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B. Tech. Mechanical Engineering

Semester -IV
[ME2106]: Manufacturing
Processes-I

Dr. Ashish Kumar

Department of Mechanical Engineering
JSPM's Rajarshi Shahu College of Engineering,
Tathawade, Pune
411033
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 Unit-I: Metrology and Inspection

Syllabus: Introduction to measuring instruments, Measurement

standards, Types and sources of errors, Accuracy and Precision, Limits,

fits and tolerances; linear and angular measurements; comparators,
form and finish measurement; tolerance analysis in manufacturing and
assembly.
Limits, Fits and Tolerances

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 Limits
LIMITS:- The maximum and minimum permissible sizes within which the actual size
of a component lies are called limits.

• Limits are fixed with reference to the basic size of that dimension.
• Upper limit (The high limit) for that dimension is the largest size permitted and the
low limit is the smallest size permitted for that dimension.

Basic Definitions
• Basic Size/Nominal Size, Actual Size
• Limits (Upper & lower), Tolerance ( Shaft & Hole)
• Deviation (Upper, Lower & Fundamental)

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 Basic Definitions
• Basic Size: It is the size with reference to which upper or lower limits of size are
defined.
• Shaft and Hole: These terms are used to designate all the external and internal
features of any shape and not necessarily cylindrical.
• Hole Designation: By upper case letters from A, B, … Z, Za, Zb, Zc(excluding I, L,
O, Q, W and adding Js, Za, Zb, Zc) -28 nos.
• Shaft Designation: By lower case letters from a, b, … z, za, zb, zc(excluding i, l, o, q,
w and adding js, za, zb, zc) -28 nos.
• Upper Deviation: The algebraic difference between the maximum limit of size (of
either hole or shaft) and the corresponding basic size, like ES, es.
 Basic Definitions
• Lower Deviation: The algebraic difference between the minimum limit of size (of either
hole or shaft) and the corresponding basic size, like EI, ei.
• Fundamental Deviation: It is one of the two deviations which is chosen to define the
position of the tolerance zone.
• Or The distance from basic size to where tolerance zone is situate is called fundamental
deviations
• Tolerance: The algebraic difference between upper and lower deviations. It is an absolute
value.
• Limits of Size: There are two permissible sizes for any particular dimension between
which the actual size lies, maximum and minimum.
• Basic Shaft and Basic hole: The shafts and holes that have zero fundamental deviations.
The basic hole has zero lower deviation whereas, the basic shaft has zero upper deviation.
• Allowance – The minimum clearance or maximum interference between parts
• Fit – Degree of tightness between two parts
 Maximum and Minimum/Least Material Condition
Shaft
Hole Raw
Material Raw Material

Minimum Material Condition (MMC) Upper Limit Basic

Or Upper Limit Size
Least material condition (LMC)
Maximum Material Condition (MMC)

Lower Limit
Maximum Material Condition (MMC) Minimum Material Condition (MMC)/
Least material condition (LMC)

Lower Limit

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 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.

Metrology
 Clearance Fit
Clearance Fit:- This means there is a gap between the two mating parts.
• The diameter of the shaft is smaller than the diameter of the hole. There is a clearance
between the shaft and the hole. Hence the shaft can easily slide into the hole.

1. Max. Clearance = Max. size of the

Hole-Min. size of the Shaft

2. Min. Clearance = Min. size of the

Hole- Max. size of the Shaft

• In clearance fit the difference between the maximum size of the hole and the
minimum size of the shaft is known as the Maximum clearance and the difference
between the minimum size of the hole and the maximum size of the shaft is known as
the Minimum clearance.
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 Interference Fit
Interference Fit:- The diameter of the shaft is larger than the hole diameter.
• There will be the intersection of two mating components will be occurred. Hence the
shaft will need additional force to fit into the hole.

1. Max. Interference = Max. size of the

Shaft-Min. size of the Hole

2. Min. Interference = Min. size of the

Shaft- Max. size of the Hole

• In Interference fit the difference between the maximum size of the shaft and the
minimum size of the hole is known as the Maximum Interference and the difference
between the minimum size of the shaft and the maximum size of the hole is known as
the Minimum Interference.
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 Transition Fit
Transition Fit:- Transition fit is neither loose nor tight as like clearance fit and
interference fit.
• The tolerance zones of the shaft and the hole will be overlapped between the
interference and clearance fits.
1. Interference Fit = Max. size of the
Shaft > Min. size of the Hole

2. Clearance Fit= Max. size of the Hole >

Min. size of the Shaft

• Transition Fit can be sub-classified as Push Fit and Force Fit or Shrink Fit

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 TOLERANCES
• Tolerance is a permissible limit and variation in dimensions or in physical
parameters.
• It is possible to achieve dimensions and physical parameter exactly but it is very time
consuming and economically unjustified or costly. It is quite often not necessary to
achieve exact dimensions, in such functions or cases some permissible variation or
tolerance is given.
• The permissible variation in size or dimension is tolerance. The difference between
the upper limit (high limit) and the lower limit of a dimension represents the margin
for variation to workmanship, and is called a tolerance zone.

• There are two ways of writing tolerances:

(a) Unilateral tolerance

(b) Bilateral tolerance Metrology

 International Tolerance (IT) Grades
Grade of Tolerance: It is an indication of the level
of accuracy. There are 20 grades of tolerances –IT
01, IT 0, IT 1 to IT 16
• IT 01 to IT 4 -For production of gauges, plug
gauges, measuring instruments
“i” =
• IT 5 to IT 7 -For fits in precision engineering
Standard
applications
Tolerance
• IT 8 to IT 11 –For General Engineering Limit
• IT 12 to IT 14 –For Sheet metal working or press
working
• IT 15 to IT 16 –For processes like casting, general
cutting work
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IS 919-1965 SYSTEM OF TOLERANCES

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Standard Tolerance: Various grades of tolerances are defined using the ‘standard
tolerance unit’, (i), which is a function of basic size.

(microns)

Where, D is the geometric mean of the lower and upper diameters of a particular
diameter step within which the chosen the diameter D lies.

• The above equation is used when D=500mm or D<500mm.

• If the value of D is grater than 500mm than,

i = 0.004D+2.1 (microns)

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50 H 6 g 7

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 Gauge Design

Taylor’s Principle
According to Taylor, ‘Go’ and ‘No Go’ gauges should be designed to check
maximum and minimum material limits which are checked as below.

‘Go’ Limit. This designation is applied to that limit of the two limits of size
which corresponds to the maximum material limit consideration, i.e. upper
limit of a shaft and lower limit of a hole.

‘No Go’ Limit. This designation is applied to that limit of the two limits of
size which corresponds to the minimum material condition, i.e. the lower
limit of a shaft and the upper limit of a hole
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 Plug Gauges (For Hole)
They are used only to determine, whether the product size is within
specified limits or not
 Plug Gauges (For Hole)

(LL)

(UL)

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 Snap/Ring Gauges (For Shaft)

They are used only to determine, whether the product size is within
specified limits or not

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 Snap/Ring Gauges (For Shaft)

ACCEPTED REJECTED

If GO Snap enters the shaft: (UL) If GO Snap fails to enter the shaft:

Shaft size is smaller than the maximum size Shaft size is grater than the maximum
limit of shaft and thus accepted. size limit of shaft and thus rejected.

If NO-GO Snap fails to enters the shaft: If NO-GO Snap enters the shaft:
(LL)

Shaft size is grater than the minimum size Shaft size is smaller than the minimum
limit of shaft and thus accepted. size limit of shaft and thus rejected.

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 Comparators

A comparator works on relative measurements, i.e. to say, it gives only dimensional

differences in relation to a basic dimension. So a comparator compares the unknown
dimensions of a part with some standard or master setting which represents the basic
size, and dimensional variations from the master setting are amplified and measured.

(1) Mechanical comparators

(2) Optical comparators
(3) Electrical comparators
(4) Pneumatic comparators