:
1. Dimensional deviations
2. Shape deviations
3. Position deviations
4. Surface roughness deviations

Limits and their classification:

Fig. 1 : Graphical Illustration of Limits

Limits and their classification:

What is Limits ?
Actual machines size between the max. and min
limits.
Maximum limits :
Maximum permissible machine size corresponding to
basic size.
Example :
Fig. 1, 30 mm is = 30 + 0.035 = 30. 035 mm.

Basic size

Maximum limit

Limits and their classification:

Minimum limits :
Minimum allowable machine size corresponding to basic size.
Example :
In Fig. 1, 30 mm is = 30 - 0.215 = 29. 785 mm.

Basic size

Minimum limit

Fits and their classification:

What is Fits ?
When two parts are to be assembled, the relation
resulting from the difference between their sizes
before assembly is called a fit.
A fit may be defined as the degree of tightness and
looseness between two mating parts.
Example :
Width of the slot & the thickness of the key
Shaft & holes

Fits and their classification:

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The important terms related to the fit are given below :

Clearance
In a fit, this is the difference between the sizes of the hole
and the shaft, before assembly, when this difference is
positive.
The clearance may be maximum clearance and minimum
clearance.
Minimum clearance in the fit is the difference between the
maximum size of the shaft and the minimum size of the
hole.

Fits and their classification:

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The important terms related to the fit are given below :

Interference
It is the difference between the sizes of the hole and the
shaft before assembly, when the difference is negative.
The interference may be maximum or minimum.
Maximum interference is arithmetical difference between
the minimum size of the hole and the maximum size of the
shaft before assembly.
Minimum interference is the difference between the
maximum size of the hole and the minimum size of the
shaft.

Transition
It is between clearance and interference, where the
tolerance zones of the holes and shaft overlap.

Fits and their classification:

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Classifications / types of FITS :

(1) Clearance Fit
(2) Interference Fit
(3) Transition Fit
(1) Clearance Fit
Clearance exists between the mating parts e.g. between
the shaft and hole.
For Example : the largest shaft is always smaller
than the smallest hole (max. shaft < min hole).
A clearance fit has positive allowance, i.e. there is
minimum positive clearance between high limits of the
shaft and low limits of the hole.

Fits and their classification:

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(1) Clearance Fit

B
A

Min hole Max Shaft = + ve clearance fit.

Clearance Fit

Fits and their classification:

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(1) Clearance Fit

Exercise :

A spindle slide freely in a bush. The basic size of the fit is

50 mm. If the tolerance quoted are +0.062, 0 for holes and

-0.080, -0.180 for the shaft, find the upper limits and lower
limits and the minimum clearance.

Fits and their classification:

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(1) Clearance Fit

Answer :
The upper limit of the hole will be 50.062mm and lower

limits for the hole is the same as basic size of 50.00mm.

The shaft upper limit will be : 50.00-0.080= 49.92 mm

The shaft lower limits will be : 50.00-0.180 = 49.82mm.
The minimum clearance/ allowance is 50.00-49.92 =
0.08mm

Fits and their classification:

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(2) Interference Fit

Require the mating parts be pressed of forced together.
For example : the size of the shaft is bigger than size
of hole . (Min. shaft > Max. hole)
A negative difference between diameter of the hole and
the shaft is called interference.
In such cases, the diameter of the shaft is always larger
than the hole diameter.
Interference fit has a negative allowance, i.e.
interference exists between the high limit of hole and low
limit of the shaft.
In such a fit, the tolerance zone of the hole is always
below that of the shaft. The shaft is assembled by
pressure or heat expansion.

Fits and their classification:

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(1) Interference Fit

Max hole Min Shaft = - ve interferance fit

Interference Fit

Fits and their classification:

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(2) Interference Fit

Exercise :
A dowel pin is required to be inserted in a base. For this

application H 7 fit for hole and a P 6 fit for the shaft are
chosen. The tolerance quoted are +0.025, 0 for the hole and

+0.042, +0.026 for the shaft. Find the upper and lower limits
of the hole and also dowel pin, and the maximum
interference between dowel pin and the hole. The basic size
of the fit is 50.00mm

Fits and their classification:

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(2) Interference Fit

Answer :
The upper limit for the hole will be : 50.000 + 0.025=

50.025mm.
The lower limit for the hole will be : 50.000 + 0 = 50.000
mm
The upper limit for dowel pin will be : 50.000 + 0.042 =
50.042 mm.
The lower limit for dowel pin will be : 50.000 + 0.026 =
50.026mm.
The maximum interference between dowel pin and the
hole is : 50.042 50.000 = 0.042 mm.

Fits and their classification:

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(3) Transition Fit

It may result in either clearance fit or interference fit
depending on the actual value of the individual tolerances
of the mating components.
Transition fits are a compromise between clearance and
interference fits.
They are used for applications where accurate location is
important but either a small amount of clearance or
interference is permissible.
For example : the largest shaft is larger than the
largest hole but the smallest shaft may be fit into the
largest hole. (Hole min < Shaft min < Hole max < Shaft
max)

Fits and their classification:

(3) Transition Fit

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Fits and their classification:

(3) Transition Fit

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Fits and their classification:

LOOSE FIT

TRANSITION

TIGHTEST FIT

CLEARANCE FIT

TRANSITION FIT

INTEFERENCE FIT

SHAFT HOLE ALLOWANCE SHAFT HOLE ALLOWANCE SHAFT HOLE ALLOWANCE

Max allowance
= max hole min shaft = +ve

Max allowance
= max hole min shaft = +ve

Max allowance
= max hole min shaft = -ve

Min allowance
= min hole max shaft = +ve

Min allowance
= min hole max shaft = -ve

Min allowance
= min hole max shaft = -ve

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Systems of Fit:
A fit system is the systems of standard allowance to
suit specific range of basic size. If these standard
allowances are selected properly and assigned in
mating parts ensures specific classes of fit.
There are two systems of fit for obtaining clearance,
interference or transition fit. These are :
(i) Hole basis system
(ii) Shaft basis system

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Systems of Fit:
(i) Hole basis system
In the hole basis system, the size of the hole is kept
constant and shaft sizes are varied to obtain
various types of fits.
In this system, lower deviation of hole is zero, i.e.
the low limit of hole is same as basic size. The high
limit of the hole and the two limits of size for the shaft
are then varied to give desired type of fit.
The hole basis system is commonly used because it is
more convenient to make correct holes of fixed sizes,
since the standard drills, taps, reamers and branches
etc. are available for producing holes and their sizes
are not adjustable. On the other hand, size of the shaft
produced by turning, grinding, etc. can be very easily
varied.

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Systems of Fit:
(i) Hole basis system

Clearance Fit
B

Interference Fit
C

Hole Basis System

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Systems of Fit:
(i) Hole basis system

Hole Basis System

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Systems of Fit:
(i) Hole basis system
Grades of Holes

MANUFACTURING PROCESS USED

H5

Fine Boring, Fine Grinding, Honing

H6

Fine Boring, Honing, Hand Reaming

H7

Int. Grinding, Broaching, Reaming

H8

Boring, Machine Reaming

H9

Boring & Reaming

H10

Not for diameter fits; used for milled widths, drilled

holes

H11

Not used in fits; punching, coarse drilling drawn

recesses

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Systems of Fit:
Combination of
Hole and Shaft
H6 j5 fine
H7 j6 normal

Quality of Fit
Clearance
transition

Very small clearance is obtained - used for fits where a

slight interference is permissible - coupling spigots and
recesses, gear rings clamped to steel hubs.

True
transition

Fits averaging no clearance where slight interference can

be tolerated , with the object of eliminating vibration - ball
bearings races of light duty.

H8 j7 coarse
H6 k5 fine

H7 k6 normal
H8 k7 coarse
H6 m5 fine
H7 m6 normal

Typical uses

Interference
transition

Fits averaging slight interference - used for ball bearing

races of medium duty.

H8 m7 coarse
H6 p5 fine

Press fit

H7 p6 normal

H6 r5 fine

Drive fit

H7 r6 normal
H6 s5 fine

Drive fit

H7 s6 normal
H6 u5 fine
H7 u6 normal

Force or
shrink fit

Light press fit for nonferrous parts which can be dismantled

when required-bearing bushes-press fit for steel, cast iron
or brass to steel assemblies- bush in a gear.
Medium drive fit for ferrous parts and light drive fit for
non-ferrous parts that can be dismantled.
Permanent or semi permanent assemblies of steel and cast
iron with considerable gripping force- collars pressed on to
shafts, valve seatings etc. For light alloys this gives a press
fit.

High interference fit a thorough investigation into the

degree of grip and the stresses in the part must be made.

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Systems of Fit:
(ii)

Shaft basis system

In the shaft basis system, the size of the shaft is kept

constant and different fits are obtained by varying
the size of the hole. Shaft basis system is used when
the ground bars or drawn bars are readily available.
These bars do not require further machining and fits
are obtained by varying the sizes of the hole.
In this system, the upper deviation (fundamental
deviation) of shaft is zero, i.e. the high limit of the shaft
is same as basic size and the various fits are obtained
by varying the low limit of shaft and both the limits of
the hole.

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Systems of Fit:
(ii)

Shaft basis system

Shaft Basis System

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Systems of Fit:
To summarize:
Hole basis

The minimum hole size equals the basic hole size.

The allowance is applied to the shaft.
Uses the symbol H in the tolerance specification.
Shaft basis

The maximum shaft size equals the basic shaft size.

The allowance is applied to the hole.
Uses the symbol h in the tolerance specification.

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Systems of Fit:

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Tolerance and its Classification:

The permissible variation in size or dimension is
tolerance. Thus, the word tolerance indicates that a
worker is not expected to produce the part of the exact
size, but definite a small size error is permitted. The
difference between the upper limit (high limit) and the
lower limit of a dimension represents the margin for
variation to workmanship, and is called a tolerance
zone.
Tolerance can also be defined as the amount by which
the job is allowed to go away from accuracy and
perfectness without causing any functional trouble,
when assembled with its mating part and put into actual
service.

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Tolerance and its Classification:

Tolerance

There are two ways of writing tolerances

(a) Unilateral tolerance
(b) Bilateral tolerance.

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Tolerance and its Classification:

(a) Unilateral tolerance
Deviations are allowed in only one direction from
the basic size.
The deviation in the other direction is zero.

Hence, either the maximum limit or the minimum

limit will be equal to the basic size.

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Tolerance and its Classification:

(a) Unilateral tolerance

Unilateral tolerance

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Tolerance and its Classification:

(a) Unilateral tolerance
Unilateral system is preferred in interchangeable
manufacture, especially when precision fits are required,
because :
(a) it is easy and simple to determine deviations,
(b) another advantage of this system is that Go Gauge
ends can be standardized as the holes of different
tolerance grades have the same lower limit and all the
shafts have same upper limit, and
(c) this form of tolerance greatly assists the operator,
when machining of mating parts. The operator
machines to the upper limit of shaft (lower limit for hole)
knowing fully well that he still has some margin left for
machining before the parts are rejected.

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Tolerance and its Classification:

(b) Bilateral tolerance
Deviations are allowed in both the directions from
the basic size.
One of the limits

above the basic size.

Other limits

below the basic size.

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Tolerance and its Classification:

(b) Bilateral tolerance

Bilateral tolerance

In this system, it is not possible to retain the same fit when

tolerance is varied and the basic size of one or both of the
mating parts are to be varied. This system is used in mass
production when machine setting is done for the basic size.

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EXERCISE (1) :
A 50 mm diameter of shaft is made to rotate in the bush. The
tolerances for both shaft and bush are 0.050mm.
Determine the dimension of the shaft and bush to give
maximum clearance of 0.075mm within the hole basis
system.

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ANSWER:
In hole basis system,
Lower deviation of hole is zero,
Therefore low limit of hole = 50.00 mm
High limit of hole = low limit + tolerance
= 50.00 +0.050 = 50.050mm

Max clearance is 0.075mm, means that

max hole min shaft = 0.075 mm
so min shaft = 50.050-0.075 = 49.975mm
High limit of shaft = low limit of shaft + tolerance
= 49.975 + 0.050 = 50.025mm

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EXERCISE (2) :
In a hole and shaft assembly of 30mm nominal size, the
tolerance for hole and shaft are as below ;
Hole : 30 (+0.02, -0.00)mm
Shaft : 30 (-0.040, -0.070)mm

Determine :
1) Max and Min clearance obtained
2) Hole and shaft tolerance
3) The type if FIT.

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Answer (2) :
1) Max and Min clearance obtained
Maximum clearance = Max hole Min shaft
= 30.02-29.93 = 0.09mm
Minimum clearance = Min hole Max shaft
= 30.00- 29.96 = 0.04 mm
2) Hole and Shaft tolerance
High limit hole = 30.02
Low limit hole = 30.00
Hole tolerance = 30.02-30.00 = 0.02 mm
High limit of shaft = 30-0.04 = 29.96 mm
low limit of shaft = 30-0.07 = 29.93 mm
shaft tolerance = 29.96- 29.93 = 0.03 mm

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Answer (2) :
3) If we consider high limits of hole with high limit of shaft,
then allowance = 30.02 29.96 = 0.06 mm

if we choose low limit of hole and either high limit or low

limit of shaft then the allowance is positive in each case , for
example :
30- 29.96 = + 0.04mm
Or
30- 29.93 = + 0.07 mm
Hence, the type of fits is Clearance fit