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
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 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, Ø20-f H

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 Table 1 – Permissible deviations for linear dimensions except for broken edges
(external radii and chamfer heights, see table 2)
Values in millimeters

Tolerance Class Permissible deviations for basic size range

0.5 Over Over Over Over Over Over Over

Design Descriptio up to 3 6 30 120 400 1000 2000
ation n 3 up to up to up to up to up to up to up to
6 30 120 400 1000 2000 4000

f fine ±0,05 ± 0,05 ± 0,1 ± 0,15 ± 0,2 ± 0,3 ± 0,5 -

m medium ± 0,1 ± 0,1 ± 0,2 ± 0,3 ± 0,5 ± 0,8 ± 1,2 ±2

c coarse ± 0,2 ± 0,3 ± 0,5 ± 0,8 ± 1,2 ±2 ±3 ±4

v very - ± 0,5 ±1 ± 1,5 ± 2,5 ±4 ±6 ±8

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 Permissible deviations for basic size range

Designation Description 0.5 up to 3 over 3 up to6 over 6

f fine
± 0,2 ± 0,5 ±1
m medium
c coarse
± 0,4 ± 0,1 ±2
v very coarse
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

Permissible deviations for ranges of lengths, in millimeters,

Tolerance class of the shorter side of the angle concerned
Designation Description up to 10 over 10 up to 50 over 50 up to over 120 up to over 400
120 400
f fine ± 10 ± 00 30’ ± 00 20’ ± 00 10’ ± 00 5’
m medium
c coarse ± 10 30’ ± 10 ± 00 30’ ± 00 15’ ± 00 10’
v very coarse ± 30 ± 20 ± 10 ± 00 30’ ± 00 20’
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 Table 1 – General tolerances on straightness and flatness
Values in millimeters

Straightness and flatness tolerances for ranges of nominal lengths

Tolerance Over
Class over 10 up over 300
over 30 over 100 1000
up to 10 to up to
up to 100 up to 300 up to
30 1000
3000

H 0,02 0,05 0,1 0,2 0,3 0,4

K 0,05 0,1 0,2 0,4 0,6 0,8

L 0,1 0,2 0,4 0,8 1,2 1,6

Table-2 General tolerances on perpendicularity

Values in millimeters
Perpendicularity tolerances for ranges of nominal lengths of the
Tolerance shorter side
Class over 100 up over 300 over 1000
up to 100
to 300 up to 1000 up to 3000

H 0,2 0,3 0,4 0,5

K 0,4 0,6 0,8 1

L 0,6 1 1,5 2 6
 Table-3 – General tolerances on symmetry
Values in mm

Symmetry tolerances for ranges of

nominal lengths
Tolerance
Class over 100 up over 300 over 1000
up to 100
to 300 up to 1000 up to 3000

H 0,5

K 0,6 0,8 1

L 0,6 1 1,5 2

Table 4 – General tolerances on circular run-out

Values in mm

Tolerance class Circular run-out tolerances

H 0,1
  K 0,2

L 0,5

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 IS 2102 – PART – 2

• VALUES FOR - Straightness / Perpendicularity / Symmetry / Runout specified

• Circularity - Limited to diameter tolerance or runout value
• Cylindricity - Limited to combined effect of CIRCULARITY & PARALLELISM.
• Parallelism - Limited to Dimensional Tolerance & flatness tolerance.
• Coaxiality - Limited to runout tolerance.
ISO 2768 - m
• General Engg. Tolerance class medium

IS 2102 – f
• General Engg. Tolerance class fine

ISO–mK
• 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.

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 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 IT7, 8 OR 9
• GRINDING IT 5, OR 7
• MILLING IT 6, 7, OR 8
• LAPPING IT 1, 2, 3, OR 4
• SAND CASTING IT 16, 17, 18
• PRESS WORKING IT 10, 11 OR 12
• INJ. MOULDING 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 IT grades
Lapping 1,2,3,4
Honing 3-5
Laser beam machining 5,6,7
Super finishing 4-6
Grinding 4-8
Electric Discharge machining 6-7
Boring 5-9
Reaming 5-8
Broaching 5-9
Turning (Diamond tools) 4-7
Turning 7-12
Milling 8-10
Shaping 10-14

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 Manufacturing process IT grades

Drilling 11 – 14

Extrusion 9 – 12

Blanking 12 – 18

Drawing 10 – 14

Die Casting 12 – 15

Sand casting 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 Standard tolerance grades

mm IT12) IT22) IT32) IT42) IT52) IT6 IT7 IT8 IT9 IT10 IT11 IT12 IT13 IT143) IT153) IT163) IT173) IT183)
Up to
and
Above Tolerance in microns Tolerance in mm
includ
ing
- 33 0,8 1,2 2 3 4 6 10 14 25 40 60 0,1 0,14 0,25 0,4 0,6 1 1,4
3 6 1 1,5 2,5 4 5 8 12 18 30 48 75 0,12 0,18 0,3 0,48 0,75 1,2 1,8
6 10 1 1,5 2,5 4 6 9 15 22 36 58 90 0,15 0,22 0,36 0,58 0,9 1,5 2,2
10 18 1,2 2 3 5 8 11 18 27 43 70 110 0,18 0,27 0,43 0,7 1,1 1,8 2,7
18 30 1,5 2,5 4 6 9 13 21 33 52 84 130 0,21 0,33 0,52 0,84 1,3 2,1 3,3
30 50 1,5 2,5 4 7 11 16 25 39 62 100 160 0,25 0,39 0,62 1 1,6 2,5 3,9
50 80 2 3 5 8 13 19 30 46 74 120 190 0,3 0,46 0,74 1,2 1,9 3 4,6
80 120 2,5 4 6 10 15 22 35 54 87 140 220 0,35 0,54 0,87 1,4 2,2 3,5 5,4
120 180 3,5 5 8 12 18 25 40 63 100 160 250 0,4 0,63 1 1,6 2,5 4 6,3
180 250 4,5 7 10 14 20 29 46 72 115 185 290 0,46 0,72 1,15 1,85 2,9 4,6 7,2
250 315 6 8 12 16 23 32 52 81 130 210 320 0,52 0,81 1,3 2,1 3,2 5,2 8,1
315 400 7 9 13 18 25 36 57 89 140 230 360 0,57 0,89 1,4 2,3 3,6 5,7 8,9
400 500 8 10 15 20 27 40 63 97 155 250 400 0,63 0,97 1,55 2,5 4 6,3 9,7
2
500 630 9 11 16 22 32 44 70 110 175 180 440 0,7 1,1 1,75 2,8 4,4 7 11
2
630 800 10 13 18 25 36 50 80 125 200 320 500 0,8 1,25 2 3,2 5 8 12,5
2
800 1000 11 15 21 28 40 56 90 140 230 360 560 0,9 1,4 2,3 3,6 5,6 9 14
2
1000 1250 13 18 24 33 47 66 105 165 260 420 660 1,05 1,65 2,6 4,2 6,6 10,5 16,5
2
1250 1600 15 21 29 39 55 78 125 195 310 500 780 1,25 1,95 3,1 5 7,8 12,5 19,5
1600 20002 18 25 35 46 65 92 150 230 370 600 920 1,5 2,3 3,7 6 9,2 15 23
2
2000 2500 22 30 41 55 78 110 175 280 440 700 1100 1,75 2,8 4,4 7 11 17,5 28
2
2500 3150 26 36 50 68 96 135 210 330 540 860 1350 2,1 3,3 5,4 8,6 13,5 21 33

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 Standard tolerance grades

mm
IT1 2( IT2 2( IT3 2( IT4 2( IT5 2( IT6 IT7 IT8 IT9 IT10 IT11

Above Up to and Tolerances in microns

including

--- 33 0.8 1.2 2 3 4 6 10 14 25 40 60

3 6 1 1.5 2.5 4 5 8 12 18 30 48 75

6 10 1 1.5 2.5 4 6 9 15 22 36 58 90

10 18 1.2 2 3 5 8 11 18 27 43 70 110

18 30 1.5 2.5 4 6 9 13 21 33 52 84 130

30 50 1.5 2.5 4 7 11 16 25 39 62 100 160

50 80 2 3 5 8 13 19 30 46 74 120 190

80 120 2.5 4 6 10 15 22 35 54 87 140 220

120 180 3.5 5 8 12 18 25 40 63 100 160 250

180 250 4.5 7 10 14 20 29 46 72 115 185 290

250 315 6 8 12 16 23 32 52 81 130 210 320

315 400 7 9 13 18 25 36 57 89 140 230 360

400 500 8 10 15 20 27 40 63 97 155 250 400

500 630 9 11 16 22 32 44 70 110 175 180 440

630 800 10 13 18 25 36 50 80 125 200 320 500

800 1000 11 15 21 28 40 56 90 140 230 360 560

1000 1250 13 18 24 33 47 66 105 165 260 420 660

1250 1600 15 21 29 39 55 78 125 195 310 500 780

1600 2000 18 25 35 46 65 92 150 230 370 600 920

2000 2500 22 30 41 55 78 110 175 280 440 700 1100

2500 3150 26 36 50 68 96 135 210 330 540 860 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 Standard tolerance grades

mm IT12 IT13 IT14 3)
IT153) IT163) IT173) IT183)

Up to and Tolerances
Above
including
mm
- 33 0,1 0,14 0,25 0,4 0,6 1 1,4
3 6 0,12 0,18 0,3 0,48 0,75 1,2 1,8
6 10 0,15 0,22 0,36 0,58 0,9 1,5 2,2
10 18 0,18 0,27 0,43 0,7 1,1 1,8 2,7
18 30 0,21 0,33 0,52 0,84 1,3 2,1 3,3
30 50 0,25 0,39 0,62 1 1,6 2,5 3,9
50 80 0,3 0,46 0,74 1,2 1,9 3 4,6
80 120 0,35 0,54 0,87 1,4 2,2 3,5 5,4
120 180 0,4 0,63 1 1,6 2,5 4 6,3
180 250 0,46 0,72 1,15 1,85 2,9 4,6 7,2
250 315 0,52 0,81 1,3 2,1 3,2 5,2 8,1
315 400 0,57 0,89 1,4 2,3 3,6 5,7 8,9
400 500 0,63 0,97 1,55 2,5 4 6,3 9,7
2
500 630 0,7 1,1 1,75 2,8 4,4 7 11
630 8002 0,8 1,25 2 3,2 5 8 12,5
800 10002 0,9 1,4 2,3 3,6 5,6 9 14
1000 12502 1,05 1,65 2,6 4,2 6,6 10,5 16,5
1250 16002 1,25 1,95 3,1 5 7,8 12,5 19,5
1600 20002 1,5 2,3 3,7 6 9,2 15 23
2
2000 2500 1,75 2,8 4,4 7 11 17,5 28
2500 31502 2,1 3,3 5,4 8,6 13,5 21 33

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.

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Schematic
representation of the
positions of
fundamental
deviations
17
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/h6,
 40 H7/k6,  40 H7/p6,
 

19
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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