Tolerances and Fits

• The term tolerances refers to the permissible

deviation of a dimension from the specified basic
size.
• The proper performance of a machine
can depend on the tolerances specified for its parts,
particularly those that must fit together for location
or for suitable relative motion.

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Tolerances and Fits, Contd.
• The term fit usually refers to the clearances that are
permissible between mating parts in a mechanical
device that must assemble easily and that must often
move relative to each other during normal operation
of the device.
• Such fits are usually called running or sliding fits.
• Fit can also refer to the amount of interference that
exists when the inside part should be larger than the
outside part.
• Interference fits are used to ensure that mating
parts do not move relative to each other.

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Tolerances and Fits, Contd.

where:
d=D ... basic size
Dmax , Dmin ... limits of size for the hole
dmax , dmin ... limits of size for the shaft
ES ... hole upper deviation EI ... hole lower deviation
es ... shaft upper deviation ei ... shaft lower deviation

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Tolerances and Fits, Contd.
Depending on the mutual position of tolerance zones of the
coupled parts, 3 types of fit can be distinguished:
– Clearance fit, A
– Transition fit, B
– Interference fit, C

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System of Fit
Although there can be generally coupled parts without any
tolerance zones, only two methods of coupling of holes and
shafts are recommended due to constructional, technological
and economic reasons.
Hole basis system
The desired clearances and interferences in the fit are achieved
by combinations of various shaft tolerance zones with the hole
tolerance zone "H". In this system of tolerances and fits, the
lower deviation of the hole is always equal to zero.
Shaft basis system
The desired clearances and interferences in the fit are achieved
by combinations of various hole tolerance zones with the shaft
tolerance zone "h". In this system of tolerances and fits, the
upper deviation of the hole is always equal to zero.

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Type of Fit
Depending on the mutual position of tolerance zones of the
coupled parts, 3 types of fit can be distinguished:
• Clearance fit
It is a fit that always enables a clearance between the hole
and shaft in the coupling. The lower limit size of the hole is
greater or at least equal to the upper limit size of the shaft.
• Transition fit
It is a fit where (depending on the actual sizes of the hole
and shaft) both clearance and interference may occur in the
coupling. Tolerance zones of the hole and shaft partly or
completely interfere.
• Interference fit
It is a fit always ensuring some interference between the
hole and shaft in the coupling. The upper limit size of the
hole is smaller or at least equal to the lower limit size of the
shaft.

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Type of Fit, Contd.

where:
d=D ... basic size
//// ... hole tolerance zone
\\\\ ... shaft tolerance zone

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Recommended Fits
Clearance fits:
• H11/a11, H11/c11, H11/c9, H11/d11, A11/h11, C11/h11, D11/h11
Fits with great clearances with parts having great tolerances.
Use: Pivots, latches, fits of parts exposed to corrosive effects,
contamination with dust and thermal or mechanical deformations.
• H9/C9, H9/d10, H9/d9, H8/d9, H8/d8, D10/h9, D9/h9, D9/h8
Running fits with greater clearances without any special requirements for
accuracy of guiding shafts.
Use: Multiple fits of shafts of production and piston machines, parts
rotating very rarely or only swinging.
• H9/e9, H8/e8, H7/e7, E9/h9, E8/h8, E8/h7
Running fits with greater clearances without any special requirements for
fit accuracy.
Use: Fits of long shafts, e.g. in agricultural machines, bearings of pumps,
fans and piston machines.
• H9/f8, H8/f8, H8/f7, H7/f7, F8/h7, F8/h6
Running fits with smaller clearances with general requirements for fit
accuracy.
Use: Main fits of machine tools. General fits of shafts, regulator
bearings, machine tool spindles, sliding rods.

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Recommended Fits
Clearance fits:
• H8/g7, H7/g6, G7/h6
Running fits with very small clearances for accurate guiding of shafts.
Without any noticeable clearance after assembly.
Use: Parts of machine tools, sliding gears and clutch disks, crankshaft
journals, pistons of hydraulic machines, rods sliding in bearings,
grinding machine spindles.
• H11/h11, H11/h9
Slipping fits of parts with great tolerances. The parts can easily be slid
one into the other and turn.
Use: Easily demountable parts, distance rings, parts of machines fixed
to shafts using pins, bolts, rivets or welds.
• H8/h9, H8/h8, H8/h7, H7/h6
Sliding fits with very small clearances for precise guiding and centring
of parts. Mounting by sliding on without use of any great force, after
lubrication the parts can be turned and slid by hand.
Use: Precise guiding of machines and preparations, exchangeable
wheels, roller guides.

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Recommended Fits, Contd.
Transition fits:
• H8/j7, H7/js6, H7/j6, J7/h6
Tight fits with small clearances or negligible interference. The parts
can be assembled or disassembled manually.
Use: Easily dismountable fits of hubs of gears, pulleys and bushings,
retaining rings, frequently removed bearing bushings.
• H8/k7, H7/k6, K8/h7, K7/h6
Similar fits with small clearances or small interferences. The parts
can be assembled or disassembled without great force using a rubber
mallet.
Use: Demountable fits of hubs of gears and pulleys, manual wheels,
clutches, brake disks.
• H8/p7, H8/m7, H8/n7, H7/m6, H7/n6, M8/h6, N8/h7, N7/h6
Fixed fits with negligible clearances or small interferences. Mounting
of fits using pressing and light force.
Use: Fixed plugs, driven bushings, armatures of electric motors on
shafts, gear rims, flushed bolts.

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Recommended Fits, Contd.
Interference fits:
• H8/r7, H7/p6, H7/r6, P7/h6, R7/h6
Pressed fits with guaranteed interference. Assembly of the parts can be
carried out using cold pressing.
Use: Hubs of clutch disks, bearing bushings.
• H8/s7, H8/t7, H7/s6, H7/t6, S7/h6, T7/h6
Pressed fits with medium interference. Assembly of parts using hot
pressing. Assembly using cold pressing only with use of large forces.
Use: Permanent coupling of gears with shafts, bearing bushings.
• H8/u8, H8/u7, H8/x8, H7/u6, U8/h7, U7/h6
Pressed fits with big interferences. Assembly using pressing and great
forces under different temperatures of the parts.
Use: permanent couplings of gears with shafts, flanges.

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EXAMPLE LIMITS AND FITS USING HOLE BASIS

Description Hole Shaft

Loose Running H11 c11

Free Running H9 d9
Loose Running H11 c11
Easy Running - Good quality easy to do- H8 f8
Sliding H7 g6
Close Clearance - Spigots and locations H8 f7
Location/Clearance H7 h6
Location- slight interference H7 k6
Location/Transition H7 n6
Location/Interference- Press fit which can be
H7 p6
separated
Medium Drive H7 s6
Force H7 u6

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Factors Affecting Tolerances and Fits

• The option of the system for the specified type of

product or production is always influenced by the following
factors:
• Constructional design of the product and the method of
assembly.
• Production procedure and costs for machining the part.
• Type of semi-product and consumption of material.
• Costs for purchase, maintenance and storage of gauges
and production tools.
• Machine holding of the plant.
• Options in use of standardized parts.
Hint: Although both systems are equivalent in the view of
functional properties, the hole basis system is used
preferably.

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Factors Affecting Tolerances and Fits

• Consider the plain surface bearings. A critical part

of the design is the specification of the
diametrical clearance between the journal and the
bearing.
• The typical value is just a few thousandths of an
inch.
• But some variation must be allowed on both the
journal outside diameter and the bearing inside
diameter for reasons of economy of manufacture.

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Factors Affecting Tolerances and Fits
• There will be variation of the actual clearance in
production devices, depending on where the individual
mating components fall within their own tolerance
bands.
• Too small a clearance could cause seizing.
• Conversely, too large a clearance would reduce the
precision of the machine and adversely affect the
lubrication.

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Tolerances, Production Processes, and Costs

• A unilateral tolerance deviates in only one direction

from the basic size.
• A bilateral tolerance deviates both above and below
the basic size.
• The total tolerance is the difference between the
maximum and minimum permissible dimensions.

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Tolerances, Production Processes, and Costs

• The term allowance refers to an intentional

difference between the maximum material limits of
mating parts.
• For example, a positive allowance for a hole/shaft
pair would define the minimum clearance between
mating parts from the largest shaft mating with the
smallest hole.
• A negative allowance would result in the shaft being
larger than the hole (interference).

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Tolerances, Production Processes, and Costs

• The term fit refers to the relative looseness

(clearance fit) or tightness (interference fit) of
mating parts, especially as it affects the motion of
the parts or the force between them after assembly.
• Specifying the degree of clearance or interference is
one of the tasks of the designer.

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Tolerances, Production Processes, and Costs

• It is costly to produce components with very small

tolerances on dimensions.
• It is the designer’s responsibility to set the
tolerances at the highest possible level that results in
satisfactory operation of the machine.
• The production of part features with small tolerances
usually involves finer surface finishes.

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Machining Costs Versus Surface Finish Specified

This shows the general

relationship between the
surface finish and the
relative cost of producing a
part.
The typical total tolerance
produced by the processes
described is included in the
figure.
The increase in cost is
dramatic for the small
tolerances and fine finishes.

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Machining Costs Versus Surface Finish Specified

• The term tolerance grade refers to a set of

tolerances that can be produced with an
approximately equal production capability.
• The actual total tolerance allowed within each grade
depends on the nominal size of the dimension.
• Smaller tolerances can be achieved for smaller
dimensions, and vice versa.

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Tolerance Grades
4 5 6 7 8 9 10 11

Lapping & Honning

Cylindrical Grinding
Surface Grinding
Diamond Turninig
Diamond Boring
Broaching
Powder Metal-Sizes
Reaming
Turning
Powder Metal Sintered
Boring
Milling
Planning & Shaping
Drilling
Punching
Die Casting

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Tolerances of Different Processes

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Cost of Tolerances

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Preferred Basic Sizes
• The first step in specifying a dimension for a part is
to decide on the basic size, that dimension to which
the tolerances are applied.
• The analysis for strength, deflection, or performance
of the part determines the nominal or minimum size
required.
• Unless special conditions exist, the basic size should
be chosen from the lists of preferred basic sizes in
Table for fractional-inch sizes, decimal-inch sizes,
and metric sizes from the SI.

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The ISO system of tolerances and fits (ISO 286-1)
The designation of an ISO standard tolerance would be, respectively
to the tolerance grade, IT01, IT3, and IT12 etc. (i.e. increasing
tolerance. )

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Geometrical Tolerances
• Geometrical Matl Cond, Tertiary
Tolerances: specified Matl Cond, Secondary
for an individual Matl Cond, Primary
feature by means of a Matl Cond, Tolerance
feature control frame Value
(a rectangle) divided
into compartments Type
D. R. Primary
containing the GTOL
symbol followed by the
D. R. Secondary

tolerance value.
D. R. Tertiary

• Where applicable, it Matl Cond, Primary, Compound

also follows the
tolerance with a Matl Cond, Primary, Basic
material condition
symbol. Datum Ref, Primary, Basic

Datum Ref, Primary, Compound

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Geometrical Tolerances
• Geometric tolerances specify the maximum variation
that is allowed in form or position from true
geometry.
• The geometric tolerance is, in essence, the width or
diameter of tolerance zone within which a surface or
axis of hole or cylinder can lie, which results in
resulting feature being acceptable for proper function
and interchangeability.

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GTOL Symbols

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Tolerance Frame Variations
• The tolerance frame can be divided
into two or more compartments.
These compartments include from
left to right
• The symbol for the feature to be
toleranced
• The tolerance value. If the tolerance
zone is circular or cylindrical it is
preceded with a
• Letters for datum when the
toleranced feature is specified in
relation to one, or more datum.
• If more than one datum is specified
then additional partitions are
provided

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Maximum Material Indication in
Tolerance Frame
The maximum material
condition, when used, is
indicated by a symbol
placed after the
tolerance value, after
the datum letter, or
both.

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Additional Frames- Notes

If a single frame cannot

convey sufficient information
it is acceptable to stack
additional frames and/or
provide additional notes..

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Surface Texture (Finish)
• The quality of machined surface is
characterized by the accuracy of its
manufacture with respect to the
dimensions specified by the designer.
• Every machining operation leaves
characteristic evidence on the
machined surface. This evidence in
the form of finely spaced micro
irregularities left by the cutting tool.
• Each type of cutting tool leaves its
own individual pattern which therefore
can be identified.
• This pattern is known as surface
finish or surface roughness.

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Surface Texture , Contd.
1. Roughness :
Roughness consists of surface irregularities which result from the
various machining process. 2. Roughness Height :
It is the height of the irregularities with respect to a reference line.
2. Roughness Height:
It is the height of the irregularities with respect to a reference line.
3. Roughness Width :
The roughness width is the distance parallel to the nominal surface
between successive peaks or ridges which constitute the predominate
pattern of the roughness.
4. Roughness Width Cut Off :
Roughness width cut off is the greatest spacing of respective surface
irregularities to be included in the measurement of the average
roughness height.
5. Lay :
Lay represents the direction of predominant surface pattern produced
and it reflects the machining operation used to produce it.

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Surface Texture , Contd.
6. Waviness :
This refers to the irregularities which are outside the roughness width
cut off values. Waviness is the widely spaced component of the surface
texture.
7. Waviness Width :
Waviness height is the peak to valley distance of the surface profile.
8. Arithmetic Average (AA):
A close approximation of the arithmetic average roughness-height can
be calculated from the profile chart of the surface. If X is the
measured value from the profilometer, then the AA value can be
calculated as shown below.
9. Root Mean Square (rms)
The rms value can be calculated as shown below. Its numerical value is
about 11% higher than that of AA.

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Surface Texture, Contd.

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Surface Texture , Contd.
• Surface texture Ra is a measurement of the average distance between the
median line of the surface profile and its peaks and troughs
• The relevant English standard is BS1134- Assessment of surface texture.
(measurement units mm (micro.m))
• ANSI B46.1 is used in USA (measurement units minch(micro.inch) )
• The ISO standard is DIN ISO 1302 which uses N numbers .
• Rules of Thumb for surface finish
– (Rough turned with visible toolmarks....N10 (12.5mm (micro.m))
– Smooth machined surface....N8(3.2mm (micro.m))
– Static mating surfaces (or datums).... N7(1.6mm(micro.m))
– Bearing Surfaces.... N6(0.8mm (micro.m))
– Fine lapped surfaces.... N1(0.025mm (micro.m))

(mm)(micro.m) 0.025 0.05 0.1 0.2 0.4 0.8 1.6 3.2 6.3 12.5 25 50
(minch)(micro.inch) 1 2 4 8 16 32 63 125 250 500 1000 2000
N-Grade N1 N2 N3 N4 N5 N6 N7 N8 N9 N10 N11 N12
Smooth Medium
Finish Ground Finishes Rough Machined
Turned Turned

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Roughness Average
50 25 12.5 6.3 3.2 1.6 0.80 0.40 0.20 0.10 0.05
Process (2000) (1000) (500) (250) (125) (63) (32) (16) (8) (4) (2)
Flame Cutting

Snagging

Sawing
(Micro inches µ in.)
In Micrometers µm

Planing, Shaping

Drilling

Chemical Milling

Elect. Discharge
Mach.

Milling

Broaching

Reaming

Electron Beam

Laser

Electro-Chemical

Boring, Turning

Barrel Finishing

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Roughness Average
50 25 12.5 6.3 3.2 1.6 0.80 0.40 0.20 0.10 0.05 0.025
Process
(2000) (1000) (500) (250) (125) (63) (32) (16) (8) (4) (2) (1)
In Micrometers µm (Microinches µ in.)

Roller Burnishing

Grinding

Honing

Electro-Polish

Polishing

Lapping

Superfinishing

Sand Casting

Hot Rolling

Forging

Perm Mold Casting

Investment Casting

Extruding

ld Rolling, Drawing
Die Casting
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