Metrology and Measurement MEC314

Sunil Sharma

Fits and tolerances

Important terms
Nominal size = a dimension used to describe the general size Basic size = the theoretical size used as a starting point for the application of tolerances
Actual size = the measured size of the finished part after machining Limits = the max and min sizes shown by the toleranced dimension Allowance = the min clearance or maximum interference between parts, or the tightest fit between two mating parts

Tolerancing why is it needed?

Tolerance = the total amount a dimension may vary and is the difference between the maximum and minimum limits (e.g. 4.650 0.003)

Tolerances are used to control the variation existing on all manufactured parts. Toleranced dimensions control the amount of variation on each part of an assembly. Tolerances allow for interchangeable parts. Parts made by different companies functionally fit although they may not perfectly fit.

Tolerancing why is it needed?

Tolerance = the total amount a dimension may vary and is the difference between the maximum and minimum limits (e.g. 4.650 0.003)

Tolerances are used to control the variation existing on all manufactured parts. Toleranced dimensions control the amount of variation on each part of an assembly. Tolerances allow for interchangeable parts. Parts made by different companies functionally fit although they may not perfectly fit.

Tolerancing why is it needed?

Tolerance = the total amount a dimension may vary and is the difference between the maximum and minimum limits (e.g. 4.650 0.003)

Tolerances are used to control the variation existing on all manufactured parts. Toleranced dimensions control the amount of variation on each part of an assembly. Tolerances allow for interchangeable parts. Parts made by different companies functionally fit although they may not perfectly fit.

Important terms (cont)

Tolerance = the total allowable variance in a dimension Max material condition (MMC) = the condition of a part when it contains the greatest amount of material
Least material condition (LMC) = the condition of a part when it contains the least amount of material possible

Tolerancing

Maximum Material Condition (MMC)- when it contains the most material (Weighs the most) Least Material Condition (LMC)when it contains the least material (Weighs the least)

Tolerancing why is it needed?

Tolerance = the total amount a dimension may vary and is the difference between the maximum and minimum limits (e.g. 4.650 0.003)

Tolerances are used to control the variation existing on all manufactured parts. Toleranced dimensions control the amount of variation on each part of an assembly. Tolerances allow for interchangeable parts. Parts made by different companies functionally fit although they may not perfectly fit.

Tolerance Dimensioning
Tolerance is the total amount that a specific dimension is permitted to vary; It is the difference between the maximum and the minimum limits for the dimension. For Example a dimension given as 1.625 .002 means that the manufactured part may be 1.627 or 1.623, or anywhere between these limit dimensions.

Tolerances

The Tolerance is 0.001 for the Hole as well as for the Shaft

Tolerances
Plus-or-minus Dimensioning Unilateral Tolerance

Bilateral Tolerance

Fits

Basic Systems for Fit Specification

In order to standardize dimensioning of fits, two basic systems are used

1) Basic Hole System (BHS)

Minimum hole diameter is taken as the basis. Lower deviation for the hole is equal to zero. Dmax is prescribed according to the specified tolerance.

2) Basic Shaft System (BSS)

Maximum shaft diameter is taken as the basis. Upper deviation for the Shaft is equal to zero. dmin is prescribed according to the specified tolerance.

Basic Systems for Fit Specification

tolerance zone

Fund. Dev.

BHS

BSS

tolerance zone

Fund. Dev. hole

basic size

hole

basic size

shaft shaft tolerance zone

International Tolerance Grade Numbers

In order to establish a preferred fit we need 1) The magnitude of the tolerance zone for the shaft and the hole 2) Fundamental deviation for the shaft (in BHS) Fundamental deviation for the hole (in BSS) International tolerance grade numbers (IT numbers) designate groups of tolerances such that tolerances for a particular IT number have the same relative level of accuracy but vary depending on the basic size. The magnitude of the tolerance zone is the variation in part size. The tolerance zones are specified in international tolerance grade numbers called IT numbers. These numbers range from IT0 to IT16. The smaller grade numbers specify a smaller tolerance zone.

International Tolerance Grade Numbers

Application,Process Slip blocks, reference gages High quality gages, plus gages Good quality gages, gap gages Fits produced by lapping Tolerance (mm) 1-2 2-3 3-5 4-10 5-12 IT Grade 1 2 3 4 5

Ball bearings, Diomand or fine boring, fine grinding Grinding, fine honing
High quality turning, broaching Center lathe turning and boring, reaming Horizontal or vertical boring machine Milling, slotting, planing, metal rolling or extrusion Drilling, rough turning and boring, precision tubing

6-20
12-35 14-50 30-80 50-100 70-140

6
7 8 9 10 11

Light press work, tube drawing

Press work, tube rolling Die casting or molding, rubber moulding Stamping Sand casting, flame cutting

120-240
150-500 250-1000 400-1400 500-2000

12
13 14 15 16

Fit Types
There are three types of fits a) Clearence Fits b) Interference Fits c) Transition Fits
Clearence Fits The mating parts have such upper and lower limits that a clearence always results when the mating parts are assembled.

hole

Cmin

d max 25.95 mm d min 25.93 mm

Dmax 26.03 mm
shaft

Ts 0.02 mm Th 0.03 mm

Dmin 26.00 mm

Allowance of the fit corresponds to maximum material condition (Cmin). Allowance can be calculated by considering tightest fit.

Fit Types
There are three types of fits a) Clearence Fits b) Interference Fits c) Transition Fits Interference Fits The mating parts have such limits that the lowest shaft diameter is larger than the largest hole diameter.

hole

shaft

d max 25.04 mm d min 25.02 mm

Dmax 25.01 mm Dmin 25.00 mm

Ts 0.02 mm Th 0.01 mm

I max

Allowance of the fit corresponds to maximum material condition (Imax).

Fit Types
There are three types of fits a) Clearence Fits b) Interference Fits c) Transition Fits Transition Fits Either a clearance or an interference may result depending on the exact value of the dimensions of the machined shaft and hole within the specified tolerance zones

d max 25.04 mm
hole shaft

d min 25.02 mm Dmax 25.03 mm Dmin 25.00 mm

Ts 0.02 mm

I max

Th 0.03 mm

Allowance of the fit corresponds to maximum material condition (Imax).

Specification for the Fits

tolerance zone

Fund. Dev.

25 H7/g6
BHS
basic size

fund. dev. for the hole IT grade for the hole

IT grade for the shaft

fund. dev. for the shaft

H/(a-z) BHS (fund. dev. for the hole is zero) (A-Z)/h BSS (fund. dev. for the shaft is zero) Letters I, L, O, Q, W, i, l, o, q, w are not used.

Fundamental Deviations (Letter Specification)

+
A

BHS: H/(a-g) (negative) H/(j-k) (depends on size) H/(m-z) (positive)

BC DE

BSS: (A-G)/h (positive) (J-K)/h (depends on size) (M-Z)/h (negative) t

dF

rs p mn

uv

yz

basic size
J K MN

dF

dF
PR ST UV XY

dF
b
a

cd

ef

j gh

HOLE

SHAFT

Tolerance on the Fit

Tolerance on the fit is defined as the sum of the tolerance on the hole an tolerance on the shaft.

T f Th Ts Dmax Dmin d max d min

clearence interference

Cmin

Cmax

Imin

Imax

T f Cmax Cmin
Cmax

T f I max I min
Imax

transition

T f I max Cmax

Example
For a nominal diameter of 25 mm and for a fit specification of H7/j5 determine the following: a) b) c) d) e) f) g) Type of the tolerancing system Tolerance on the hole Tolerance on the shaft Upper and lower limits of the hole (Dmax, Dmin) Upper and lower limits of the shaft (dmax, dmin) Type of the fit Tolerance on the fit

Example
a) H7/j5 Basic Hole System b) D = 25 mm, from the given table:
H7 21 mm 0 mm j5 5 mm - 4 mm

+ c) Ts 9 mm

H7

nominal size j5
Th 21 mm

Example
d) Dmin 0, (Basic Hole System)
Dmax 25 0.021 25.021 mm

e) d min 25 0.004 24.996 mm

d max 25 0.005 25.005 mm

f)

Interference fit.

g)

Tolerance on the fit:

T f Th Ts 21 9 30 mm
or, I max 5 mm, Cmax 21 4 25 mm.

T f I max Cmax 30 mm.

 Tolerance is denoted by 2 symbols, a letter symbol and a number symbol, called a grade Letter symbols range from A to ZC for holes and from a to zc for shafts

18 grade of tolerances are known as fundamental tolerances

Fundamental deviations

Fundamental Deviations (Letter Specification)

+
A

BHS: H/(a-g) (negative) H/(j-k) (depends on size) H/(m-z) (positive)

BC DE

BSS: (A-G)/h (positive) (J-K)/h (depends on size) (M-Z)/h (negative) t

dF

rs p mn

uv

yz

basic size
J K MN

dF

dF
PR ST UV XY

dF
b
a

cd

ef

j gh

HOLE

SHAFT

 Runout of gear reflects total variation of specific elements of the tooth surface from axis of rotation of the gear. Runout is commonly measured in direction perpendicular to axis of rotation of gear, the radial runout Also determined by measuring the variation of specific gear surface elements in a direction parallel to axis of rotation, the axial runout Runout is twice the eccentricity