Unit 1 Introduction - Symbols and Terms Introduction to Geometric Dimensioning and Tolerancing A Brief History ASME Standards related to Product Definition and Metrology ISO Standards related to Product Definition and Metrology Common Symbols Common Symbol Application Millimeter vs. Inch Conventions Tolerances in Perspective Features of Size and Features without Size Geometric Tolerancing Characteristic Symbols Feature Control Frame Geometric Tolerance Zone Shapes Geometric Tolerance Categories Symbols Associated with a Feature Control Frame Symbols Related to Datum Identification Index Plate - Practical Example Index Plate - Matching a Perfect DRF to an Imperfect Part Index Plate - Practical Example in 3D Definitions Fundamental Rules Material Conditions - MMC and LMC Workshop Exercise 1.1 Workshop Exercise 1.2 Workshop Exercise 1.3 Geolol Pro 1-1Introduction to Geometric Tolerancing Geometric Dimensioning and Tolerancing (GD&T) is an international engineering language that is used on drawings to express the allowable geometry of a part. It uses a series of symbols and feature control frames, rather than words, to describe the worst-case limits of a product. These symbols and frames are applied to the features and provide a clear definition of design intent. Quality control also uses these limits to develop a plan for verification, set rigid accepUreject criteria, and guides the reporting of the measurement data The buzz term “GD&T” is often thought of as one set of concepts, however it can be separated into two ideas: dimensioning and tolerancing. Dimensions are used to describe the perfect geometry of a part including distances, sizes, and angles of features. Because of slight manufacturing defects, no part could ever be made to this theoretically perfect geometry. Therefore, tolerances are added to a drawing to define the worst-case variations of these defects while still allowing part function. Dimensioning has been used in the mechanical engineering world for hundreds and even thousands of years to describe the geometry of a part. It is also used in civil engineering and architecture for layouts of buildings and bridges. Tolerancing is not necessary in applications with artisan! crafisman-style manufacturing. Cut-to-match, file-to-fit, match drilling, shim packing are all ‘methods to work around the manufacturing defects. However, this custom fitting often leads to more costly and time-consuming production, Serviceability can also be difficult because a replacement part must be custom-made again by a skilled craftsman. Tolerancing is a somewhat unique concept implemented to mechanical engineering drawings for two reasons: part interchangeability and quality control, ‘There are two different tolerancing systems: plus/minus tolerancing and geometric tolerancing (GeoTol). Plus/minus tolerancing was the original dimension-based tolerancing system with somewhat arbitrary definitions not backed by any official standard. Geometric tolerancing a more modem feature-based tolerancing system with definitions defined in an industry and government backed set of standards (Y14.5 and ISO-GPS). It describes the form, orientation and location of part features within theoretical tolerance zones relative to a defined coordinate system. ‘The GeoTo! system is an engineering language with a strong mathematical base which is essent for parts with precise and complicated geometry. This exact language also becomes more necessary asthe design, manufacturing, and inspection team gets bigger and more separated with more diverse supply chains. GeoTol is similar to any other language such as French, German, or Spanish, and therefore there are certain grammar and punctuation rules that must be leaned and practiced. This is important because we want to avoid “slang” in communication which could lead to incorrect interpretations of the design intent and accepting nonfunctional parts. Because of the mathematical base, the language is machine readable and many verifications may become more automated. Like any language, it takes a while to learn the GD&T system. People from various companies and backgrounds possess different knowledge levels. There are some personnel who might be considered conversational, others can read it but not write it, and others might be linguistic experts. Ittakes time, practice and effort to thoroughly understand the GD&T system. A Brief History of Tolerancing ‘The plus/minus toleraneing system Prior to the 1800s, manufacturing of parts was done in artisan/craftsman style. There were no tolerances and assembly relied on human skill to hand-file machined parts to match-to-fit sizes for precision use like in military weapons. Parts were generally not interchangeable. 1-2 GeoTol ProAlthough small degrees of interchangeability have been used since medieval times, more robust approaches to the concepts started on military components in France in the late 1700's. General Jean-Baptiste de Gribeauval started his "system of uniformity" with standardized weapons using standardized parts. He tasked his general inspector for the French arsenal, Honore Blane, to reduce the time and cost of producing muskets with less skilled labor. Borrowing from the ideas of go/ no-go gages for measuring cannon balls, Blanc was able to create 50 gun locks within plus/minus tolerances and demonstrated interchangeability. The idea never took off in France however, as fellow gunsmiths were skeptical and maybe even fearful of loosing their livelihood. Unfortunately Blanc’s workshop and most samples were lost in the French revolution. However, one witness to his demonstration in 1785 was the American ambassador to France, Thomas Jefferson (also later the 3rd president of the US). He took Blanc’s samples and the tolerance idea back to the US as a way to promote interchangeability back home. In the US, the interchangeability idea was approached by many independent gunsmiths supplying ‘weapons to the US army with varying levels of success in small batches throughout the late 1700's and carly 1800's. The problem was eventually tasked to two US armories, Harpers Ferry Armory and Springfield Armory. John Hall at an independent workshop inside Harpers Ferry achieved interchangeability in gun locks in 1825. He collaborated with fellow gunsmith Simeon North, who ranasmall workshop at Springfield Armory, to expand interchangeability at two different workshops in 1834, Although ittook time (another 60-70 years), tolerancing eventually spread beyond military ‘weapons to other industries including sewing machines, typewriters and automotive. Another notable story is with Eli Whitney, a firearms manufacturer that is sometimes falsely credited with the invention of interchangeability. In 1799 before US congress, he made a presentation of assembly with ten sets of musket parts and claimed the same parts and mechanisms through the use of tolerancing. Although Whitney did secure a contract for 10,000 muskets, he struggled with that order and never achieved the concept of interchangeability himself. It was later found that his, presentation was faked and the pieces were not fully interchangeable. Even though Whitney did not implement the concept, the idea of plus/minus tolerancing and interchangeability was brought further to the forefront at that time. The idea was simple: dimensions have a plus/minus tolerance and gages are used to verify them within the limits. The difficult problem was the precision required for interchangeability was beyond manufacturing and inspection abilities at the time. Full widespread use of tolerancing didn’t happen before the invention of mechanized manufacturing equipment such as the lathe and milling machines, better inspection equipment such as the micrometer and the dial test indicato-, and more precise US standards for length, The Start of Geometric Tolerancing Plus/minus tolerancing with a mix of artisan-style no-tolerance manufacturing was used thru the early 1900s and World War 1. It wasn’t until the ramp up to World War 2, Stanley Parker from the Royal Torpedo Factory in Scotland realized there were problems with the plus/minus tolerancing system for locating holes. Parker was one of the first people to initiate the use of round tolerances for holes rather than square zones, Although symbols were not used on the drawing, the concept of position tolerance was written in notes The United States Department of Defense saw a need for more robust standardization of drawings including dimensioning and tolerancing after World War II. Military parts were made for the war effort by many outside manufacturers from automotive to consumer products. They did not have the tribal knowledge that was needed with the plus/minus tolerances to understand the design intent, The DOD mandated the use of the carly Mil standard 8 for drawings of military parts where GeoTol Pro 1-3interchangeability was essential. The Mil standards eventually merged with the SAE Aero/Auto, and ASA Y14.5 to create the USASI Y14.5-1966 standard. This standard is now written by the Y14.5 committee comprised of industry experts from US government agencies, universities, and companies in defense, aerospace, automotive, medical, consumer products, measurement devices and software. The meetings are coordinated and standards published by ASME (American Society of Mechanical Engineers) with ANSI (government body) approval. The committee roster has rotated through the years to create a standard that is ir constant flux. A new edition is released about every 10 years with each edition clarifying concepts and adding new symbology as technology and knowledge improves. Evolution of Dimens yning and Tolerancing Standards in the USA: Mil Std 8 from 1949-1963 ASA Y14.5-1957 SAE/Aero from 1946-1963, USASI Y14.5-1966 (one unified national standard) ANSI Y14.5-1973 ANSI Y14.5M-1982 ASME Y14.5M-1994 ASME Y14.5-2009 ASME Y14.5-2018 ‘The latest American National Standard on dimensioning and tolerancing is the ASME Y14.5- 2018. There have been many clarifications, enhancements, and a few new concepts over past standards. In Appendix A of this book you will find a list of the major changes from the previous ASME Y14.5-2009 and ASME Y14.5M-1994 standards. There is a standard on the Mathematical Definitions of Dimensioning and Tolerancing: ASME Y14.5.1-2019. This document is primarily used in the development of software and provides a clear mathematical definition to the worded concepts of Y14.5. There is also a certification program and standard on the subject called the ASME Y14.5.2-2017, Certification of Geometric Dimensioning, and Tolerancing Professionals. There are other Y14 drawing standards written by different subcommittees that define drawing views (Y14.3), line conventions (Y14.2), casting symbols (Y14.8), Digital Product Definition Data Practices (Y14.41) to name a few. The Y14 standards are all about product definition and documentation. There is a separate group of subcommittees that writes the B89 series of standards on metrology and measurement of the specifications. See the next page for a list. ‘The ISO-GPS standards There is also a competing series of geometric tolerancing standards called ISO-GPS (International Organization for Standardization - Geometrical Product Specification). ISO combines telerancing with measurement in the GPS series of documents written by the Technical Committee (TC) 213. The ISO dimensioning and presentation in the drawing is covered by the TPD (Technical Product Documentation) series written by TC/10. See the next pages for a list of these standards. ‘The ISO working groups consist of people representing standards institutes from different countries (the countries are called member bodies). The US is a member body in these ISO standards called the US TAG (Technical Activity Group) through ASME and ANSI. The definitions of most dimensioning and tolerancing symbols are similar between ASME and ISO, with only slight differences. For consistency, this book will show examples and give definitions of symbols from ASME Y14,5. However, any major differences are highlighted in the units with a full summary in Appendix B of this book. 1-4 GeoTol ProASME Standards Related to Product Definition and Metrology The following is a reference list of ASME standards that are related to product definition (Y) and metrology (B) that are active at the print date of this book. The date of publication must be listed when referencing these documents. The notation (R208) after is the reaffirmed date. Standards must be either revised or reaffirmed every 5 years or are withdrawn, The (rev) after shows these standards are currently in the process of being reaffirmed or revised. For more detailed information on the status and current available standards, see the ASME website: [Link] ASME Y14.1-2012 (rev), Decimal Inch Drawing Sheet Size and Format ASME Y14,1M-2012 (rev), Metric Drawing Sheet Size and Format ASME Y14.2-2014 (R2020), Line Conventions and Lettering ASME Y 143.2012 (R2018), Orthographic and Pictorial Views ASME Y14.5-2018, Dimensioning and Tolerancing ASME Y14.5.1-2019, Mathematical Definition of Dimensioning and Tolerancing Principles ASME Y14.5.2-2017, Certification of Geometric Dimensioning and Tolerancing Professionals ASME Y14.6-2001 (R2018), Serew Thread Representation ASME Y14.8-2009 (R2014) (rev), Castings, Forgings, and Molded Parts ASME Y14.24-2012 (rev), Types and Applications of Engineering Drawings ASME Y14.31-2014 (R2019), Undimensioned Drawings ASME Y14.34-2013 (R2018), Associated Lists ASME Y14.35-2014 (R2019), Revision of Engineering Drawings and Associated Decuments ASME Y14.36-2018, Surface Texture Symbols ASME Y14.37-2019, Composite Part Drawings ASME Y14.38-2019, Abbreviations and Acronyms for Use on Drawings and Related Documents ASME Y 14,39 Draft, Prefered limits and fits (consolidating B4.1 and B4.2) ASME Y14.41-2019, Digital Product Definition Data Practices ASME Y14.43-201I (tev), Dimensioning and Tolerancing Principles for Gages and Fixtures ASME Y 14.44.2008 (R2014) (rev), Designations for Electrical and Electronies Parts and Equip ASME Y14.45-2021, Measurement Data Reporting ASME Y14.46-2017, Product Definition for Additive Manufacturing. ASME Y14.47-20.9, Model Organization Practices ASME ¥ 14.48 Draft, Universal Direction and Load Indicators. ASME Y14.100-2017, Engineering Drawing Practices ANSI B4.1-1967 (22009) (rev), Preferred Limits and Fits for! ANSI B4.2-1978 (22009) (rev), Preferred Metric Limits and Fits ASME BI.1-2003 (R2008), Unified Inch Screw Threads ‘ASME BI.13M-2005 (R201), Metric Screw Threads: M Profile ASME B5.10-1994 (R2013), Machine Tapers — Self Holding and Steep Taper Series ASME B46.1-2009, Surface Texture, Surface Roughness, Waviness, and Lay ASME PDS-1.1-2013, Dimensioning, Tolerancing, Surface Texture, and Metrology Standards - Rules for Drawings With Incomplete Reference to Applicable Drawing Standard ASME B89. 1.10-2013, Dial Indicators for Linear Measurements ASME B89_1, 13-2013, Micvometers ASME B89.1.14-2018, Calipers ASME B89.3.7-2013, Granite Surface Plates ANSI B89.3.1-1972 (R2003), Measurement of Out-of-Roundness ASME B89.4.10360.2-2008 Acceptance Test and Reverification Test for Coordinate Measuring Machines (CMMs) art 2: CMMs Used for Measuring Linear Dimensions (Technical Report) ASME B89.4.21.1 -2020, Environmental Effects on Coordinate Measuring Machine Measurements [Tech Report] ASME B89.4.22 - 2004, Methods for Performance Evaluation of Articulated Arm Coordinate Measuring Machines ASME B89.6.2-1973 (R2017), Temp and Humidity Environment for Dimensional Measurement ASME B89.7.2-20:4 Dimensional Measurement Planning ASME B89.7.3.1-2001 Considering Measurement Uncertainty for Conform To Specs ASME B89.7.3.2.2007 Guidelines for Evaluation of Dimensional Measurement Uncertainty GeoTol Pro 1-5ISO Standards Related to Product Definition and Metrology 1SO-GPS (Geometrical Product Specification) is the system used to define the geometrical requirements of parts in engineering specifications, and the requirements for their verification. 1SO-TPD (Technical Product Documentation) includes standards for technical drawings, model based (3D), computer based (2D) or manually produced for technical purposes, Below are the notable standards that define general [SO-TPD and ISO-GPS concepts. ISO standards are noted with the ISO number, colon and then year of publication: ISO 128-1 (TPD) General principles of representation Part |: Intro and fund requirements ISO 128-2 (TPD)General principles of representation Part 2: Basic conventions for lines ISO 128-3 (TPD) General principles of representation Part 3: Views, sections and cuts ISO 128-100 (TPD) General principles of representation — Part 100: Index ISO 129-1:2018/AMD 1:2020 (TPD) Presentation of dims and tols Part 1: General principles ISO 6410-1:1993 (TPD) - Screw threads and threaded parts — Part 1: General conventions ISO 16792:2015 (TPD)- Digital product definition data practices ISO 1:2016 Standard temperature for spec of geometrical and dimensional properties ISO 8015:2011 Fundamentals -- Concepts, principles and rules ISO 286-1 and ISO 286-2:2010 Tolerance classes and fits ISO 1101:2017 Geometrical tolerancing -- Tolerances of form, orientation, location, and runout ISO 1660:2017 Geometrical tolerancing ~- Profile tolerancing ISO 2692:2014 Geometrical tolerancing —- Maximum material requirement (MMR), least material requirement (LMR) and reciprocity requirement (RPR) ISO 5458:2018 Geometrical tolerancing -- Pattern and combined gcometrical specification ISO 5459:2011 Geometrical tolerancing ~ Datums and datum systems (under development) ISO 2768-1:1989 General tolerances -- Part 1: Tolerances for linear and angular dimensions without individual tolerance indications ISO 2768-2:1989 General tolerances -- Part 2: Geometrical tolerances for features without individual tolerance indications ISO 14405-1:2016 Dimensional tolerancing -- Part 1: Linear sizes ISO 14405-2:2018 Dimensional tolerancing -- Part 2: Dimensions other than linear sizes, ISO 14405-3:2016 Dimensional tolerancing -- Part 3: Angular sizes ISO 14406:2010 Extraction ISO 16610-1:2015 (many in this series): Filtration -- Part 1: Overview and basic concepts ISO 17450-1:2011 General concepts Part 1: Model for geometrical specification and verification ISO 17450-2:2012 General concepts Part 2: Basic tenets, specifications, operators, uncertainties ISO 17450-3:2016 General concepts Part 3: Toleranced features ISO 17450-4:2017 General concepts Part 4: Geometrical characteristies for quantifying GPS deviations ISO 14638 is the matrix model that provides an overview of the structure of the ISO GPS system. ‘Most of the basic principles and tolerancing concepts are found in ISO 8015 and ISO 17450 but the basic geometric tolerancing principles are in ISO 1101. ‘There are many other GPS standards that cover inspection of the specifications and measuring equipment not listed here. For a full and current list, [Link]/committee/54924/x/catalogue/ 1-6 GeoTol ProCommon Symbols The table below shows dimensioning symbols found on drawings. Note the comparison with the TSO standards. Most symbols have been in 14.5 since at least 1994, Newer symbols introduced in Y14,5-2009 are indicated with 09 next to them. There were no new symbols in the dimensioning section in Y14.5-2018. a eo ea fee me Se [oie Ta a a Counterbore Cylindrical Counterbore olin | Countersink Countersink Depth Depth i = 09] Continuous Feature ‘Common Tolerance Feature of Size Statistical Tolerance None (default) Envelope Principle GeoTol Pro 1-7 ler 09Common Symbol Application Many of the common dimensioning symbols from the chart on the previous page are shown on the drawing below. The symbols are a standard method of describing part geometry and specifying requirements without the use of words. Most of these symbols are used on example drawings throughout this book. Drawing with practical application of common dimensioning symbols Size tolerance All around symbol Feazure control frame, Square symbol J Diameter symbol J ‘Radius symbol / Basic dimension Reference dimension 840.1 \¥ 9920.3 X 90°21" \ Countersink symbol <— Datum feature symbol Number of places Counterbore symbol Depth symbol Basic dimensions are theoretically exact and define the perfect geometry of a feature. Reference dimensions are repeats of dimensions or are derived from other values shown on the drawing or related drawings. Reference dimensions are auxiliary information. Repetitive features, such as holes, may be specified by stating the number of places and an “X”. Where used with a basic dimension, the number of places and the X may be placed either inside or outside the basic dimension box. Note the X is also used as “by” when specifying a countersink. with diameter 9 by 90 degrees or a slot width 10X20. The countersink, counterbore, and depth symbols could be defined with normal dimensioning techniques. However, these symbols organize a set of coaxial features on the drawing and make it easier to read. ‘The details of size tolerance, the datum feature symbol, feature control frame, and basic dimensions will be explained later in this unit. 1-8 GeoTol ProMillimeter vs. Inch Units Although the ASME Y14.5 (and most other ASME standards) use millimeter (mm) values for dimensions and tolerances, inches (in) may also be used. On drawings where all dimensions are in millimeters or all dimensions are in inches, individual identification of linear units is not required, However, the drawing shall contain a note stating UNLESS OTHERWISE SPECIFIED, ALL DIMENSIONS ARE IN MILLIMETERS (or IN INCHES, as applicable). This book will use a variety of both units in examples because of the wide range of industry audience. The book will adhere to the following rules set by section 4.3 of Y14.5 when switching units: imeter Dimensioning (a) Where the dimension is less than 1 mm, a zero shall precede 0.5 not 5 the decimal point. (b) Where the dimension is a whole number, neither the decimal 12 not 120 point nor a zero shall be shown (©) Where the dimension exceeds a whole number by a decimal 0.5 not 0.500 fraction of | mm, the last digit to the right of the decimal point shall not be followed by a zero. NOTE: This practice differs for tolerances expressed bilaterally +0.25 12.25 or as limits. O12 040 © Pi1190 Inch Dimensioning (@) A zero shall not be used before the decimal point for 5 or.500 not 0.5 values less than 1 in (b) A dimension shell be expressed to the same number of decimal places as its tolerance. Zeros are added to the right of the decimal point where necessary. -500+.005 not .50#.005 The tolerancing “lingo” Tolerances are often small values with a lot of zeros in front. It can be difficult to speak about these numbers quickly. Here are a few semi-standard ways to talk about these numbers: 005 inch —_“point-zero-zero-five” can instead be said as “five thousandths” or “five thou” .020 inch —“:wenty thousandths” or “twenty thou” .0002 inch “wo ten-thousandths” or “two tenths” Inch values are expressed in thousandths of an inch (not tenths or hundredths) Note: in some industries .005 is expressed as “5 mills” This comes from the prefix “milli-” which refers to thousandths of something (5 milli-inches). However, mills often gets mixed up with milli- meters and is not recommended. Paint thickness and coatings are still often expressed in “mills” 0.005 mm — “zero-point-zero-zero-five” can instead be said as “five microns” 0.02mm “twenty microns” A micron is short for a micrometer. This is only necessary when the tolerances get small enough that the number of zeros makes them hard to say. Note that this “lingo” is not documented in Y14.5 but rather is “shop talk” and slang that could be helpful to know. Geolol Pro 1-9Tolerances in Perspective ‘Tolerances values on engineering drawings can be very small and difficult to keep in perspective. Small tolerances can be compared to germs, Our parents always told us to wash our hands to stay free cf germs so we don’t get sick. But when we look at our hands, we do not see any germs. Tolerances are also often small and not visible with the naked eye. Holding a machined part, the surfaces look flat and square, but if you view the parts with precise inspection equipment such as micrometers, dial indicators, or CMMs, you would find that there are differences from the dimensions on the drawing and from one manufactured part to the aext. The engineer designs the parts with perfect geometry in CAD, but the produced parts are never perfect. To understand ‘geometric tolerancing, you must think of all parts being imperfect to some degree. ‘The produced parts shown in this book are drawn with exaggerated error, to help the user understand how to match perfect tolerance zones with the imperfect geometry of the part. Some form of imagination is required when visualizing these small tolerances. apes Drawing produced by CAD Actual produced part with error The illustration below provides a perspective of tolerance values with a magnified whisker from a common house cat. Note that a flatness tolerance of .001 inch (0.025 mm) is holding the surface to a tolerance of one quarter the size of the whisker. These tight tolerances are often necessary, but important to keep in perspective. ooo nen os. @ 001 inch (about 0.1 mm) (about 0.025 mm) ® .0001 inch (about 0.0025 mm) ‘Small tolerances can increase cost in the manufacture, inspection and tooling of parts. Tooling tolerances are genevally 30% of part tolerances, and quality strives for measurement uncertainties of 10% of part tolerances. Tolerances applied to the design push even tighter requirements tarough the manufacturing and verification process. The two goals of a designer: allow tolerances as large as possible while preserving the function of the part, 1-10 GeoTol ProFeatures of and Features without Size Geometric tolerancing is a feature based system. A feature is a general term applied to a physical portion of a part such as a surface, pin, tab, hole or slot, Parts are composed of many features. ‘There are two types of features: Features of size and features without size (surfaces). This is an important distinction in geometric tolerancing Examples of features without size: (Surfaces) Y p Examples of features of size r? 625 000 shaftipin ~S Ro Cex. J - EXD @.500+.005, 0 Hole ~~ CK $02 slot 1.200.001 eT > Width/tab hi Regular features of size are usually controlled a size tolerance and have an easily determined axis ot median plane (through the unrelated actual mating envelope). Geolol Pro 1-11Geometric Tolerancing Characteristic Symbols ‘There are 12 geometric tolerancing characteristics with the corresponding symbols shown below: ‘These symbols are placed in the first compartment of a feature control frame and define the geometry characteristic of the feature that is to be controlled. The charecteristics are grouped into four types of tolerance: form, orientation, location, and runout. The general primary control with a few notes is also shown. This is only a quick summary and a ‘more complete definition can be found later in the text pepe) fee feature of size | — | STRAIGHTNESS Datum feature reference not allowed Does not control relationship [fo] CIRCULARITY between features PERPENDICULARITY Controls til/angle of a surface or feature of size pA en PARALLELISM Orientation | Datum feature reference required Optional: Angularity symbol may be Jancurarry | used for all orientation controls Locates features of size POSITION Also controls orientation PROFILE OF A ji la | PROFILE Location | Locates surfaces ‘Also controls form and orientation PROFILE OF A Can also control size LINE TOTAL Centers a surface of revolution RUNOUT Runout | around a datum axis, Also controls form and orientation CIRCULAR Note: Geometric characteristic symbols of concentricity and symmetry were removed in ASME Y14.5-2018. See unit 13 for more explanation.Feature Control Frame Geometric Primary Datum Feature Characteristic Secondary Datum Feature Optional Modifiers \ J, ny Datum Feature / \ (e[eos]alelc] (@[sos@[a[s@lc] toteance 2 zone shape Tolerance The feature control frame (in ASME) or tolerance indicator (in ISO) is the symbolic means of expressing the tolerance requirements for a feature or set of features. The frame is divided into rectangular compartments: ‘The first compartment contains one of the 12 geometric characteristic symbols. There can never be more than one of these symbols in one frame. Multiple feature control frames or a composite tolerance are used for multiple requirements. ‘The second compartment contains the shape of the tolerance zone followed by the tolerance. The default tolerance zone shape (without a symbol) is parallel planes/total wide zone. A diameter symbol (@), or spherical diameter symbol (SQ) may be added to change the tolerance zone to a cylindrical or spherical shaped zone. ‘The tolerance is expressed as a total value and never a plus/minus. Modifiers may be added behind the tolerance value. These modifiers can be MMC, LMC, projected tolerance zone, free state, tangent plane, statistical tolerance, unequally disposed profile, and dynamic profile. See later units for detailed explanations. ‘The third, fourth, and fifth compartments contain the datum feature reference(s) to create the datum reference frame. Depending on the specification, these compartments are not always necessary, The alphabetical order of the datum references has no significance but rather the order of precedence reading from left to right as primary, secondary and tertiary. These compartments define the datum reference frame and represent the constraints for the tolerance zone. See unit 4 for detailed explanations. Modifiers for the datum features may be added behind each datum feature letter, These modifiers can be MMB, LMB, [BSC], and translation. See unit 7 for detailed explanations. Other aspects of the feature control frame contain other information about the tolerance. The tolerance controls the surface when the frame is attached to the surface thru extension lines or leader lines. The tolerance controls the axis, center plane, or center point of the feature when the frame is placed under the size tolerance. Features may be grouped into a pattern with notations nX, INDICATED, multiple leader lines, all around symbol, or all over symbol. Symbols of “between” or “from-to” may be used to indicate the extent of the control. See units 11 and 12 for detailed explanations, 72S fies SEES paEaET GeoTel Pro 1-13Geometric Tolerance Zone Shapes AA feature control frame creates a geometrically shaped tolerance zone within which the feature ‘must lie, The tolerance zones may be a variety of shapes usually defined by the geometric characteristic in the first compartment and other symbology in the second compartment. The tolerance zone may or may not be constrained relative to a datum reference frame. While 3D tolerance zones are the most common, 2D tolerance zones may also be used for cross-sectional control of a feature. Common tolerance zone shapes: Parallel Square or planes rectangle Cylinder Spherical a=W oo mniform —Corical Concentric uundary cylinders SO ®f @Ot Lea -NUOa Tolerances ‘Tolerances ‘The Datum Reference Frame is a coordinate system used to constrain tolerance zones and establish the origin ‘of measurement, All basic dimensions will be defined from this datum reference frame. Basic Dimensions (in ASME) or Theoretically Exact Dimensions (in ISO) Basic dimensions are theoretically exact dimensions used to define the perfect location of a feature, Dimensions are indicated as basic dimensions by 4.000) a rectangular box around the value or by a general note on the drawing such as: ALL DIMENSIONS ARE BASIC. The default tolerances (2) stated in the title block ofa drawing do not apply to basic dimensions. There will be more explanation of basic dimensions and their use in unit 3 1-14 GeoTol ProGeomet Tolerance Categories Geometric tolerancing is a feature-based tolerarcing system and the tolerances are divided into three main types: form, orientation, and location. Form tolerances control the “shape” of a feature (to itself) and are often used as a refinement of size Orientation tolerances control the “tilVangle” of a feature to a datum reference frame and are associated with basic angle dimensions. They are often used as a refinement to location, If applied to surfaces, orientation tolerances also control form. Location tolerances control location/distance of features to each other or to a datum reference frame and are associated with basic linear dimensions. Position locates the center plane or axis of a feature of size. Position also controls orientation. Profile locates a surface, Profile also controls orientation and form, It can also control size. “Happy Features” Form Tolerances control “shape” Flatness Straightness Cireularity Cylindricity @ans Orientation Tolerances control “tilt” Angularity Parallelism Perpendicularity 1 Location ‘Tolerances control “distance” Profile Locates Axis or Median Plane Locates Surfaces GeoTal Pro 1-15Symbols associated with a Feature Control Frame The table below lists symbols that may be placed inside or associated with a feature control frame. Italso compares terms and symbols with the ISO-GPS standards. Most symbols have been in Y14.5, since at least 1994. Symbols with 09 next to them were first introduced in Y14.5-2009. Symbols with 18 were first introduced in Y14.5-2018. Maximum Material Condition (MMC) (when applied to a tolerance) ‘Maximum Material Boundary (MMB) (when applied to a datum reference) Maximum Material Requirement (MMR) Least Material Condition (LMC) (when applied to a tolerance) Least Material Boundary (LMB) (when applied to a datum reference) Least Material Requirement (iMR) Diameter Diameter Spherical diameter Spherical diameter Projected tolerance zone Projected tolerance zone Ile evleaasie| © | © Free state Free state condition Tangent plane Tangent feature @ 09| Translation (default) Distance variable [DV] 09| Unequally disposed profile Specified tolerance zone offset | UZ 18| Dynamic profile Unspecified tolerance zone offset | _OZ All around All around ee 09] All over Allover a Between Between o> 18| From-to None (proposed) None Major diameter MAJOR | Major Diameter [MD] Minor diameter MINOR | Minor Diameter (Lo) Pitch diameter PITCH | Pitch Diameter [PD] None None | Combined zone cz None (default) None | United feature UF None None | Orientation only constraint >< None None_| Any cross-section ACS Note: There are many more modifiers in ISO-GPS standards. This list shows equivalent concepts with ASME Y14.5 plus a few other notable symbols. See the appendix on ISO differences. 1-16 GeoTol ProSymbols Related To Datum Feature Identification This table identifies terms and symbols that are associated with establishing datums from datum features. A more complete definition and description of cach these specifications can be found later in units 4 and 8. The movable datum target symbol marked with 09 was new for the ASME Y14.5-2009 standard, Datum Feature ANSI Y14.5M-1982 (former standard) Datum Target Datum Target Point Datum Target Line Datum Target Area 09 | Movable Datum Target Dimension Origin Geollol Pro 1-17Index Plate - Practical Example The establishment of a Datum Reference Frame (DRF) and geometric tolerances are based on functional design requirements, An index assembly is shown below. The top index plate clamps on its face and is centered by the pilot pin. The plate is rotationally aligned with the side planar surface and secured with three screws. Study the functional requirements below. Faces must Index Assembly Screws must seal within 0.2 Bottom surface fit into holes insertion must bbe within +0.1 Outside eylinder edges must not Pilot pin must mismatch more fitinto hole than 04 Flat edges must not mismatch more than 0.2 ‘The ABC DRF is established from datum features based on mating conditions. The primary datum feature A is the large planar face, and its form is qualified with a flatness. The secondary datum feature B is the pilot pin, and its orientation relationship to datum A is controlled with a perpendicularity tolerance. ‘The tertiary datum feature C is the planar surface to stop rotation and its location relationship to ABis controlled with a profile tolerance of 0.2 for the mismatch with the mating part. The three holes are given a size tolerance and position of 0.4 to the ABC DRF to align with the mating tapped holes and accept the screws. ‘The top surface of the pilot pin is located with a profile tolerance of 0.2 for the insertion depth requirement. The outside diameter surface is located with a profile tolerance of 0.4 for the ‘mismatch on the outside edges. The last surface is toleranced with large profile tolerance of 0.6 because itis relatively unimportant, ‘Index Plate Drawing Pe axoo'3? [— @25104 1-18 GeoTol ProIndex Plate - Matching a Perfect DRF to an Imperfect Part ‘The produced index plate is shown below with exaggerated variation from manufacturing. The perfect geometry of the DRF, true geometric counterparts and tolerance zones are mated to the imperfect geometry of the produced part. The construction of the DRF and corresponding terminology is shown below. This example is only meant to be an initial introdcution to the subject. More detail on the establishment of a DRF and these terms can be found later in unit 4. Establishment of ABC DRF on the produced index plate. Datum A is a perfect plane established by the high points of datum feature A. ‘Measurements originate from this plane. Datum Feature A is the imperfect surface on the part, Variations of the feature are controlled with a flatness tolerance. ‘Datum Feature B is the imperfect pilot dia on the part. Its axis is oriented to datum plane A with a persendicularity tolerance. ‘True Geometric Counterpart (TGC) B (related actual mating envelope) is the smallest circumscribed cylinder perpendicular to datum plane A that contacts the high points of datum feature B. Datum B (Related) is the axis of the TGC. This is the axis of the AB DRF. Measurements originate from this axis. Feature Axis is the axis of the unrelated actual mating envelope. ‘The unrelated AME is the smallest circumscribed cylinder unrelated to any datums. } 0.2 Profile tolerance tolerance _-Pe#pendicularity Tolerance Zone is, zone locates the surface. ‘one 0.1 cylindrical tolerance zone that is perpendicular to datum plane A. The feature axis must fall within this zone, Datum Feature C is the imperfect planar surface on the part. It is located to the AB DRF with a profile tolerance. ‘True Geometric Counterpart C is a perfect plane perpendicular to datum plane A that progresses towards datum B axis to make maximum contact with datum feature C and constrain rotation. This plane sets the orientation planes of the DRF around datum axis B. 0.2 Profile tolerance zone locates the surface relative to datum A. Geometric tolerances are related to the perfect datums and not the imperfect datum features. Datum A. Geollal Pro 1-19index Plate - Practical Example in 3D Geometric wlerancing may be applied to the Index Plate model per ASME Y14.41-2019. Basic dimensions define the geometry of the perfect model and do not need to be displayed. Each feature is controlled with a geometric tolerance in a feature control frame. ‘The model may be rotated in a CAD system or lightweight viewer. Each tolerance has associativity to the feature and is machine readable. When the tolerance is queried, the associated toleranced feature shall highlight. This can be sent to a supplier for bid without the need for a 2D drawing. This toleranced model may be imported into a CMM or tolerance 3D Model Tolerancing analysis program to save hours of manual import. Features are the building blocks of a part, and GeoTol is a feature-based toleraneing system. The variation on these surfaces, holes, pins, slots are controlled with size and geometric tolerances. Three features are selected as datum features (A,B,C) that constrain the part and create a datum reference frame. Other features are located to this DRF with position and profile tolerances. Every feature shall have a tolerance. ‘This surface located within 0.6 This surface located within 0.4 These 3 holes have size of B8.9-9.3 and located within 0.4 This surface located within 0.2. This is datum feature C ‘This surface flat within 0.1. This is datum feature A ‘This surface This pin has size of @24.9-25.1 and perpendicular within 0.1. located within 0.2 This is datum feature B 1-20 Geolol ProDefinitions The definitions below are terms used in this text and the ASME Y 14.5-2018 standard. Feature - A physical portion of a part such as a surface, pin, hole, or slot or its representation on drawings, models, or digital data files. Feature Axis - The axis of the unrelated actual mating envelope of a feature. Feature Center Plane - The center plane of the unrelated actual mating envelope of a feature. Actual Mating Envelope (AME) - A similar perfect feature(s) counterpart of smallest size that can be contracted about an external feature(s) or of largest size that can be expanded within an intemal feature(s) so that it coincides with the surface(s) at the highest points. This envelope is on or outside the material. There are two types of AMEs, as described below. a. Unrelated Actual Mating Envelope (Unrelated AME) - A similar perfect feature(s) counterpart expanded within an in internal feature(s) or contracted about an external feature(s) and not constrained to any datum(s), b, Related Actual Mating Envelope (related AME) - A similar perfect feature(s) counterpart expanded within an in intemal feature(s) or contracted about an external feature(s) while constrained either in orientation or location or both to the applicable datum(s). Geometric tolerances applied to a hole or The related AME is the orientation constrained pin at MMC or RFS control the feature axis. _or location constrained mating envelope. This ‘The feature’s axis is established from the term is used to explain other concepts unrelated actual mating envelope (largest including the establishment of secondary and inscribed cylinder for a hole) tertiary datums, also in the evaluation of the MMB boundaries. See unit 4 and unit 7. Feature axis N Unrelated AME: Related AME Datum A A Note: Geometric tolerances with LMC modifiers control the axis of the unrelated actual minimum material envelope. This is a similar perfect feature(s) counterpart contracted about an internal feature(s) or expanded within an external feature(s), and not constrained to any datums. See unit 3 for more information. Note: Straightness of a median line controls the derived median line and not the axis. Flatness of a median plane controls the median plane and not the center plane. See unit 10. GeoTol Pro 1-21Fundamental Rules Section 4.1 of Y14.5-2018 defines fundamental rules of dimensioning and tolerancing. Most of the rules are carry overs from the 2009 version with small updates/clarifications to include model based practices. Rules (q) and (8) are new for 2018. The statements below represent a shorter list of the most notable rules with some truncated for clarity. See Y14.5-2018 for the full list: (a) Each feature shall be toleranced. Tolerances may be applied directly to size dimensions. Tolerances shall be applied using feature control frames when feature definition is basic. Tolerances may also be indicated by a note or located in a block of the drawing format. (b) Dimensioning and tolerancing shall be complete so there is full understanding of the characteristics of each feature. Values may be expressed in an engineering drawing or in a CAD definition data set. (©) Each necessary dimension of an end product shall be shown or defined by model data, No more dimensions than those necessary for complete definition shall be given. The use of reference dimensions on a drawing should be minimized, (@) Dimensions shall be selected and arranged to suit the function and mating relationship ofa part and, shall not be subject to more than one interpretation. (e) The drawing should define a part without specifying manufacturing methods. Thus, only the diameter of a hole is given without indicating whether it is to be drilled, reamed, punched, or made by another operation. However, in those instances where manufacturing, information is essential to the definition of engineering requirements, the information shall be specified, (h) Dimensions in orthographic views should be shown in true profile views and refer to visible outlines. ‘When dimensions are shown in models, the dimensions shall be applied in a manner that shows the true value. (j) An implied 90° angle shall apply where center Tines and fines depicting features are shown on orthographic views at right angles and no angle is specified. The applicable tolerance is the same as for all other angular features shown on the field ofthe drawing governed by general angular tolerance notes or general tolerance block values. (&) An implied 90° basic angle shall apply where center lines of features or surfaces shown at right angles on an orthographic view are located or defined by basic dimensions and no angle is specified. The applicable tolerance(s) are provided by a feature control frame or note that governs the orientation of features. (A zero basic dimension shall apply where axes, center planes, or surfaces are shown coincident on orthographic views and geometric tolerances establish the relationship between the features. On CAD. models, the distance is basic when queried model distances are zero and geometric tolerances establish the relationship between the features. The applicable tolerance(s) are provided by a feature control frame or note that governs the location of features. (m) UOS, all dimensions and tolerances are applicable at 20°C (68°F) in accordance with ASME. 'B89.6.2. Compensation may be made for measurements made at other temperatures. (a) UOS, all dimensions and tolerances apply in a free state condition. (0) UOS, all tolerances and datum features apply for full depth, length, and width of the feature. (p) Dimensions and tolerances apply only at the drawing level where they are specified. A dimension specified for a given feature on one level of drawing (e.g., a detail drawing) is not mandatory for that feature at any other level (e.g., an assembly drawing), (q) UOS by a drawing/model note or reference to a separate document, the as-designed dimension value does not establish a functional or manufacturing target. (5) UOS, elements of a surface include surface texture and flaws (¢.g., burrs and scratches). All elements ‘ofa surface shall be within the applicable specified tolerance zone boundaries. 1-22 GeoTol ProMaterial Conditions - MMC and LMC Features of size (such as holes, slots, tabs and pins) have size tolerance that allow them to be large or small within the tolerance limits. There is often a need to refer to a feature at a specific size limit. Maximum Material Condition (MMC) and Least Material Condition (LMC) are terms for the worst-case size limits of a hole, pin, slot, or width, ‘Maximum Material Condition (MMC) - The condition where the feature contains the maximum. ‘material within the stated limits of size. For example: the smallest hole or biggest pin. Least Material Condition (LMC) - The condition where the feature contains the least material within the stated limits of size. For example: the smallest pin or biggest hole. MMC and LMC examples: The MMC and LMC is shown for each feature of size. MMC size 80.2 3x 99104 IMC size 79.6 MMC size 25.06 LMC size 9.4 LMC size 25.02 MMC size 8.6 1640.25 \ LMC size 16.25 MMC slze 15.75 25.08 Limit vs. Unilateral ys Bilateral Tolerancing ‘The size tolerance of a @15 mm or 0.500 inch hole may displayed in a variety of ways shown below. Each of these display methods has the same meaning with two worst case limits of MMC and LMC. It is a matter of preference which display method is used. 15.3 +03 +0.4 mm 0449 014.9-15.3 915.120.2 O15 54 o149"5 Limit Bilateral Equal jlateral Unequal inch 305 @.500-.504 .500+,002 o.501 "008 Note: the term nominal is sometimes confused in these designations. From ASME Y14.5-2018: Nominal size: the designation used for purposes of general identification. (USAS B4. 1). ‘Therfore, any number between .500 to .504 could be called the nominal size of the hole above. Also note rule (q) from the fundamental rules: UOS, the as-designed dimension value does not establish a functional or manufacturing target. GeoTol Pro 1-23Workshop Exercise 1.1 1. What is the name and date of the latest American National Standard on dimensioning and tolerancing? 2. What is the name and date of the latest American National Standard on mathematical definitions of dimensioning and tolerancing? 3. What is the name and date of the latest American National Standard on certification of dimensioning and tolerancing professionals? 4, InISO, there are many documents that cover geometric tolerancing. What is the number and date of the ISO standard that covers the generalities of geometric tolerancing? Tolerancing of form, orientation, location and runout? On the drawing below, find and label the following symbols. 5, Feature control frame 11. Countersink symbol 6. Radius symbol 12, Counterbore symbol 7. Basic dimension 13, Datum feature symbol 8. Two places designation 14, Reference dimension 9. Square symbol 15. Depth symbol 10. All around symbol 16, Diameter symbol AB A o6 ' 38 Gs) (60) Go] { 2x G820.2 1____, a ba] Ris) 38. 40 98202 LU g1020.2 ¥5205 p720.2 YY 0920.4 x 90721" 1-24 Geollal ProWorkshop Exercise 1.1 17. In the table below, sketch the proper symbol next to the geometric characteristic term. Select from the symbols shown below. Also, identify the type of tolerance such as: form, orientation, location, and runout. HY LA A Aa oo A ¢ 4 4% = STRAIGHTNESS CYLINDRICITY CIRCULARITY PERPENDICULARITY PARALLELISM ANGULARITY PROFILE OF ALINE TOTAL RUNOUT CIRCULAR RUNOUT POSITION PROFILE OF A SURFACE GeoTol Pro 1-25Workshop Exercise 1.2 Label the terms for the symbols shown in the table. Choose from the terms listed below. Free State Spherical Radius Spherical Diameter Projected Tolerance Zone Dynamic Profile Tangent Plane All Over Least Material Condition All Around Unequally Disposed Tolerance Continuous Feature Translation Maximum Material Condition o i ae ae eo ae eal ia Ee eee ae [a aaa CoE Aa |.) EL 1 2Oaaal ESS ess | eb oas RD ee |O| [= pee ae on ©) ae eee | ca Rn ea | 1-26 GeoTal ProWorkshop Exercise 1.3 1, Next to the dimensions, write the Maximum Material Condition (MMC) and Least Material Condition (LMC) of the five features of size below. 1. oe | + 005 “| *.005 D750" O09 +002 91.005 O05 503 7 “t (000.006 2. The following five dimensions/tolerances use unit conventions from ASME Y14.5-2018. Label which are in inches and which are in millimeters. +002 0.85 6.250" D5 0.4 £0.06 6.000 + .002 O80 (Goo) 3. Label the parts of the feature control frame. Choose from the terms below. Shape of tolerance zone Primary datum feature Tertiary datum feature Geometric characteristic Secondary datum feature Feature tolerance Material condition modifier J Geol Pro 1-27