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Limits,Fits,andTolerances
1
Introduction
Notwopartscanbeproducedwithidenticalmeasurementsby
anymanufacturingprocess.
Inanyproductionprocess,regardlessofhowwellitisdesignedor
howcarefullyitismaintained,acertainamountofnatural
variabilitywillalwaysexist.
Thesenaturalvariationsarerandominnatureandarethe
cumulativeeffectofmanysmall,essentiallyuncontrollablecauses.
Usually,variabilityarisesfromimproperlyadjustedmachines,
operatorerror,toolwear,and/ordefectiverawmaterials.
2
Introduction
Suchcharacteristicvariabilityisgenerallylargewhencomparedto
thenaturalvariability.
Thisvariability,whichisnotapartofrandomorchancecause
pattern,isreferredtoasassignablecauses.
Characteristicvariationscanbeattributedtoassignablecauses
thatcaneasilybeidentifiedandcontrolled.
Iftheprocesscanbekeptundercontrol,thatis,alltheassignable
andcontrollablecausesofvariationshavebeeneliminatedor
controlled,thesizevariationswillbewellwithintheprescribed
limits.
3
Introduction
Somevariabilityindimensionwithincertainlimitsmustbe
toleratedduringmanufacture,howeverprecisetheprocessmaybe.
Thepermissibleleveloftolerancedependsonthefunctional
requirements,whichcannotbecompromised.
Nocomponentcanbemanufacturedpreciselytoagiven
dimension;itcanonlybemadetoliebetweentwolimits,upper
(maximum)andlower(minimum).
Thedesignerhastosuggestthesetolerancelimits,whichare
acceptableforeachofthedimensionsusedtodefineshapeand
form,andensuresatisfactoryoperationinservice.
4
Introduction
Whenthetoleranceallowedissufficientlygreaterthanthe
processvariation,nodifficultyarises.
Thedifferencebetweentheupperandlowerlimitsistermed
permissivetolerance.
Forexample,ashafthastobemanufacturedtoadiameterof40
0.02mm.
Thismeansthattheshaft,whichhasabasicsizeof40mm,will
beacceptableifitsdiameterliesanywherebetweenthelimitsof
sizes,thatis,anupperlimitof40.02 mm andalowerlimitof
39.98mm.Thenpermissivetoleranceisequalto40.0239.98=
0.04.
5
Tolerances
Tolerancecanbedefinedasthemagnitudeofpermissiblevariationof
adimensionorothermeasuredvaluefromthespecifiedvalue.
Itcanalsobedefinedasthetotalvariationpermittedinthesizeofa
dimension,andisthealgebraicdifferencebetweentheupperand
loweracceptabledimensions.Itisanabsolutevalue.
Thebasicpurposeofprovidingtolerancesistopermitdimensional
variationsinthemanufactureofcomponents,adheringtothe
performancecriterionasestablishedbythespecificationanddesign.
6
Tolerances
Ifhighperformanceisthesolecriterion,thenfunctional
requirementsdictatethespecificationoftolerancelimits;otherwise,
thechoiceofsettingtolerance,toalimitedextent,maybeinfluenced
anddeterminedbyfactorssuchasmethodsoftoolingandavailable
manufacturingequipment.
Theindustryfollowscertainapprovedaccuracystandards,suchas
ANSI(AmericanNationalStandardsInstitute)andASME(American
SocietyofMechanicalEngineers),tomanufacturedifferentparts.
7
ManufacturingCostandWorkTolerance
Itisverypertinenttorelatetheproductionofcomponentswithinthespecified
tolerancezonetoitsassociatedmanufacturingcost.
Asthepermissivetolerancegoesondecreasing,themanufacturingcost
incurredtoachieveitgoesonincreasingexponentially.
Whenthepermissivetolerancelimitsarerelaxedwithoutdegradingthe
functionalrequirements,themanufacturingcostdecreases.
8
Tolerances
ClassificationofTolerance
Tolerancecanbeclassifiedunderthefollowingcategories:
1.Unilateraltolerance
2.Bilateraltolerance
3.Compoundtolerance
4.Geometrictolerance
UnilateralTolerance
Whenthetolerancedistributionisonlyononesideofthebasicsize,itis
knownasunilateraltolerance.
Inotherwords,tolerancelimitsliewhollyononesideofthebasicsize,
eitheraboveorbelowit.
10
Tolerances
BilateralTolerance
Whenthetolerancedistributionliesoneithersideofthebasicsize,itisknownas
bilateraltolerance.
Inotherwords,thedimensionofthepartisallowedtovaryonbothsidesofthe
basicsizebutmaynotbenecessarilyequallydisposedaboutit.
Example:+0.02
40 0.02, 40 0.01
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Tolerances
CompoundTolerance
Whentoleranceisdeterminedbyestablishedtolerancesonmorethanone
dimension,itisknownascompoundtolerance.
Forexample,toleranceforthedimensionRisdeterminedbythecombined
effectsoftoleranceon40mmdimension,on60,andon20mmdimension.
ThetoleranceobtainedfordimensionRisknownascompoundtolerance
(Fig.3.4).Inpractice,compoundtoleranceshouldbeavoidedasfaras
possible.
12
GeometricTolerance
Geometrictolerancesareusedtoindicatetherelationshipofonepart
ofanobjectwithanother.ConsidertheexampleshowninFig.3.5.
13
Tolerances
Formtolerances:Formtolerancesareagroupofgeometric
tolerancesappliedtoindividualfeatures.Theylimittheamountof
errorintheshapeofafeatureandareindependenttolerances.Form
tolerancesassuchdonotrequirelocatingdimensions.Theseinclude
straightness,circularity,flatness,andcylindricity.
Orientationtolerances:Orientationtolerancesareatypeof
geometrictolerancesusedtolimitthedirectionororientationofa
featureinrelationtootherfeatures.Thesearerelatedtolerances.
Perpendicularity,parallelism,andangularityfallintothiscategory.
Positionaltolerances:Positionaltolerancesareagroupofgeometric
tolerancesthatcontrolstheextentofdeviationofthelocationofa
featurefromitstrueposition.Thisisathreedimensionalgeometric
tolerancecomprisingposition,symmetry,andconcentricity.
14
Consider the example shown if figure 3.6.
+ 0.02 + 0.02 + 0.02
Let LA = 30 0.01 mm, LB = 20 0.01 mm and LC = 10 0.01 mm
The overall length of the assembly is the sum of the individual length of components
given as
L = LA + LB + LC
L = 30 + 20 + 10 = 60 mm
15
Then,cumulativeuppertolerancelimitis0.02+0.02+0.02=0.06mmand
cumulativelowerlimit= 0.01 0.01 0.01= 0.03mm
+0.06
Thereforedimensionoftheassembledlengthwillbe=60 0.03 mm
16
MaximumandMinimumMetalConditions
Letusconsiderashafthavingadimensionof40 0.05mm.
Themaximummetallimit(MML)oftheshaftwillhaveadimensionof40.05mm
becauseatthishigherlimit,theshaftwillhavethemaximumpossibleamountof
metal.
Theshaftwillhavetheleastpossibleamountofmetalatalowerlimitof39.95
mm,andthislimitoftheshaftisknownasminimumorleastmetallimit(LML).
Similarly,consideraholehavingadimensionof45 0.05mm.
Theholewillhaveamaximumpossibleamountofmetalatalowerlimitof44.95
mmandthelowerlimitoftheholeisdesignatedasMML.
Forexample,whenaholeisdrilledinacomponent,minimumamountofmaterial
isremovedatthelowerlimitsizeofthehole.Thislowerlimitoftheholeisknown
asMML.
ThehigherlimitoftheholewillbetheLML.Atahighlimitof45.05mm,thehole
willhavetheleastpossibleamountofmetal.
ThemaximumandminimummetalconditionsareshowninFig.3.8 17
FITS
Fits
Manufacturedpartsarerequired
tomatewithoneanotherduring
assembly.
Therelationshipbetweenthetwo
matingpartsthataretobe
assembled,thatis,theholeand
theshaft,withrespecttothe
differenceintheirdimensions
beforeassemblyiscalledafit.
Anidealfitisrequiredforproper
functioningofthematingparts.
Threebasictypesoffitscanbe
identified,dependingontheactual
limitsoftheholeorshaft:
18
FITS
1. Clearancefit
2.Interferencefit
3. Transitionfit
Clearancefit:Thelargestpermissible
diameteroftheshaftissmallerthanthe
diameterofthesmallesthole.
Thistypeoffitalwaysprovidesclearance.
Smallclearancesareprovidedforaprecise
fitthatcaneasilybeassembledwithoutthe
assistanceoftools.Whenrelativemotions
arerequired,largeclearancescanbe
provided,forexample,ashaftrotatingina
bush.
Incaseofclearancefit,thedifference
betweenthesizesisalwayspositive.The
clearancefitisdescribedinFig.3.9.
19
FITS
Interferencefit:Theminimumpermissiblediameteroftheshaft
exceedsthemaximumallowablediameterofthehole.
Thistypeoffitalwaysprovidesinterference.Interferencefitisa
formofatightfit.Toolsarerequiredforthepreciseassemblyoftwo
partswithaninterferencefit.
Whentwomatingpartsareassembledwithaninterferencefit,it
willbeanalmostpermanentassembly,thatis,thepartswillnot
comeapartormoveduringuse.Toassemblethepartswith
interference,heatingorcoolingmayberequired.
Inaninterferencefit,thedifferencebetweenthesizesisalways
negative.
20
Allowance
Allowance:Anallowanceistheintentionaldifferencebetweenthemaximum
materiallimits,thatis,LLHandHLS(minimumclearanceormaximum
interference)ofthetwomatingparts.Itistheprescribeddifferencebetween
thedimensionsofthematingpartstoobtainthedesiredtypeoffit.
Allowancemaybepositiveornegative.Positiveallowanceindicatesaclearance
fit,andaninterferencefitisindicatedbyanegativeallowance.
Allowance=LLHHLS
21
FitTypes
Type 1: Clearance fit = Occurs when two toleranced mating
parts will always leave a space or clearance when assembled
Type 2: Interference fit = Occurs when two toleranced mating
parts will always interfere when assembled
22
OxfordUniversityPress2013.Allrightsreserved.
FitTypes
Type 3: Transition fit = Occurs when two toleranced mating
parts are sometimes and interference fit and sometimes
clearance fit when assembled.
23
OxfordUniversityPress2013.Allrightsreserved.
GeneralTerminologyinFits
Basicsize:Thisisthesizeinrelationtowhichalllimitsofsizearederived.
Basicornominalsizeisdefinedasthesizebasedonwhichthedimensional
deviationsaregiven.Thisis,ingeneral,thesameforbothcomponents.
Limitsofsize:Thesearethemaximumandminimumpermissiblesizes
acceptableforaspecificdimension.Theoperatorisexpectedto
manufacturethecomponentwithintheselimits.Themaximumlimitofsize
isthegreaterofthetwolimitsofsize,whereastheminimumlimitofsizeis
thesmallerofthetwo.
Tolerance:Thisisthetotalpermissiblevariationinthesizeofadimension,
thatis,thedifferencebetweenthemaximumandminimumlimitsofsize.It
isalwayspositive.
Allowance:ItistheintentionaldifferencebetweentheLLHandHLS.An
allowancemaybeeitherpositiveornegative.
Allowance=LLHHLS
24
GeneralTerminologyinFits
Grade:Thisisanindicationofthetolerancemagnitude;thelowerthegrade,the
finerthetolerance.
Deviation:Itisthealgebraicdifferencebetweenasizeanditscorrespondingbasic
size.Itmaybepositive,negative,orzero.
Upperdeviation:Itisthealgebraicdifferencebetweenthemaximumlimitofsize
anditscorrespondingbasicsize.ThisisdesignatedasESforaholeandases fora
shaft.
Lowerdeviation:Itisthealgebraicdifferencebetweentheminimumlimitofsize
anditscorrespondingbasicsize.ThisisdesignatedasEIforaholeandaseifora
shaft.
Actualdeviation:Itisthealgebraicdifferencebetweentheactualsizeandits
correspondingbasicsize.
Fundamentaldeviation:Itistheminimumdifferencebetweenthesizeofa
componentanditsbasicsize.Thisisidenticaltotheupperdeviationforshaftsand
lowerdeviationforholes. 25
GeneralTerminologyinFits
Zeroline:Thislineisalsoknownasthelineofzerodeviation.Theconvention
istodrawthezerolinehorizontallywithpositivedeviationsrepresentedabove
andnegativedeviationsindicatedbelow.Thezerolinerepresentsthebasicsize
inthegraphicalrepresentation.
Shaftandhole:Thesetermsareusedtodesignatealltheexternalandinternal
featuresofanyshapeandnotnecessarilycylindrical.
Fit:Itistherelationshipthatexistsbetweentwomatingparts,aholeanda
shaft,withrespecttotheirdimensionaldifferencebeforeassembly.
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GeneralTerminologyinFits
27
GeneralTerminologyinFits
BasicHoleSystem
Thebasicholesystemisusedtoapplytolerances
toaholeandshaftassembly.
28
GeneralTerminologyinFits
Tolerancesymbols:Theseareusedtospecifythetoleranceandfitsfor
matingcomponents.Forexample,in40H8f7,thenumber40indicatesthe
basicsizeinmillimeters;capitalletterHindicatesthefundamental
deviationforthehole;andlowercaseletterfindicatestheshaft.The
numbersfollowingthelettersindicatecorrespondingITgrades.
29
GeneralTerminologyinFits
30
GeneralTerminologyinFits
The ISO System of Limits and Fits (referred to as the ISO system) is
covered in national standards throughout the world, as shown by the
following list:
31
GeneralTerminologyinFits
32
ClearanceFit (e.g.:H7/f6)
33
ClearanceFit (pl.H7/f6)
34
ClearanceFit (pl.H7/f6)
35
TransitionFit
37
TransitionFit (e.g.:H7/j6)
38
TransitionFit (e.g.:H7/j6)
39
TransitionFit (e.g.:H7/j6)
40
InterferenceFit
41
InterferenceFit(H7/n6)
42
InterferenceFit (H7/n6)
43
InterferenceFit(H7/n6)
44
Example:50H7/f6
OnlinecalculationofFits
http://www.tss.trelleborg.com/global/en/service/fits_tolerance/fits_tolerance_1.html
Hole Shaft
LowerLimit 50 49.959
45
Twowaysofindicatingtolerancesontechnical
drawings
Limits of a dimension or the tolerance values are
specified directly with the dimension.
46
Indicatingtolerances
47
SpecifyingFitsintechnicalDrawing
48