Fits and Tolerances

By: Tamer Elnady

INTRODUCTION
When you tell someone in the workshop to turn a certain shaft to a diameter of 70 mm, of course you dont expect him to give you the shaft exactly 70 mm; because there is nothing exact in engineering. This diameter is called the Nominal Dimension of the spindle and it will be plus or minus something, but are you going to accept this something? Your decision will depend on the accuracy of the spindle. Wait! There is nothing in engineering that is called something! Therefore, you must specify to him something that is called Tolerance. Tolerance is the allowable deviation from a nominal value. This depends on the needed accuracy; when accuracy increases, the deviation (or tolerance) decreases. But, the production cost also increases.

TOLERANCE AND ACCURACY

Hence, for each grade of accuracy, there is a certain Tolerance Zone Width. Grades of accuracy are divided into sixteen grades called Tolerance Grades or IT [IT1 to IT16] according to the field of application and the production process. Note that the tolerance zone width depends also on the dimension itself. The Tolerance Limits are the limits within which the dimension is acceptable. The difference between the upper and lower tolerance limits equals the tolerance zone width. Table 1 shows the bases upon which we choose the tolerance grade, and Table 2 shows the tolerance zone width for each grade.
Table 1 Choice of tolerance grades. Tolerance Grade IT1 IT2 IT3 IT4 IT5 IT6 IT7 IT8 IT9 IT10 IT11 IT12 IT13 IT14 IT15 IT16 Production Process Field of Application

Used for gauges Lapping - Very fine grinding - High quality boring. Fine grinding - Fine honing. Grinding - High quality turning - honing Broaching. Fine turning - Fine boring - Reaming. Turning - Fine milling - Boring - Slotting. Shaping - Milling - Rolling - Extrusion. Rough turning - Drilling - Precision tube drawing. Light presswork - Tube drawing. General presswork - Tube rolling. Die casting. Casting - Forging.

Piston pin holes in engines. Accurate bushes and bearings. Bushes and high quality cylindrical bores. Good quality general holes. Unimportant mating parts. Very coarse fits e.g. bolts and washers.

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Table 2 Choice of tolerance zone width. Dimension More Up Than To 3 3 6 6 10 10 18 18 30 30 50 50 80 80 120 120 180 180 250 250 315 315 400 400 Tolerance Zone Width IT1 1.5 1.5 1.5 1.5 1.5 2 2 3 4 5 6 7 8 IT2 2 2 2 2 2 3 3 4 5 7 8 9 10 IT3 3 3 3 3 4 4 5 6 8 10 12 13 15 IT4 4 4 4 5 6 7 8 10 12 14 16 18 20 IT5 5 5 6 8 9 11 13 15 18 20 23 25 27 IT6 7 8 9 11 13 16 19 22 25 29 32 36 40 IT7 9 12 15 18 21 25 30 35 40 46 52 57 63 IT8 14 18 22 27 33 39 46 54 63 72 81 89 97 IT9 25 30 36 43 52 62 74 87 100 115 130 140 155 IT10 40 48 58 70 84 100 120 140 160 185 210 230 250 IT11 60 75 90 110 130 160 190 220 250 290 320 360 400 IT12 90 120 150 180 210 250 300 350 400 460 520 570 630 IT13 140 180 220 270 330 390 460 540 630 720 810 890 970 IT14 250 300 360 430 520 620 740 870 1000 1150 1300 1400 1550 IT15 400 480 580 700 840 1000 1200 1400 1600 1850 2100 2300 2500 IT16 600 750 900 1100 1300 1600 1900 2200 2500 2900 3200 3600 4000

For the dimensions not related to another part, the tolerance zone width is distributed symmetrically around the nominal dimension. The diameter is written as follows: 70half the tolerance zone width. This is sometimes called (js) tolerance.

FITS
But what happens when the previously mentioned shaft is related to another part? Say a hub of a gear or pulley. We must first decide the relation between the shaft and the hub (clearance or interference); this is called Fit. For the clearance case, the shaft diameter must be smaller than the hub diameter; and for the interference case, the shaft diameter has to be larger than the hub diameter. As we say smaller and larger, we must set a reference diameter and relate the other to it. This is what we call Basic Shaft and Basic Hole systems. For example in the basic shaft system, the shaft diameter is set as reference and the hub diameter determines the type of fit.

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A Basic shaft system B C D E h F G H J K M N P nominal size R S

U X Z

Basic hole system x p r s t u

H deviation e d c b a tolerance zone width f g h

nominal size

CHOICE OF THE APPROPRIATE FIT AND DETERMINATION OF THE ASSOCIATED TOLERANCES:

With the international ISA-tolerances now in use, two tolerance symbols are necessary along with nominal size for every fit. One of the symbols specifies the limits for the internal dimension (hole) and the other for the corresponding external dimension (shaft). The alphabetical character specifies the position (deviation) of the tolerance zone with reference to the zero line (nominal size); small letters for shafts and capital letters for holes, the hole symbol is written first. The numerical character (1 to 16) indicates the quality grade.

Table 3 shows the recommended fits for various applications, and Table 4 shows the deviation of the tolerance zone from the nominal size for different types of fits. Note that in clearance and interference cases, the deviation value does not change if we use basic hole or basic shaft systems; while in the transition case, the deviation value depend on the system followed.

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Table 3 Recommended fits for different uses. Type of relation Application For easily assembled parts with large tolerance spacer sleeves. hinge pins. spring and brake holders. bearings for rollers and guides. Plenty of play transmission shafts. counter shafts. Considerable play idler pulleys. machine tool shafts in several bearings. Perceptible play sliding bearings. sliding sleeves. pistons in cylinders. Can be moved without perceptible play sliding gears and clutches. indicator pistons. For effortlessly axial moving fitting parts change gears. spindle sleeve of tail stock. adjustment rings for transmissions. pins in mechanisms. centering registers for couplings and pipes. Using a wooden hammer or by hand All can be hubs needing easy removal. used for: Good for hand hammer couplings keys. clutches Difficult with hand hammer gears outer rings of ball bearings. belt pulleys electric motor shafts. Using press inner rings of ball bearings. armatures on motor shafts. Ease of dismantle and assembly bronze rims on cast iron hubs. bearing bushes in housings and connecting rods. hubs of couplings, clutches, gears and pulleys. Heavy drive for permanent assembly wheels and flywheels. valve seats. shaft flanges. shrink fits. Recommended fit

coarse fit

H/a H/b H/c

extra loose running fit loose running fit Clearance

H/d

H/e

running fit

H/f

close running fit

H/g

slide fit

H/h H/g

push fit holding fit Transition drive fit

H/j H/k H/m

tight fit

H/n

Interference

medium force fit

H/p H/r

force fit

H/s H/t H/u

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Table 4 Deviations of the tolerance zone from the nominal size for different types of fits. Deviation of the tolerance zone from the nominal size Dimension a b c Clearance j More Up To Than 0 3 6 10 14 18 24 30 40 50 65 80 100 120 140 160 180 200 225 250 280 315 355 400 450 3 6 10 14 18 24 30 40 50 65 80 100 120 140 160 180 200 225 250 280 315 355 400 450 d e f g 2 4 5 6 7 9 h 5,6 270 140 60 20 14 6 270 140 70 30 20 10 280 150 80 40 25 13 290 150 95 50 32 16 300 160 110 65 40 20 310 320 340 360 380 410 460 520 580 660 740 820 920 1050 1200 1350 1500 170 180 190 200 220 240 260 280 310 340 380 420 480 540 600 680 760 120 130 140 150 170 180 200 210 230 240 260 280 300 330 360 400 440 80 50 25 0 0 0 0 0 0 0 0 -2 -2 -2 -3 -4 BH 7 -4 -4 -5 -6 -8 8 -6 6 B Sh 7 8 BH 0 0 0 0 0 0 0 0 Transition k B Sh >8 0 0 0 0 0 0 0 0 0 -1+D -1+D -1+D -2+D -2+D -2+D -3+D 4-7 othr < 9 BH 2 4 6 7 8 9 m B Sh <9 -2 -4+D -6+D -7+D -8+D -9+D BH n B Sh <9 >8 6 10 14 12 15 19 15 19 23 18 23 28 22 28 35 26 34 43 32 37 41 43 51 54 63 65 68 77 80 84 94 98 108 114 126 53 59 71 79 92 100 108 122 130 140 158 170 190 208 232 41 48 54 66 75 91 104 122 134 146 166 180 196 218 240 268 294 330 18 20 23 28 28 34 40 33 45 41 54 48 64 60 80 70 97 87 122 102 146 124 178 144 210 170 248 190 280 210 310 236 350 258 385 284 425 315 475 350 525 390 590 435 660 490 740 26 35 42 50 60 73 88 112 136 172 210 258 310 365 415 465 520 575 640 710 790 900 1000 1100 p r s t u x z 3 4 5 6 7 8 1 2 1 3 4 6 1 2 2 3 6 7 1 2 3 3 7 9 2 2 3 4 8 12 2 3 4 5 9 14 2 3 5 6 11 16 2 4 5 7 13 19 Interference D

+2 +4 +6 0 +5 +6 +10 +1 +5 +8 +12 +1 +6 +10 +15 +1 +8 +12 +20 +2 +10 +14 +24 +2 +13 +18 +28 +2 +16 +22 +34 +3

4 -4 -4 8 -8+D 0 10 -10+D 0 12 -12+D 15 -15+D 17 -17-D 0 0 0 0 0

-5 -10 -7 -12 -9 -15

100 60 30 10 120 72 36 12

11 -11+D 20 -20-D 13 -13+D 23 -23+D

145 85 43 14

-11 -18

+18 +26 +41 +3

-3+D

15 -15+D 27 -27+D

43

3 4 6 7 15 23

170 100 50 15

-13 -21

+22 +30 +47 +4

-4+D

17 -17+D 31 -31+D

50

3 4 6 9 17 26

190 110 56 17 210 125 62 18 230 135 68 20

0 0 0

-16 -26 -18 -28 -20 -32

+25 +36 +55 +4 +29 +39 +60 +4 +33 +43 +66 +5

0 0 0

-4+D -4+D -5+D

0 0 0

20 -20+D 34 -34+D 21 -21+D 37 -37+D 23 -23+D 40 -40+D

0 0 0

56 62 68

4 4 7 9 20 29 4 5 7 11 21 32 5 5 7 13 23 34

1650 840 480

132 252 360 540 820 1250

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NOTES:
Fits are stated on the assembly drawing, while the tolerances are stated on the working drawings. In most cases, the tolerance grade of the hole is greater than the grade of the shaft. Usually, the basic hole system is used in general machine construction; whilst the basic shaft system is rarely used except in cases of a standard shaft (e.g. of a ball bearing) or hinges. Transition fits may be used in selective assembly. Selective assembly serves to give an actual amount of interference or clearance. The following gives some help to the designer in preparing the working drawings and the process sheets. Table 5 shows RMS values of surface roughness for different accuracy grades.

Dimention MoreT Up To han 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

IT5 0.2 0.4

IT6

IT7 0.4

RMS values of surface roughness IT8 IT9 IT10 IT11 IT12 0.8 1.6 3.2 1.6 3.2 6.3 3.2 12.5 6.3 3.2 12.5 6.3 25 12.5 6.3 25 12.5 50 6.3

IT13

IT14 12.5

0.4 0.8 0.8

12.5 25

0.8 1.6 1.6 3.2

1.6

25 50

3.2

50 100

Table 5 RMS values of surface roughness for different accuracy grades.

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