Outline

Introduction

Limits, fits and tolerances

Alignment tests

Types of measurements and instruments

 Introduction to engineering metrology
Metrology is the science of measurement (Ostwald and Munoz
1997)
Importance terms in metrology:
Precision: the repeatability of measurement
Accuracy: a measurement proximity to the true value
Measurement of dimensions such as length, thickness,
diameter, angle, flatness, profile and others.

Dimensional tolerance permissible variation in the dimension

of the part

Rule of thumb the smaller the tolerance, the higher the

production cost
 Limits and fits
It is impossible to make a part to a exact size and if,
by chance, an exact size is achieved it is impossible
to measure it accurately enough to prove it.

Since a part can not be made to an exact size it is

necessary to specify the amount by which the size
may deviate from the ideal size.
The successful functioning of most manufactured
items depends not only upon the individual sizes of
the parts but also upon the relationships of those
parts in an assembly:
 Limits and fits

A perfect part can not be produced.

Therefore it is necessary to specify the amount by

which a size may deviate from its ideal size and
still fulfill its required functions.

Therefore it is necessary to specify the amount by

which a size may deviate from its ideal size and
still fulfill its required functions.
Metric nomenclature
 Limits and fits

Basic Size- size to which limits or deviations are

assigned
Deviation- algebraic difference between size and
corresponding basic size
Upper deviation- indicates maximum difference
Lower deviation- indicates minimum difference
Fundamental deviation- which of the above is closer to the
basic size
 Limits and fits

Tolerance- difference between max. and min. size

limits

International tolerance grade numbers (IT)-

designated groups of tolerances that vary depending
on basic size

Hole basis- system of fits corresponding to hole sizes

(H is the fundamental deviation)

Shaft basis- system of fits corresponding to shaft size

(h is the fundamental deviation)
 Tolerance control

Tolerances are added to:

Control the products that are produced

Dimensions can not be reproduced exactly

Control the accuracy of the process and to reduce

functional or assembly failures.

Create more careful production procedures and more

rigorous inspection
 Tolerance control

There are two different types of conventional tolerances:

Unilateral: specify dimensional variation from the basic

size in one direction.

Bilateral: specified dimensional variation from the basic

size in both directions.

Tighter tolerances improve the quality of the product but

generally increase the manufacturing cost.
Tolerance control
 Type of fits and their description
Type of fit Description Symbol

Clearance Loose running fit: for wide commercial tolerances or allowances on external members H11/c11

Free running fit: not for use where accuracy is essential, but good for large temperature H9/d9
variations, high running speeds, or heavy journal pressures
Close running fit: for running on accurate machines and for accurate location at moderate H8/f7
speeds and journal pressures
Sliding fit: where parts are not intended to run freely, but must have and run freely and locate H7/g6
accurately
Locational clearance fit: Provides snug fit for location of stationary parts, but can be freely H7/h6
assembled and disassembled
Transition Locational transitional: fit for accurate location, a compromise between clearance and H7/k6
interference
Locational transitional fit for more accurate location where greater interference is permissible H7/n6

Interference Locational interference fit: for parts requiring rigidity and alignment with prime accuracy of H7/p6
location but without special bore pressure requirements
Medium drive fit: for ordinary steel parts or shrink fits on light sections, the tightest fit useable H7/s6
with cast iron

Force fit: Suitable for parts which can be highly stressed or for shrink fits where the heavy H7/u6
pressing forces are impractical
Limits and fits
 Type of fits
Clearance fit: The largest permitted shaft diameter is smaller
than the diameter of the smallest hole.
LMC of the hole LMC of the shaft = Clearance
Interference fit: The minimum permitted diameter of the
shaft is larger than the maximum permitted diameter of
the hole.

Least amount of Interference is: Greatest amount of Interference:

LMC Shaft = 1.2513 MMC Shaft = 1.2519
- LMC Hole = 1.2506 - MMC Hole = 1.2500
Min Interference = .0007 Max Interference = .0019
 Type of fits
Transitional fit: The diameter of the largest permitted hole is
greater than that of the smallest permitted shaft and the
smallest permitted hole is smaller than the largest
permitted shaft.

LMC Hole = 1.2506

- LMC Shaft = 1.2503
- Positive Clearance = .0003

MMC Shaft = 1.2509

- MMC Hole = 1.2500
Negative Allowance (Interference) = .0003
 Type of fits systems
These different types of fits are used in conjunction with two
distinct bases:
1. Hole basis system: The desired clearances and
interferences in the fit are achieved by combinations of
various shaft tolerance zone with the hole tolerance zone
H. In this system of tolerance and fits, the lower
deviation of the hole is always equal to zero.
2. Shaft basis system: The desired clearances and
interferences in the fit are achieved in the combination of
various hole tolerance zone with the shaft tolerance zone
h. In this system of tolerance and fits, the upper
deviation of the hole is always equal to zero
 Limits example
Journal bearings are designed to operate at high
rotational speeds.
If the clearance between inner and the outer
diameter is too small the bearing will sieze.
If the clearance is too big the shaft will vibrate.
Limits on the size of the shaft and hole provide
correct operation.
Nominal diameter 20 mm.
Close running fit H8 f7
H8 hole= 20,000 to 20.033
f7 shaft= 19,980 to 19,959 clearance= 20 to 74
micron
 Limits example
Spool valve has a shaft that translates.
This time the clearance should be a sliding fit.
Nominal diameter 20 mm.
Sliding fit H7/g6.
g6 shaft= 19,993 to 19,980
H7 hole = 20,000 to 20, 021
Clearance= 7 to 28 microns
 Limits example
A 20 mm nominal diameter journal/shaft is to
have a clearance, but close accurate running fit.
Within what size tolerances should the parts be
manufactured? Use the basic hole system.

Solution: A H8/f7 fit is suitable. From the BS

chart, for a 20 mm diameter nominal size the H8
limits are + 0.033 and 0.000 and the f7 limits are-
0.020 and -0.041 mm. Hence the hole diameter
should be between 20.000 and 20.003 mm and the
shaft diameter should be between 19.959 and
19.980 mm.
 Example

A fit is designated as diameter 130 H7 p6

1. State the classification of fit produced
2. Determine the limits of size both the shaft and the hole.
3. State the extremes of fit i.e. the maximum or minimum
interference or clearance.
4. Determine the fundamental deviations on both the hole
and the shaft.
5. State the tolerance grades for both the hole and shaft.
 Solution
1. Classification of fit: Interference
2. Hole: + 0.040 Shaft: + 0.068, + 0.043
Hole: 130.040 shaft: 130.068, 130.043
3. Maximum interference occurs between the
smallest hole and the largest shaft;
i.e. 130.000 130.068 = - 0.068 mm
Minimum interference occurs between the largest
hole and the smallest shaft;
i.e. 130.040 130.043 = - 0.003 mm
 Solution
4. Fundamental deviation for Hole = + 0.040 and +
0.000,
Fundamental deviation for shaft = + 0.068, + 0.043
5. Tolerance grade for Hole is IT7 = 0.040
Tolerance grade for shaft is IT6= 0.025
 Question: loose running fit

Determine the loose running fit tolerances for a shaft and hole that
have a basic diameter of 32 mm. 32H11/32c11
Tolerance Grade Hole Shaft

Upper deviation 0.160 mm -0.120 mm

Lower deviation 0.000 mm -0.280 mm
Max Diameter 32.160 mm 31.880 mm
Min Diameter 32.000 31.720 mm
Average Diameter 32.080 mm 31.800 mm
Max Clearance Dmax- dmin=0.44 mm
Min Clearance Dmin-dmax=0.12 mm

Dimensions Hole Shaft

tolerance in 32.080 +0.080 31.800 +0.080
drawing - 0.080 0.080
 Question: loose running fit

Determine the medium drive force fit tolerances for a shaft and hole
that have a basic diameter of 32 mm. 32H7/32s6
Tolerance Grade Hole Shaft

Upper deviation 0.025 mm 0.059 mm

Lower deviation 0.000 mm 0.043 mm
Max Diameter 32.025 mm 32.059 mm
Min Diameter 32.000 mm 32.043 mm
Average Diameter 32.013 mm 32.051 mm
Max Clearance Dmax-dmin= - 0.018 mm
Min Clearance Dmin-dmax= - 0.059 mm
Example
 Types of measurement and instrument
Measurement Instrument Sensitivity
m
Linear Steel rule, 0.5 mm
vernier caliper, 25
micrometer 2.5

Angle Bevel protractor with vernier 5 min

Sine bar 1
Comparative length Dial indicator 1
Gauge blocks 0.05
Straightness Autocollimator 2.5
Flatness Interferometry 0.03
roundness Dial indicater circular tracing 0.03
Profile Dial indicator 1
Optical comparator 125
GO NOT GO
 Limit gauges
The limits for GO and NOT GO gauges for an internal
diameter component are found as follows:

The workpiece tolerance is 0.200 mm. From the column 4

of Table 1, the limits for GO gauges are:
+ 0.021, +0.012, therefore, the size of the GO gauge is:
+75.021 mm, + 75.012 mm.
 Limit gauges
The limits for GO and NOT GO gauges for an internal
diameter component are found as follows:

The workpiece tolerance is 0.200 mm.

From the column 5 of Table 1, the limits for NOT GO
gauges are:
+ 0.0, -0.009, therefore, the size of the NOT GO gauge is:
+75.200 mm, + 74.991 mm.
 Limit gauges
The limits for GO and NOT GO gauges for a shaft are
found as follows:

The workpiece tolerance is 0.040 mm.

From the column 6 of Table 1, the limits for GO
gauge are: -0.002 mm, - 0.005 mm
+ 0.0, -0.009, therefore, the size of the GO gauge is:
+44.928 mm, + 44.925 mm.
 Limit gauges
The limits for GO and NOT GO gauges for a shaft are
found as follows:

The workpiece tolerance is 0.040 mm.

From the column 7 of Table 1, the limits for NOT GO
gauge are: +0.003 mm, - 0.000 mm
therefore, the size of the NOT GO gauge is:
+44.893 mm, + 44.890 mm.
 References

1. S. Kalpakjian, S.R. Schmid: Manufacturing Engineering &

Technology, 5th edition, Prentice-Hall International, 2006.
2. E. Paul Degarmo, J. R. Black, R. A. Kohser; Materials and
Processes in Manufacturing, 9th edition, John Wiley & Sons, Inc,
2003.
3. R. L. Timings, S. P. Wilkinson: Manufacturing Technology, 2nd
edition, Pearson Education Limited, London, 2000.
4. J. F. W. Galyer, C. R. Shotbolt: Metrology for Engineers, Cassell &
Co. Ltd, 3rd edition, 1977.
5. Data Sheet BS 4500A: 1970