Limits and Fits

Dimensioning:
Interchangeable manufacturing, by means of which, parts can be made in widely separated
localities, and then be brought together for assembly, where the parts will fit together properly, is
an essential element of mass production. Without interchangeable manufacturing, modern Industry
could not exist and without size control by the design engineer, interchangeable manufacturing
could not be achieved.
In the automobile industry, a manufacturer not only gub contracts the manufacture of many of the
parts to other companies but be must also be concerned with parts for replacement. parts in each
category must be near enough alike so that any of them will fit properly in any assembly. Since it
is almost impossible to manufacture a part to exact size, a part may be manufactured very close to
the exact size, the degree of accuracy depending on the functional requirement of the part. A
system of tolerances is necessary to allow for the variations in accuracy that are bound to occur
during manufacture and still provide for interchangeability and correct functioning of the part.
A tolerance is the difference between the upper and lower limits of a dimension. The tolerance
range will depend on the accuracy of the manufacturing organization, the machining process and
the magnitude of the dimension. The greater the tolerance range, the cheaper the manufacturing
process.
Sheet 1 show the basic terminology relating to 11rn1ts and fits.
A unilateral tolerance is one where the tolerance zone is disposed on one side of the nominal
dimension.
A bilateral tolerance is one where the tolerance zone is disposed on both sides of the nominal
dimension. Sheet No. 2.
Fits depend on the relationship between the tolerance zones of two mating parts and may be
broadly classified into three main categories.
a. Clearance Fit with positive allowance.
b. Interference Pit where the allowance is always negative.
c. Transition Fit where the allowance may be positive or negative (Clearance or interference).
B.S. 4500 ISO Limits and Fits:
This system consists of suitable combinations of 18 grades of tolerance for normal size ranges
produced in various grades of accuracy during manufacturing processes ranging from the finest
precision machining to sand casting and flame cutting. These tolerances are denoted by IT01,
0,1,2,3, IT16 (sheet 5).
In addition, there are 27 fundamental deviations, both for the shafts and for the holes. A capital
letter Is used to denote the fundamental deviation of a hole, while a shaft is allotted a small letter.
See Sheet 5b. As can be seen from the diagrams r the system encompasses a range of shaft and
hole sizes from considerably undersize to considerably oversize.
Designation of Fits:
To specify a hole or shaft It is necessary to refer to its basic size, fundamental deviation and grade
of tolerance, e.g. 50 H8 hole. This designation refers to an H hole of grade IT8 and basic size 50
mm. Similarly, 50 f 7 shaft refers to an f shaft of grade IT7 and basic diameter 50 nun. between a
mating pair may be specified in the brief form SO H8/f7.

a. Suppose an average running fit Is required between a shaft and Its housing. This may be
accomplished in one of three ways:
b. by making the hole bigger and the shaft smaller than the basic size,
c. by making the upper 1 limit of the shaft equal to, and the upper end lower Limits of the
hole greater than the basic size — unilateral shaft basis system,
d. by making the Lower limits of the hole equal to and the upper and lower 1 limits of the
shaft legs than the basic size — unilateral hole basis system. (Sheet 6a).
System (a) is rarely used.
System (b) is useful when bar stock is being used.
System (c) a standard is the most commonly used, since it: is easier to produce size hole by drilling,
reaming, etc. and easier to machine a shaft.
Notes on The System:
Clearance Fits:
The following are the standard clearance fits:
g. This Is the fit with least clearance, the minimum clearance being rather small for a normal
working bearing. It is Intended for close location fits and exists only in qualities g5 and g6.
f. This is the first intended for use as a normal working fit. It: is widely used as a normal grease
or oil lubricated bearing, but not necessarily at high temperature as the minimum clearance is still
small. It exists only in qualities f6, f 7 and f8.
e. This Is intended for use on loose clearance fits or, for example, lubricated bearings which run
hot. It exists only in qualities e7, e8 and This is intended for appreciably loose fits OE less
accurate work. It exists only in qualities d 8, d9, d 10 and d11. Some of these are suitable for
production by other than machining processes (rolling or drawing).
Transition Fits:
h. This is the particular fit: where the upper shaft is zero and therefore the same size as the
hole lower limit. In practice the probability is that the fit will be one of slight clearance. This f Is
widely used for non-running parts, such as bolts, or even parts which must occasionally rotate
(particularly on cheaper products). It is useful also for normal location or spigot fits. It exists in all
qualities from h5 to h11.
j. This is a true transition fit averaging a slight clearance. It can be used on location fits where
slight interference can be tolerated (e.g., assembly by light hammer blows) and where the
maximum clearance must be legs than with the h " shaft in order to improve the accuracy of
location.
All holes whose minimum diameter coincides with the basic size are assigned the letter H, and so
this is the only class of hole which be found in a unilateral hole basis system. Similarly, the
unilateral shaft basis system Is based on the "h" shaft.
B.S. 4500 suggests a limited range of selected fits for holes and shafts taken from the following
list:
Selected hole tolerances: H7; H8; H9; HI 1.
Selected Shaft tolerances; C11; d10; e9; f 7; g6; h6; k; n6; p6; s6.
for unusual applications such as precision instrument manufacture, the selected fits mentioned may
not supply adequate grades of tolerances. In such circumstances, use should be made of the tables
given in BS 4500.
Use of Selected (preferred) Tables:
Sheet 6b shows the suggested combinations of holes and shafts within the selected tolerance range.
As can be seen from the table, the unilateral hole basis system is used. These suggested combitions
are shown to scale for one basic size on Sheet 6c.
The basic or nominal sizes are listed vertically in the left-hand column and fit designations are
listed across the top. By choosing the correct combination of horizontal row and vertical column
the following figures can be found:

It exists in qualities 35, 36 and 37.

k. This Is a true transition fit averaging Virtually no clearance, being nearest in size to hole H
itself. It can be used on location fits where some Interference can be tolerated (e.g. assembly by
comparatively heavy It: is used for ball hammer blows in the extreme case). race f Its. It exists in
qualities k5, k6 and k7.
n. This is a true transition fit averaging some interference (n5 is used and giving clearance only
on extreme sizes. ag a press f with hole 116 — see below.) It is not likely to be used for
dismantlable spigots or locating fits, but is more suitable for some press fits, general "tight" fits,
interference fits with selective assembly It exists only in qualities n5, n6 and ball race f Its. and n7.
Interference Fits:
The following are the standard interference fits — It being noted that proper interference fits occur
in some cases only with certain holes.
H6/n5. This is the first interference fit with hole H6, i.e. the fit with the smallest minimum
interference. Owing to the fine tolerance quality of hole and shaft it will be used on precision
components to give an Interference fit of some delicacy, and is obviously costly to manufacture.
H6/p7. This is the first interference fit: with hole H7, the fit with the smallest minimum
interference. the standard true fit for steel, cast iron or It can normally be dismantled and brass
parts. reassembled as the degree of interference is not likely to overstrain the parts. Assembly on
normal sized parts is possible with an arbor press or by hammer.
This ss the first interference fit with hole H8, the fit with the smallest minimum interference. The
degree of grip with ferrous parts is appreciable but it is more or less Interchangeable with K7/p6
where one or both components are in light alloy (or material of equivalent: elasticity). These fits
involve an Increasing degree of Interrace and no general recommendation can be made. A thorough
Investigation into the degree of grip required and the stresses in the parts which will be. involved
must be made.