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DIMENSIONAL ENGINEERING

Compiled & Edited

Velmurugan Sivaraman
 DIMENSIONAL
ENGINEERING
Based on the ASME Y14.5M-1994
Dimensioning and Tolerancing Standard

Compiled & Edited

Velmurugan Sivaraman

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What is dimension?
Dimension (Latin, "measured out") is a
parameter or measurement required to
define the characteristics of an object -
i.e. length, width, and height or size and
shape.
Types
2nd dimensional
For example, locating a point on a plane
requires two parameters - latitude and
longitude.

3rd dimensional
Locating the exact position of an aircraft
in flight (relative to the Earth) requires
another dimension (altitude) with latitude
and longitude.

4th dimension
aircraft's estimated "speed" may be
calculated from a comparison between
the times associated with any two
positions.
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 Angle of projections

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What is tolerance?

What is tolerance?
It is almost impossible to maintain the strict
degree of accuracy as listed on a plan. To
accommodate this, it is normal to display
measurements with a plus or minus (+/-)
tolerance which allows for some margin of
error.

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Geometric standard deviation

Describes how spread out are a set of

numbers whose preferred average is the
geometric mean.

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Tolerances of
Form

Straightness Flatness

Circularity Cylindricity

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Straightness
(Flat Surfaces)
0.5 0.1

25 +/-0.25

0.1 Tolerance

0.5 Tolerance

Straightness is the condition where an element of a

surface or an axis is a straight line

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Straightness
(Flat Surfaces)
0.5 Tolerance Zone

25.25 max
24.75 min

0.1 Tolerance Zone

In this example each line element of the surface must lie within a
tolerance zone defined by two parallel lines separated by the
specified tolerance value applied to each view. All points on the
surface must lie within the limits of size and the applicable
straightness limit.

The straightness tolerance is applied in the view where the elements

to be controlled are represented by a straight line.

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Straightness
(Surface Elements)
0.1

0.1 Tolerance Zone

MM
C

0.1 Tolerance Zone

MMC

0.1 Tolerance Zone

MMC

In this example each longitudinal element of the surface must lie within a
tolerance zone defined by two parallel lines separated by the specified
tolerance value. The feature must be within the limits of size and the
boundary of perfect form at MMC. Any barreling or waisting of the
feature must not exceed the size limits of the feature.

Outer Boundary = Actual Feature Size + Straightness Tolerance

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Straightness (MMC)
15
14.85
0.1 M

0.1 Diameter
15
Tolerance Zone
(MMC)

15.1 Virtual Condition

14.85 0.25 Diameter

(LMC) Tolerance Zone

15.1 Virtual Condition

In this example the derived median line of the feature’s actual local size
must lie within a tolerance zone defined by a cylinder whose diameter is
equal to the specified tolerance value at MMC. As each circular element
of the feature departs from MMC, the diameter of the tolerance cylinder
is allowed to increase by an amount equal to the departure from the
local MMC size. Each circular element of the feature must be within the
specified limits of size. However, the boundary of perfect form at MMC
can be violated up to the virtual condition diameter.

Virtual Condition = MMC Feature Size + Straightness Tolerance

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Flatness
0.1

25 +/-0.25

0.1 Tolerance Zone

0.1 Tolerance Zone

25.25 max
24.75 min

In this example the entire surface must lie within a tolerance

zone defined by two parallel planes separated by the specified
tolerance value. All points on the surface must lie within the
limits of size and the flatness limit.

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

plane. Flatness must fall within the limits of size. The flatness
tolerance must be less than the size tolerance.

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Circularity
(Roundness)

0.1

90
0.1
90

0.1 Wide Tolerance Zone

In this example each circular element of the surface must lie within a
tolerance zone defined by two concentric circles separated by the
specified tolerance value. All points on the surface must lie within
the limits of size and the circularity limit.

Circularity is the condition of a surface where all points of the

surface intersected by any plane perpendicular to a common axis
are equidistant from that axis. The circularity tolerance must be less
than the size tolerance

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Cylindricity

0.1

0.1 Tolerance Zone

MMC

In this example the entire surface must lie within a tolerance zone
defined by two concentric cylinders separated by the specified
tolerance value. All points on the surface must lie within the limits of
size and the cylindricity limit.

Cylindricity is the condition of a surface of revolution in which all

points are equidistant from a common axis. Cylindricity is a
composite control of form which includes circularity (roundness),
straightness, and taper of a cylindrical feature.

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Tolerances of
Orientation
Angularity

Perpendicularity

Parallelism

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Angularity
(Feature Surface to Datum Surface)
20 +/-0.5

0.3 A

o
30

A
19.5 min 20.5 max

o o
30 30

0.3 Wide
A 0.3 Wide
Tolerance
A Tolerance
Zone Zone

The tolerance zone in this example is defined by two parallel planes

oriented at the specified angle to the datum reference plane.
Angularity is the condition of the planar feature surface at a
specified angle (other than 90 degrees) to the datum reference
plane, within the specified tolerance zone.
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Angularity
(Feature Axis to Datum Surface)
NOTE: Tolerance applies to
feature at RFS

0.3 A

0.3 Circular
0.3 Circular Tolerance Zone
Tolerance Zone

o
60

A A

The tolerance zone in this example is defined by a cylinder equal to

the length of the feature, oriented at the specified angle to the
datum reference plane.
Angularity is the condition of the feature axis at a specified angle
(other than 90 degrees) to the datum reference plane, within the
specified tolerance zone
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Angularity
(Feature Axis to Datum Axis)

NOTE: Feature axis must lie within tolerance zone cylinder

0.3 A

NOTE: Tolerance
applies to feature
at RFS

A 0.3 Circular
0.3 Circular Tolerance Zone
Tolerance Zone

45 o

Datum Axis A

The tolerance zone in this example is defined by a cylinder equal to

the length of the feature, oriented at the specified angle to the datum
reference axis.
Angularity is the condition of the feature axis at a specified angle
(other than 90 degrees) to the datum reference axis, within the
specified tolerance zone.
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 Perpendicularity
(Feature Surface to Datum Surface)
0.3 A

A
0.3 Wide 0.3 Wide
Tolerance Zone Tolerance Zone

A A

The tolerance zone in this example is defined by two parallel

planes oriented perpendicular to the datum reference plane.
Perpendicularity is the condition of the planar feature surface at
a right angle to the datum reference plane, within the specified
tolerance zone.

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Perpendicularity
(Feature Axis to Datum Surface)

0.3 Diameter
Tolerance Zone

NOTE: Tolerance applies to

feature at RFS
C
0.3 Circular
Tolerance Zone 0.3 Circular
Tolerance Zone
0.3 C

The tolerance zone in this example is defined by a cylinder

equal to the length of the feature, oriented perpendicular to the
datum reference plane.
Perpendicularity is the condition of the feature axis at a right
angle to the datum reference plane, within the specified
tolerance zone.
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 Parallelism
(Feature Surface to Datum Surface)

0.3 A

25 +/-0.5

0.3 Wide Tolerance Zone 0.3 Wide Tolerance Zone

25.5 max 24.5 min

A A
The tolerance zone in this example is defined by two parallel planes
oriented parallel to the datum reference plane.
Parallelism is the condition of the planar feature surface equidistant
at all points from the datum reference plane, within the specified
tolerance zone.
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Parallelism
(Feature Axis to Datum Surface)
NOTE: The specified tolerance
does not apply to the orientation
of the feature axis in this direction

NOTE: Tolerance applies to

feature at RFS 0.3 Wide
Tolerance Zone
0.3 A

A A
The tolerance zone in this example is defined by two parallel planes
oriented parallel to the datum reference plane.
Parallelism is the condition of the feature axis equidistant along its
length from the datum reference plane, within the specified
tolerance zone.
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Parallelism
(Feature Axis to Datum Surfaces)

0.3 Circular
Tolerance Zone

NOTE: Tolerance applies to

feature at RFS
0.3 Circular
Tolerance Zone 0.3 Circular
Tolerance Zone
0.3 A B

A A
The tolerance zone in this example is defined by a cylinder equal to
the length of the feature, oriented parallel to the datum reference
planes.
Parallelism is the condition of the feature axis equidistant along its
length from the two datum reference planes, within the specified
tolerance zone.
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Parallelism
(Feature Axis to Datum Axis)
The tolerance zone in this example is
defined by a cylinder equal to the
length of the feature, oriented
parallel to the datum reference axis.

NOTE: Tolerance applies to

feature at RFS
0.1 Circular
Tolerance Zone 0.1 A

0.1 Circular Datum Axis A

Tolerance Zone

Parallelism is the condition of the feature axis equidistant along its

length from the datum reference axis, within the specified tolerance
zone.

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Tolerances of
Profile

Profile of a Line
(ASME Y14.5M-1994, 6.5.2b)

Profile of a Surface
(ASME Y14.5M-1994, 6.5.2a)

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Profile of a Line
The profile tolerance zone in this example is defined by two
parallel lines oriented with respect to the datum reference frame.
The profile tolerance zone is free to float within the larger size
tolerance and applies only to the form and orientation of any
individual line element along the entire surface.

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Profile of a Surface

Location &
0.5 A Orientation
0.1 Form Only
25

0.1 Wide Tolerance Zone

25.25
24.75

Composite Profile of Two Coplanar

Surfaces w/o Orientation Refinement
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Profile of a Surface
0.5 A Location
0.1 A Form & Orientation

25

0.1 Wide Tolerance Zone

25.25

A 0.1 Wide Tolerance Zone

24.75

Composite Profile of Two Coplanar

Surfaces With Orientation Refinement

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Tolerances of
Location

True Position

Concentricity

Symmetry

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 Coordinate vs Geometric
Tolerancing Methods
8.5 +/- 0.1
1.4 A B C
8.5 +/- 0.1
Rectangular Circular Tolerance
Tolerance Zone Zone

10.25 +/- 0.5 10.25

B

10.25 +/- 0.5 10.25 C

Coordinate Dimensioning Geometric Dimensioning

Increased Effective Tolerance
+/- 0.5
1.4

+/- 0.5

Rectangular Tolerance Zone Circular Tolerance Zone

Circular Tolerance Zone

57% Larger
Tolerance Zone
Rectangular Tolerance Zone

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Positional Tolerance Verification
(Applies when a circular tolerance is indicated)
X
Z
Feature axis actual
location (measured)

Positional
tolerance
Y
zone cylinder
Actual feature Feature axis true
boundary position (designed)

Formula to determine the actual radial

position of a feature using measured
coordinate values (RFS)

Z= X2 + Y 2
Z positional tolerance /2
Z = total radial deviation

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Positional Tolerance Verification
(Applies when a circular tolerance is indicated)
X
Z
Feature axis actual
location (measured)

Positional
tolerance
Y
zone cylinder
Actual feature Feature axis true
boundary position (designed)

Formula to determine the actual radial position of a

feature using measured coordinate values (MMC)
2 2
Z = X + Y
Z +( actual - MMC)
= positional 2tolerance
Z = total radial deviation
X 2 = “X” measured deviation
Y 2 = “Y” measured deviation
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Bi-directional True Position
Rectangular Coordinate Method
2X 1.5 A B C

2X 0.5 A B C

C A

10
B As Shown
10 35 on Drawing
2X 6 +/-0.25

Means This:
True Position Related
1.5 Wide to Datum Reference Frame
Tolerance
Zone Each axis
must lie
C within the 1.5
X 0.5
rectangular
tolerance
zone
10 basically
B located to
the datum
10 35 0.5 Wide
reference
Tolerance Zone frame

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Bi-directional True Position
Noncylndrical Features (Boundary Concept)

2X 13 +/-0.25 2X 6 +/-0.25
1.5 M A B C 0.5 M A B C
BOUNDARY BOUNDARY

C A

10
B As Shown
10 35 on Drawing

5.75 MMC length of slot

Means This: -0.50 Position tolerance
Both holes must be within the size limits and 5.25 maximum boundary
no portion of their surfaces may lie within the
area described by the 11.25 x 5.25 maximum
boundaries when the part is positioned with 12.75 MMC width of slot
respect to the datum reference frame. The -1.50 Position tolerance
boundary concept can only be applied on 11.25 Maximum boundary
an
MMC basis. True position boundary related
to datum reference frame

90 o
10 A
10 35 B
Velmurugan Sivaraman 37 1/21/2016
 Location (Concentricity)
Datum Features at RFS

6.35 +/- 0.05

0.5 A
A

15.95
15.90

As Shown on Drawing
Means This: Axis of Datum 0.5 Coaxial
Feature A Tolerance Zone

Derived Median Points of

Diametrically Opposed Elements
Within the limits of size and regardless of feature size, all median
points of diametrically opposed elements must lie within a Ø 0.5
cylindrical tolerance zone. The axis of the tolerance zone coincides
with the axis of datum feature A. Concentricity can only be applied
on an RFS basis.
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 Location (Symmetry)
Datum Features at RFS

6.35 +/- 0.05

0.5 A
A

15.95
15.90

As Shown on Drawing
Means This: Center Plane of 0.5 Wide
Datum Feature A Tolerance Zone

Derived Median
Points
Within the limits of size and regardless of feature size, all median
points of opposed elements must lie between two parallel planes
equally disposed about datum plane A, 0.5 apart. Symmetry can
only be applied on an RFS basis.

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Tolerances of
Runout

Circular Runout
(ASME Y14.5M-1994, 6.7.1.2.1)

Total Runout
(ASME Y14.5M-1994 ,6.7.1.2.2)

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Features Applicable to
Runout Tolerancing
Internal surfaces
constructed around
a datum axis

External surfaces
constructed around
a datum axis Angled surfaces
constructed around
a datum axis
Datum axis (established
from datum feature

Surfaces constructed
perpendicular to a
datum axis
Datum feature
Velmurugan Sivaraman 41 1/21/2016
Circular Runout
Total Circular runout can only be applied on
Tolerance an RFS basis and cannot be modified
to MMC or LMC.

Maximum Minimu
m

Full Indicator
Movement

Maximum Minimum
Reading Reading Measuring position #1
(circular element #1)
-
0
+

Full Part
Rotation

Measuring position #2
(circular element #2)

When measuring circular runout, the indicator must be reset to zero at each measuring
position along the feature surface. Each individual circular element of the surface is
independently allowed the full specified tolerance. In this example, circular runout can
be used to detect 2-dimensional wobble (orientation) and waviness (form), but not 3-
dimensional characteristics such as surface profile (overall form) or surface wobble
(overall orientation).

Velmurugan Sivaraman 42 1/21/2016

Circular Runout (Angled
Surface to Datum Axis)

0.75 A

50 +/-0.25

o o
50 +/- 2
As Shown
on Drawing

Means This: The tolerance zone for any individual circular

element is equal to the total allowable movement
of a dial indicator fixed in a position normal to the
Allowable indicator true geometric shape of the feature surface when
reading = 0.75 max. the part is rotated 360 degrees about the datum
( Full Indicator
Movement ) axis. The tolerance limit is applied independently
to each individual measuring position along the
-
0
+ feature surface.

Collet or Chuck
When measuring circular
runout, the indicator must
be reset when
Datum axis A
repositioned along the
feature surface.

360 o Part
Rotation

NOTE: Circular runout in this example only

controls the 2-dimensional circular elements
Single circular (circularity and coaxiality) of the angled feature
element
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not theSivaraman 43
entire angled feature surface
Total Runout

Total Total runout can only be applied on

Tolerance an RFS basis and cannot be modified
to MMC or LMC.

Maximum Minimu
m

Full Indicator
Movement

Maximum Minimu
Reading m
Reading
+
0
-

Indicator Full Part

Path Rotation

+
0
-

When measuring total runout, the indicator is moved in a straight line along the feature
surface while the part is rotated about the datum axis. It is also acceptable to measure
total runout by evaluating an appropriate number of individual circular elements along
the surface while the part is rotated about the datum axis. Because the tolerance
value is applied to the entire surface, the indicator must not be reset to zero when
moved to each measuring position. In this example, total runout can be used to
measure surface profile (overall form) and surface wobble (overall orientation).
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Total Runout (Angled
Surface to Datum Axis)

0.75 A
A

50 +/-0.25

o o
50 +/- 2
As Shown
on Drawing

Means This: The tolerance zone for the entire angled surface
is equal to the total allowable movement of a dial
indicator positioned normal to the true geometric
When measuring total runout, the
indicator must not be reset when shape of the feature surface when the part is
repositioned along the feature rotated about the datum axis and the indicator is
surface. moved along the entire length of the feature
-
0
+ surface.

Allowable indicator reading = 0.75 max.

-
0
+
(applies to the entire feature surface)

Collet or Chuck

Full Part Datum axis A

Rotation

NOTE: Unlike circular runout, the use of total runout

will provide 3-dimensional composite control of the
cumulative variations of circularity, coaxiality,
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Velmurugan 45
and profile of the angled surface
Total Runout (Surface
Perpendicular to Datum Axis)

0.75 A
10

35
50 +/-0.25

A
As Shown
on Drawing

Means This: The tolerance zone for the portion of the feature surface
indicated is equal to the total allowable movement of a dial
indicator positioned normal to the true geometric shape of the
feature surface when the part is rotated about the datum axis
and the indicator is moved along the portion of the feature
surface within the area described by the basic dimensions.

-
0
+
When measuring total runout, the indicator
10 -
0
+ must not be reset when repositioned along
the feature surface.

35 Allowable indicator reading = 0.75 max.

(applies to portion of feature surface
indicated)

Full Part
Rotation Datum axis A

NOTE: The use of total runout in this example will

provide composite control of the cumulative
variations of perpendicularity (wobble) and
flatness (concavity or convexity) of the feature
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Velmurugan Sivaraman 46
 Fixed and
Floating
Fastener
Exercises

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 Floating Fasteners
In applications where two or more mating details are assembled, and all
parts have clearance holes for the fasteners, the floating fastener formula
shown below can be used to calculate the appropriate hole sizes or
positional tolerance requirements to ensure assembly. The formula will
provide a “zero-interference” fit when the features are at MMC and at
their extreme of positional tolerance

2x M10 X 1.5
(Reference)
General Equation Applies
to Each Part Individually

A H=F+T or T=H-F
B H= Min. diameter of clearance hole
F= Maximum diameter of fastener
T= Positional tolerance diameter

2x 10.50 +/- 0.25

?.? M Calculate Required
Positional Tolerance
T=H-F
H = Minimum Hole Size = 10.25
F = Max. Fastener Size = 10
T = 10.25 -10
A
T = ______
remember: the size tolerance must be
??.?? +/- 0.25 added to the calculated MMC hole size
Calculate 2x to obtain the correct nominal value.
Nominal Size
0.5 M
H = F +T
F = Max. Fastener Size = 10
T = Positional Tolerance = 0.50
B H = 10 + 0.50
H = ______
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 Floating Fasteners
In applications where two or more mating details are assembled, and all
parts have clearance holes for the fasteners, the floating fastener formula
shown below can be used to calculate the appropriate hole sizes or
positional tolerance requirements to ensure assembly. The formula will
provide a “zero-interference” fit when the features are at MMC and at
their extreme of positional tolerance

2x M10 X 1.5
(Reference)
General Equation Applies
to Each Part Individually

A H=F+T or T=H-F
B H= Min. diameter of clearance hole
F= Maximum diameter of fastener
T= Positional tolerance diameter

2x 10.50 +/- 0.25

0.25 M Calculate Required
Positional Tolerance
T=H-F
H = Minimum Hole Size = 10.25
F = Max. Fastener Size = 10
T = 10.25 -10
A
T = 0.25
remember: the size tolerance must be
Calculate 2x 10.75 +/- 0.25 added to the calculated MMC hole size
Nominal Size to obtain the correct nominal value.
0.5 M
H = F +T
F = Max. Fastener Size = 10
T = Positional Tolerance = 0.5
B H= 10 + .5
H= 10.5 Minimum
1/21/2016 REMEMBER!!! All Calculations Apply at MMC
Velmurugan Sivaraman 49
Fixed Fasteners
In fixed fastener applications where two mating details have equal
positional tolerances, the fixed fastener formula shown below can be used
to calculate the appropriate minimum clearance hole size and/or
positional tolerance required to ensure assembly. The formula provides a
“zero-interference” fit when the features are at MMC and at their extreme
of positional tolerance. (Note that in this example the positional tolerances
indicated are the same for both parts.)

APPLIES WHEN A PROJECTED TOLERANCE ZONE IS USED

2x M10 X 1.5
(Reference)

General Equation Used When

Positional Tolerances Are Equal

10 A H=F+2T or T=(H-F)/2
H= Min. diameter of clearance hole
B F= Maximum diameter of fastener
T= Positional tolerance diameter

remember: the size tolerance

Calculate Required must be added to the calculated
Clearance Hole Size. 2x ??.?? +/- 0.25
MMC size to obtain the correct
0.8 M nominal value.

A
H = F + 2T
Nominal Size
F = Max. Fastener Size = 10.00
2X M10 X 1.5 (MMC For Calculations) T = Positional Tolerance = 0.80
0.8 M P 10
H = 10.00 + 2(0.8)
H = _____

Velmurugan Sivaraman 50 1/21/2016

Surface finish
Surface finish is a characteristic of any machined surface. It
is
sometimes called surface texture or roughness. The design
engineer is usually the person that decides what the surface
finish of a work piece should be. They base their reasoning
on what the work piece is supposed to do.

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Types of Surface finish?

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Surface Texture Analysis
of cylinder bore

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