Professional Documents
Culture Documents
GDT Imperial Automotive
GDT Imperial Automotive
Geometric Dimensioning
and Tolerancing
Mark A. Morris
Contact Information
2
Geometric Characteristic Symbols
Form Tolerances
Profile Tolerances
Orientation Tolerances
Runout Tolerances
Location Tolerances
3
Section 1
4
Engineering Drawings
Engineering drawings are the vehicle used to
communicate requirements for manufactured
parts.
Graphic Representations
Words
Numbers
Symbols
6
Orthographic and
Isometric Projection
7
Orthographic and
Isometric Projection
8
1st vs. 3rd Angle Projection
Number of Standards 10 - 16 1
10
ASME Y14.5M – 1994 Structure
Scope, Definitions, and General Dimensioning
Symbology
Datum Referencing
Tolerances of Location
11
History of the Standard
Stanley Parker has been credited with bringing
to light the problems that existed with limit
dimensioning while working at the Royal
Torpedo Factory in Scotland.
ANSI Y14.5M1964
ANSI Y14.5M-1973
ANSI Y14.5M-1982
ASME Y14.5M-1994
Dimensioning and Tolerancing
ASME Y14.5.1M-1994
Mathematical Definitions
12
Identify the Standard Used
ASME Y14.5M-1994 requires the standard be
identified on the drawing when it is applied.
A
-A-
ANSI Y14.5-1982 ASME Y14.5-1994
13
General Information
International System of Units (SI) have been
used.
U.S. Customary Units could have been used.
14
Foundations of Mechanical Accuracy
The Four Mechanical Arts
Geometry
Standards of Length
15
Development of Flatness
Step 1 – Alternate between plates 1 and 2 until a
relative match is achieved.
Plate 1 agrees with plate 2
None are known to be flat
16
Development of Flatness
Step 3 – Alternate between plates 2 and 3 until a
relative match is achieved.
Plate 2 agrees with plate 3
Plates 2 and 3 are known to be flatter that plate 1
None are known to be flat
17
Development of Flatness
Step 5 – Alternate between plates 1 and 3 until a
relative match is achieved.
Plate 1 agrees with plate 3
Plates 1 and 3 are known to be flatter that plate 2
None are known to be flat
Step 6 – Consider plate 3 as the master plate and work
plate 2 to plate 3.
Plate 1 agrees with plate 3
Plate 2 agrees with plate 3
None are known to be flat
All are of nearly equal flatness
Continue reducing the error until all three plates agree.
18
3 Documents for Product Quality
Product Drawing
Process Definition
19
Section 2
20
Key Definitions
Datum – Theoretically exact point, axis, or plane
derived from the true geometric counterpart.
Datum Feature – Actual feature on a real part used
to establish a datum.
Datum Feature Simulator – A surface of sufficient
precision to establish a simulated datum.
Simulated Datum – A point, axis, or plane
established by processing or inspection equipment.
Datum Target – A specified point, line, or area on a
part used to establish the datum scheme.
21
Key Definitions
Feature of Size – A cylindrical or spherical surface,
or two opposing elements or parallel surfaces.
Least Material Condition – This occurs where a
feature of size contains the least material allowed by
the stated limits of size.
Maximum Material Condition – This occurs where
a feature of size contains the most material allowed
by the stated limits of size.
Regardless of Feature Size – A term that indicates
that a geometric tolerance or datum reference
applies for any increment of size within its size
tolerance.
22
Key Definitions
Tolerance – The total permissible variation in size
for a specified dimension.
Bilateral Tolerance – A tolerance zone where the
boundary conditions contain the specified dimension.
Geometric Tolerance – A general term that refers
any of the 14 symbols used to control form,
orientation, profile, runout, or location.
Unilateral Tolerance – A tolerance zone that only
exists on one side of the specified dimension.
True Geometric Counterpart – The theoretically
perfect boundary or best fit (tangent) plane of a
specified datum feature.
23
Fundamental Rules
Each dimension shall have a tolerance.
(except for those dimensions specifically identified
as reference, maximum, minimum, or stock)
Ensure full understanding of each feature.
Show the detail needed and no more.
Serve function needs, no misinterpretation.
Manufacturing methods are not specified.
Non-mandatory dimensions are OK.
Designed of optimal readability.
24
Fundamental Rules
Dimension materials made to gage numbers.
90o apply when features are shown as .
90o apply when centerlines are shown .
Dimensions apply at 20oC (68oF).
Dimensions apply in a free state.
Tolerances apply for full size of feature.
Dimensions and tolerances only apply at the drawing
level where they were specified.
25
Limits of Size
Actual Size is a general term for the size of a
feature as produced. It has two interpretations.
26
Rule #1 – The Taylor Principle
“Where only a tolerance of size is specified, the limits
of size of an individual feature prescribe the extent to
which variations in its geometric form, as well as
size, are allowed.”
ASME Y14.5M-1994
Simply put:
Limits of size for an individual feature control the
allowable variation to its form and its size.
27
Size Controls Form
This on a drawing According to Rule #1, a true
geometric counterpart at MMC
25.4 must pass through the hole.
25.0
25.4
(LMC)
25.4
(LMC) 25.0 (MMC)
28
Size Controls Form
This on a drawing
12.2
12.0
According to Rule #1, a true
geometric counterpart at MMC
must pass over the pin.
12.0 (LMC)
29
Features with and without Size
Definition: A feature is a physical portion of a
part such as a surface, hole, tab, slot, pin,
etc.
Features Without Size:
Any Plane Surface
30
Features With & Without Size
31
MMC & LMC Workshop
Determine MMC and LMC for each feature of size below.
+.001 .752
.375 -.000 .750
.375
+.0002
-.0002
2.742
2.748
32
Rule #2
33
Angular Units
Angular Dimensioning
34
Millimeter Dimensioning
+0
Use a single 0 to describe 25 -0.25
unilateral tolerances where the
intended value is nil.
For bilateral tolerances, use + 0.10
the same number of significant 25 -0.25
digits in both limits of size.
For limit dimensioning, use the
same number of significant 25.10
digits both limits of size. 24.75
35
Decimal Inch Dimensioning
For unilateral tolerances, use + .000
the same number of zeros when 1.000 - .010
the intended value is nil.
For bilateral tolerances, use
the same number of significant + .004
digits in dimension and limits. 1.000 - .010
For limit dimensioning, use the
same number of significant 1.004
digits both limits of size. .990
For basic dimensions, use the
same number of significant 1.000
digits as in the feature control
frame.
36
Location of Features
Rectangular Coordinate Dimensioning
Tabular Dimensioning
38
Chain Dimensioning
10.05 7.55 12.55 13.35 What are the min and
9.95 7.45 12.45 13.25
max values between
surfaces X and Y?
Totals
39
Base Line Dimensioning
What are the min and
43.35
43.25 max values between
30.05
29.95
surfaces X and Y?
17.55
17.45
10.05
9.95
Totals
40
Direct Dimensioning
30.05
29.95
What are the min and max values
17.55
17.45
between surfaces X and Y?
10.05
9.95
X
23.35
23.25
Totals
41
Use of Basic Dimensions
Basic dimensions define the perfect location
of features with respect to the datum
reference frame.
42
Understand Perfect Geometry
Perhaps the best way to comprehend GD&T is
first to envision the geometry of the perfect
part defined by basic dimensions.
43
Using Tables to
Define Basic Dimensions
Diameter
Spherical Diameter S
45
Feature Control Frame Elements
Label the elements of the feature control frame using the following terms:
Datum Modifier Geometric Characteristic
Diameter Symbol Primary Datum
Feature Modifier Secondary Datum
Feature Tolerance Tertiary Datum
.014 M A B M C
46
Feature Control Frames Example
B A
47
Feature Control Frames Example
.005 A
.005 A B
.005
.005 A .005
B A
48
Feature Control Frame Placement
Locate the Feature Control Frame below or attached
to the leader-directed dimension or callout.
49
Other Common Symbols
Description Symbol
Radius R
Spherical Radius SR
Controlled Radius CR
Reference ( )
Between
All Around
Number of Places 8X
Counter Bore or Spot Face
Countersink
Depth or Deep
50
Feature Control Frames Example
1.010
.010 M A B C
1.000
2.000 .020 A B C
A
A B
o
30
3.000
1.500
B
.005 A
1.750
.005
5.000
B
.005 A B
A
C
51
Geometric Characteristic Symbols
Type of
Application Tolerance Characteristic Symbol 2D or 3D
Flatness
Individual Straightness
Features Circularity
Cylindricity
Perpendicularity
Parallelism
Angularity
Related
Position
Features
Symmetry
Concentricity
Circular Runout
Total Runout
Either Individual or Profile of a Line
Related Features Profile of a Surface
52
Some Other General Rules
53
Section 3
54
Form Tolerances
Flatness
Straightness
Circularity
Cylindricity
55
Form Tolerances
Datum references are never made for form
tolerances.
Rule #1 says that limits of size control
variation in form.
Generally, form tolerances are only necessary
to refine (require a tighter tolerance) limits of
size.
Form tolerances are often applied to features
to qualify them as acceptable datum features.
56
Flatness
Definition Flatness exists when a surface has
all of its elements in one plane.
57
Checking for Flatness
58
Proper Application of Flatness
No datum is referenced.
59
Straightness
Definition Straightness exists when an
element of a surface or an axis is a straight
line.
60
Checking for Straightness
61
Proper Application of Straightness
applied to a Surface Element
No datum is referenced.
62
Straightness of a Feature of Size
63
Proper Application of Straightness
applied to a Feature of Size
No datum is referenced.
64
Circularity (roundness)
Definition Circularity exists when all of the
points on a perpendicular cross section of a
cylinder or a cone are equidistant to its axis.
65
Checking for Circularity
66
Proper Application of Circularity
No datum is referenced.
67
Cylindricity
Definition Cylindricity exists when all of the
points on the surface of a cylinder are
equidistant to a common axis.
68
Checking for Cylindricity
69
Proper Application of Cylindricity
No datum is referenced.
70
Decisions for Form Tolerances
Form
Tolerances
Consider
Limits of Size
Surface Axis or
Elements Center Plane
Consider
Material Condition
RFS MMC
71
Orientation Tolerances
Angularity
Perpendicularity
Parallelism
72
Orientation Tolerances
Datum references are always used for orientation
tolerances.
Orientation tolerances applied to a surface control
the form of toleranced surface.
Only a tangent plane may need control.
Orientation tolerances may be applied to control both
features of size and features without size.
Orientation tolerances do not control size or location.
Generally, profile tolerances are used to locate
features without size and position tolerances are
used to locate features of size.
73
Angularity
Definition Angularity exists when all of the
points on a surface create a plane or a feature
axis is at the specified angle, when compared
to a reference plane or axis.
Tolerance Zone Two parallel planes at the
true angle to a reference plane and contain
the entire surface surface.
Datum Feature
Datum Plane
75
Proper Application of Angularity
Datum reference is specified.
76
Perpendicularity
Definition Perpendicularity exists when all of
the points on a surface, median plane, or axis
are at a right angle to a reference plane or
axis.
Tolerance Zone Two parallel planes that are
perpendicular to a reference plane and
contain the entire surface surface.
Datum Feature
Datum Plane
78
Proper Application of
Perpendicularity
Datum reference is specified.
79
Parallelism
Definition Parallelism exists when all of the
points on a surface, median plane, or axis are
equidistant to a reference plane or axis.
Tolerance Zone Two parallel planes that are
parallel to a reference plane and contain the
entire surface surface.
Datum Feature
Datum Plane
81
Proper Application of Parallelism
Datum reference is specified.
82
Decisions for Orientation Tolerances
Orientation
Tolerances
Consider
Limits of Size
Consider
Material Condition
True Position
Symmetry
Concentricity
84
Location Tolerances
Datum references are always used for location
tolerances.
Location tolerances are reserved for tolerancing
applications on features of size.
They are always located by basic dimensions back to
the datum scheme.
Location tolerances shown on the same centerline
are assumed to have a basic dimension of zero.
Symmetry and concentricity application are centered
about the datum scheme specified for the controlled
feature.
85
True Position
Definition True position is the exact intended
location of a feature relative to a specified
datum scheme.
Tolerance Zone Most frequently, the
tolerance zone is a cylinder of specified
diameter within which the true axis of the
feature must lie.
87
Traditional Fastener Tolerances
Threaded Fastener 3/8 – 16
Clearance Hole 13/32
Larger
Original
Tolerance
Tolerance
Zone 89
Zone
Maximum Material Condition (MMC)
Largest permissible external feature.
Outside Diameter
External Feature Size
Key
90
Maximum Material Condition
.760
4X .750
.014 M A B C
Size Tolerance
MMC
91
Least Material Condition (LMC)
Smallest permissible external feature.
Outside Diameter
External Feature Size
Key
92
Least Material Condition
.760
4X .750
.014 L A B C
Size Tolerance
LMC
94
Regardless of Feature Size
.760
4X .750
.014 A B C
Size Tolerance
96
Applications for
Least Material Condition
.503
The purpose of the hole is to .501 .002 L
locate the PLP pin below.
97
Applications for
Least Material Condition
.503
The purpose of the hole is to .501 .002 L
locate the PLP pin below.
98
Applications for
Least Material Condition
.503
The purpose of the hole is to .501 .002 L
locate the PLP pin below.
99
Virtual and Resultant Conditions
Virtual Condition is the constant boundary generated
by the collective effects of a feature’s specified MMC or
LMC and the geometric tolerance for that material
condition (i.e, the premise for functional gaging).
100
Virtual and Resultant Conditions
Given MMC
Ø 25.5
25.1
Internal Feature of Size
Ø 0.1 M
Virtual Resultant
Condition Condition
Constant Variable
Value Value
Ø Hole Ø Tol V Cond R Cond
101
Inner and Outer
Boundary Conditions
Ø 25.5
25.1
Ø 0.1 M
Virtual Condition
Size
Inner
Boundary
Tolerance Zone
At MMC
Outer
Hole at LMC
Boundary
Bonus Tolerance
At LMC
102
Virtual and Resultant Conditions
Given MMC
Ø 24.9
24.5
External Feature of Size
Ø 0.1 M
Virtual Resultant
Condition Condition
Constant Variable
Value Value
Ø Pin Ø Tol V Cond R Cond
103
Virtual and Resultant Conditions
Given LMC
Ø 25.5
25.1
Internal Feature of Size
Ø 0.1 L
Virtual Resultant
Condition Condition
Constant Variable
Value Value
Ø Hole Ø Tol V Cond R Cond
104
Virtual and Resultant Conditions
Given LMC
Ø 24.9
24.5
External Feature of Size
Ø 0.1 L
Virtual Resultant
Condition Condition
Constant Variable
Value Value
Ø Pin Ø Tol V Cond R Cond
105
Inner and Outer Boundaries
Given RFS
Ø 25.5
25.1
Internal Feature of Size
Ø 0.1
Variable Variable
Value Value
Ø Hole Ø Tol I. B. O. B.
25.3 0.1
25.4 0.1
106
Inner and Outer Boundaries
Given MMC
Ø 24.9
24.5
External Feature of Size
Ø 0.1
Variable Variable
Value Value
Ø Pin Ø Tol O. B. I. B.
24.7 0.3
24.6 0.4
107
Zero Tolerance at MMC
Where zero tolerance is specified at MMC, the
tolerance is totally based on the actual
mating size of the feature specified.
Location and orientation must be perfect
when the feature is at MMC.
As the feature departs from MMC the
allowable tolerance is based on the size the
feature compared to its MMC.
108
Logic for Zero Tolerance at MMC
Ø 1.006 + .003
Ø .004 M A
B
Ø .514 + .003
Ø .005 M A B M
A
Ø .994 + .003
Ø .002 M A
Ø .500 + .001 B
Ø .005 M A B M
A
109
Logic for Zero Tolerance at MMC
Ø .999
Ø .506 Virtual
Virtual Condition
Condition Boundary
Boundary
Functional
Extremes are
Ø .991 and Ø .999
110
Logic for Zero Tolerance at MMC
Ø .994 + .003
Ø .002 M A
111
Logic for Zero Tolerance at MMC
Ø .995 + .004
Ø .000 M A
Why not give the entire tolerance to the manufacturing process and let
the process divide it up as needed? This is what happens when we
specify zero tolerance at MMC.
112
Verification of Position at MMC
Determine tolerance at MMC.
Determine actual mating size.
Calculate positional tolerance allowed.
Determine positional error in location.
Compare positional error in location to
positional tolerance allowed.
Decide to accept or reject.
113
Specification of Position at MMC
.760
.750
.010 M A B C
C
2.000
1.000
1.250 3.000 B
114
Verification of Position at MMC
115
Verification of Position at LMC
Determine tolerance at LMC.
Determine actual mating size.
Calculate positional tolerance allowed.
Determine positional error in location.
Compare positional error in location to
positional tolerance allowed.
Decide to accept or reject.
116
Specification of Position at LMC
.760
.750
.010 L A B C
C
2.000
1.000
1.250 3.000 B
117
Verification of Position at LMC
118
Proper Application of Position
Position control is applied to a feature of size.
Datum references are specified and logical for the
application.
Basic dimensions establish the desired true position
of the feature of size.
Tangent plane modifier is not used.
Diameter symbol is used to specify axis control.
Diameter symbol is not used to specify center plane
control.
MMC, LMC, or RFS may be specified.
119
Symmetry
Definition Symmetry defines the location of
non-cylindrical features about a derived
median plane.
Tolerance Zone The tolerance zone is defined
by two planes, equidistant to a datum center
plane. The derived median points must fall A
within these two planes.
120
Set Up for Symmetry
121
Proper Application of Symmetry
A planar feature of size to be controlled uses
the same center plane as the datum scheme.
122
Concentricity
Definition Concentricity defines the location of
cylindrical features about an axis of rotation.
Tolerance Zone The tolerance zone is defined
as a cylinder about the datum axis that must
contain the median points of diametrically
opposed elements of a feature. A
123
Checking for Concentricity
124
Proper Application of Concentricity
The surface of revolution to be controlled is
coaxial to the axis of the datum scheme.
125
Decision Matrix for Coaxial Features
126
Decisions for Location Tolerances
Location
Tolerances
Center
Axis
Plane
Determine
Tolerance
Profile of a Line
2-D Application
Profile of a Surface
3-D Application
128
Profile Tolerances
Profile tolerances are used to control multiple
coplanar surfaces.
Perfect geometry must be defined via basic
dimensions.
The default interpretation for the tolerance zone is
bilateral and equal about the true perfect geometry.
Profile tolerances are not used to control features of
size so MMC, LMC, and RFS do not apply.
Profile features can be used as datum features or
they must be related to a defined datum scheme.
129
Profile 3-D Application 2-D Application
130
Profile for Cam Application
131
Functional Gaging of Profile
132
Proper Application
of Profile Tolerances
Profile features are used as datum features or
related to a defined datum scheme.
and
Basic dimensions relate the true profile back
to the datum scheme.
or
The profile tolerance value must be a
refinement of dimensions used to locate the
true profile.
133
Decisions for Profile Tolerances
Profile
Tolerances
Consider
Limits of Size
Profile of a Profile of a
Line Surface
Consider
Tolerance Zone
Unilateral Bilateral
Circular Runout
2-D Application
Total Runout
3-D Application
135
Runout 3-D Application 2-D Application
136
Checking for Runout
137
Proper Application of Runout
The surface to be controlled is either coaxial
or perpendicular to the axis of the datum
scheme.
138
Decisions for Runout Tolerances
Runout
Tolerances
Consider
Limits of Size
Circular Total
Runout Runout
139
Geometric Characteristics
for Round Features
Circularity (roundness)
Evaluates cross section of surface to its own axis
Cylindricity
Evaluates entire surface to its own axis
Runout
Evaluates cross section of surface to a defined axis
Total Runout
Evaluates entire surface to a defined axis
Concentricity
Evaluates best fit axis of feature to a defined axis
140
Tolerance Design Flow Chart
Design
Requirements
Establish
Datums
Individual
Features Related Individual or
Features Related Features
Form
Tolerances Profile
Tolerances
141
Section 4
142
Reference Planes
(The Point of Known Return) Ted Busch, 1962
143
Theoretically Perfect
Geometry
Three mutually perpendicular planes.
3 Datum Planes
define the Origin
Datum
of Measurement
Point
144
Criteria for Selecting Datum Features
146
Datum Features of Size
MMC callouts on a datum features of size can
allow a datum shift on the exact location of
the datum feature.
147
Decisions for Datum Selection
Select
Datum Feature
Feature
Surface
of Size
Center
Axis
Plane
Consider
Material Condition
1. Functional Requirements
1. Production Requirements
• Measurement Requirements
149
What Are We Really Interested In?
• Location of Features
150
Introduction to Datum Workshop
Select datums based on function.
Some features are leaders, others are followers.
Sequence of considerations:
Establish the datum reference frame (DRF).
Qualify the datum features to the DRF.
Relate remaining features to the DRF.
For consistency, assume .005” tolerance zones unless
otherwise specified.
Select and qualify the datum features and identify the
datum point as specified in the following examples.
151
Locate the part on the back
surface first, then the bottom
Datum Workshop edge, then the left side.
152
Locate the part on the back
surface first, then the bottom
Datum Workshop edge, then the right hand side
of the bottom slot.
153
Locate the part on the back
surface first, then the bottom
Datum Workshop edge, then centrally to the
bottom slot with a .998 virtual
size key.
1.000
1.005
154
Locate the part on the front
surface first, then by a 1.504
Datum Workshop virtual size hole for the large
boss, then by a .996 virtual
size key for the right hand slot.
1.500
1.502
1.000
1.004
155
Locate the part on the front
surface first, then by a 1.502
Datum Workshop virtual size hole for the large
boss, then by the bottom edge.
The bottom edge must lie in a
tolerance zone from 2.490 to
1.500
1.502 2.510 from the large boss.
2.500
156
Section 5
Tolerancing Strategies
157
Process for Tolerance Analysis
Establish Performance Requirements
158
Statement of the Problem
159
Assembly Stack-Up Analysis
End
Start
- + +/- Tol Description
Totals
160
Component Tolerances
.055
.045
.227
.217
.070
.060
2.906 2.805
2.896 2.795
3.116
3.096
.080
.077
.050
.045
161
Stack Analysis Result
End
Start
162
Worst Case Evaluation
Assembly Length
A B C
163
Worst Case Pros and Cons
Pros
No risk of components not interacting properly.
100% interchangeability of components.
Cons
Method is conservative.
Underutilization of full tolerance range.
Tolerances for interacting dimensions are smaller
than necessary, which may increase cost.
164
Statistical Method of
Linear Evaluation
Assembly Length
A B C
To statistically calculate the tolerance we take the root of the sum of the
squared values of the individual tolerances (RSS).
165
Some Critical Assumptions
Component dimensions are independent.
Components are assembled randomly.
Component should be normally distributed.
The actual average value for each component is
equal to the nominal value specified for that
component. (Otherwise, the nominal value for
the assembly will not be met and the tolerances
will not be realistic.) Process control is needed.
166
From Part Tolerances to an
Assembly Tolerance
B
Assembly
C
167
Statistical Tolerancing
Pros and Cons
Pros
Larger tolerances on interacting dimensions.
Cons
Small percent of final assemblies fall outside limits.
Special Considerations
Averages of interacting dimensions must be
controlled via variables measurements.
Interacting dimensions must be independent and
normally distributed.
Lot size should be moderately large.
168
From an Assembly Tolerance
back to Component Tolerances
Assembly
C
In practice, we are often required to begin with a defined end result and
determine appropriate tolerances for the components.
169
Two Theorems of Relevance
Two theorems hold great importance in the
interrelationship of tolerances.
The first is similar to the Pythagorean Theorem
170
Composite Tolerances and
Single Segment Tolerances
.030 M A B C
.030 M A B C
.010 M A
171
Standard Positional Tolerance
.760
4X
.750
.030 M A B C
2.000
1.000
1.250 3.000 B A
172
Functional Gage for Virtual
Condition of Holes to Datums
4X .720
Datum Surface A
2.000
1.250 3.000
1.000
173
Composite Tolerance with One
Datum in the Lower Segment
.760
4X
.750
.030 M A B C
.010 M A
C
2.000
1.000
1.250 3.000 B A
174
Composite Tolerance
Feature Control Frame
Pattern Locating
Tolerance Zone
PLTZF locates and orients Framework
features to the specified One Tolerance
datums via basic dimensions. (PLTZF)
Zone Symbol
FRTZF locates the features
within the pattern via basic .030 M A B C
dimensions to each other
and controls their orientation .010 M A
relative to the specified
datum(s).
FRTZF releases the pattern Feature Relating
from the requirements given Tolerance Zone
by basic dimensions to their Framework
datum features.
(FRTZF)
175
Two Functional Gages
for the Composite Tolerance
.030 M A B C
.010 M A
4X .720 4X .740
2.000 2.000
1.250 3.000 3.000
1.000
176
Composite Tolerance with Two
Datums in the Lower Segment
.760
4X
.750
.030 M A B C
.010 M A B
C
2.000
1.000
1.250 3.000 B A
177
Two Functional Gages
for the Composite Tolerance
.030 M A B C
.010 M A B
4X .720 4X .740
2.000 2.000
1.250 3.000 3.000
1.000
178
Two Single Segments with Two
Datums in the Lower Segment
.760
4X
.750
.030 M A B C
.010 M A B
C
2.000
1.000
1.250 3.000 B A
179
Two Functional Gages for the
Two Single Segment Tolerances
.030 M A B C
.010 M A B
4X .720 4X .740
2.000 2.000
1.250 3.000 3.000
1.000 1.000
B B
180
Fixed and Floating
Fastener Calculations
Floating Fastener scenario exists when the fastener
must pass through two clearance holes in mating
parts.
181
Threaded Holes
182
Two Clearance Holes –
Floating Formula Application
Two Pieces Required
What should we use as the + .007
4X .406
positional tolerance for each - .002
.XXX M A B C
of these two mating parts?
C .029 M A B C .502
.500
Assuming a 3/8 – 16
threaded fastener…
.404 2.000
- .375
.029
1.000
1.250 3.000 B A
.502
C .015 M P .502 A B C
.502 C .014 M A B C
.500 .500
2.000 2.000
1.000 1.000
MMC of clearance hole minus MMC of fastener must be shared between the
two positional tolerance of the two pieces.
184
Topics Worthy of Discussion
Definition of Functional Requirements
185
Sources of Variation
The following primary contributors to body-in-white
variability were identified as part of the Auto Body
Consortium’s 2mm Program for Variation Reduction:
Locator Pins 28.4%
Incoming Material 21.3%
Welding 19.1%
Clamping 13.5%
Robot Programming 5.0%
Carriers 3.5%
Rough Locators 2.8%
NC Blocks 2.8%
186
Sources of Variation
A summary of the sources of locator pin problems:
Size 22.5%
Pin Interference with Panel 17.5%
Loose Pins 12.5%
Pin Too Short 7.5%
PLP Quantity 7.5%
Pin PLP Selection 7.5%
Pins Needed Rotating 5.0%
Worn Pins 5.0%
Missing Pins 5.0%
Pin Shape 2.5%
Pin Too Long 2.5%
187
Other Sources of Variation
Gravity Material
Functional Gaging
189
Merits of Functional Gaging
Simple Functional Checks for Conformity
190
Functional Gaging
Pros and Cons
Pros
Reduces risk of shipping bad product.
Reduces risk of scrapping good product.
Reduces inspection costs.
Provides attribute data.
Cons
Doesn’t provide variables data.
Usually won’t qualify for PPAP submission.
May not correlate with CMM data.
191
Functional Gaging of Profile
192
What to Do About Design Errors…
The first thing you want to do about design error is
to find them early.
193
Some things to Look
for in Design Reviews
Datum schemes that don’t make sense.
194
Some things to Look
for in Design Reviews
Geometric tolerances that aren’t referenced to a
datum scheme when they should be.
195
Some things to Look
for in Design Reviews
Use of geometric tolerances that don’t refine either
the limits of size or other tolerances.
196
Process for Design Change
Quality management systems require a defined
process for design changes within the scope of
design control.
197