TOLERANCES OF FORM AND POSITION Introduction

In certain circumstances, tolerances of size are not always sufficient to provide the required control of form. For example, in Fig.1a, the shaft has the same diameter measurement in all possible positions but is not circular, in Fig.1 b the component has the same thickness throughout but is not flat, in Fig. 1c, the component is circular in all cross sections but is not straight. The forms of these components can be controlled by means of geometrical tolerances. For an internal feature of a hole, the variation of size, form and position is illustrated in Fig. 2.

(a)

(b) Fig. 1 Errors of form

(c)

a - Error of Size

b - Error of form

c - Error of position

Fig. 2 Geometric tolerances of internal feature

Form Variation
It is a variation of the actual condition of a form feature (surface, line) from geometrically ideal form.

Position Variation
It is a variation of the actual position of the form feature (surface, line) form the geometrically ideal position, with reference to another form feature, called datum feature.

Geometrical tolerance
Geometrical tolerance is defined as the maximum permissible overall variation of form or position of a feature.

Geometrical tolerances are used, i. to specify the required accuracy in controlling the form of a feature, i. to ensure correct functional positioning of the feature, ii. to ensure the interchangeability of components, and iii. to facilitate the assembly of mating components.

The form of a single feature is deemed to be correct, when the distance of its individual points from a superimposed surface of ideal geometrical form is equal to or less than the value of the specified tolerance. The orientation of the ideal surface should be so chosen that the maximum distance between this and the actual surface of the feature concerned is the least possible value. Referring Fig. 3, possible orientation of ideal surface are A1 B1, A2 B2, A3 B3 and the corresponding maximum distances are h1,h2, and h3. The relation between the distance is h1 < h2 < h3.

Fig. 3 Orientation of ideal surface

Therefore, the orientation of the ideal surface is A1 B1 and h1 must be equal to or less than the specified tolerance value. According to the feature which is to be toleranced and the manner in which it is dimensioned, the tolerance zone may be one of the following:

i. The area within a circle ii. The area between two concentric circles iii. The area between two parallel lines iv. The space within a sphere v. The space within a cylinder or between two co axial cylinders vi. the space between two parallel surface vii.The space within a parallelopiped.

The feature may be of any form or orientation within this tolerance zone, unless a more restricted indication is given by an explanatory note. Further, unless otherwise specified, the tolerance applies to the whole length or surface of the feature considered.

Tolerance Zone
It is an imaginary area or volume, within which the controlled feature of the manufactured component must be completely contained, as shown in Figs. 4 a and b.
Element Tolerance zone Element

Tolerance zone a Tolerance area b Tolerance Volume

Fig. 4

Definitions Datum
It is a theoretically exact geometric reference such as axes, planes, straight lines, etc., to which the tolerance features are related (Fig. 5).

Datum Feature
A datum feature is a feature of a part, such as an edge, surface or a hole, which forms the basis for a datum or is used to establish its location (Fig. 5).

Datum Triangle
The datums are indicated by a leader line, terminating in a filed or an open triangle (Fig. 5).

Fig. 5

Datum Letter
To identify a datum for reference purpose, a capital letter is enclosed in a frame, connected to the datum triangle (Fig. 5).

Datum System
Datum system is a group of two or more separated datums, used as a combined reference for tolerance features. In this case, the sequence of datums referred, has considerable influence on the result obtained ( Fig. 6).

The datum feature is the feature to which the tolerance of orientation, position and run out are related. Further, the form of datum feature should be sufficiently accurate for its purpose and it may therefore be necessary in some cases to specify tolerances of form from the datum features. Table 1 gives the symbols which represent the feature characteristics to be controlled by the tolerance.

Fig. 6 Datum System

Indication of geometrical tolerances on a drawing

To eliminate the need for descriptive notes, geometrical tolerances are indicated on drawings by symbols, tolerances and datums, all contained in compartments of a rectangular frame, as shown in Fig.5.

Advantages of using geometrical tolerances

1. Geometrical tolerances convey very briefly and precisely, the complete geometrical requirements on engineering drawings.

2. The use of symbols and boxes, eliminates the need for lengthy descriptive notes and corresponding dimensions, because of which the drawings are much clearer to read. 3. The symbols used are internationally recommended. Hence, the language barrier is minimized and misunderstanding is eliminated. 4. One type of geometrical tolerance can control another form. For instance, squareness can correct flatness and straightness.

Indication of features controlled

The feature controlled by geometrical tolerance is indicated by an arrow head at the end of a leader line, from the tolerance frame. The tolerance frame is connected to the tolerance feature by a leader line, terminating with an arrow in the following ways:

On the outline of the feature, on extension of the outline, but not a dimension line, when the tolerance refers to the line or surface itself ( Fig.7 a,b,c), and On the projection line, at the dimension line, when the tolerance refers to the axis or median plane of the part so dimensioned ( Fig. 7d) or on the axis, when the tolerance refers to the axis or median plane of all features, common to that axis or median plane ( Fig.7e).

a - correct

b - correct

c - Incorrect

d - correct

e - correct

Fig. 7 Indication of feature controlled (outline or surface only)

Indication of Datum features

The datum features are indicated by a leader line, terminating in a solid triangle, the base of which lies, 1. On the outline of the feature or an extension of the outline ( but not a dimension line), when the datum feature is the line or surface itself (Fig. 8a), and 2. On the projection line, at the dimension line, when the datum feature is an axis or median plane of the part so determined ( Fig. 8b), or on the axis or median plane of all the features, common to that axis or median plane ( Fig. 8c), if such an axis can be determined with sufficient accuracy.

Note : The leader line shown on the right hand side is to be connected to the feature to the toleranced with reference to that datum indicated.

Fig. 8 Indication of datum features

If the tolerance frame cannot be connected in a clear and simple manner with the datum feature, a capital letter (different for every datum feature) is used (Fig. 9). If the tolerance is applied to a specified length, lying any where, the value of this length should be added after the tolerance value and separated from it by an oblique stroke (Fig.10).

Fig. 9 Identification of a datum feature

//

0.01/100

Fig. 10 Tolerance over specified length

In the case of a surface, the same indication is used. This means that the tolerance is applied to all the lines of specified length in any position and direction.

Boxed dimensions
These dimension are enclosed as 40 , 20. When the dimensions are boxed, the corresponding actual dimensions of the part are subjected only to the position tolerance. Profile tolerance, angularity tolerance and size tolerances are not given to the dimension.

Tolerances of form for single features Tolerance of straightness

The tolerance or perfect straightness of a line on a surface may be defined as the condition in which the distance between any two points on that line is always the shortest possible, when measured along the line. The tolerance zone for controlling errors of straightness is the area between two parallel lines, and the tolerance value is the distance between these lines. The line on the surface of the feature in Fig. 11 a can take any form, provided it lies in an axial plane between two parallel straight lines, 0.02 mm apart, as shown in Fig. 11 b.

Fig. 11 Tolerances of straightness

Tolerance of flatness
The theoretical or perfect flatness of a surface may be defined as the condition in which the distance between any two points on that surface is always the shortest possible, when measured along that surface. The tolerance zone for controlling errors of flatness is the space between two parallel planes, and the tolerance value is the distance between these planes. The surface controlled as shown in Fig. 12 a can take any form, provided it lies in the space between two parallel flat planes, 0.04 mm apart, as shown in Fig. 12 b.

a - Example

b - Interpretation

Fig. 12 Tolerances of flatness

Tolerances of Roundness
The theoretical or perfect roundness of a surface may be defined as the condition in which the surface has the form of a perfect circle, i.e., the distance between any point on the circumference and the centre is always equal to the radius of the circle. The tolerance zone for controlling errors of roundness is the annular area between two concentric coplanar circles, and the tolerance value is the radial distance between these circles. In Fig. 13 a, the circle controlled, which may represent the periphery at any cross-section, perpendicular to the axis, can take any form, provided it lies in the space between two concentric circles, 0.03 mm radially apart, as shown in Fig.13b.

a - Example

b - Interpretation

Fig. 13 Tolerance of roundness

Tolerances of Cylindricity
Theoretical or perfect Cylindricity may be defined as the condition in which all cross sections of solid are perfect circles, with their centres lying on a straight axis. The tolerance zone for controlling errors of Cylindricity is the annular space between two perfect cylindrical surfaces lying on the same straight axis, and the tolerance value is the radial distance between these surfaces. The surface controlled as shown in Fig. 14 a may take any form provided it lies between two perfect concentric cylinders, 0.03 mm apart, as shown in Fig.14 b

a - Example

b - Interpretation

Fig. 14 Tolerance of Cylindricity

Profile tolerance of a line

The theoretical or perfect form of a profile is defined by boxed dimensions, which locate the true position of any point on the line. The tolerance zone has a constant width equal to the tolerance value, normal to the theoretical profile and equally disposed about it. The tolerance zone is the area between two lines which envelope circles of diameter equal to the tolerance value. The profile line controlled in Fig. 15 a can take any form provided it lies between two lines 0.05 mm apart, as shown in Fig.15b.

a - Example

b - Interpretation

Fig. 15 Profile tolerance of a line

Profile tolerances of a surface

The theoretical or perfect form of a surface is defined by boxed dimensions which locate the true position of any point on that surface. The tolerance zone is the space between two surfaces, which envelope spheres of diameter equal to the tolerance value, with their centers lying on the theoretical surface of the correct geometrical shape. The curved surface of the part controlled as shown in Fig. 16a is required to lie between two surfaces, as shown in Fig. 16b.

a - Example

b - Interpretation

Fig. 16 Profile tolerance of a surface

Tolerances of Orientation (related features) Tolerances of parallelism

Theoretical or perfect parallelism may be defined as the condition in which all the perpendicular distances between the line or the surface controlled and the datum feature are always the same. The tolerance zone for controlling errors of parallelism is the area between two parallel straight lines or the space between two parallel planes, which are parallel to the datum feature. The tolerance value is the distance between the lines or planes. The controlled top surface of the part as shown in Fig. 17 a is required to lie between two planes, 0.06 mm apart and parallel to the datum line or surface, as shown in Fig.17b.

a - Example

b - Interpretation

Fig. 17 Tolerances of parallelism

Tolerances of squareness
Theoretical or perfect squareness may be defined as the condition in which the feature controlled is truly perpendicular to the datum feature. The axis of the vertical pillar as shown in Fig. 18 a is required to be contained within a tolerance cylinder of 0.05 mm diameter, the axis of which is perpendicular to the datum surface A, as shown in Fig. 18 b. The tolerance value here is preceded by the symbol . The controlled end surface of the second component is required to lie between two planes, 0.06 mm apart and perpendicular to the axis of the left side cylindrical portion (datum axis B).

a - Example

b - Interpretation

Fig. 18 Tolerances of squareness

Tolerances of Angularity
Theoretical or perfect angularity may be defined as the condition in which the controlled feature is inclined to the datum feature at a specified true angle. The tolerance zone for controlling errors of angularity is the area between two parallel straight lines or the space between the parallel planes which are inclined to the datum feature at a specified angle. The tolerance value is the distance between the lines or planes. The controlled inclined surface of the part in Fig. 19 a are to lie between two planes, 0.1 mm apart which are inclined at 60o to the datum axis of the cylindrical portion or the datum surface, as shown in Fig. 19b.

a - Example

b - Interpretation

Fig. 19 Tolerances of Angularity

Tolerances of location for related features Tolerances of position

The theoretical position of a feature is the specified true position of the feature as located by boxed dimensions. The actual point shown in Fig. 20 a is required to lie within a tolerance circle, 0.1 mm diameter, centered on the specified true point of intersection, as shown in Fig. 20 b. The axis of the hole is required to be contained within a tolerance cylinder 0.08 mm diameter, centered on the specified true position.

a - Example

b - Interpretation

Fig. 20 Tolerances of Position

Tolerances of Concentricity
Theoretical or perfect concentricity may be defined as the condition in which the controlled features which may be circles or cylinders lie truly on the same centre or axis, as the datum features. The tolerance zone for controlling errors of concentricity is a circle or cylinder within which the center or axis of the controlled feature is to be contained. The tolerance value is the diameter of the tolerance zone. The axis of the right side cylindrical portion of the component as shown in Fig.21a is to be contained within a cylinder, 0.08 mm diameter and is to be co axial within the axis of the left side portion, which is the datum, as shown in Fig. 21b.

a - Example

b - Interpretation

Fig. 21 Tolerance of Concentricity

Tolerances of symmetry
Theoretical or perfect symmetry may be defined as the condition in which the position of the feature is specified by its perfect symmetrical relationship to a datum. The tolerance zone for controlling errors of symmetry is the area between two parallel lines or the space between the parallel planes, which are symmetrically disposed about the datum feature. The median plane of the slot controlled as shown in Fig.22a, is required to lie between two parallel planes, 0.08 mm apart, which are symmetrically disposed about the datum plane, as shown in Fig.22b.

a - Example

b - Interpretation

Fig. 22 Tolerance of symmetry

Tolerance of run out

Theoretical radius may be defied as the condition in which the controlled features lie truly on a cylinder, with the same centre or axis as the datum features. (i) Radial run out The tolerance zone in this case limited within any plane, perpendicular to the axis, by two concentric circles, a distance t apart. The radial run out a shown in Fig. 23a, must not be greater than 0.1 mm in any measuring plane, during one completed revolution about the common axis of the surfaces A and B.

(ii) Axial run out The tolerance zone is limited for any measuring point, by two circles, a distance t apart, lying on the measuring cylinder. The axial run out must not be grater than 0.1 mm in any measuring cylinder, during one complete revolution, about the axis of the surface in Fig. 23b.

a Radial run - out

b Axial run - out

Fig. 23 Tolerance of run out