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Introduction to Geometric

Dimensioning and Tolerancing (GD&T)

Based on ASME
Y14.5M 1994 standard

Feature
A feature is a general term applied to a
physical portion of a part, such as a surface,
hole, slot, boss, tab, etc.

Feature of Size

A feature of size (FOS) is one cylindrical or


spherical surface, or a set of 2 opposed
elements or parallel surfaces, associated
with a size dimension.
An axis, median plane or center point can be
derived from a feature of size.

Actual Local Size


Actual local size is the value of any individual
distance (two-point measurement) at any
cross-section of a feature of size

Actual Mating Envelope (AME)

Defined according to the type of feature of


size being considered
AME of an external feature of size is a
similar perfect feature counterpart of the
smallest size that can be circumscribed
around the feature so that it just contacts the
surfaces at the highest points. Eg. Smallest
cylinder or two parallel planes at a minimum
separation

Actual Mating Envelope (AME)

Actual Mating Envelope (AME)

AME of an internal feature of size is a


similar perfect feature counterpart of the
largest size that can be inscribed within the
feature so that it just contacts the surfaces at
the highest points. Eg. Largest cylinder or
two parallel planes at a maximum separation

Actual Mating Envelope (AME)

Actual Mating Envelope (AME)

AME is a variable value: it is derived from an


actual part
If a feature of size is controlled by a
positional or orientation tolerance with the
MMC or LMC modifier, the AME is relative to
the appropriate datums

Actual Mating Envelope (AME)

Internal Feature
(Hole)

External Feature
(Shaft)

Feature Control Frame


A series of compartments containing symbols
and values that describe the geometric
tolerance of a feature. The order and purpose
of these compartments follow a consistent
standard.

Feature Control Frame: Components


1.
2.
3.

Geometric characteristic being controlled.


Feature tolerance value
Datums to reference

Datum Reference Frame (DRF)

Frame of reference to which all


requirements are attached.
In geometric tolerancing, we can relate
engineering, manufacturing and inspection
together by using this DRF.
Three planes are called primary plane,
secondary plane and tertiary plane.

Datum Reference Frame (DRF)

Datum Reference Frame (DRF)

Datums and DRF indicate the origin of a dimensional


relationship to a toleranced feature of a part.
True geometric counterpart (TGC) of datum feature
actually establishes the datum.
Being theoretical, measurements cannot be made
from the true geometric counterpart. Hence,
simulated datums are assumed to exist and be
simulated with manufacturing/inspection equipment.
Measurements then originate from the simulated
datums and not from the features themselves.

Datum Reference Frame (DRF)

DRF Defines Design Intent

DRF Defines Design Intent

Datum Features without Size

Datum Features without Size

Datum Features with Size

Datum Features with Size: TGC

Placement of Datum Feature Symbol

Datum: Pattern of Features

The Y14.5 standard tells us we can use a


pattern of features to establish a datum or
datums.

Datum: Pattern of Features

Unfortunately, the explanation in the Standard only covers a


pattern of holes at MMC. There is no support for using a
pattern of features of size RFS.
Where two parallel holes are used as a pattern to help
establish a datum reference frame, it is pretty certain that two
datum planes will result - one plane through the two holes and
a second plane midway between the holes.
Once more than two holes are used as a pattern to establish a
datum, the resulting datum reference frame is unclear.
Recommendation: Avoid using a pattern of more than two
holes to establish datums when referenced RFS.

Single Datum from Two Features

Datum Targets

Datum Targets

Taylor Principle

Also known as Envelope Principle or Rule


#1
Unless otherwise specified, the limits of size
of a feature prescribe the extent within which
variations of geometric form, as well as size,
are allowed. This control applies solely to
individual features of size.
Does not apply to features left in the "as
furnished" condition (eg. stock)

Taylor Principle

Basic Dimension
A theoretically perfect, linear or angular
dimension, which serves to specify
(1) The form, and the orientation and location of
tolerance zones relative to one another and
relative to specified DRFs
(2) The mutual orientation and location of
datums, and
(3) The mutual orientation and location of datum
targets.

Symbology

Straightness (Line element)

Tolerance zone between 2 parallel lines


Value must be smaller than size tolerance
Material modifier cannot be applied
Datum cannot be referenced

Straightness (Axis/Median plane)

Tolerance zone is cylindrical or 2 parallel


planes.
Value must be smaller than size tolerance.
Material modifier can be applied.
Datum cannot be referenced.

Straightness (Axis/Median plane)

Median plane or (median) axis is very difficult


(and hence expensive) to determine.
Can only be applied to features of size.
Differentiated from Straightness of line
elements by positioning the FCF differently.

Straightness of Median Plane

Straightness of Cylindrical Axis

Straightness of Cylindrical Surface

Flatness

Tolerance zone between 2 parallel planes


Material modifier cannot be applied
Datum cannot be referenced
0.0 0 1

p a r al l e l
p lanes

1.000 ' 0.002


0 .0 01

Straightness/Flatness: Unit Basis

Flatness and straightness on a unit basis are


good controls to use when you don't want an
abrupt change in a surface.
If you don't limit the overall variation,
however, a larger than expected out of
flatness or straightness may result.

Straightness/Flatness: Unit Basis


The maximum radius of
curvature allowed by the
flatness of 0.2/50 is:
R2 = 252 + (R - .2)2
R = 1562.6
Solving the other
triangle for B:
1562.62 - 1002 = B2
B = 1559.4
Therefore the maximum
out of flatness could be:
R - B = 3.2

Straightness/Flatness: Unit Basis


To avoid this unintended accumulation of
tolerance, it is usually best to include an overall
flatness control when applying flatness or
straightness on a unit basis.

Circularity (Roundness)

On a cylindrical/conical feature: Applies to a


cross-section obtained as a result of the
intersection by any plane perpendicular to a
common axis.
On a sphere: Applies to a cross-section
obtained as a result of the intersection by
any plane passing thru a common center.

Circularity (Roundness)

Tolerance zone bounded by two concentric


circles.
Material modifier cannot be applied.
Datum cannot be referenced.
Value should be smaller than size
tolerance.

Circularity (Roundness)

Cylindricity

Tolerance zone bounded by two concentric


cylinders within which the surface must lie.
3D counterpart of 2D circularity.
Material modifier cannot be applied.
Datum cannot be referenced.
Value should be smaller than size tolerance.

Cylindricity

Perpendicularity

A surface, median plane, or axis at right


angles to the datum plane or axis.
Automatically controls flatness.
Datum must be referenced.
Datum may be modified.
Material modifier may be applied.

Perpendicularity

Perpendicularity Tangent Plane

Perpendicularity Axis of Cylinder

Angularity
A surface, median plane or axis at a specified
angle (other than 0 or 90) from a datum plane or
axis. Can have more than one datum specified.

Parallelism
The condition of a surface equidistant at all
points from a datum plane, or an axis
equidistant along its length to a datum axis.

Parallelism

Runout or Circular Runout

A 2D geometric tolerance that controls the


form, orientation, and location (but not size)
of each element of a cylindrical part as it
rotates about a datum axis.
As the part rotates 360 about the datum
axis, the error must be within the tol limit.
Datum must be specified but material
modifier cannot be applied.

Circular Runout

Circular runout does not protect


against barrelling or waisting

Circular Runout

Circular runout does not protect against sphericity or


conicity. Nor does it locate the surface.

Total Runout

A 3D geometric tolerance that controls the


form, orientation, and location (but not size)
of the entire length of a cylindrical part as it
rotates about a datum axis.
As the part rotates 360 about the datum
axis, the error must be within the tol limit.
Datum must be specified but material
modifier cannot be applied.

Total Runout
Total runout controls cumulative variation of
circularity, cylindricity, straightness, coaxiality,
angularity, taper, and profile when it is applied
to surfaces constructed around a datum axis.

Total Runout
When it is applied to surfaces constructed at
right angles to a datum axis, it controls
perpendicularity (and thereby flatness).

Runout: Straightness of Shafts

Straightness of an axis on an RFS basis will be


functional but may cause problems in inspection.
The straightness control automatically provided by
Rule #1 and the size tolerance is an alternative.
Since size tolerances on shafts are usually tight to
assure good fit in bearings, this approach frequently
results in a straightness requirement that is tighter
than required. This is especially true when the
length/diameter ratio is large. Also, Rule #1 does not
apply for diameters left "as furnished".
Runout callout with datum targets is an alternative.

Runout: Straightness of Shafts


The datum targets are located where the shaft contacts
the bearings. Circular runout controls the circularity and
concentricity of each slice of the feature. If the shaft is
out of straight, some slices will be eccentric to the
datum axis and will show up in the inspection.

Position

A 3-D location tolerance that describes the


exact location with respect to a datum
reference.
Sometimes, when a pattern of features carry
a position tolerance, then a datum reference
may be omitted. It then controls the individual
features to each other.

Position: Cylindrical Feature

For a cylindrical feature (of size), typically, a


symbol is specified with the tolerance,
indicating a cylindrical tolerance zone for the
axis of the actual mating envelope of the
feature.
2 datum planes may be referenced for
locating the feature in a plane perpendicular
to its axis. Another plane may be referenced
for perpendicularity.
Alternately, datum axes may be specified.

Position: Cylindrical Feature

Position: Cylindrical Feature

Position: Single Planar Surface

For a single planar surface, the position


tolerance specifies a tolerance zone between
two parallel planes located to the datum and
oriented parallel to it, within which the
surface must lie.
An additional datum plane may be
referenced for perpendicularity.
Same as a profile of a surface control.

Position: Single Planar Surface

Position: 2 Opposed Planar Surfaces

For two opposed planar surfaces (planar


feature of size), the position tolerance
specifies a tolerance zone between two
parallel planes located to the datum and
oriented parallel to it, within which the
median of the actual mating envelope of the
feature of size must lie.
An additional datum plane may be
referenced for perpendicularity.

Position: 2 Opposed Planar Surfaces

Position

Material modifier may be applied for position


control of features of size.
Datum features of size, if specified, may be
modified.

Composite Position Tolerance

Composite Position Tolerance

Composite Position Tolerance

Compound Position Tolerance

Projected Tolerance Zone

Generally used for threaded holes and holes that


will receive a pin (usually a press fit).
Concern is that the screw or pin projecting from
the hole might interfere with the surface of the
clearance hole in the mating part.
More important to know where stud or fastener
will be rather than where hole or tapped hole is.
Projected value is usually max thickness of the
mating part or max height of the pin or stud.

Projected Tolerance Zone

Concentricity

A 3-D location tolerance that describes the


location of opposing points in cylindrical
features with respect to a datum reference.
Controls median points. Hence, maybe
expensive to check.
Datum axis must be specified; cant be
modified.
Feature tolerance cant be modified.
Concentricity ignores the size, roundness
and cylindricity of the feature.

Concentricity

Symmetry

A 3-D location tolerance that describes the


location of opposing points with respect to a
datum reference.
Controls median points. Hence, maybe
expensive to check.
Datum plane must be specified; cant be
modified.
Feature tolerance cant be modified.

Symmetry

Symmetry vs. Position

Profile

A tolerancing method of controlling irregular


surfaces, lines, arcs or normal planes.
Controls form, orientation, location and size.
Hence, it is the most powerful control.
The profile tolerance specifies a uniform
boundary along the true profile within which
the elements of the surface must lie.

Profile

Profile

Datums can be specified and modified.


Tolerance cannot be modified.
Profiles can be individual line elements
(Profile of a line) or the entire surface (Profile
of a surface)
Referencing datums (to lock all relevant
DOFs) for a profile of a line control is
equivalent to a profile of a surface.

Profile

Profile of a Line vs. Surface

Profile of a Line vs. Surface

Profile of a Surface - Composite


Acceptable
Configurations

Unacceptable Configurations

Profile of a Surface - Composite

Profile of a Surface - Composite

Position to Control Location of


Irregular Features: Boundary Concept

Position to Control Location of


Irregular Features: Boundary Concept

Position to Control Location of


Irregular Features: Boundary Concept

Material Condition Modifiers

Can only be applied to features of size


MMC: Condition when a feature contains the
maximum material within stated limits of size
LMC: Condition when a feature contains the
least material within stated limits of size
RFS: Indicates that a geometric tolerance
applies at any increment if size within limits

Material Condition Modifiers

Effect of MMC Modifier

Diameter
Feature Size

Diameter Tol
Zone Allowed

.260

.005

.261

.006

.262

.007

.263

.008

.264

.009

.265

.010

.266

.011

.267

.012

.268

.013

Effect of LMC Modifier

Diameter
Feature Size

Diameter Tol
Zone Allowed

.268

.005

.267

.006

.266

.007

.265

.008

.264

.009

.263

.010

.262

.011

.261

.012

.260

.013

Effect of No Material Modifier (RFS)

Virtual Condition
A constant "worst case" imaginary boundary
defined by the collective effects of a feature's
size, geometric tolerance, and material
condition.

Virtual Condition: Shaft


For an external feature of size, the virtual
condition is equal to the size at MMC plus the
size of the tolerance zone at MMC.
Virtual Size

Tolerance
Zone at MMC

MMC Size

Virtual Condition: Hole


For an internal feature of size, the virtual
condition is equal to the size at MMC minus the
size of the tolerance zone at MMC.
Virtual Size

Tolerance
Zone at MMC

MMC Size

Resultant Condition
A variable "worst case" boundary, opposite the
virtual condition, that equals the feature's
actual mating envelope and its location
tolerance.

Resultant Condition: Shaft


For an external feature of size, the resultant
condition is the actual mating size minus the
actual size of the tolerance zone utilized.
Actual
Tolerance Zone
Utilized

Actual Mating
Envelope

Resultant Size

Resultant Condition: Hole


For an internal feature of size, the resultant
condition is the actual mating size plus the
actual size of the tolerance zone utilized.
Actual Mating
Envelope

Resultant Size

Actual
Tolerance Zone
Utilized

Inner/Outer Boundary

The combination of size and position tolerance


causes a feature of size to "act" larger and smaller
than the actual size from a fit and slop standpoint.
The smallest the feature may act is called the inner
boundary. It represents the closest the surface of
the feature may ever get to the basic location
relative to the referenced datums.
The largest the feature may act is called the outer
boundary. It represents the farthest the surface of
the feature may ever get from the basic location
relative to the referenced datums.

Inner/Outer Boundary: Shaft

The smallest a shaft may act is called its inner


boundary. It represents the closest the surface of
the shaft may ever get to the basic location relative
to the referenced datums. This boundary often
affects the slop between mating parts.
The largest a shaft may act is called its outer
boundary. It represents the farthest the surface of
the shaft may ever get from the basic location
relative to the referenced datums. This boundary
often affects the fit of mating parts.

Inner/Outer Boundary: Hole

The smallest a hole may act is called its inner


boundary. It represents the closest the surface of
the hole may ever get to the basic location relative to
the referenced datums. This boundary often affects
the fit of mating parts.
The largest a hole may act is called its outer
boundary. It represents the farthest the surface of
the hole may ever get from the basic location relative
to the referenced datums. This boundary often
affects the slop between mating parts or the wall
thickness on the component.

Inner/Outer Boundary: Hole (Eg.)

IB

IB

OB

OB

IB

OB

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