Fits and Tolerance:

Introduction:
Tolerance can be defined as the magnitude of permissible variation ofa dimension or
other measured value from the specified value.
It can also be defined as the total variation permitted in the size of a dimension, and is
the algebraic difference between the upper and lower acceptable dimensions. It is an
absolute value.
The basic purpose of providing tolerances is to permit dimensional variations in the
manufacture of components, adhering to the performance criterion as established by
the specification and design.
Tolerances set the allowable deviation from assigned dimensions. The use of
tolerances helps to ensure that the final product is readily usable, especially if it is a
part of a larger assembly.
Not setting a tolerance in a critical area may render the part unusable according to the
design intent, as each fabrication method comes with a certain level of inaccuracy.
However, pinpointing a suitable tolerance makes sure that the manufacturing
company knows to tackle a few specific points in the production process with more
attention. This can be the difference between perfectly mating parts and scrap metal.
The term fits refers to the degree of tightness or looseness between two mating parts.
Depending upon the actual limits of the hole and shaft.
Manufactured parts are required to mate with one another during assembly
The relationship between the two mating parts that are to be assembled, that is, the
hole and the shaft, with respect to the difference in their dimensions before assembly
is called a fit.
An ideal fit is required for proper functioning of the mating parts. Three basic types
of fits can be identified, depending on the actual limits of the hole or shaft
Fits may be classified into the following three types shown in the figure:
The following terms and definitions are important from the subject point of view:
Shaft:
The term shaft refers not only to the diameter of a circular shaft but to any external
dimension on a component.
Hole:
The term hole refers not only to the diameter of a circular hole but to any internal
dimension of a component.
Basic Size:
The term basic size refers to the size from which the limits of size are derived by the
application of tolerance (i.e. upper and lower deviation). The basic size or nominal
size of a part is often the same and it is termed as zero line.
Limits of Size:
The term limits of size referred to the two extreme permissible sizes for a dimension
of a part, between which the actual size should lie. The largest permissible size for a
dimension is called upper or high or maximum limit, whereas the smallest size is
called lower or minimum limit.
Nominal Size:
The term nominal size refers to the size of a part specified in the drawing for
convenience to shop floor.
Hole Basis System:
In hole basis system, the size of the hole is constant and different fits are obtained by
varying the size of shaft as shown in figure:

Shaft Basic System:

In shaft basic system, the size of the shaft is constant and different fits are obtained
by varying the size of the hole, as shown in figure:
Fits may be classified into the following three types:
1. Clearance fit:

Clearance fit is one in which two assembled parts are always free to move relative to
each other in the assembly. In the clearance fit, the largest permitted shaft diameter is
smaller than the diameter of the smallest hole. The difference between the size of the
hole and the size of the shaft is defined as clearance. Clearance fits have limits of the
size prescribed so that a clearance always results in a positive allowance, or air space
is left between mating parts. The parts can be assembled by hand. Clearance fit is of
two kinds namely sliding and running fits.
Examples of clearance fit are door hinges, wheel, and axle, shaft and bearing, etc.
used in the assembly of parts.
Clearance fits may be classified into the following types:

1. Running Fit
For a running fit, the dimension of the 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
bearing may be used.

2. Slide Fit
It is used on those mating parts where great precision is required. It provides medium
allowance and is used in tool slides, slide valves, automobile parts, etc.

2. Transition fit:

In this type of fit, the diameter of the largest allowable hole is greater than that of the
smallest shaft, but the smallest hole is smaller than the largest shaft so that small
positive or negative clearance between the shaft and hole member is employable.
Thus, transition fit has limits of the size of the hole and shaft such that either a
clearance or an interference fit may result when two specific parts from the lot are
assembled. Here the tolerance zones of the hole and shaft overlap. Transition fits are
a compromise between clearance and interference fit where a small amount of either
clearance or interference is permissible. Transition fit is of two kinds namely push-fit
and light keying fits. That is, sometimes the shaft is slightly larger than the hole and
sometimes slightly smaller than the hole. Spigot in mating holes, coupling rings and
recesses are the examples of transition fit.
Transition fit can be sub-classified as follows

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

2. 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.

3. Interference fit:

In the interference fit, mating parts in sub-assembly or main assembly are joined
tightly together and no relative motion is possible. The minimum permitted diameter
of the shaft is larger than the maximum allowable diameter of the hole.
In this case, the shaft and the hole member in any sub-assembly or main assembly
are to be attached permanently and used as a solid component but according to the
application of this combination, this type of fit can be varied. Interference fit is used
for permanent or semi-permanent assembly of parts, which require rigidity and
alignment and no relative motion, such as dowel pins and bearings in casting.
The difference between the size of the shaft and the size of the hole in any sub-
assembly or main assembly is called interference or negative clearance or negative
allowance.
Interference fit has limits of size so prescribed that interference always results when
mating parts are assembled. Transition fits are of two kinds namely driving or press-
fit and shrink or force fit. To assemble, parts are usually pressed together using an
arbor press.
The interference fit can be sub-classified as follows:

1. Shrink Fit or Heavy Force Fit

It refers to the maximum negative allowance.
In the assembly of the hole and the shaft, the hole is expanded by heating and then
rapidly cooled in its position. It is used in the fitting of rims etc.
2. 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.

3. 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.

Examples:

Example 1

Example 2