Geometrical Dimensioning And Tolerancing

Geometrical Dimensioning and Tolerancing By: Mahender Kumar

ANSI Y14.5 Y14 5-1994 1994 Standard This standard establishes uniform practices for defining and interpreting dimensions, and tolerances, and related requirements for use on engineering drawings.

What is a ‘good good level of tolerance’? tolerance ?

Designer: tight i h tolerance l is i better b (less vibration, less wear, less noise) Machinist: large g tolerances is better (easier to machine, faster to produce, easier to assemble)

Tolerancing application: an example The type of fit between mating features Designer needs to specify: basic diameter and the tolerance of shaft: S±s/2 basic diameter and the tolerance of hole: H±h/2 Allowance: a = Dhmin – Dsmax.

Tolerancing • Definition: Allowance for specific variation in the size and g geometry y of a p part • Need for Tolerancing – It is IMPOSSIBLE to manufacture a part to an EXACT size or geometry – Since variation from the drawing is inevitable we must p y the acceptable p degree g of variation specify – Large variation may affect part functionality – Small allowed variation affects the part cost • requires i precise i manufacturing f t i • requires inspection and potential rejection of parts

Tolerance Follows Function • Assemblies: – Parts will not fit together if their dimensions do not fall with in a certain range of values

• Interchangeable I t h bl P Parts: t – If a replacement part is used it must duplicate the original g p part within certain limits of deviation

• The relationship between functionality and size/shape of an object varies with the part – Automobile Transmission is Very Sensitive to the Size & Shape of the Gears – A Bicycle is NOT Too Sensitive to the Size & Shape of the Gears (sprockets)

Two Forms of Physical Tolerance • Size – Limits specifying the allowed variation in each dimension (length, width, height, diameter, etc.) are given on the drawing

• Geometry – Geometric G t i Dimensioning Di i i &T Tolerancing l i (GD&T) • Allows for specification of tolerance for the geometry of a part separate from its size • GD&T uses special symbols to control different geometric features of a part

Cost Sensitivity • Cost generally increases with “tighter” tolerances – Th There is i generally ll a ceiling ili tto thi this relationship l ti hi where larger tolerances do not affect cost • e.g.; If the Fabricator ROUTINELY Holds to ±0.5 mm, Th a ±3 mm S Then Specification ifi ti will ill NOT reduce d Cost C t

– Tolerances at the Limits of the Fabricator’s Capability cause an exponential increase in cost – Parts with small tolerances often require special methods of manufacturing – Parts with small tolerances often require greater inspection, and higher part-rejection rates

• Do NOT specify a SMALLER Tolerance than i NEEDED is

Tolerance Spec Hierarchy • Generally Three Levels of Tolerances – DEFAULT: Placed in the Drawing Title-Block by The Engineering Firm • Typically Conforms to Routine Tolerance Levels

– GENERAL: Placed on the Drawing By the Design-Engineer as a NOTE • Applies to the Entire Drawing • Supercedes the DEFAULT Tolerance

– SPECIFIC: Associated with a SINGLE Dimension or Geometric Feature

Fit Between Parts • Clearance fit: The shaft maximum diameter is smaller than the hole minimum diameter. • Interference fit: The shaft minimum diameter is larger than the hole maximum diameter. • Transition fit: The shaft maximum diameter and hole minimum have an interference fit,, while the shaft minimum diameter and hole maximum diameter have a clearance fit Clearance Fit

Interference Fit

Transition Fit

Classes of Fit The limits to sizes for various types of fit of mating parts are defined by the standard ANSI B4.1

There are five basic classes of fit: 1. Running and sliding clearance (RC) 2 Location clearance (LC) 2. 3. Location transition (LT) 4. Location interference (LN) 5. Force fits (FN)

Unilateral and Bilateral Tolerances: nominal dimension means a range

1.00 + - 0.05

0.95 - 1.05

tolerance

unilateral bilateral

0.95

+ 0.10 0 10 - 0.00

1.00 + - 0.05

1.05

+ 0.00 0 00 - 0.10

Overview of Geometric Tolerances Geometric tolerances define the shape of a feature as opposed to its size.

We will focus on three basic types of dimensional tolerances: 11. 2. 3.

Form tolerances: straightness, straightness circularity, circularity flatness flatness, cylindricity; Orientation tolerances; perpendicularity, parallelism, angularity; and Position tolerances: position, symmetry, concentricity.

COMMON TERMS AND DEFINITIONS

Basic Dimension A numerical value used to describe the theoretically exact size, profile, orientation, or location of a feature or datum target. It is the basis from which permissible variations are established by tolerances on other dimensions dimensions, in notes notes, or in feature control frames frames.

Datum A theoretically exact point, axis, or plane derived from the true geometric counterpart of a specified datum feature. A datum is the origin from which the location or geometric characteristics of features of a part are established.

Datum Target A specific line, or area on a part used to establish a datum.

Maximum Material Condition (MMC) The condition in which a feature of size contains the maximum amount of material within the stated limits of size-for example, minimum hole diameter, maximum shaft diameter.

Least Material Condition (LMC) The condition in which a feature of size contains the least amount of material within the stated limits of size-for example, maximum hole diameter, minimum shaft diameter.

Regardless of Feature Size (RFS): The term used to indicate that a g geometric tolerance or datum reference applies pp at any y increment of size of the feature within its size tolerance. Full Indicator Movement The total movement of an indicator when appropriately applied to a surface to measure its variations (formerly called total indicator reading-TIR). reading TIR) Virtual Condition The boundary generated by the collective effects of the specified MMC limit of size of a feature and any applicable geometric tolerances.

Feature Control Frame The feature control frame consists of: A) type of control (geometric characteristic), B) tolerance zone, C) tolerance zone modifiers (i (i.e., e MMC or RFS) RFS), D) datum references if applicable and any datum reference modifiers.

PROFILE TOLERANCES

Profile of a Line A uniform two dimensional zone limited by two parallel zone lines extending along the length of a feature.

Profile of a Surface A uniform three dimensional zone contained between two envelope surfaces separated by the tolerance zone across the entire length of a surface.

ORIENTATION TOLERANCES

Angularity A l it The distance between two parallel planes, inclined at a specified basic angle in which the surface, axis, or center plane of the feature must lie.

Perpendicularity (squareness) The condition of a surface surface, axis axis, median plane plane, or line which is exactly at 90 degrees with respect to a datum plane or axis axis.

Parallelism The condition of a surface or axis which is equidistant at all points from a datum of reference.

LOCATIONAL TOLERANCES

True Tr e Position A zone within which the center, axis, or center plane of a feature of size is permitted to vary from its true (theoretically exact) position.

Concentricity A cylindrical tolerance zone whose axis coincides with the datum axis and within which all cross-sectional axes of the feature being controlled must lie. (Note: Concentricity is very expensive and time-consuming to measure. Recommended that you try position or runout as an alternative tolerance.)

RUNOUT TOLERANCES

Runout A composite tolerance used to control the relationship of one or more features of a part to a datum axis during a full 360 degree rotation about the datum axis. Circular Runout Each circular element of the feature/part must be within the runout tolerance.

Total Runout All surface elements across the entire surface of the part must be within the runout tolerance.

FORM TOLERANCES

Flatness A two dimensional tolerance zone defined by two parallel planes within which the entire surface must lie.

Straightness A condition where an element of a surface or an axis is a straight line.

Circularity A condition on a surface of revolution ((cylinder, y , cone,, sphere) p ) where all points p of the surface intersected by any plane perpendicular to a common axis (cylinder, cone) or passing through a common center (sphere) are equidistant from the axis of the center.

Cylindricity A condition on a surface of revolution in which all points of the surface are equidistant from a common axis.

Feature Control Frame A geometric tolerance is prescribed using a feature control frame. It has three components: 1. the tolerance symbol, 2. the tolerance value, 3. the datum labels for the reference frame.

Order of Precedence The part is aligned with the datum planes of a reference frame using 3-2-1 contact alignment. • 3 points of contact align the part to the primary datum plane; • 2 points of contact align the part to the secondary datum plane; • 1 point of contact aligns the part with the tertiary datum plane

Straightness of a shaft

Straightness of a Shaft • A shaft has a size tolerance defined for its fit into a hole. A shaft meets this tolerance if at every point along its length a diameter measurement fall within the specified values. • This allows the shaft to be bent into any shape. A straightness tolerance on the shaft axis specifies the amount of bend allowed.

• Add th the straightness t i ht tolerance t l to t th the maximum i shaft h ft size i (MMC) tto obtain bt i a ““virtual it l condition” Vc, or virtual hole, that the shaft must fit to be acceptable.

Straightness of a Hole

• The size tolerance for a hole defines the range of sizes of its diameter at each point along the centerline. This does not eliminate a curve to the hole. • The straightness tolerance specifies the allowable curve to the hole. • Subtract the straightness tolerance from the smallest hole size (MMC) to define the virtual condition Vc, or virtual shaft, that must fit the hole for it to be acceptable.

Straightness of a Center Plane • The size dimension of a rectangular part defines the range of sizes at any cross-section. • The straightness tolerance specifies the allowable curve to the entire side. • Add the straightness tolerance to the maximum size (MMC) to define a virtual condition Vc that the part must fit into in order to meet the tolerance.

Flatness Tolerance zone defined by two parallel planes. 0.0 01

1.000 '

±0.002

p ar al l e l p lanes 0.0 01

Flatness

Flatness, Circularity and Cylindricity

Flatness

Circularity

Cylindricity

• The flatness tolerance defines a distance between parallel planes that must contain the highest and lowest points on a face. • The circularity tolerance defines a pair of concentric circles that must contain the maximum and minimum radius points of a circle. • The cylindricity tolerance defines a pair of concentric cylinders that much contain the maximum and minimum radius points along a cylinder.

Circularity (Roundness)

CYLINDRICITY Tolerance zone bounded by two concentric cylinders within which the cylinder must lie.

0.01

1.00 ' ±0.05

Rotate in a V

0.01

R t t b Rotate between t points i t

Parallelism

Parallelism Tolerance A parallelism tolerance is measured relative to a datum specified in the control frame. If there is no material condition (ie. regardless of feature size), then the tolerance defines parallel planes that must contain the maximum and minimum p points on the face. If MMC is specified for the tolerance value: • If it is an external feature, then the tolerance is added to the maximum dimension to define a virtual condition that the part must fit; • If it is an internal feature, then the tolerance is subtracted to define the maximum dimension that must fit into the part. part

Perpendicularity • A perpendicular tolerance is measured relative to a datum plane. plane • It defines two planes that must contain all the points of the face. • A second datum can be used to locate where the measurements are taken.

Perpendicular Shaft, Hole, and Center Plane Shaft

Hole

• Shaft: The maximum shaft size plus the tolerance defines the virtual hole. hole • Hole: The minimum hole size minus the tolerance defines the virtual shaft. • Plane: The tolerance defines the variation of the location of the center plane.

Center Plane

Angularity

An angularity tolerance is measured relative to a datum plane. It defines a pair planes that must 1. contain all the points on the angled face of the part, or 2. if specified, the plane tangent to the high points of the face.

Concentricit Tolerance Note Concentricity .007 007

.007 Tolerance Zone

A

A

XX

YY

This cylinder (the right cylinder) must be concentric within .007 with the Datum A (the left cylinder) as measured d on the th diameter di t

What It Means

TRUE POSITION Dimensional tolerance 1 .0 0 ± 0 .0 1

1 .2 0 ± 0 .0 1

O .8 0 ± 0 .0 2 O 0 .0 1 M A B

True position t l tolerance

Hole center tolerance zone

Tolerance zone 0 .0 0 1 dia

1 .0 0

B A

1.2 0

Position Tolerance for a Hole • • • •

The position tolerance for a hole defines a zone that has a defined shape, size, location and orientation. It has the diameter specified by the tolerance and extends the length of the hole. Basic dimensions locate the theoretically exact center of the hole and the center of the tolerance zone. Basic dimensions are measured from the datum reference frame.

Position Tolerance on a Hole Pattern A composite control frame signals a tolerance for a ppattern of features,, such as holes.

• The first line defines the position tolerance zone for the holes. • The second line defines the tolerance zone for tthee patte pattern,, which w c iss generally ge e a y smaller. s a e.

Virtual Condition Envelope All Required Tolerances 20.06 Maximum Envelope

0.06 0 06 Maximum Allowable Curvature

20.00 20 00 Maximum Allowable Diameter

PROFILE

A uniform boundary along the true profile within whcih the elements of the surface must lie. 0 .0 05 A B

B

A

0.0 01

RUNOUT A composite tolerance used to control the functional relationship of one or more features of a part to a datum axis. Circular runout controls the circular elements of a surface. As the part rotates 360° about the datum axis,, the error must be within the tolerance limit. A

1.500 "

±0.005 0 .0 0 5 A

0.361 "

±0.002

Dat um ax is

Deviat ion on each circular check ring is less t han t he t olerance.

TOTAL RUNOUT A

1.500 "

±0.005 0 .0 0 5 A

0 361 " 0.361

±0 002 ±0.002

Dat um ax is

Deviat D i t ion i on t he h t ot al swept when t he part is rot at ing is less t han t he t olerance.

Runout

Geometric Tolerancing Definitions • Maximum Material Condition ((MMC)) – The condition in which a feature of size contains the maximum amount of material with the stated limits of size, - fore example, minimum hole diameter and maximum shaft diameter • Least Material Condition (LMC) – Opposite of MMC, the feature contains the least material. For example, maximum hole diameter and minimum shaft diameter • Virtual Condition – The envelope or boundary that describes the collective effects of all tolerance requirements on a feature (See Figure 7 7-25 25 TG)

Material Condition Modifiers RFS

If the tolerance zone is prescribed for the maximum material condition (smallest hole). Then the zone expands by the same amount that the hole is larger in size. size Use MMC for holes used in clearance fits.

MMC

No material condition modifier means the tolerance is “regardless of feature size.” Use RFS for holes used in interference or press fits.

MMC HOLE LMC hole

MMC hole hole axis t olerance zone

MMC peg will f it in t he hole , axis must be in t he t olerance zone

Given th Gi the same peg (MMC peg), ) when h th the produced hole size is greater than the MMC hole, the hole axis true position tolerance zone can be enlarged by the amount of difference between the produced hole size and the MMC hole size.

TOLERANCE VALUE MODIFICATION O 1 .0 0 ± 0 .0 2 O 0 .0 1 M A B

Produced

1 .0 0

B A

hole size 1 .2 0

The default modifier for true position is MMC.

0.97 MMC

LMC

S

out of diametric tolerance

0 98 0.98

0 01 0.01

0 05 0.05

0 01 0.01

0.99

0.02

0.04

0.01

1.00

0.03

0.03

0.01

1.01

0.04

0.02

0.01

1.02

0.05

0.01

0.01

1.03 For M

True Pos tol M L

out of diametric tolerance

the allowable tolerance = specified tolerance + (produced hole size - MMC hole size)

Thanks Any question?