TOLERANCE AND FITS(ADJUSTMENTS)

TOLERANCE

The permissible variation of a size is called tolerance. It is the difference between the maximum
and minimum permissible limits of the given size.
No component can be manufactured precisely to a given dimension repeatedly in a cost-effective
way.
 This necessitates the manufacturing to be carried out with some deviation from desired
size
 This permissible deviation of dimension from the desired size is known as ‘Tolerance’
 Tolerance is the acceptable error in manufacturing
If the variation is provided on one side of the basic size, it is termed as unilateral tolerance.
Similarly, if the variation is provided on both sides of the basic size, it is known as bilateral
tolerance.
Great care and judgement must be exercised in deciding the tolerances which may be
applied on various dimensions of a component. If tolerances are to be minimum, that is, if the
accuracy requirements are severe, the cost of production increases. In fact, the actual specified
tolerances dictate the method of manufacture. Hence, maximum possible tolerances must be
recommended wherever possible.
TYPES OF TOLERANCE
There are two types of tolerances namely:
– Dimensional Tolerance (DT)
– Geometrical Tolerance (GT)

 DIMENSIONAL TOLERANCE
It is subdivided into Unilateral tolerance and Bilateral tolerance

Figure 3.6 : Tolerance

UNILATERAL TOLERANCE
In this system, the dimension of a part is allowed to vary only on one side of the basic size, i.e.
tolerance lies wholly on one side of the basic size either above or below it

Examples of unilateral tolerance are :

Unilateral system is preferred because:
◦ Easy and simple to determine tolerances
◦ GO gauge may be standardized
◦ Easier in manufacture
◦ Tolerances may be revised without altering the fit
BILATERAL TOLERANCE
In this system, the dimension of the part is allowed to vary on both the sides of the basic size,
i.e. the limits of tolerance lie on either side of the basic size, but may not be necessarily equally
dispose about it

Examples of bilateral tolerance:

It can be express in EQUAL BILATERAL TOLERANCE and UNEQUAL BILATERAL
TOLERANCE as shown below

In this system, it is not possible to retain the same fit when tolerance is varied and the basic size
of one or both of the mating parts are to be varied. This system is used in mass production when
machine setting is done for the basic size.
The above figure shows the tolerances (in microns or in micrometers) that may be obtained
by various manufacturing processes and the corresponding grade number.

FUNDAMENTAL TOLERANCES

Tolerance is denoted by two symbols, a letter symbol and a number symbol, called the grade.
Figure 15.3 shows the graphical illustration of tolerance sizes or fundamental deviations for
letter symbols and Table below lists the fundamental tolerances of various grades.
It may be seen from the above figure that the letter symbols range from A to ZC for holes and
from a to zc for shafts. The letters I, L, O, Q, W and i, l, o, q, w have not been used. It is also
evident that these letter symbols represent the degree of closeness of the tolerance zone (positive
or negative) to the basic size. The fundamental tolerance is a function of the nominal size and its
unit is given by the emperical relation, standard tolerance unit,
Di=0.45 × √3 D+0.001 D

where i is in microns and D is the geometrical mean of the limiting values of the basic steps
mentioned above, in millimetres. This relation is valid for grades 5 to 16 and nominal sizes
from 3 to 500 mm. For grades below 5 and for sizes above 500 mm, there are other emperical
relations for which it is advised to refer IS: 1919–1963. THE Table below gives the relation
between different grades of tolerances and standard tolerance unit i.

Example 1 Calculate the fundamental tolerance for a shaft of 100 mm and grade 7.
The shaft size, 100 lies in the basic step, 80 to 120 mm and the geometrical mean is
3
D= √80 × 120=98 mmThe tolerance unit i=0.45 √ 98+0.001(98) = 2.172 microns

For grade 7, as per the Table 15.1A, the value of tolerance is,
16i = 16 × 2.172 = 35 microns
!-
The symbols used (Fig. 15.3) for the fundamental deviations for the shaft and hole are as
follows :

FITS
When two parts are to be assembled, the relation resulting from the difference between their
sizes before assembly is called a fit. A fit may be defined as the degree of tightness and
looseness between two mating parts.
FIT SYMBOL
A fit is specified by the basic size common to both components, followed by a symbol
corresponding
BASIC TERMS USED IN FITTING
BASIC TERMINOLOGY: HOLES AND SHAFT
  Shaft: External dimension of a component.
 Hole: Internal dimension of a component.
 Basic size: The size obtained for a part from strength calculations. – It is same for
both shaft and hole.
 Actual size: The dimension of a manufactured component.
Fits: The relationship resulting from the difference between the sizes of the two features
(the hole and the shaft) which are to be assembled.

 Limits of sizes: Maximum and minimum permissible sizes of a component. – Shown as

high limit and low limit in the diagram shown aside.
 Tolerance: Maximum size - minimum sizes of a component
 Upper Deviation: Maximum limit - basic size of component.
 Lower Deviation: Minimum limit - basic size component
Upper Deviation: The difference between the maximum limit and the basic size of a component
– Expressed as ES for hole and es for shaft respectively

Lower Deviation: The difference between the minimum limit and the basic size of a component
– Expressed as EI and ei for holes and shaft respectively

fits depend upon the actual limits of the hole and or shaft and can be divided into three general
classes :
(i) Clearance Fit.
(ii) Interference Fit.
(iii) Transition Fit.

CLEARANCE FIT

In clearance fit, an air space or clearance exists between the shaft and hole as shown in Figure
below. Such fits give loose joint. A clearance fit has positive allowance, i.e. there is minimum
positive clearance between high limit of the shaft and low limit of the hole.

Clearance fit can be sub-classified as follows :

LOOSE FIT
It is used between those mating parts where no precision is required. It provides minimum
allowance and is used on loose pulleys, agricultural machineries etc.

RUNNING FIT
For a running fit, the dimension of shaft should be smaller enough to maintain a film of oil for
lubrication. It is used in bearing pair etc. An allowance 0.025 mm per 25 mm of diameter of
boaring may be used.

SLIDE FIT OR MEDIUM FIT

It is used on those mating parts where great precision is required. It provides medium allowance
and is used in tool slides, slide valve, automobile parts, etc.
 INTERFERENCE FIT
A negative difference between diameter of the hole and the shaft is called interference. In such
cases, the diameter of the shaft is always larger than the hole diameter. In Figure 3.2.
Interference fit has a negative allowance, i.e. interference exists between the high limit of hole
and low limit of the shaft.

In such a fit, the tolerance zone of the hole is always below that of the shaft. The shaft is
assembled by pressure or heat expansion. The interference fit can be sub-classified as follows :

SHRINK FIT OR HEAVY FORCE FIT

It refers to maximum negative allowance. In assembly of the hole and the shaft, the hole is
expanded by heating and then rapidly cooled in its position. It is used in fitting of rims etc.

MEDIUM FORCE FIT

These fits have medium negative allowance. Considerable pressure is required to assemble the
hole and the shaft. It is used in car wheels, armature of dynamos etc.
TIGHT FIT OR PRESS FIT
One part can be assembled into the other with a hand hammer or by light pressure. A slight
negative allowance exists between two mating parts (more than wringing fit). It gives a semi-
permanent fit and is used on a keyed pulley and shaft, rocker arm, etc.

Transition fit can be sub-classified as follows :

PUSH FIT
It refers to zero allowance and a light pressure (10 cating dowels, pins, etc.) is required in
assembling the hole and the shaft. The moving parts show least vibration with this type of fit. It
is also known as snug fit.

FORCE FIT OR SHRINK FIT

A force fit is used when the two mating parts are to be rigidly fixed so that one cannot move
without the other. It either requires high pressure to force the shaft into the hole or the hole to be
expanded by heating. It is used in railway wheels, etc.

WRINGING FIT
A slight negative allowance exists between two mating parts in wringing fit. It requires pressure
to force the shaft into the hole and gives a light assembly. It is used in fixing keys, pins, etc.
 SYSTEMS OF FIT
A fit system is the systems of standard allowance to suit specific range of basic size. If these
standard allowances are selected properly and assigned in mating parts ensures specific classes
of fit. There are two systems of fit for obtaining clearance, interference or transition fit. These
are :
(i) Hole basis system.
(ii) Shaft basis system
HOLE BASIS SYSTEM
In the hole basis system, the size of the hole is kept constant and shaft sizes are varied to obtain
various types of fits. In this system, lower deviation of hole is zero, i.e. the low limit of hole is
same as basic size. The high limit of the hole and the two limits of size for the shaft are then
varied to give desired type of fit. The hole basis system is commonly used because it is more
convenient to make correct holes of fixed sizes, since the standard drills, taps, reamers and
branches etc. are available for producing holes and their sizes are not adjustable. On the other
hand, size of the shaft produced by turning, grinding, etc. can be very easily varied.

SHAFT BASIS SYSTEM

In the shaft basis system, the size of the shaft is kept constant and different fits are obtained by
varying the size of the hole. Shaft basis system is used when the ground bars or drawn bars are
readily available. These bars do not require further machining and fits are obtained by varying
the sizes of the hole. In this system, the upper deviation (fundamental deviation) of shaft is zero,
i.e. the high limit of the shaft is same as basic size and the various fits are obtained by varying
the low limit of shaft and both the limits of the hole.