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Basic dimension
When GD&T is used, the geometric tolerances apply to the features - not the dimensions. Therefore when BASIC dimensions
are used with geometric tolerances, several different dimensioning schemes may be used without changing the meaning of the
drawing. The first drawing below is an example of baseline dimensioning. The other two illustrate chain dimensioning. Since the
position tolerance is related to datum A, B and C, all three drawings have the same meaning even though the dimensioning is
different. This would not be true if the dimensions locating the holes were toleranced rather than BASIC. Because the meaning
of these drawings is the same

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Feature of Size Example 1:
It is essential to be able to identify a feature of size when reading geometric tolerances. Many geometric tolerances,
where applied to a feature of size, are controlling the feature’s center point, axis or center plane. If you do not recognize
the feature as a feature of size, you might think the tolerance is being applied to the surface.

Features of size are unique because they;

1. Contain opposed points
2. Have a reproducible derived median point, axis or center plane
3. Have limits (are not basic)

Caliper Rule -- Opposed Points This rule is not found in the Standard but it is pretty helpful. The left end of the caliper
shown is used if the feature being measured has opposed points. Since these features have a toleranced dimension and
contain opposed points, they are features of size. Toleranced dimensions that are measured using the probe on the
other end of the caliper do not have opposed points and are not features of size. This rule of thumb is intended to help
you identify features of size and is not intended to suggest that calipers are the best way to measure size dimensions

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Example 2:

Here is another case where angularity cannot fully define the feature. The original drawing had angularity rather than
position applied to the 10mm wide slot. The drawing shows that the center of the slot should be in line with datum axis B.
Angularity would assure that the slot is at the 60° basic angle but ignore that the slot center plane should pass through the
datum axis. To keep the slot in line with the datum axis, position needs to be applied to the slots size dimension. If the angle
of the slot needs to be controlled better than the angularity provided by the position tolerance, an angularity tolerance may
be added as a refinement. As we teach in our GD&T seminars, for features of size, locate first with position and refine with
orientation, in this case angularity, only if necessary.

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Actual Mating Envelope

Internal feature: The actual mating envelope for an internal feature of size is the largest, similar, perfect, feature
counterpart that can be inscribed
within the feature so that it just contacts the surface(s) at the highest
points. For example, the actual mating envelope of a hole is the largest
precision pin that just fits inside the hole contacting the surface at the
highest points.
The actual mating envelope of a feature, controlled by an orientation or
a position tolerance, is oriented to the specified datum(s). For example, the
actual mating envelope may be the largest pin that fits through the hole
and is perpendicular to the primary datum plane illustrated in Fig. 3-16.

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 Calculating additional tolerance permitted when a position tolerance is modified at MMC.

Position and orientation tolerances, such as this perpendicularity tolerance, that are associated with the size dimension
apply to the axis of the Unrelated Actual Mating Envelope (UAME).

Where an MMC modifier is applied to one of these tolerances, any available bonus tolerance is the difference between the
MMC size and the size of the UAME.

The position tolerance applies to the axis of the Unrelated Actual

Mating Envelope (UAME). Because datum feature B is a secondary
datum feature that applies RFS, the datum feature simulator is the
Related Actual Mating Envelope (RAME).
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 importance

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 Hole MMC LMC

10.75 +0.25/-0 10.75 11

23.45 +0.05/-0.25 23.2 23.5

123. 5 +/-0.1 123.4 123.6

.895 .890 .895

.890

Shaft MMC LMC

10.75 +0/-0.25 10.75 10.5

23.45 +0.05/-0.25 23.5 23.2

123. 5 +/-0.1 123.6 123.4

.890
.890 .885
.885
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 Basic Dimension : In technical drawing, a basic dimension is a theoretically exact dimension, given from a
datum to a feature of interest. In Geometric dimensioning and tolerancing, basic dimensions are used to
communicate the critical design dimensions of a part. Basic dimensions represent an ideal case and as such, have
no tolerance. To facilitate manufacturability, a feature control frame is often used to assign a manufacturing tolerance
to a basic dimension.
Basic dimension are denoted by enclosing the number of the dimension in a rectangle.

What is Projected Tolerance?

The projected tolerance is a GD&T modifier used for threaded and press fit holes in order to ensure the proper fitments of
the mating parts by means of studs or bolts. Let’s see the following example:

Say, you have a plate with a hole in which a stud will be inserted. The projected portion of the stud will secure another mating
plate. See the drawing of the bottom plate with thestud hole (top mating plate is in dotted line):

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 Now with only the positional tolerance of 0.2 specified in the drawing, the hole-axis of the bottom plate can be varied
like below at the worst case:

From the figure it is clear that if the stud axis follows the worst case then the stud may interfere with the mating plate.
And for avoiding that interference specifying the projected tolerance in the drawing is required. The below figure will
show how project tolerance will avoid such interference:

You can see projected tolerance of 20 has been mentioned in the drawing by separate frame below the previous GD&T
frame. The meaning of the projected tolerance of 20 is the positional tolerance zone of 0.2 will extend by 20mm beyond the
surface of the bottom plate. And by doing so, the variation of the axis has been reduced substantially as you can see from
the figure above.

Conclusion
Geometric dimensioning and tolerancing or GD&T helps create more universally interpreted engineering drawings. The
projected tolerance modifier is used for the long bolts or studs that secure two mating plates
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Projected Tolerance Zone
The Projected tolerance zone modifier is generally used for threaded holes and holes that will receive a pin (usually a press
fit) and the designer is concerned that the screw or pin projecting from the hole might interfere with the surface of the
clearance hole in the mating part. In these cases it is more important to know where the stud or fastener will be rather than
where the hole or tapped hole is.

The projected value is usually the maximum thickness of the mating part or the maximum height of the pin or stud.

The specified value for the projected tolerance zone is a minimum. The specified tolerance applies only to the projection of
the hole indicated by the projected tolerance.

The symbol is placed in the feature control frame as of the 1994 Standard. Prior to this, the symbol was placed in a separate
frame under the feature control frame.
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 The amount the tolerance is projected is usually written next to the symbol. For clarity the direction and height of the projected
tolerance may be indicated with a heavy chain line drawn closely adjacent to an extension of the center line of the hole.

Straightness
There are two kinds of straightness tolerance - (1) Straightness of an axis or center plane and (2) surface
straightness. The type of straightness is determined by the placement of the feature control frame.

When the feature control frame is next to the size dimension, it is controlling the axis or center plane. An inspector
must derive the median plane or median axis. This can be extremely time consuming and expensive to measure.

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 Tangent Plane
Where the tangent plane modifier is applied to a geometric tolerance, it does not provide any form control. In this
example, the profile tolerance is modified with the tangent plane symbol. Without the tangent plane symbol, the profile
tolerance is controlling the location of the surface to the datum reference frame established by A-B C. It would also control
the perpendicularity of the feature to datum axis A-B and flatness within 0.2. Some processes such as casting and
molding often result in surfaces with depressions called sink. Where the design can allow for these depressions and still
achieve the function, the tangent plane modifier may be used to accept more functional parts. The tangent plane modifier
means that the form error, flatness and straightness, of the surface is ignored. Therefore, it is necessary to provide some
form control. In this case, a flatness control with a value larger than the profile tolerance would be appropriate. Where the
tangent plane modifier is not present, a flatness control would have to be smaller than the profile tolerance.

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 Free state
Use the new free state symbol for your plastic, sheet metal and other flexible parts. In section 1.4 FUNDAMENTAL RULES of
Y14.5, paragraph (l) tells us that "All dimensions and tolerances apply in a free state condition. This principle does not apply to
nonrigid parts as defined in paras. 2.7.1.3(b) and 6.8." The default, then, is that all parts are considered rigid unless there is
some indication that the part may be flexed or distorted for inspection. A way to indicate that a part is not rigid is to add a
constraint note. If some tolerances are to be checked with the part not constrained, the new free state symbol may be added
to specific tolerances. Many useable sheet metal and plastic parts will pass inspection and be functional if clamped to a
condition that simulates the assembled or functional state. Usually when a constraint note is applied to a drawing, at least one
tolerance should be inspected in the free state to limit the free state variation. In this example the entire part is inspected with
the part constrained except for the flatness spec which would be checked unrestrained in the free state.

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 Planar Datum Features Constrain 3 Degrees of Freedom

Planar Datum Feature Where a planar feature is identified as a datum feature, the practical simulator is a high quality
plane such as a surface plate which contacts the high points of the feature. This simulator establishes a datum plane
which constrains 1 translational and 2 rotational degrees of freedom.

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Two Holes as Datum Features Example 1:

Often two holes are used as datum features. There are several ways to accomplish this. The two holes may be used as a
pattern (linear extruded feature) or one may serve as a datum feature that establishes an axis (origin of measurement) and
the other orients the two perpendicular datum planes that intersect at this axis and, of course, the modifiers applied to these
datum features will have an effect.
Keep in mind that parts are made up of features and datum reference frames (composed of 3 mutually perpendicular datum
planes) exist in the processing equipment. Processing equipment should always include the inspection equipment and
sometimes the production equipment. Datum feature referencing in feature control frames indicates how Inspection is to align
a part to the datum reference frame. Often Production may take advantage of this to assure that they are producing “in-spec”
parts.
On this part datum feature A establishes the first datum plane of the datum reference frame. The hole labeled datum feature
B establishes the origin of measurement based on the related actual mating envelope (biggest cylinder, like a gage pin, held
at 90° to the first datum plane or electronically it would be the largest inscribed cylinder that is perpendicular to the first datum
plane) that fits the hole. The actual mating envelope of datum feature C, which is related to the first datum plane and the
datum axis established by datum feature B, is used to orient the planes of the datum reference framework. Any tolerances
that reference A, B, C will use these datum planes to establish an origin of measurement.

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Two Holes as Datum Features Example 2:

The first Tip in this series (indexed as "Two Holes as Datum Features") showed a simple part where two holes were used as
datum features. The holes were on a horizontal plane. On this drawing the two holes are on a diagonal. So, the datum
planes are oriented at the angle established by these holes. Usually inspectors prefer measuring in the horizontal and
vertical directions. No problem! A 30° basic angle is used to create auxiliary vertical and horizontal measurement
planes. Once you locate and orient the part using the two holes that are datum features B and C, you simply rotate the set-
up by 30° to establish the vertical and horizontal measurement planes.
As long as basic dimensions are used, it is possible to establish auxiliary measurement planes that are translated and/or
rotated relative to the datum reference frame without changing the meaning of the drawing.

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FLATNESS

Flatness is the condition of a surface having all of its elements in one plane. The tolerance zone for a flatness control is three
dimensional

Interpretation of Flatness tolerance: It consist of two parallel planes within which all the surface elements must lie. The
distance between the parallel planes is equal to the flatness control tolerance value

In this example, the flatness has been applied to datum

feature A. Three possible inspection methods are illustrated
as below

In the first case, the part is leveled on the surface plate. If

the surface is convex, the part will rock making it difficult to
determine the minimum indicator reading over the entire
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 In the second illustration, the surface is leveled by placing it
on three equal height gage blocks. The indicator is then
moved across the surface. Ideally, the gage blocks should be
placed under the high points on the surface. Otherwise, the
indicator movement may not be the lowest possible

In the third illustration, the CMM will mathematically

"level" the points of the surface contacted by the probe. Of
course, a CMM will automatically align the points to evaluate
the flatness error. Often insufficient points are taken to
evaluate the flatness error. As a result, an out of spec surface
may be accepted.

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 GD&T
Flatness
When Inspecting Flatness, There Is No Datum.
Flatness is another geometric tolerance that is challenging to inspect. It requires isolating the feature from the rest of the part
since there can never be a datum referenced with flatness. In this example, the flatness has been applied to datum feature A.
Three possible inspection methods are illustrated. In all cases, the considered feature is isolated from the rest of the part and
aligned relative to the indicator. In the first case, the part is leveled on the surface plate. In the second illustration, the surface
is leveled by placing it on three equal height gage blocks. The indicator is then moved across the surface. In the third illustration,
the CMM will mathematically "level" the points of the surface contacted by the probe. In all cases the FIM
(Full Indicator Movement) may not exceed 0.2mm.

Problem: If the surface is convex, the part will rock Problem: Ideally, the gage blocks should be placed under the high
making it difficult to determine the minimum indicator points on the surface. Otherwise, the indicator movement may not
reading over the entire surface. be the lowest possible.
Examples 1 and 2 the problem may cause an acceptable surface to be rejected.

Of course, a CMM will automatically align the points to evaluate the flatness error.

Problem: Often insufficient points are taken to evaluate the flatness error. As a result,
an out of spec surface may be accepted.
Bottom line, inspecting flatness requires time and patience.
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 Tolerance : Tolerances are often set by design engineers and published in specifications or
contracts. Many technical standards have tolerances agreed upon by consensus discussions and
sometimes formal voting procedures.
The tolerance may be specified as a factor or percentage of the nominal value, a maximum
deviation from a nominal value, an explicit range of allowed values, be specified by a note or
published standard with this information, or be implied by the numeric accuracy of the nominal
value. Tolerance can be symmetrical, as in 40±0.1, or asymmetrical, such as 40+0.2/−0.1.
It is often desirable to specify the largest possible tolerance while maintaining proper functionality.
Closer or tighter tolerances are more difficult, and hence costly, to achieve. Conversely, larger or
looser tolerances may significantly affect the operation of the device.
Tolerance is different from safety factor, but an adequate safety factor will take into account relevant
tolerances as well as other possible variations.

Considerations when setting tolerances

A primary concern is to determine how wide the tolerances may be without affecting other factors or the outcome
of a process. This can be by the use of scientific principles, engineering knowledge, and professional experience.
Experimental investigation is very useful to investigate the effects of tolerances: Design of experiments, formal
engineering evaluations, etc.
A good set of engineering tolerances in a specification, by itself, does not imply that compliance with those
tolerances will be achieved. Actual production of any product (or operation of any system) involves some inherent
variation of input and output. Measurement error and statistical uncertainty are also present in all measurements.
With a normal distribution, the tails of measured values may extend well beyond plus and minus three standard
deviations from the process average. One, or both, tails might extend beyond the specified tolerance.
The process capability of systems, materials, and products needs to be compatible with the specified engineering
tolerances. Process controls must be in place and an effective Quality management system, such as Total Quality
Management, needs to keep actual production within the desired tolerances. A process capability index is used to
indicate the relationship between tolerances and actual measured production.
The choice of tolerances is also affected by the intended statistical sampling plan and its characteristics such as
the Acceptable Quality Level. This relates to the question of whether tolerances must be extremely rigid (high
confidence in 100% conformance) or whether some small percentage of being out-of-tolerance may sometimes
be acceptable.

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 Allow the designer to communicate the Tolerance zone
appropriate method of part setup to the that applies when
inspector the holes are their
smallest diameter
Allow the designer to
communicate the
appropriate method of part
setup to the inspector

GD&T Symbol. It specifies a

cylindrical tolerance zone

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 Perfect form at MMC is not required if it is desired to allow the surface(s) of a feature to exceed the boundary of perfect form
at MMC. In such cases, the note, PERFECT FORM ATMMCNOT REQD, may be specified on the drawing.

The relationship between individual features is not controlled by the limits of size. If features on a drawing are shown
coaxial, or symmetrical to each other and are not controlled for location, the drawing is incomplete. Figure 3-19A is incomplete
because there is no control of coaxiality between the inside diameter and the outside diameter. Figure 3-19B shows one way of
specifying the coaxiality of the inside and outside diameters.

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Rule 1 can be paraphrased as "perfect from at MMC"
The form of a FOS is controlled by its limits of size in the following ways:
•The surfaces of a FOS shall not extend beyond a boundary (envelop) of perfect form (perfect flatness, straightness,
circularity, and cylindricity) at MMC
•When the actual size of a FOS has departed from MMC toward LMC, the form is allowed to vary by the same amount
•The actual local size of an individual feature of size must be within the specified tolerance of size
•There is no requirement for a boundary of perfect form at LMC. If a feature is produced at LMC, the geometric form
may vary between the LMC and MMC boundaries

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DATUM SHIFT EXAMPLE 1
When datum features are modified at MMC or LMC, the datum feature and the features being controlled may be able to shift
relative to the datum axis or center plane. On the drawing shown below, datum feature B, in the position callout of the four hole
pattern, is modified at MMC. This means the datum simulator for datum feature B would have a theoretical design size of 19.6.

Since the actual datum feature could be produced as large as 20.2, the datum feature could shift as much as 0.6 total. This
means the four-hole pattern may shift out of position in one direction while the datum feature shifts in the other direction as
shown. A very common error made at inspection is to use this allowed datum shift as a bonus on the features being controlled.
This would allow the features to be out of position to each other more as the datum feature departs from MMC. This practice
does not agree with the drawing or a hard gage, should one be produced

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EXAMPLE 2
Referencing a datum feature at MMC or LMC does not change the tolerance on the feature(s) being toleranced. These modifiers,
however, may allow the part to float or shift relative to the datum reference frame. Notice that the 15mm diameter hole references
both B and C at their MMC. Therefore, if both B and C are produced at their MMC, there is no shift of the datum feature relative to
the datum reference frame established by A, B and C. If, however, datum feature B happened to be produced at 8.1 (its LMC
size) and was perfectly perpendicular to the primary datum, the part could shift as much as 0.2mm total, relative to the datum
reference frame. In other words, the part could be slid left or right 0.2mm total while maintaining contact with datum A in order to
bring the 15mm hole into its allowable position tolerance zone. Some inspectors treat this 0.2mm shift as an additional bonus
tolerance on the 15mm hole which would allow additional deviation in all directions. This would be incorrect since no movement of
the part is allowed perpendicular to the primary datum.

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