GD&T PPT General

Imperial Automotive Industries
Geometric
Dimensioning and
Tolerancing
Mark A. Morris
Contact Information
John Lindland
President Consultant Seminar Leader

QualSAT, Inc.
JLindland@qualsat.com
Mark A. Morris
(734) 369-3120
(734) 878-6569
Representing QualSAT, Inc.

mark@MandMconsulting.com
Geometric Characteristic
Symbols
Form Tolerances
Profile Tolerances
Orientation Tolerances
Runout Tolerances
Location Tolerances
3
Section 1
Background, History, and the
Importance of GD&T
Engineering Drawings
Engineering drawings are the vehicle
used to communicate requirements for
manufactured parts.
Graphic Representations
Words
Numbers
Symbols
Engineering drawings are used to

communicate contractual requirements.
5
We Need Operational
Definitions
Without an operational definition,
investigations of a problem will be costly and
ineffective, almost certain to lead to endless
bickering and controversy.
W. Edwards Deming, Ph.D.
Operational definitions provide three components:

1.
Specify Test to determine Compliance
2.
Set Criteria for Judgment
3.
Make Decisions based on the Criteria
6
Orthographic and
Isometric Projection
Orthographic and
Isometric Projection
1st vs. 3rd Angle Projection
First Angle Projection
Third Angle Projection
Note: Third angle projection is more common in the

USA, first angle projection is more common in Europe.
9
ISO vs. ASME

Comparing the ISO and the ASME Approaches to GD&T
Issue or Topic
Approach
Explanation
Cost of Standards
Number of Standards
ISO
ASME
Theoretical
Functional
Graphical, Few Words
Comprehensive
700 1000 USD
< 100 USD
10 - 16
Based on the work of Alex Kulikowski, 1998
10
ASME Y14.5M 1994

Structure
1. Scope, Definitions, and General Dimensioning
2. General Tolerancing and Related Principles
3. Symbology
4. Datum Referencing
5. Tolerances of Location
6. Tolerances of Form, Profile, Orientation, and
Runout
11
History of the Standard

Stanley Parker has been credited with bringing
to light the problems that existed with limit
dimensioning while working at the Royal
Torpedo Factory in Scotland.
ANSI Y14.5M
1964
ANSI Y14.5M-1973
ANSI Y14.5M-1982
ASME Y14.5M-1994
Dimensioning and Tolerancing
ASME Y14.5.1M-1994
Mathematical Definitions
12
Identify the Standard Used

ASME Y14.5M-1994 requires the
standard be identified on the drawing
when it is applied.
Methods change as standards evolve.
For example:
-AANSI Y14.5-1982
ASME Y14.5-1994
13
General Information
International System of Units (SI) have been
used.
U.S. Customary Units could have been used.
Figures are intended as illustrations to aid

in understanding. They show one possible
solution.
Capital letters on figures are intended to
appear on finished drawings.
14
Foundations of Mechanical
Accuracy
The Four Mechanical Arts
Geometry
Standards of Length
Dividing the Circle
Roundness
Wayne R. Moore
15
Development of Flatness
Step 1 Alternate between plates 1 and 2 until
a relative match is achieved.
Plate 1 agrees with plate 2

None are known to be flat
Step 2 Consider plate 1 as the master plate

and work plate 3 to plate 1.

Based on the work of Sir Joseph Whitworth
16
Step 3 Alternate between plates 2 and 3 until
a relative match is achieved.

Plates 2 and 3 are known to be flatter that plate 1
Step 4 Consider plate 2 as the master plate

and work plate 1 to plate 2.

All are of nearly equal flatness
17
Step 5 Alternate between plates 1 and 3 until a
relative match is achieved.

Plates 1 and 3 are known to be flatter that plate 2
Step 6 Consider plate 3 as the master plate and work

plate 2 to plate 3.

All are of nearly equal flatness
Continue reducing the error until all three plates agree.
18
3 Documents for Product

Quality
Product Drawing
Process Definition
Quality Control Plan
19
Section 2
Definitions, Rules, and Symbols
20
Key Definitions
Datum Theoretically exact point, axis, or plane derived from
the true geometric counterpart.
Datum Feature Actual feature on a real part used to
establish a datum.
Datum Feature Simulator A surface of sufficient precision
to establish a simulated datum.
Simulated Datum A point, axis, or plane established by
processing or inspection equipment.
Datum Target A specified point, line, or area on a part used
to establish the datum scheme.
21
Key Definitions
Feature of Size A cylindrical or spherical surface, or
two opposing elements or parallel surfaces.
Least Material Condition This occurs where a
feature of size contains the least material allowed by
the stated limits of size.
Maximum Material Condition This occurs where a
feature of size contains the most material allowed by
the stated limits of size.
Regardless of Feature Size A term that indicates
that a geometric tolerance or datum reference applies
for any increment of size within its size tolerance.
22
Key Definitions
Tolerance The total permissible variation in size for a specified
dimension.
Bilateral Tolerance A tolerance zone where the boundary
conditions contain the specified dimension.
Geometric Tolerance A general term that refers any of the 14
symbols used to control form, orientation, profile, runout, or
location.
Unilateral Tolerance A tolerance zone that only exists on one
side of the specified dimension.
True Geometric Counterpart The theoretically perfect
boundary or best fit (tangent) plane of a specified datum
feature.
23
Fundamental Rules
Each dimension shall have a tolerance.
(except for those dimensions specifically identified as reference,
maximum, minimum, or stock)
Ensure full understanding of each feature.
Show the detail needed and no more.
Serve function needs, no misinterpretation.
Manufacturing methods are not specified.
Non-mandatory dimensions are OK.
Designed of optimal readability.
24
Fundamental Rules
Dimension materials made to gage numbers.
90o
apply when features are shown as
90o
apply when centerlines are shown
.
.
Dimensions apply at 20oC (68oF).

Dimensions apply in a free state.
Tolerances apply for full size of feature.
Dimensions and tolerances only apply at the drawing level where they were
specified.
25
Limits of Size
Actual Size is a general term for the size of a
feature as produced. It has two interpretations.
Actual Local Size is the value of the individual
distance at any cross section of any feature of size.
Actual Mating Size is the dimensional value of
the actual mating envelope.
Limits of Size are the specified minimum and
maximum values for a feature of size.
26
Rule #1 The Taylor

Principle
Where only a tolerance of size is specified,
the limits of size of an individual feature
prescribe the extent to which variations in its
geometric form, as well as size, are allowed.
ASME Y14.5M-1994
Simply put:
Limits of size for an individual feature control
the allowable variation to its form and its size.
27
Size Controls Form

This on a drawing
Allows this
According to Rule #1, a true

geometric counterpart at MMC
must pass through the hole.
Or this
28
Size Controls Form

This on a drawing
According to Rule #1, a true
geometric counterpart at MMC
must pass over the pin.
Allows this
Or this
29
Features with and without

Size
Definition: A feature is a physical
portion of a part such as a surface, hole,
tab, slot, pin, etc.
Features Without Size:
Any Plane Surface
Features With Size:
Cylindrical Surface
Spherical Surface
A Set of 2 Opposing Elements or Parallel Planes
30
Features With & Without Size
31
MMC & LMC Workshop

Determine MMC and LMC for each feature of size below.
.752
.750
+.001
.375 -.000
.375
+.0002
-.0002
2.742
2.748
32
Rule #2
RFS applies to geometric
tolerances defining individual
tolerance, datum reference, or
both, where no modifying symbol
has been specified. MMC and LMC
must be specified where required.
33
Angular Units
Angular
Dimensioning
Either degrees, minutes,
and seconds or decimal
degrees may be used.
Precede small angles
with zeros for degrees
and minutes as place
holders.
25o 30 45
or
25.5125o
0o 0 55
34
Millimeter Dimensioning
Use a single 0 to describe
unilateral tolerances where the
intended value is nil.
For bilateral tolerances, use the
same number of significant digits
in both limits of size.
For limit dimensioning, use the
same number of significant digits
both limits of size.
For basic dimensions, tolerance
control is accomplished by the
feature control frame. Follow
rules for millimeter dimensions.
+0
25 -0.25
+ 0.10
25 -0.25
25.10
24.75
25
35
Decimal Inch
Dimensioning
For unilateral tolerances, use
the same number of zeros when
the intended value is nil.
+ .000
1.000 - .010
For bilateral tolerances, use

the same number of significant
digits in dimension and limits.
1.000 - .010
For limit dimensioning, use the

same number of significant
digits both limits of size.
For basic dimensions, use the
same number of significant
digits as in the feature control
frame.
+ .004
1.004
.990
1.000
36
Location of Features
Rectangular Coordinate Dimensioning
Rectangular Coordinates w/o Dimension Lines
Tabular Dimensioning
Polar Coordinate Dimensioning
Repetitive Features or Dimensions
Use of X to indicate by
37
Tolerancing and Related

Principles
General Practices
Direct Tolerancing Methods
Tolerance Expression
Interpretation of Limits
Single Limits
Tolerance Accumulation
Chain Dimensioning
Base Line Dimensioning
Direct Dimensioning
38
Chain Dimensioning
What are the min and
max values between
surfaces X and Y?
39
Base Line Dimensioning

What are the min and
max values between
surfaces X and Y?
40
Direct Dimensioning
What are the min and max values
between surfaces X and Y?
41
Use of Basic Dimensions

Basic dimensions define the perfect
location of features with respect to the
datum reference frame.
Basic dimensions define the theoretical
exact size and location for features.
Feature control frames define the
intended tolerance for features.
42
Understand Perfect Geometry

Perhaps the best way to comprehend
GD&T is first to envision the geometry
of the perfect part defined by basic
dimensions.
Then we can apply the tolerances given
in the feature control frames to define
the allowable variation from the perfect
part.
43
Using Tables to
Define Basic Dimensions
Paragraph 1.9 discusses locations of features.
Paragraph 1.9.3 allows the use of tables that
list the location of features as rectangular
coordinates from mutually perpendicular
planes.
Tables may be prepared in any suitable
manner that adequately locates features.
44
Feature Control Frame

Symbols
Description
Symbol
.010
Diameter
Spherical Diameter
Maximum Material Condition
Least Material Condition
Projected Tolerance Zone
M
L
Free State
P
F
Tangent Plane
Statistical Tolerance
ST
45

Elements
Label the elements of the feature control frame using the following term
Datum Modifier
Diameter Symbol
Primary Datum
Feature Modifier
Secondary Datum
Feature Tolerance
Tertiary Datum
46
Feature Control Frames

Example
47

Example
48

Placement
Locate the Feature Control Frame below or attached
to the leader-directed dimension or callout.
Run the leader from the frame to the feature.
Attach a side or an end of the frame to an extension
line from the feature.
Attach a side or an end of the frame to an extension
of the dimension line related to the feature in
question.
49
Other Common Symbols

Description
Radius
Symbol
R
Spherical Radius
SR
Controlled Radius
CR
Reference
( )
Between
All Around
Number of Places
8X
Counter Bore or Spot Face

Countersink
Depth or Deep
50

Example
51
Symbols
52
Some Other General Rules

Statistical Tolerancing Assignment of component
tolerances to meet assembly needs of statistical stacks.
Radius and Diameter Callouts R, CR, SR, , and S .
Non-Rigid Parts Method of restraint must be specified.
Screw Threads, Gears and Splines Screw threads
are evaluated at their pitch diameter unless otherwise
specified. Gears and splines must be specified.
53
Section 3
Applications of Tolerance Zones
54
Form Tolerances
Flatness
Straightness
Circularity
Cylindricity
55
Form Tolerances
Datum references are never made for
form tolerances.
Rule #1 says that limits of size control
variation in form.
Generally, form tolerances are only
necessary to refine (require a tighter
tolerance) limits of size.
Form tolerances are often applied to
features to qualify them as acceptable
datum features.
56
Flatness
Definition Flatness exists when a
surface has all of its elements in one
plane.
Tolerance Zone Two parallel planes
within which the surface must lie.
57
Checking for Flatness
58
Proper Application of Flatness

No datum is referenced.
It is applied to a single planar feature.
No modifiers are specified.
Tolerance value is a refinement of other
geometric tolerances or Rule #1.
59
Straightness
Definition Straightness exists when an
element of a surface or an axis is a
straight line.
Tolerance Zone Two parallel lines in the
same plane for two-dimensional
applications. A cylindrical tolerance
zone that contains an axis for threedimensional applications.
60
Checking for Straightness
61
Proper Application of
Straightness
applied to a Surface Element
It is applied to a surface element.

It is applied in a view where the element to be
controlled is shown as a line.
Tolerance value is a refinement of other
geometric tolerances or Rule #1.
62
Straightness of a Feature of
Size
When straightness is applied to a
feature of size:
Tolerance zone applies to the axis or

centerplane.
Rule #1 does not apply.
The tolerance value may be larger
that the limits of size for the feature
of size.
63
Straightness applied to a
Feature of Size
It is applied to a planar or cylindrical feature of size.

If a planar feature of size, the diameter symbol is not used.
If a cylindrical feature of size, the diameter symbol is used.
P
, T , and L modifiers are not specified.

Tolerance value is a refinement of other geometric
tolerances.
64
Circularity
(roundness)
Definition Circularity exists when all of the
points on a perpendicular cross section of a
cylinder or a cone are equidistant to its axis.
Tolerance Zone Two concentric circles that
contain each circular element of the surface.
Note: Circularity also applies to spheres.
65
Checking for Circularity
66
Circularity
It is applied to a circular feature.
Tolerance value is a refinement of limits
of size on the diameter or of other
specified geometric tolerances.
67
Cylindricity
Definition Cylindricity exists when all of
the points on the surface of a cylinder
are equidistant to a common axis.
Tolerance Zone Two concentric cylinders
that contain the entire cylindrical
surface.
68
Checking for Cylindricity
69
Cylindricity
It is applied to a cylindrical feature.
Tolerance value is a refinement of limits
of size on the diameter or of other
specified geometric tolerances.
70
Decisions for Form

Tolerances
Form
Tolerances
Consider
Limits of Size
Flatness
Straightness
Surface
Elements
Circularity
Cylindricity
Axis or
Center Plane
Consider
Material Condition
RFS
MMC
71
Angularity
Perpendicularity
Parallelism
72
Datum references are always used for orientation
tolerances.
Orientation tolerances applied to a surface control
the form of toleranced surface.
Only a tangent plane may need control.
Orientation tolerances may be applied to control
both features of size and features without size.
Orientation tolerances do not control size or
location.
Generally, profile tolerances are used to locate
features without size and position tolerances are
used to locate features of size.
73
Angularity
Definition Angularity exists when all of the
points on a surface create a plane or a
feature axis is at the specified angle, when
compared to a reference plane or axis.
Tolerance Zone Two parallel planes at the
true angle to a reference plane and contain
the entire surface surface.
Datum Feature
Datum Plane
Note: Applies to median planes and axes too.

74
Checking for Angularity
75
Angularity
Datum reference is specified.
Surface applications may use tangent plane modifier.
Feature of size applications may use MMC, LMC,
diameter, of projected tolerance zone modifiers.
Basic angle defines perfect geometry between the
datum reference and the toleranced feature.
Specified tolerance is a refinement of other geometric
tolerances that control angularity of the toleranced
feature.
76
Perpendicularity
Definition Perpendicularity exists when all
of the points on a surface, median plane, or
axis are at a right angle to a reference
plane or axis.
Tolerance Zone Two parallel planes that are
perpendicular to a reference plane and
contain the entire surface surface.
Datum Feature
Datum Plane

77
Checking for
Perpendicularity
78
Perpendicularity
tolerances that control the perpendicularity of the
toleranced feature.
79
Parallelism
Definition Parallelism exists when all of the
points on a surface, median plane, or axis
are equidistant to a reference plane or axis.
Tolerance Zone Two parallel planes that are
parallel to a reference plane and contain the
entire surface surface.
Datum Feature
Datum Plane

80
Checking for Parallelism
81
Parallelism
tolerances that control parallelism of the toleranced
feature.
82
Decisions for Orientation

Tolerances
Orientation
Tolerances
Angularity
Parallelism
Perpendicularity
Consider
Limits of Size
Feature
of Size
Consider Limits
Of Location
Plane
Surface
Consider
Material Condition
RFS
MMC
LMC
83
Location Tolerances
True Position
Symmetry
Concentricity
84
Location Tolerances
Datum references are always used for location
tolerances.
Location tolerances are reserved for tolerancing
applications on features of size.
They are always located by basic dimensions back
to the datum scheme.
Location tolerances shown on the same centerline
are assumed to have a basic dimension of zero.
Symmetry and concentricity application are
centered about the datum scheme specified for
the controlled feature.
85
True Position
Definition True position is the exact
intended location of a feature relative to a
specified datum scheme.
Tolerance Zone Most frequently, the
tolerance zone is a cylinder of specified
diameter within which the true axis of the
feature must lie.
Note: True position can also be applied to
median planes relative to specified datums.
86
Positional Tolerancing
Traditional tolerancing (say + .005)
consist of 2-D rectangular boundaries.
A circular boundary with the same
worst-case conditions increases the
area of the tolerance zone by 57%, prior
to any bonus tolerance.
87
Traditional Fastener
Tolerances
Threaded Fastener
Clearance Hole
1/64 = .0156
Perfect Condition
3/8 16
13/32
.0015
Clearance
Worst-Case Condition
88
Bonus Tolerances
When tolerancing features of size,
bonus tolerances may be applicable.
With MMC, as the size of a hole
increases, so does the acceptable
tolerance zone, provided the hole does
Larger
Larger
not exceedHole
itsatlimits of size.
Hole
MMC
Original
Tolerance
Zone
Hole
Larger
Tolerance
Zone
89

(MMC)
Largest permissible external feature.
Outside Diameter
External Feature Size
Key
Smallest permissible internal feature.
Holes
Slots
Key Way
90
Note: Datum feature A is the back surface.

91

(LMC)
Smallest permissible external feature.
Outside Diameter
External Feature Size
Key
Largest permissible internal feature.
Holes
Slots
Key Way
92

93
Regardless of Feature Size

(RFS)
RFS is no longer documented except in
rare cases where it is required for
clarity.
RFS is assumed for features of size
when neither MMC nor LMC are
specified.
94

95
Applications of
Material Condition Modifiers
M
Used for clearance application.
Used for location applications.

Used to protect wall thickness.
Used when size and location do not interact.

96
Applications for
The purpose of the hole is to
locate the PLP pin below.
.503
.501
.002
Worst Case Scenario
.500
.499
Hole diameter at .503 (LMC)

Pin diameter at .499 (LMC)
Clearance is .004
Pin can shift .002 in any direction
Tolerance for hole location is .002 at LMC
Hole can be off location .001 in any direction
Pin can be off location .003 in any direction
97
Applications for
.503
.501
.002
Hole at MMC Pin at LMC
.500
.499
Hole diameter at .501 (MMC)

Pin diameter at .499 (LMC)
Clearance is .002
Tolerance for hole location is .004 at MMC
98
Applications for
.503
.501
.002
Hole at MMC Pin at MMC
.500
.499
Hole diameter at .501 (MMC)

Pin diameter at .500 (MMC)
Clearance is .001
Tolerance for hole location is .004 at MMC
99
Virtual and Resultant

Conditions
Virtual Condition is the constant boundary generated
by the collective effects of a features specified MMC or
LMC and the geometric tolerance for that material
condition (i.e, the premise for functional gaging).
Resultant Condition is the variable boundary
generated by the collective effects of a features
specified MMC or LMC, its geometric tolerance for that
material condition, the size tolerance, and any
additional geometric tolerance derived from the
features departure from its specified material condition
(e.g., extreme boundary allowed for a given situation).
100

Conditions
Given
MMC
Internal Feature of Size
25.5
25.1
0.1
Virtual
Condition
Resultant
Condition
Constant
Value
Variable
Value
Inner
Boundary
Outer
Boundary
V Cond
Hole
Tol
25.1
0.1
25.2
25.2
0.2
25.4
25.3
0.3
25.4
0.4
25.8
25.5
0.5
26.0
25.0
R Cond
25.6
101
Inner and Outer

Boundary Conditions
25.5
25.1
0.1
Inner
Boundary
Outer
Boundary
Virtual Condition
Size
Tolerance Zone
At MMC
Hole at LMC
Bonus Tolerance
At LMC
102

Conditions
Given
MMC
External Feature of Size
24.9
24.5
0.1
Virtual
Condition
Resultant
Condition
Constant
Value
Variable
Value
Outer
Boundary
Inner
Boundary
V Cond
Pin
Tol
24.9
0.1
24.8
24.8
0.2
24.6
24.7
0.3
24.6
0.4
24.2
24.5
0.5
24.0
25.0
R Cond
24.4
103

Conditions
Given
LMC
25.5
25.1
0.1
Virtual
Condition
Resultant
Condition
Constant
Value
Variable
Value
Outer
Boundary
Inner
Boundary
V Cond
Hole
Tol
25.1
0.5
24.6
25.2
0.4
24.8
25.3
0.3
25.4
0.2
25.2
25.5
0.1
25.4
25.6
R Cond
25.0
104

Conditions
Given
LMC
24.9
24.5
0.1
Virtual
Condition
Resultant
Condition
Constant
Value
Variable
Value
Inner
Boundary
Outer
Boundary
V Cond
Pin
Tol
24.9
0.5
25.4
24.8
0.4
25.2
24.7
0.3
24.6
0.2
24.8
24.5
0.1
24.6
24.4
R Cond
25.0
105
Inner and Outer Boundaries

Given RFS
25.5
25.1
0.1
Variable
Value
Inner
Boundary
Variable
Value
Outer
Boundary
Hole
Tol
I. B.
25.1
0.1
25.0
25.2
0.1
25.3
0.1
25.4
0.1
25.5
0.1
O. B.
25.6
106
Inner and Outer Boundaries

Given MMC
24.9
24.5
0.1
Variable
Value
Outer
Boundary
Variable
Value
Inner
Boundary
Pin
Tol
O. B.
24.9
0.1
25.0
24.8
0.2
24.7
0.3
24.6
0.4
24.5
0.5
I. B.
24.4
107
Zero Tolerance at MMC

Where zero tolerance is specified at MMC,
the tolerance is totally based on the actual
mating size of the feature specified.
Location and orientation must be perfect
when the feature is at MMC.
As the feature departs from MMC the
allowable tolerance is based on the size the
feature compared to its MMC.
108
Logic for Zero Tolerance at

MMC
1.006 + .003
.004 M
B
.514 + .003
.005 M
B M
.994 + .003
.002 M
.500 + .001
.005 M
B M
109

MMC
.506
Virtual
Condition
Boundary
.999
Virtual
Condition
Boundary
Functional
Extremes are
.991 and .999
110

MMC
.994 + .003
.002 M
Based on assumptions about process variation, we may have arbitrarily

divided the total tolerance of .008 into .006 for size and .002 for
orientation. We could have divided the tolerance into .004 + .004,
or .002 + .006, or even .008 + .000.
111

MMC
.995 + .004
.000 M
Why not give the entire tolerance to the manufacturing process and let
the process divide it up as needed? This is what happens when we
specify zero tolerance at MMC.
112
Verification of Position at
MMC
1. Determine tolerance at MMC.
2. Determine actual mating size.
3. Calculate positional tolerance allowed.
4. Determine positional error in location.
5. Compare positional error in location to
positional tolerance allowed.
6. Decide to accept or reject.

113
Specification of Position at
MMC
114
MMC
115
LMC
1. Determine tolerance at LMC.
2. Determine actual mating size.
3. Calculate positional tolerance allowed.
4. Determine positional error in location.
5. Compare positional error in location to
positional tolerance allowed.
6. Decide to accept or reject.

116
Specification of Position at
LMC
117
LMC
118
Proper Application of Position

Position control is applied to a feature of size.
Datum references are specified and logical for
the application.
Basic dimensions establish the desired true
position of the feature of size.
Tangent plane modifier is not used.
Diameter symbol is used to specify axis control.
Diameter symbol is not used to specify center
plane control.
MMC, LMC, or RFS may be specified.
119
Symmetry
Definition Symmetry defines the location
of non-cylindrical features about a
derived median plane.
Tolerance Zone The tolerance zone is
defined by two planes, equidistant to a
A
datum center plane. The derived
median points must fall within these two
planes.
120
Set Up for Symmetry
121
Symmetry
A planar feature of size to be controlled
uses the same center plane as the datum
scheme.
Diameter symbol is never used to specify
the symmetry tolerance.
MMC, LMC, tangent plane, and projected
tolerance zone modifiers may not be
specified.
122
Concentricity
Definition Concentricity defines the
location of cylindrical features about an
axis of rotation.
Tolerance Zone The tolerance zone is
defined as a cylinder about the datum
axis that must contain the median
points of diametrically opposed
elements of a feature.
123
Checking for Concentricity
124
Concentricity
The surface of revolution to be controlled
is coaxial to the axis of the datum scheme.
Diameter symbol is used to specify the
concentricity tolerance.
specified.
125
Decision Matrix for Coaxial

Features
Position
(RFS)
Total Runout
Concentricity
Cost
to
Produce
$$$
$$
Cost
to
Inspect
$$
$$$
Location
and
Orientation
Location
Orientation
and Form
Location
and
Orientation
Characteristi
cs
under
Control
126
Decisions for Location

Tolerances
Location
Tolerances
Concentricity
Position
Symmetry
Center
Plane
Axis
Determine
Tolerance
For Position Only

Consider Material Condition
RFS
MMC
LMC
127
Profile Tolerances
Profile of a Line
2-D Application
Profile of a Surface
3-D Application
128
Profile Tolerances
Profile tolerances are used to control multiple
coplanar surfaces.
Perfect geometry must be defined via basic
dimensions.
The default interpretation for the tolerance zone
is bilateral and equal about the true perfect
geometry.
Profile tolerances are not used to control features
of size so MMC, LMC, and RFS do not apply.
Profile features can be used as datum features or
they must be related to a defined datum scheme.
129
Profile
3-D Application
2-D Application
Definition Profile defines the

theoretically exact position of a surface
(3-D) or the cross section of a surface (2D).
Tolerance Zone A uniform boundary on
either side of the true profile that must
contain either the surface or line.
130
Profile for Cam Application
131
Functional Gaging of
Profile
132
Proper Application
of Profile Tolerances
Profile features are used as datum features
or related to a defined datum scheme.
and
Basic dimensions relate the true profile
back to the datum scheme.
or
The profile tolerance value must be a
refinement of dimensions used to locate
the true profile.
133
Decisions for Profile

Tolerances
Profile
Tolerances
Consider
Limits of Size
Profile of a
Line
Profile of a
Surface
Consider
Tolerance Zone
Unilateral
Inside
Outside
Bilateral
Equal
Unequal
134
Runout Tolerances
Circular Runout
2-D Application
Total Runout
3-D Application
135
Runout
3-D Application
2-D Application
Definition Runout is a composite control

used to specify functional relationships
between part features and a datum axis.
Tolerance Zone Circular runout is a 2-D
application that evaluates full indicator
movement on a perpendicular cross section
rotating about a datum axis. Total runout
evaluates full indicator movement of the
full surface rotating about a datum axis.
136
Checking for Runout
137
Proper Application of Runout

The surface to be controlled is either
coaxial or perpendicular to the axis of
the datum scheme.
Diameter symbol is never used to
specify a runout tolerance.
specified for a runout tolerance.
138
Decisions for Runout

Tolerances
Runout
Tolerances
Consider
Limits of Size
Circular
Runout
Total
Runout
139
Geometric Characteristics
for Round Features
Circularity (roundness)
Evaluates cross section of surface to its own axis
Cylindricity
Evaluates entire surface to its own axis
Runout
Evaluates cross section of surface to a defined axis
Total Runout
Evaluates entire surface to a defined axis
Concentricity
Evaluates best fit axis of feature to a defined axis

140
Tolerance Design Flow

Chart
Design
Requirements
Establish
Datums
Individual
Features
Related
Features
Form
Tolerances
Location
Tolerances
Individual or
Related Features
Profile
Tolerances
Orientation
Tolerances
Runout
Tolerances
141
Section 4
Datums and Datum Schemes
142
Reference Planes
(The Point of Known Return)
Ted Busch, 1962
Define the datum reference frame.

Use of mutually perpendicular planes.
The goal is the replication of measurements.
Immobilize the part in up to six degrees of
freedom.
143
Theoretically Perfect
Geometry
Three mutually perpendicular planes.
3 Datum Planes
define the Origin
of Measurement
Datum
Point
144
Criteria for Selecting Datum

Features
Geometric Relationship to Toleranced Feature
Geometric Relationship to Design Requirements
Accessibility of the Feature
Sufficient in Size to be Useful
Readily Discernable on the Part
145
Designating Precedence of
Datums
Alphabetical order is not relevant.
Order of precedence is shown in the
feature control frame.
Consider function first.
Then, consider the process next.
Finally, consider measurement processes.

146
Datum Features of Size

MMC callouts on a datum features of size
can allow a datum shift on the exact
location of the datum feature.
This applies to:
Cylindrical Surfaces (internal or external)

Spherical Surfaces
A Set of 2 Opposing Elements or Parallel Planes
A Pattern of Features such as a Bolt Hole
Pattern
147
Decisions for Datum

Selection
Select
Datum Feature
Feature
of Size
Surface
Center
Plane
Axis
Consider
Material Condition
RFS
MMC
Are Other Datums Required?
LMC
148
Rational Strategy
for Datum Selection
It is reasonable to prioritize the datum
selection process as follows:
1.
Functional Requirements
1.
Production Requirements
1.
Measurement Requirements
149
What Are We Really Interested

In?
1. Error in Geometric Forms
2. Size for Features of Size
3. Location of Features
150
Introduction to Datum
Workshop
Select datums based on function.
Some features are leaders, others are followers.
Sequence of considerations:
Establish the datum reference frame (DRF).

Qualify the datum features to the DRF.
Relate remaining features to the DRF.
For consistency, assume .005 tolerance zones

unless otherwise specified.
Select and qualify the datum features and identify
the datum point as specified in the following
examples.
151
Datum Workshop
Locate the part on the back

surface first, then the bottom
edge, then the left side.
152
Datum Workshop

edge, then the right hand side
of the bottom slot.
153
Datum Workshop

edge, then centrally to the
bottom slot with a .998 virtual
size key.
154
Datum Workshop
Locate the part on the front

surface first, then by a 1.504
virtual size hole for the large
boss, then by a .996 virtual
size key for the right hand slot.
155
Datum Workshop
Locate the part on the front

surface first, then by a 1.502
virtual size hole for the large
boss, then by the bottom edge.
The bottom edge must lie in a
tolerance zone from 2.490 to
2.510 from the large boss.
156
Section 5
Tolerancing Strategies
157
Process for Tolerance

Analysis
Establish Performance Requirements
Develop a Loop Diagram
Convert Dimensional Requirements to
Target Values with Equal Bilateral Tolerances
Determine the Target Value for Requirement
Select the Method of Analysis
Calculate Variation for Performance Requirement
158
Statement of the Problem

A problem well defined is half solved.
John Dewey
Thorough problem definition may lead directly to

its solution.
Hans Bajaria
The formulation of a problem is far more often

essential than its solution, which may be merely
a matter of mathematical or experimental
skill.
Albert Einstein
159
Assembly Stack-Up Analysis
What is the minimum and maximum

gap between the bottom of the collar
and the upper bearing?
160
Component Tolerances
161
Stack Analysis Result
What is the minimum and maximum

gap between the bottom of the collar
and the upper bearing?
162
Worst Case Evaluation

Assembly Length
1.000
+ .002
.500
+ .001
2.000
+ .004
Nominal Assembly Length = 1.000 + .500 + 2.000 = 3.500

Tolerance of Assembly Length = .002 + .001 + .004 = + .007
While this approach of adding component tolerances is mathematically
correct, in practical application it is often too conservative.
163
Worst Case Pros and Cons

Pros
No risk of components not interacting properly.

100% interchangeability of components.
Cons
Method is conservative.
Underutilization of full tolerance range.
Tolerances for interacting dimensions are
smaller than necessary, which may increase
cost.
164
Statistical Method of
Linear Evaluation
Assembly Length
1.000
+ .002
.500
+ .001
2.000
+ .004
Nominal Assembly Length = 1.000 + .500 + 2.000 = 3.500

Tolerance of Assembly Length =
.0022 + .0012 + .0042 = + .0046
To statistically calculate the tolerance we take the root of the sum

of the squared values of the individual tolerances (RSS).
165
Some Critical Assumptions

Component dimensions are independent.
Components are assembled randomly.
Component should be normally distributed.
The actual average value for each component is
equal to the nominal value specified for that
component. (Otherwise, the nominal value for the
assembly will not be met and the tolerances will
not be realistic.) Process control is needed.
166
From Part Tolerances to an

Assembly Tolerance
Variances are additive while
standard deviations are not.
B
Assembly
C
167
Statistical Tolerancing
Pros and Cons
Pros
Larger tolerances on interacting dimensions.
Cons
Small percent of final assemblies fall outside

limits.
Special Considerations
Averages of interacting dimensions must be

controlled via variables measurements.
Interacting dimensions must be independent and
normally distributed.
Lot size should be moderately large.
168
From an Assembly Tolerance

back to Component
Tolerances
A
B
Assembly
In practice, we are often required to begin with a defined end result

and determine appropriate tolerances for the components.
169
Two Theorems of
Relevance
Two theorems hold great importance in
the interrelationship of tolerances.
The first is similar to the Pythagorean
Theorem
sum (12 22 32 ... n2)
The second theorem appears less
B
12 (12 22)
obvious:
A
170
Composite Tolerances and

Single Segment Tolerances
There are times when

it is more important
to control the
relationships between
features than to
control their locations
to the datums.
171
Standard Positional Tolerance
172
Functional Gage for Virtual

Condition of Holes to Datums
173
Composite Tolerance with

One Datum in the Lower
Segment
174
Composite Tolerance
PLTZF locates and orients
features to the specified
datums via basic
dimensions.
FRTZF locates the features
within the pattern via basic
dimensions to each other
and controls their
orientation relative to the
specified datum(s).
FRTZF releases the pattern
from the requirements
given by basic dimensions
to their datum features.
One Tolerance
Zone Symbol
Pattern Locating
Tolerance Zone
Framework
(PLTZF)
Feature Relating
Tolerance Zone
Framework
(FRTZF)
175
Two Functional Gages

for the Composite Tolerance
176
Composite Tolerance with

Two Datums in the Lower
Segment
177
Two Functional Gages

for the Composite Tolerance
178
Two Single Segments with

Two Datums in the Lower
Segment
179
Two Functional Gages for the

Two Single Segment
Tolerances
180
Fixed and Floating

Fastener Calculations
Floating Fastener scenario exists when the
fastener must pass through two clearance
holes in mating parts.
Fixed Fastener scenario exists when one of the
parts has threaded holes and the other part
has clearance holes.
Projected Tolerance Zone should be used to
specify the height out of the threaded hole
that the tolerance zone applies.
181
Threaded Holes
Threaded holes arent really holes.
They are a vehicle to locate and
orientate mating parts.
Carl Lance
Nubs on a shower head behave the

same as a threaded hole.
182
Two Clearance Holes

Floating Formula Application
What should we use as the
positional tolerance for each
of these two mating parts?
Two Pieces Required
Assuming a 3/8 16
threaded fastener
.404
- .375
.029
MMC of clearance holes minus MMC of fastener is given to the positional

tolerance of both pieces.
183
Threaded Hole with Clearance

Hole
.404
What tolerances should we use for positional
-.375
Fixed
Fastener
Application
tolerances
for these two mating
parts?
.029
MMC of clearance hole minus MMC of fastener must be shared

between the
two positional tolerance of the two pieces.
184
Topics Worthy of Discussion

Definition of Functional Requirements
Failure Mode and Effects Analysis
Consistent Tooling and Gaging Locators
Communication with Suppliers
Developing Optimal Specifications
185
Sources of Variation
The following primary contributors to body-in-white
variability were identified as part of the Auto Body
Consortiums 2mm Program for Variation Reduction:
Locator Pins
Incoming Material
Welding
Clamping
Robot Programming
Carriers
Rough Locators
NC Blocks
28.4%
21.3%
19.1%
13.5%
5.0%
3.5%
2.8%
2.8%
186
Sources of Variation
A summary of the sources of locator pin problems:
Size 22.5%
Pin Interference with Panel17.5%
Loose Pins 12.5%
Pin Too Short
7.5%
PLP Quantity
7.5%
Pin PLP Selection
7.5%
Pins Needed Rotating
Worn Pins
5.0%
Missing Pins 5.0%
Pin Shape
2.5%
Pin Too Long 2.5%
5.0%
187
Other Sources of Variation

Material
Gravity
Clamp Sequence
Methods
Equipment
Tool Interference
Environment
Tool Repeatability People
Measurement Error
Incoming Part Quality
Uncoordinated Datum Scheme
Clearance from Clamp Finger to Net Block
188
Section 6
Functional Gaging
189
Merits of Functional
Gaging
Simple Functional Checks for Conformity
Takes Advantage of Bonus Tolerances
Checks Parts for their Virtual Condition
Allows for Best-Fit Solutions
Rejects Less Functionally Good Parts
190
Functional Gaging
Pros and Cons
Pros
Reduces
Reduces
Reduces
Provides
risk of shipping bad product.

risk of scrapping good product.
inspection costs.
attribute data.
Cons
Doesnt provide variables data.

Usually wont qualify for PPAP submission.
May not correlate with CMM data.
191
Functional Gaging of
Profile
192
What to Do About Design

Errors
The first thing you want to do about design error is
to find them early.
As human nature would have it, most designers
seem to want to focus on the next design, rather
than spending their time on past mistakes.
If you can identify design errors early in the design
review process, the potential of actually getting
the drawings corrected is often much greater.
193
Some things to Look

for in Design Reviews
Datum schemes that dont make sense.
Datum schemes that dont match the physics of
assembly.
Datum schemes that are in conflict with themselves.
Datum schemes that will be difficult to manufacture.
Datum schemes that will be difficult to inspect.
194
Some things to Look

Geometric tolerances that arent referenced to a
datum scheme when they should be.
Geometric tolerances that are referenced to a
datum scheme when they shouldnt be.
Diameter symbols used where they shouldnt be
used.
Diameter symbols not used where they should
be.
195
Some things to Look

Use of geometric tolerances that dont refine
either the limits of size or other tolerances.
Patterns of holes where the quantity of holes
has not been specified.
Dimensional requirements that cant be made.
Dimensional requirements that cant be
checked.
196
Process for Design Change

Quality management systems require a
defined process for design changes within the
scope of design control.
Designers need explicit and accurate feedback
to improve both current and future designs.
If drawings arent updated to eliminate design
flaws, the odds are pretty good that youll see
that problem again in the future.
197

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Imperial Automotive Industries

President Consultant Seminar Leader

Representing QualSAT, Inc.

Engineering drawings are used to

Operational definitions provide three components:

1st vs. 3rd Angle Projection

First Angle Projection

Third Angle Projection

Note: Third angle projection is more common in the

ISO vs. ASME

Graphical, Few Words

700 1000 USD

< 100 USD

Based on the work of Alex Kulikowski, 1998

ASME Y14.5M 1994

History of the Standard

Dimensioning and Tolerancing

Identify the Standard Used

U.S. Customary Units could have been used.

Figures are intended as illustrations to aid

Plate 1 agrees with plate 2

Step 2 Consider plate 1 as the master plate

Plate 1 agrees with plate 2

Plate 2 agrees with plate 3

Step 4 Consider plate 2 as the master plate

Plate 1 agrees with plate 2

Plate 1 agrees with plate 3

Step 6 Consider plate 3 as the master plate and work

Plate 1 agrees with plate 3

Continue reducing the error until all three plates agree.

3 Documents for Product

apply when features are shown as

apply when centerlines are shown

Dimensions apply at 20oC (68oF).

Rule #1 The Taylor

Size Controls Form

According to Rule #1, a true

Size Controls Form

Features with and without

Any Plane Surface

Features With Size:

Features With & Without Size

MMC & LMC Workshop

For bilateral tolerances, use

For limit dimensioning, use the

Tolerancing and Related

Base Line Dimensioning

Use of Basic Dimensions

Understand Perfect Geometry

Feature Control Frame

Feature Control Frame

Feature Control Frames

Feature Control Frames

Feature Control Frame

Other Common Symbols

Counter Bore or Spot Face

Feature Control Frames

Some Other General Rules

Checking for Flatness

Proper Application of Flatness

Checking for Straightness

It is applied to a surface element.