FUNDAMENTALS OF LIMITS, FITS & TOLERANCES

Tolerance: Tolerance is the total permissible variation from the specified basic size of
the part. It is defined as the magnitude of permissible variation of a dimension or measured control criterion from specified value.

Basic size:

The basic size is the size on which variation permitted.

Actual size: The size of a feature obtained by measurement

Different types of tolerances are Dimensional Tolerances Form Tolerances Position Tolerances Surface Roughness values Combination Tolerances

Other details shown on drawing are Material specification Special treatments if any Heat treatments Assembly condition Special notes

TOL not specified

Follow general engineering tolerance IS 2102 fine, medium, coarse & very coarse Unless otherwise specified, it is medium. Or else it can be IT 14 VALUE, bilateral All drawings need contain conditions on general tolerance. Open tolerances or General Engineering tolerances Standards used are IS 2102 ( Part 1) 1993 / ISO 2768 - 1 : 1989

General Tolerances
Part 1: Tolerances for Linear and Angular dimensions without individual tolerance indications Part 2: Geometrical Tolerances for features without individual tolerance indications Ex: 20.0, 20-f, 20-f H

Table 1 Permissible deviations for linear dimensions except for broken edges (external radii and chamfer heights, see table 2) Values in millimeters Tolerance Class
0.5 up to 3 0,05 0,1 0,2 -

Permissible deviations for basic size range

Over 3 up to 6 0,05 0,1 0,3 0,5 Over 6 up to 30 0,1 0,2 0,5 1 Over 30 up to 120 0,15 0,3 0,8 1,5 Over 120 up to 400 0,2 0,5 1,2 2,5 Over 400 up to 1000 0,3 0,8 2 4 Over 1000 up to 2000 0,5 1,2 3 6 Over 2000 up to 4000 2 4 8

Desig nation f m c v

Descripti on fine medium coarse very coarse

For nominal sizes below 0,5 mm, the deviations shall be indicated adjacent to the relevant nominal size (s).
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Table 2 Permissible deviations for broken edges ( external radii and chamfer heights) Values in millimeters
Tolerance class Designation f m c v Description fine medium coarse very coarse Permissible deviations for basic size range 0.5 up to 3 0,2 over 3 up to6 0,5 over 6 1

0,4

0,1

For nominal sizes below 0.5 mm, the deviations shall be indicated adjacent to the relevant nominal size(s).

Table 3 Permissible deviations of angular dimensions

Tolerance class Designation f m c v Description fine medium coarse very coarse 10 30 30 10 20 00 30 10 00 15 00 30 00 10 00 20 5 Permissible deviations for ranges of lengths, in millimeters, of the shorter side of the angle concerned up to 10 10 over 10 up to 50 00 30 over 50 up to 120 00 20 over 120 up to 400 00 10 over 400 00 5

Table 1 General tolerances on straightness and flatness Values in millimeters

Straightness and flatness tolerances for ranges of nominal lengths Tolerance Class over 10 up to 30 0,05 0,1 0,2 over 30 up to 100 0,1 0,2 0,4 over 100 up to 300 0,2 0,4 0,8 over 300 up to 1000 0,3 0,6 1,2 Over 1000 up to 3000 0,4 0,8 1,6

up to 10

H K L

0,02 0,05 0,1

Table-2 General tolerances on perpendicularity Values in millimeters

Tolerance Class H K L Perpendicularity tolerances for ranges of nominal lengths of the shorter side up to 100 0,2 0,4 0,6 over 100 up to 300 0,3 0,6 1 over 300 up to 1000 0,4 0,8 1,5 over 1000 up to 3000 0,5 1 2 6

Table-3 General tolerances on symmetry Values in mm

Tolerance Class H K L 0,6 0,6 1 Symmetry tolerances for ranges of nominal lengths up to 100 over 100 up to 300 over 300 up to 1000 0,5 0,8 1,5 1 2 over 1000 up to 3000

Table 4 General tolerances on circular run-out Values in mm

Tolerance class H K L Circular run-out tolerances 0,1 0,2 0,5 7

IS 2102 PART 2 VALUES FOR Circularity Cylindricity Parallelism Coaxiality - Straightness / Perpendicularity / Symmetry / Runout specified - Limited to diameter tolerance or runout value - Limited to combined effect of CIRCULARITY & PARALLELISM. - Limited to Dimensional Tolerance & flatness tolerance. - Limited to runout tolerance.

ISO 2768 - m General Engg. Tolerance class medium IS 2102 f General Engg. Tolerance class fine ISOmK General Engg. Tolerance for dimensions - Tolerance class. m General Engg. Tolerance for form / position Tolerance class. K

ISO 2768 - K General tolerance as dim not considered. Form/position as per tolerance Class K.

SPECIFIED TOLERANCE VALUE GIVEN VALUE AND POSITIONAL STATUS GIVEN STD. SYMBOLS USED

Specificied tolerances Standards used IS 919 (Part 1) 1993 / ISO 286 1 : 1988 ISO System of Limits and Fits Part 1: Bases of tolerances, Deviations and Fits

Part 2: Tables of standard tolerance Grades and limit Deviations for Holes and shaft. Example : 20H7, 20g6, 30 + 0.02
Specific tolerance should be less than open tolerance STANDARD SPECIFICATION Need contain HOW MUCH IS THE VALUE OF TOL. WHERE IT IS DISPOSED.
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HOW MUCH IS THE VALUE

IS 919 / SP46 OR STD CHARTS SPECIFY. 18 GRADES ARE SPECIFIED. VALUE IS ATTACHED TO A GRADE IT=INTERNATIONAL TOLERANCE GRADE. AND 18 REPRESENT THE ROUGHFEST MANUFACTURING PROCESS. EVERY MANUFACTURING PROCESS IS ATTRIBUTED WITH A RANGE OF ACCURACY GRADE

HOW MUCH IS THE VALUE

FOR EX: TURNING GRINDING MILLING LAPPING SAND CASTING PRESS WORKING INJ. MOULDING IT7, 8 OR 9 IT 5, OR 7 IT 6, 7, OR 8 IT 1, 2, 3, OR 4 IT 16, 17, 18 IT 10, 11 OR 12 IT 12. 13 OR 14

Grades of tolerances obtainable by various manufacturing processes

According to IS 18 grades of tolerances or accuracy grades of manufacturing IT1, IT2, IT3.IT18 IT GRADE is generally indicated by numbers from 1 to 18

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Manufacturing Processes Lapping

IT grades 1,2,3,4

Honing
Laser beam machining

3-5
5,6,7

Super finishing
Grinding

4-6
4-8

Electric Discharge machining

Boring Reaming Broaching Turning (Diamond tools) Turning Milling Shaping

6-7
5-9 5-8 5-9 4-7 7-12 8-10 10-14
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Manufacturing process Drilling Extrusion Blanking Drawing

IT grades 11 14 9 12 12 18 10 14

Die Casting
Sand casting

12 15
14 16

HOW MUCH IS THE VALUE

EVERY DIM. ALONG WITH A GRADE RECEIVE A TOL. VALUE. FOR EX. DIM. 40 & GRADE 8, TOL= ? STD. FORMULA APPLIES TO THIS VALUE FOR CONVENIENCE, DIMES. ARE GROUPED. 0 TO 3; 3 TO 6; 6 TO 10 etc. SAME VALUE OF TOL. VALID FOR A DIA GROUP WITH ONE GRADE.

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Table 1 Numerical values of standard tolerance grades IT for basic sizes up to 3150 mm
Basic size mm
Up to and includ ing

Standard tolerance grades

IT12) IT22) IT32) IT42) IT52) IT6 IT7 IT8 IT9 IT10 IT11 IT12 IT13 IT143) IT153) IT163) IT173) IT183)

Above

Tolerance in microns

Tolerance in

mm

3 6 10 18 30 50 80 120 180 250 315 400 500 630 800 1000 1250 1600 2000 2500

33 6 10 18 30 50 80 120 180 250 315 400 500 630 800

2 2 2 2 2

0,8 1 1 1,2 1,5 1,5 2 2,5 3,5 4,5 6 7 8 9 10 11 13 15 18 22 26

1,2 1,5 1,5 2 2,5 2,5 3 4 5 7 8 9 10 11 13 15 18 21 25 30 36

2 2,5 2,5 3 4 4 5 6 8 10 12 13 15 16 18 21 24 29 35 41 50

3 4 4 5 6 7 8 10 12 14 16 18 20 22 25 28 33 39 46 55 68

4 5 6 8 9 11 13 15 18 20 23 25 27 32 36 40 47 55 65 78 96

6 8 9 11 13 16 19 22 25 29 32 36 40 44 50 56 66 78 92 110 135

10 12 15 18 21 25 30 35 40 46 52 57 63 70 80 90 105 125 150 175 210

14 18 22 27 33 39 46 54 63 72 81 89 97 110 125 140 165 195 230 280 330

25 30 36 43 52 62 74 87 100 115 130 140 155 175 200 230 260 310 370 440 540

40 48 58 70 84 100 120 140 160 185 210 230 250 180 320 360 420 500 600 700 860

60 75 90 110 130 160 190 220 250 290 320 360 400 440 500 560 660 780 920 1100 1350

0,1 0,12 0,15 0,18 0,21 0,25 0,3 0,35 0,4 0,46 0,52 0,57 0,63 0,7 0,8 0,9 1,05 1,25 1,5 1,75 2,1

0,14 0,18 0,22 0,27 0,33 0,39 0,46 0,54 0,63 0,72 0,81 0,89 0,97 1,1 1,25 1,4 1,65 1,95 2,3 2,8 3,3

0,25 0,3 0,36 0,43 0,52 0,62 0,74 0,87 1 1,15 1,3 1,4 1,55 1,75 2 2,3 2,6 3,1 3,7 4,4 5,4

0,4 0,48 0,58 0,7 0,84 1 1,2 1,4 1,6 1,85 2,1 2,3 2,5 2,8 3,2 3,6 4,2 5 6 7 8,6

0,6 0,75 0,9 1,1 1,3 1,6 1,9 2,2 2,5 2,9 3,2 3,6 4 4,4 5 5,6 6,6 7,8 9,2 11 13,5

1 1,2 1,5 1,8 2,1 2,5 3 3,5 4 4,6 5,2 5,7 6,3 7 8 9 10,5 12,5 15 17,5 21

1,4 1,8 2,2 2,7 3,3 3,9 4,6 5,4 6,3 7,2 8,1 8,9 9,7 11 12,5 14 16,5 19,5 23 28 33

1000 1250 1600 2500 3150

20002
2 2

1) Values for standard tolerance grades IT01 and IT0 for basic sizes less than or equal to 500 mm are given in ISO 286 1, annex A, table 5. 2) Values for standard tolerance grades IT1 to IT5 (incl.) for basic sizes over 500 mm are included for experimental use. 3) Standard tolerance grades IT14 to IT18 (incl.) shall not be used for basic sizes less than or equal to 1 mm.

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Table 1-Numerical values of standard tolerance grades IT for basic sizes up to 3150 mm
Basic size mm Above --3 Up to and including 33 6 0.8 1 1.2 1.5 2 2.5 3 4 Standard tolerance grades IT1 2( IT2 2( IT3 2( IT4 2( IT5 2( IT6 IT7 IT8 IT9 IT10 IT11

Tolerances in microns 4 5 6 8 10 12 14 18 25 30 40 48 60 75

6
10 18 30 50

10
18 30 50 80

1
1.2 1.5 1.5 2

1.5
2 2.5 2.5 3

2.5
3 4 4 5

4
5 6 7 8

6
8 9 11 13

9
11 13 16 19

15
18 21 25 30

22
27 33 39 46

36
43 52 62 74

58
70 84 100 120

90
110 130 160 190

80
120 180 250 315 400 500 630 800 1000 1250 1600 2000 2500

120
180 250 315 400 500 630 800 1000 1250 1600 2000 2500 3150

2.5
3.5 4.5 6 7 8 9 10 11 13 15 18 22 26

4
5 7 8 9 10 11 13 15 18 21 25 30 36

6
8 10 12 13 15 16 18 21 24 29 35 41 50

10
12 14 16 18 20 22 25 28 33 39 46 55 68

15
18 20 23 25 27 32 36 40 47 55 65 78 96

22
25 29 32 36 40 44 50 56 66 78 92 110 135

35
40 46 52 57 63 70 80 90 105 125 150 175 210

54
63 72 81 89 97 110 125 140 165 195 230 280 330

87
100 115 130 140 155 175 200 230 260 310 370 440 540

140
160 185 210 230 250 180 320 360 420 500 600 700 860

220
250 290 320 360 400 440 500 560 660 780 920 1100 1350

1) Values for standard tolerance grades IT01 and IT0 for basic sizes less than or equal to 500 mm are given in ISO 286 1, annex A, table 5. 2) Values for standard tolerance grades IT1 to IT5 (incl.) for basic sizes over 500 mm are included for experimental use. 3) Standard tolerance grades IT14 to IT18 (incl.) shall not be used for basic sizes less than or equal to 1 mm.

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Table 1 Numerical values of standard tolerance grades IT for basic sizes up to 3 150 mm
Basic size mm
Up to and including

Standard tolerance grades

IT12 IT13 IT14
3)

IT153) Tolerances

IT163)

IT173)

IT183)

Above

mm

3 6 10 18 30 50 80 120 180 250 315 400 500 630 800 1000 1250 1600 2000 2500

33 6 10 18 30 50 80 120 180 250 315 400 500 630

2

0,1 0,12 0,15 0,18 0,21 0,25 0,3 0,35 0,4 0,46 0,52 0,57 0,63 0,7 0,8 0,9 1,05 1,25 1,5 1,75 2,1

0,14 0,18 0,22 0,27 0,33 0,39 0,46 0,54 0,63 0,72 0,81 0,89 0,97 1,1 1,25 1,4 1,65 1,95 2,3 2,8 3,3

0,25 0,3 0,36 0,43 0,52 0,62 0,74 0,87 1 1,15 1,3 1,4 1,55 1,75 2 2,3 2,6 3,1 3,7 4,4 5,4

0,4 0,48 0,58 0,7 0,84 1 1,2 1,4 1,6 1,85 2,1 2,3 2,5 2,8 3,2 3,6 4,2 5 6 7 8,6

0,6 0,75 0,9 1,1 1,3 1,6 1,9 2,2 2,5 2,9 3,2 3,6 4 4,4 5 5,6 6,6 7,8 9,2 11 13,5

1 1,2 1,5 1,8 2,1 2,5 3 3,5 4 4,6 5,2 5,7 6,3 7 8 9 10,5 12,5 15 17,5 21

1,4 1,8 2,2 2,7 3,3 3,9 4,6 5,4 6,3 7,2 8,1 8,9 9,7 11 12,5 14 16,5 19,5 23 28 33

8002 10002 12502 16002 20002 2500

2

31502

1) Values for standard tolerance grades IT01 and IT0 for basic sizes less than or equal to 500 mm are given in ISO 286 1, annex A, table 5. 2) Values for standard tolerance grades IT1 to IT5 (incl.) for basic sizes over 500 mm are included for experimental use. 3) Standard tolerance grades IT14 to IT18 (incl.) shall not be used for basic sizes less than or equal to 1 mm.

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HOW MUCH IS THE VALUE

60% INCREASE IN TOL. VALUE FOR EVERY GRADE UP FOR A DIA GROUP EVERY 6TH GRADE GETS 100% MORE TOL VALUE

WHERE TO DISPOSE TOL.

TOL. CAN BE DISPOSED ABOVE BASIC DIM. BELOW BASIC DIM DISTRIBUTED ON EITHER SIDE

WHERE TO POSITION
POSITIONING IS REPRESENTED BY CAPITAL LETTERS FOR HOLES A,B,H BY SMALL LETTERS FOR SHAFTS a,b,h STD DISTANCES ARE KEPT EACH LETTER & FOR EACH DIA GROUP FROM BASIC DIM. THE DISTANCE TO THE BASIC DIM WITH LEAST VALUE IS TERMED AS FUNDEMENTAL DEVIATION FUNDAMENTAL DEVIATION IS FIXED FOR A DIA-DIM COMBINATION. 16

Schematic representation of the positions of fundamental deviations

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18

FITS
When two parts to be assembled, the relation resulting from the difference between the size before assembly is called a fit.

A fit is represented by 30 H 7 / g6, 30 H 7 / p6, 40 H7/k6, 40 H7/p6,

40 H7/h6,

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Transition fit

20

21

22

Note: G Go , N No Go , Tolerances in microns 1 micron = 0.001 mm

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MMC, LMC & RFS MMC - Dimension corresponding to Maximum Material Condition (Biggest shaft size or smallest hole size) LMC - Dimension corresponding to Least Material Condition (Smallest shaft or biggest hole size) RFS - Regardless of feature size

Actual Dimension vary from MMC limit to LMC limit Worst assembly condition exist when mating parts at MMC Functional assembly requirements can be related to actual dimension by symbol M in the drawing

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