Geometric Dimensioning and Tolerancing

Objectives
What is GD&T How GD&T scores over limit type tolerancing Symbols and interpretation Concepts Datum features Tolerance zones Material condition modifiers Composite tolerancing Advantages of GD&T Glossary

What is Geometrical Dimensioning and Tolerancing

DEFINITION
Geometric Dimensioning and Tolerancing (GD&T) is a universal language of symbols, used to efficiently and accurately communicate geometry requirements for features and components. It encourages designers to define a part based on how it functions (design intent) in the final product. ASME Y14.5M 1994 is the accepted geometric dimensioning and tolerancing standard.
Datum feature Basic dimension First glimpse: Part dimensioned using GD&T.

Feature control frame

Tolerance can be specified only where a dimension is defined. Gives an acceptable range of values of an individual dimension (limits of dimension). No provision to specify how flat a surface needs to be, or how much a hole can tilt relative to a surface.

Limit Type Tolerancing

Separates the specification of tolerance from the dimensioning. Specifies a geometric region (tolerance zones), such as an area or a volume, in which the feature must lie in order to meet the design criteria. Communicates complex geometrical descriptions not possible otherwise in language. Allows more flexibility and precise controls that relate directly to the form, fit and function and not just size of the part, leading to successful end product. Eliminates guesswork, enables mfg. according to design intent, thus reduces confusion, rejection, rework and loss of profits.

Geometric Tolerancing

Induces problems related to ambiguity, guesswork and multiple interpretation of part drawing. Results in deviation from design intent.

Feature control frame in GD&T

Basic sentence in GD&T is put in the form of a feature control frame. It states the requirement for the feature to which it is attached.

Parts of a feature control frame

Each feature control frame can state only one requirement/message. Only one set up or gage for one FCF.

Feature control frame, Broken down

First compartmentGeometric characteristic symbol: Specifies the character to which the tolerance is to be applied. E.g. Flatness , angularity ,profile , parallelism etc.
First compartment- contains one of the 14 geometric characteristic symbols.

Third compartment Datum system: Specifies datums if applicable. They are significant according to their precedence in the FCF.

Third compartment- contains the datum reference frame

Feature control frame, Broken down

Second compartment- Symbol to specify shape of tolerance zone: This symbol precedes the tolerance and specifies the shape of tolerance zone. E.g. specifies a cylindrical tolerance zone, specifies a spherical tolerance zone. If no symbol is given, the default shape is parallel planes, or a total wide zone (like in profile tolerance).

Second compartment- contains actual tolerance, material condition modifier and other symbols.

Second compartment -Material condition modifiers: Features of size can be provided bonus tolerances using these modifiers. If the feature being controlled is a feature of size, and no modifier is specified, the default is RFS.

Other symbols in the FCF

The symbols for projected tolerance zone, free state, tangent plane, and statistical tolerance always follow the material condition modifier.

New datum feature symbol has been introduced in ANSI Y14.5, 1994.

Concept of Datum System

Datum - A theoretically exact plane, point or axis from which a dimensional measurement is made. Datums are points, lines, planes, cylinders, axes, etc., a, from which the location, or geometric relationship of other part features may be established or related. Datum Feature - A datum feature is the actual component feature used (idealized) to establish a datum. Datum Feature Simulator -- A datum simulator a surface of adequate precision oriented to the high points of a designated datum from which the simulated datum is established.
Examples: gage pin, block, and surface of granite block. Diameter Symbol - the diameter symbol, indicates a circular feature when used on the field of a drawing or indicates that the tolerance is diametrical when used in a feature control frame The inspection equipment (or gage surfaces) used to establish a datum is the simulator.

Concept of Datum System

Datums are specified in the third compartment of the feature control frame. Primary Datum Feature constrained within said tolerance with respect to datums A,B
Secondary Datum

They are theoretically exact features (surfaces idealized to planes, axes etc.) from which dimensional measurements are made.

Sample part: Surfaces are idealized to eliminate ambiguity about from where dimensions are to be measured
But if both surfaces are idealized simultaneously, they may not be perpendicular to each other.

Precedence order in datum planes

If we use a set of perpendicular datum references, either of the two positions could be right. Without precedence order, either of these two could be the correct position. Final position depends on which side contacts first.

Thus, they are specified in an order of precedence governed by the part function. Therefore, the first side to be pressed against one of the edges (in this case, datum A), will make contact at the two highest points. The part now has only one degree of freedom left, it can only slide back and forth along this edge. Once we butt the perpendicular side of the part with the corresponding straight edge (datum B), we have a completely constrained position and orientation.

Concepts of Tolerance Zones

Tolerances zones can be defined in GD&T instead of limits of dimension. Defined according to functional requirement of the part. These are geometric regions (3D or 2D) in which the feature must lie to be acceptable.

Ensures closeness to real world requirements Enables specifications (like conical tolerance zones) not otherwise possible in limit type dimensioning.

Symbols in GD&T
GD&T has 14 geometric characteristic symbols. Various symbols used to specify tolerance zones for:
Form Position Profile Orientation Runout

Symbol Description
Circularity Cylindricity Flatness Straightness Concentricity Position Symmetry Profile Profile of a line Angularity Parallelism Perpendicularity Runout Total Runout

Geometry
Form Form Form Form Position Position Position Profile Profile Orientation Orientation Orientation Runout Runout

Straightness

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

Flatness

Flatness is the condition of a surface having all elements in one plane.

The surface must lie between two planes 0.25 mm apart.

Circularity

Circularity describes the condition on a surface of revolution (cylinder, cone, or sphere) where all points of the surface intersected by any plane (1) perpendicular to a common axis (cylinder, cone), or (2) passing through a common center (sphere) are equidistant from the center.

Each circular element of the surface in a plane perpendicular to the axis must lie between two concentric circles, one having a radius 0.25 mm larger than the other.

Cylindricity

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

The cylindrical surface must lie between two concentric cylinders one with radius 0.25 mm larger than the other.

Parallelism

Parallelism is the condition of a surface, line, or axis, which is equidistant at all, points from a datum plane or axis.

The surface must lie between two parallel planes 0.12 mm apart, which are parallel to datum plane A. The feature axis must lie within a 0.2 mm dia cylindrical zone parallel to datum axis A.

Perpendicularity

Perpendicularity is the condition of a surface, axis, or line, which is 90 deg. from a datum plane or a datum axis.

The feature axis must lie between two parallel planes 0.2 mm apart, perpendicular to datum axis A.

Angularity

Angularity is the condition of a surface, axis, or center plane, which is at a specified angle (other than 0, 90, 180 or 270 deg.) from a datum plane or axis.

The surface must lie between two parallel planes 0.4 mm apart inclined at an angle of 300 to datum plane A.

Profile of a surface

Profile of a surface is the condition permitting a uniform amount of profile variation, either unilaterally or bilaterally, on a surface.

Profile of a line

Profile of a line is the condition permitting a uniform amount of profile variation, either unilaterally or bilaterally, along a line element of a feature.

Profile of a line is used in conjunction with profile of surface. Profile of a surface defines the shape or location of a feature while profile of line refines it in one direction. Each line element of the surface must lie between two profile boundaries 0.006 mm apart in relation to the datum reference frame.

Circular runout

Circular runout gives the deviation from the desired form of a circular element of a part surface of revolution through one full rotation (360 deg) of the part on a datum axis

At any position, each the circular element of the surface must be within the specified runout tolerance (0.02 mm full indicator movement) when the part is rotated by 3600, about the datum axis, the indicator fixed in a position normal to the true geometric shape.
Note: circular runout controls the circular elements of the surface, not the complete surface.

Total runout

Total runout is the simultaneous composite control of all elements of a surface at all circular and profile measuring positions as the part is rotated through 360.

The entire surface must lie within the specified runout tolerance zone (0.02 mm full indicator movement) when the part is rotated by 3600 about datum axis A, with the indicator at every location along the surface in a position normal to the true geometric shape without reset of the indicator.

Concentricity

Concentricity describes a condition in which two or more features (cylinders, cones, spheres, etc.) In any combination have a common axis.

This controls location, and can have some effect on the form and orientation of a feature. The application of concentricity is complex and rare. Diametrically opposed dial indicators maybe used to check this.

Symmetry

Symmetry is a condition in which a feature (or features) is symmetrically disposed about the center plane of a datum feature

Controls opposing points (that form derived median plane). Same concept as concentricity, but applied to non-cylindrical features.

Position

Position tolerance (formerly called true position tolerance) defines a zone within which the axis or center plane of a feature is permitted to vary from true (theoretically exact) position.

Position tolerancing is used to locate features of size (profile is used to locate features that dont have a size associated with them). Defines a zone within which, the axis, median plane, or surface of a feature is permitted to lie. These tolerance zones can be cylindrical, conical, rectangular, etc.

Positional tolerance for cylindrical zone

Application
Part mounts in assembly on surfaces shown, holes provide clearance for bolts.

Position tolerance for rectangular zone

Locates features with a greater tolerance in one direction than other. Note that the diameter symbol is not present in the feature control frames indicating a distance between two parallel planes.

Here the axes of the holes must lie in a 0.012X0.028 rectangular tolerance zone

Positional tolerance for spherical zone

The centre point of the spherical diameter must lie in a spherical zone of diameter 0.03, basically located to the DRF.

Positional tolerance for conical zone

Application
Used to control features such as a deep drilled hole, closer at one surface than another.

Concepts Material condition modifiers

GD&T on holes (and shafts) provides a powerful method for increasing inspection yield without trial and error fitting or binning. Used when the size of the feature interacts with its location. If symbol appears after the tolerance, then the specified tolerance holds only at maximum material condition. As feature departs from MMC, the amount of departure can be added to the position tolerance. MMC is commonly used for clearance type applications.
This feature control frame specifies the positional tolerance zone as a circle of diameter .010 at MMC, centered according to the basic dimensions given. The size of the tolerance zone is dependent on the size of the hole. Hole diameter Tolerance
Zone diameter

MMC of hole = .250 LMC of hole = .255

.250 (MMC) .251 .252 .253 .254 .255 (LMC)

.010 .011 .012 .013 .014 .015

Concepts Material condition modifiers

Similarly, if symbol is used, the stated tolerance holds at least material condition (LMC). As the part departs from LMC, the amount of departure is added to the position tolerance. LMC is commonly used for loose fits. If no modifier is specified, (or symbol in past practice) then the stated tolerance holds regardless of material condition of feature. This is called RFS regardless of size. RFS is commonly used for pressed fits.

Rationale behind bonus tolerances.

Worst case condition.
Taking an example for MMC

Position tolerance stated at MMC

Obtained tolerance for hole at MMC

Rationale behind bonus tolerances.

The tolerance zone can therefore be enlarged by an equal amount in diameter.

Now the centre of the hole can shift further left in the worst case. The gap is now closed. With a larger hole, the hole position is less stringent, and more parts can be accepted.

W/o compromising function, tolerance increased, cost of mfg. reduced.

Concepts Composite Tolerancing

Can be used with profile and position tolerance. The symbol is entered once, and is applicable to both horizontal entities. The upper segment controls location, orientation, form, and in some cases size. The lower segment controls mainly orientation and form. It does not control location.

Example Composite Profile Tolerancing.

The upper entry controls location to the DRF (datum reference plane) The lower entry controls, size/shape and orientation (perpendicularity) to the specified datum.

The above specs allow the 0.005 tolzone to float up and down, and back and forth, and tilt or rotate within the confines of the 0.030 tolzone. It however, must stay perpendicular to A Application: Used to provide loose location but restrictive orientation. Eg. Pattern of holes to locate nameplate.

Advantages of GD&T
Functional dimensioning philosophy Round Tolerance zones. Bonus tolerance by material condition modifiers. Datum system for clarity in inspection / fixture mfg. Reduces need for drawing notes, provides more wieldable language for specifications. Supports Statistical process control (SPC)

Functional dimensioning philosophy

Tolerance and tolerance zones based on part function and requirement.
Fig. shows bolts holes for mounting a flange onto a plate (function). When mounting the flange, the position of the holes with respect to each other is important, or else the flange (or part) wont fit. Functional dimensioning leads to dimensioning the distance between the holes, instead of the distances to the edge.

Allows maximum tolerance to produce the part. Functional dimensioning can often double or triple the amount of tolerance on many component dimensions, which reduces manufacturing costs.

Dimensioning matches function.

Dimensioning does not match function.

Case Study
Tolerance analysis of gap b/w trunk lid and rear windshield in Indigo SR.
Clearance critical

Areas affecting tolerance

1
Position of holes for mounting of hinge on body Side.

Position of mounting of rubber stopper.

Areas affecting tolerance

5
Hem between inner and outer panel of trunklid Reinforcement plate connecting trunklid and hinge.

3
Position of holes for mounting trunk lid on hinge.

Sources / effect of variation no 1

Position of holes for mounting of hinge on body side have adjustment of +/- 2mm

2mm

Sources / effect of variation no 2

Position of mtg. hole for rubber stopper has an adjustment of +/- 1mm

0.5mm

+/-1mm

Sources / effect of variation no 3

Position of slots for mtg. trunk lid on hinge has an adjustment of + 4mm

4mm 4mm

Sources / effect of variation no 4

Variation in reinforcement plate connecting trunklid and hinge

+/- 0.5mm +/- 0.5

Sources / effect of variation no 5

Variation due to hem between inner and outer panel of trunklid +/-0.5 +/- 0.5mm

Analysis of variations
S No.
1. 2. 3. 4. 5.

Source of Variation
Position of holes for mounting of hinge on body side. Position of mounting of rubber stopper. Position of slots for mounting trunk lid on hinge. Variation due to reinforcement plate. Hem of inner trunk lid to outer trunk lid. Total

Amount +2 +0.5 +4 +0.5 +0.5 +7.5 -2 -0.5 -0 -0.5 -0.5 -3.5

Conclusion:

Clearance values Max: 13.5mm Min : 2.5mm

Recommendation 1:
Not important to control.

Important to control gap.

Recommendation 2:
Hole to slot edge distance to be controlled in component

Dim to be controlled

Recommendation 3:
Design position to be at center with +/- 1mm adjustment

Recommendation 4:
Operator to ensure rearmost position after adjustment, before tightening bolts

recommendations.
S No.
1. 2. 3. 4. 5.

Analysis of variation after

Source of Variation
Position of holes for mounting of hinge on body side. Position of mounting of rubber stopper. Position of slots for mounting trunk lid on hinge. Variation due to reinforcement plate. Hem of inner trunk lid to outer trunk lid. Total

Amount +0 +0.5 +1 +0.5 +0.5 +1.5 -2 -0.5 -1 -0.5 -0.5 -4.5

Round tolerance zones

Four holes drilled through the block (1), and each holes location relative to each other and the edges are specified using a limit tolerance of a distance and +.005 and -.005. Center of each of the holes must fall within a square tolerance zone .010 x .010 (2). Actual worst scenario is .014 or + .007 and -.007 (diameter) (3) Round tolerance zone over 2 square tolerance zone for the part given in 1. Thus 57% increase in available tolerance. 1

Resulting in more usable parts, more capable process, reduced manufacturing costs

Bonus Tolerances using material condition modifiers

In coordinate tolerancing, the tolerance zone is always fixed in size at all hole conditions. GD&T allows tolerance to be increased without compromising function. Parts that are functional are used, and more tolerance is allowed for production, resulting in lower operating costs. Tolerance
zone at MMC (smallest hole dia)

Material condition modifier for MMC

Example explaining bonus tolerances.

Increased Tolerance zone at largest hole dia.

Datum System
Datum - A theoretically exact plane, point or axis from which a dimensional measurement is made. Datum Feature - A part feature that contacts a datum. Datum Feature Simulator - The inspection equipment (or gage surfaces) used to establish a datum.

Datums in GD&T provide a reference frame from which the dimensions are measured. Eliminates ambiguity in inspection. Datum symbol :

How Datum systems implement functional dimensioning

Specified Datums and geometric tolerances based on functional requirements.

Clear communication of design intent. Leads to successful end product.

Improved wieldability of language

Feature control frame specifies positional tolerance of hole, bonus tolerance at max. material condition, and datum system.

Flatness of surface specified.

Improved wieldability of language

Copious notes required to specify the same in conventional tolerancing.

Statistical process control

Traditionally, quality was achieved by 100% inspection of product, accepting or rejecting based on how well it met its design specifications. SPC uses statistical tools to observe the performance of the production process and predicts significant deviations that may result in rejected product. GD&T's Datum system provides the repeatable part measurements that are necessary for making a meaningful SPC chart. Thus SPC in GD&T helps optimize inspection costs and reduce waste via rework and scrap.

How SPC works: Under normal conditions, variations in product are near the mean, following a normal distribution. In special cases, caused by some error in the manufacturing procedure, the variations move away from this distribution. This can be easily detected and corrected.

Questions.??