3a Learning Solutions

Training Program

On

“Geometrical Dimensioning & Tolerancing

(GD&T)”

Conducted by

“Mr. Vishwanathan K.”

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Basic Geometrical Dimensioning

& Tolerancing – as per ASME
Y14.5 – 2009

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Course Contents
 Pre-session Quiz
 Basic Information on the dimensioning & tolerancing
 GD & T Symbol & Terms
 Rules and Concepts of GD & T
 Form Controls
 Datum

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Course Contents –
contd..
 Orientation controls
 Positional Tolerances
 Concentricity & Symmetry controls
 Runout Controls
 Profile Controls
 Tolerance Stacks

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Course Contents –
contd..
 Group work for important concepts
 Group presentation for every group work
 Interaction with participants
 Post session Quiz
 Conclusion

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Section 1: Basic Information on the

dimensioning and tolerancing

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Basic Information
Contents:
 Engineering Drawing – Purpose & Importance
 Consequences of Poor Drawing
 Dimensions & Tolerances
 Type of Tolerances
 Three General Practices for SI units
 Dimensioning Standards

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Basic Information
Contents ( Continued..) :
 History of GD & T
 Fundamental Dimension Rules
 Coordinate Dimensioning System
 Geometric Dimensioning System
 Comparison of CD & T with GD & T

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Basic Information
 Engineering Drawing:
A Document which communicates a clear description of a part. This
description includes Pictures, words, numbers, symbols, etc.
Engineering Drawing information includes:
- Geometry (Shape, size & form of the part)
- Critical Function Relationships
- Tolerances permitted for necessary function
- Material, heat treatment, surface coatings, etc.
- Part documentation information (Part number, revision level, etc.)

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Basic Information
Importance of clear (precise) communication in the
drawing:
 Engineering Drawing is a legal document. Therefore, it
should communicate clearly (also correctly) to users
without any ambiguity.
 If the communication in the drawing is not clear, it will
affect many parts of an organization and the impact will
be huge (on cost).

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Basic Information
Consequences of Poor Drawing:
 A drawing error can be very costly to an Organization.
 If the drawing error is found in Design Dept., What will be the
impact?
 If the drawing error is found in sample development stage,
production stage, Final Product, Customer end, etc – what will
be the impact?
 Let us brain storm… Any incidences?..........

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Basic Information
 Drawing Errors cost the organization in
four ways:
 Money

 Time

 Material

 Dissatisfied Customers

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Basic Information
Dimensions:
 A numerical value expressed in appropriate units of measure
and used to define the size, location, orientation, form, or other
geometric characteristics of a part.
Tolerance:
 The total amount that feature of the part are permitted to vary
from the specified dimension. The tolerance is the difference
between the maximum and minimum limits.

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Basic Information
Types of Tolerances:
1) Uni-Lateral & 2 ) Bi-Lateral
 Uni – Lateral Tolerance (Example):
Ex: 10+0.5 or 10-0.5
 Bi – Lateral Tolerance (Example):
Ex: 10 +/- 0.5 (equal) 10 + 0.5 / - 0.3 (unequal)

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Basic Information
 Three general practices are followed
internationally for Metric Dimension Spec (SI
units):
1) When a dimension is a round number (ex: 10, 15, 12,etc), the
decimal points and zero are omitted
2) When a dimension is less than one mm, a zero precedes the
decimal point. For ex: 0.2, 0.5, 0.8, etc.
3) When a dimension is not a round number, the decimal point is
used. For ex: 10.0 – 10.2, 10.5 – 10.68, etc.

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Basic information
Dimensioning Standards:
 This GD & T course is based on
ASME Y14.5 -2009 standard.
 Other predominant standard used in many
countries is ISO (Internal Standards
Organization) for dimensioning and Tolerancing

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Basic Information
History of GD & T:
Year 1800 = Neatly inked sketch like multi-viewed master piece ( Industrial
Revolution with Manufacturing)
Year 1935 = ASA published the standard for drawings, “American Drawing &
Drafting Room Practices”
Year 1940 = Chevrolet (US) published the Draftsman’s Handbook with the
focus on the position tolerancing
Year 1944 & 1948 = British published, “pioneering drawing standards” &
“Dimensional Analysis of Engineering Design” standard
Year 1945 = U.S Army published an Ordinance manual for dimensioning and
tolerancing that introduced the use of symbols (rather than notes)

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Basic Information
History of GD & T:
Year 1946 = ASA published II edition of “American Standard Drawing and
Drafting Room Practices”
Year 1952 = SAE published the standard for aircraft industry “ SAE
Aeronautical Drafting Manual”
Year 1953 = U.S military published MIL-STD-8A along with basic symbols
Year 1957 = The first American Standard devoted to dimensioning and
tolerancing
Year 1966 = ANSI Y14.5 was published by ANSI
Year 1973 & 1982 = ANSI Y14.5 was updated and Published
Year 1994 = ASME Y14.5M-1994 was published.
Year 2009 = ASME Y14.5 2009 (current standard) published
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Basic Information
Fundamental Dimensioning Rules:
1) Each dimension shall have a tolerance except those dimension
specifically identified as reference, maximum, minimum or stock size
2) Dimensioning and tolerancing shall be complete so there is full definition
of each part feature
3) Dimensions for functions and mating relationship of a part shall not be
subject to more than one interpretation
4) The drawing should define a part without specifying the manufacturing
method
5) A 90 deg angle applies where centerline and lines depicting features are
shown on a drawing at right angles and no dimension is shown

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Basic Information
Fundamental Dimensioning Rules:

6) Unless otherwise specified, all dimensions are applicable at 20 deg C (68

deg F)
7) All dimensions and tolerances apply in the free state of condition. This
principle does not apply for non-rigid parts
8) Unless Otherwise specified, all geometric tolerances apply to the full
depth, length and width of the feature
9) Dimension and tolerances apply only at the drawing level where they are
specified. A dimension specified on a detail drawing is not mandatory
for that feature on the assembly drawing.

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Basic Information
Coordinate Tolerancing System:
 Coordinate tolerancing is dimensioning system where a part
feature is located (defined) by means of rectangular or
square tolerance zones
 Three major short comings in Coordinate Tolerancing:
1) Square or rectangular Tolerance Zones
2) Fixed-size tolerance zones
3) Ambiguous instructions for inspection

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Basic Information
Coordinate Tolerancing System:

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Basic Information
Geometric Dimensioning & Tolerancing System:

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Basic Information
Coordinate Dimension Usage:

Type of dimension Appropriate use Poor use

Size X
Chamfer X
Radius X
Locating part X
features
Controlling Angular X
Relationships
Defining the form of X
part features

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Basic Information
Geometric Dimension & Tolerancing System:
 GD & T is an international language which consists of a well
defined set of symbols, rules, definitions and conventions.
 GD & T can be used to describe the size, form, orientation
and location of a part features.
 Benefit of GD & T includes 1) Improved Communication,
2) Provides Better Product Design, 3) Increases Production
Tolerances

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Basic Information
Comparison of CD & T & GD & T:
Drawing CD & T GD & T
Concept
Tolerance Square or Rectangular Tol zone for Round tolerance zone (dia symbol)
Zone Shape hole locations resulting in less resulting 57% more tolerance for hole
tolerance for hole and higher mfg location and lower mfg cost
cost
Tolerance Tolerance zone is fixed in size Use of MMC modifier allows tol zone
Zone resulting in scrapping of functional to increase under certain condition
Flexibility parts & higher operating cost resulted in usage of functional parts
and lower operating cost
Ease of Implied datum allows choices for set The datum system communicates
Inspection up when inspecting the part resulted one set up inspection resulting in
in Scrapping of good parts and clear instruction for inspection and
accepting the bad parts eliminates disputes over part
acceptance.

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Section : 2 G D & T Symbols & Terms

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GD & T Symbol & Terms

Contents:
 Feature
 Feature of Size
 Feature of Size Dimensions
 8 Common Modifiers used in GD & T
 14 Symbols used in GD & T
 Feature Control Frame

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GD & T Symbol & Terms

Feature:
 A general term applied to physical portion of a part, such as
surface, hole, or slot. An easy way to remember this term is to
think of a feature as part surface.
Feature of Size:
 A cylindrical or spherical surface or set of two opposed elements or
opposed parallel surfaces, associated with a size dimn. A key part
of the FOS definition is that the surfaces or elements must be
opposed. An axis, median plane or centerpoint can be derived from
a feature of size

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GD & T Symbol & Terms

Feature of Size Dimensions:

 A feature of size dimension is a dimension that is associated

with a feature of size. A non-feature of size dimension is a
dimension that is not associated with a feature of size.
Whether a dimension is or is not a feature of size dimension is
an important concept in geometric tolerancing.

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GD & T Symbol & Terms

Modifiers:
 There are 8 common modifiers used in GD & T
 Modifiers communicate additional information about the
drawing or tolerancing of a part.
 MMC - M LMC - L Projected Tol Zone P
 Tangent Plane - T Diameter - Radius - R
 Controlled Radius – CR Reference - ( )

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GD & T Symbol & Terms

Maximum Material Condition (MMC):
 The condition in which a FOS contains the maximum amount
of material everywhere within the stated limits of size
Ex: Largest Shaft dia or smallest hole dia
Least Material Condition (LMC):
 The condition in which a FOS contains the least amount of
material everywhere within the stated limits of size
Ex: Smallest shaft dia or the largest hole dia

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GD & T Symbol & Terms

Regardless of Feature Size (RFS) :
 The term that indicates a geometric tolerance applies at
any increment of size of the feature within its size
tolerance (the geometric tolerance applies at whatever
size the part is produced).
 There is no symbol for RFS because it is the default
condition for all geometric tolerances.

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GD & T Symbol & Terms

Projected Tol zone:
 Changes the location of the tolerance zone on the part. It projects the
tolerance zone so that it exists above the part.

Tangent Plane:
 Denotes only the tangent plane of the tolerenced surface needs to be
within this tolerance zone.

Diameter:
 Used in two ways. Inside Feature Control Frame to denote the shape of
the tolerance zone & outside the feature control frame to simply replace
the word diameter.

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GD & T Symbol & Terms

Radius:
 Creates a zone defined by two arcs (minimum and maximum radii). The
part surface must lie within the zone. The part surface may have flats or
reversals within the tolerance zone
Controlled Radius:
 Creates a zone defined by two arcs (minimum and maximum radii). The
part surface must lie within the zone. The part surface shall not have flats
or reversals within the tolerance zone
Reference:
 Method of denoting that the information is for reference only. The
information is not to be used for manufacturing or inspection.

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GD & T Symbol & Terms

Geometric Characteristic Symbols:
 There are 14 symbols used in GD & T.
 These Symbols are divided in 5 categories: Form, Profile,
Orientation, Location and runout.
 Certain geometric Symbols never use a datum reference and
other geometric symbols may or may not use a datum
reference.
 Refer the table in next slide for the details.

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GD & T Symbol & Terms

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GD & T Symbol & Terms

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GD & T Symbol & Terms

Feature Control Frame:
 Geometric tolerances are specified on a drawing through the
use of a feature control frame. A feature control frame is
rectangular box that is divided into compartments within which
the geometric characteristic symbol, tolerance value,
modifiers and the datum references are placed.
 Refer next slide for example of a Feature Control
Frame

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GD & T Symbol & Terms

Feature Control Frame:
 Example:

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Group Work – 1 (0.5 hr Max)

Time: 15 min (Group activity)
Time: 15 min (Max) for Group
Presentation & clarification by
Trainer

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Group Work – 1

Letter Feature of Size Dimension Non - Feature of Size Dimension

A
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Section: 3 GD & T Rules and

concepts

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GD & T Rules & Concepts

Contents:
 Rule – 1, & 2 with examples
 Basic Dimensions
 Virtual Conditions & Boundary Conditions
 Bonus Tolerance

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GD & T Rules & Concepts

Rules:
 There are two rules generally as part of ASME Y14.5M-
1994.
 The first rule establishes default conditions for FOS
 The second rule establishes a default material
condition for Feature Control Frame.

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GD & T Rules & Concepts

Rule No: 1
 “Where only a tolerance of size is specified, the limits of
size of an individual feature prescribe the extent to which
variations in its form - as well as in its size – are allowed.”

 Also called as “Envelope Rule” or “Perfect form at MMC”

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GD & T Rules & Concepts

Rule No: 1 – Concept:
 Is a dimensioning rule to ensure that features of size will
assemble with one another.
 Two components in Rule – 1 : The envelope principle and
the effect on the form of a FOS as it departs from MMC.
 When the Rule – 1 applies, the limit of size define the size
as well as the form of an individual FOS.

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GD & T Rules & Concepts

Rule No: 1 – Example (Shaft)

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GD & T Rules & Concepts

Rule No: 1 – Example (Hole)

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GD & T Rules & Concepts

Rule No: 1 – Concept (continued) :
 The surfaces of a FOS shall not extend beyond a boundary (envelop) of
perfect form at MMC
 When the actual local 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.

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GD & T Rules & Concepts

Rule No: 1 – How to override?
 There are two ways the Rule No:1 can be overridden
 If a straightness control is applied to a FOS, the Rule no: 1 is
overridden
 If a note such as “PERFECT FORM AT MMC NOT REQUIRED” is
specified next to a FOS dimension, it exempts the FOS from Rule
No: 1

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GD & T Rules & Concepts

Rule No: 1 – Limitation, Exceptions & Inspection
method:
 Does not control the location, orientation or relationship between FOS
 There are two exceptions: 1) A FOS on a non-rigid parts (such as rubber,
flexible materials, etc), 2) Stock sizes (such as bar stock, sheet metal,
structural shapes, etc)
 When inspecting FOS that is controlled by Rule 1, both its size and form
to be verified. Go – No Go Gauge to be used for inspecting those FOS.

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GD & T Rules & Concepts

Rule No: 2
 RFS applies, with respect to the individual tolerance, datum
reference. or both, where no modifying symbol is specified. MMC
or LMC must be specified on the drawing where required.
 Also called as “ the applicable geometric tolerance rule”

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GD & T Rules & Concepts

Basic Dimension:
 There are two uses for basic dimension on the engineering drawing
 One is to define the theoretically exact location, size, orientation, or true
profile of a part feature.
 The other use to define the gage information (example: datum targets)
 Basic dimensions are usually specified by enclosing the numerical value in a
rectangle or in general note, such as, “Untoleranced dimensions are
basic.”

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GD & T Rules & Concepts

Virtual Conditions:
 Is a worst Case Boundary generated by the collective effects of a
FOS at MMC or at LMC and the geometric tolerance for that
material condition.
 The Virtual Condition of a FOS includes effects of the size,
Orientation, and location for the FOS.
 If a feature control frame is applied to a feature (a surface), it does
not affect its WCB. If a feature control frame is applied to a FOS
(an axis or centerplane), it does affect its WCB.

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GD & T Rules & Concepts

Worst-Case Boundary Formulas:
Part Specification FOS Type WCB
FOS with no GD & T Internal IB = MMC
specified External OB= MMC
FOS with GD & T Internal IB= MMC- Tol*
specified at RFS External OB= MMC+Tol*
FOS with GD & T Internal VC=IB=MMC-Tol*
specified at MMC External VC=OB=MMC+Tol*
FOS with GD & T Internal IB=MMC-Tol* - Bonus
specified at LMC
External OB= MMC + Tol* + Bonus
* Tol represents the geometric control tolerance value

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GD & T Rules & Concepts

Bonus Tolerance:
 Is an additional tolerance for a geometric control
 Bonus tolerance is only permissible when an MMC (or LMC) modifier is
shown in the tolerance portion of a feature control frame
 Bonus tolerance comes from the FOS tolerance
 Bonus tolerance is the amount the actual mating size departs from MMC (or
LMC)

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Group Work – 2 (0.5 hr Max)

Time: 15 min (Group activity)
Time: 15 min (Max) for Group
Presentation & clarification by
Trainer

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Group Work - 2

Letter MMC Value LMCValue Does Not Apply

A
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Section: 4 Form controls

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Form Controls
Contents:
 Flatness Control
 Straightness Control
 Circularity Control
 Cylindricity Control
 Legal Specification Test for all the Form Controls

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Form Controls
Flatness:
 The condition of a surface having all the elements in one plane
 Tolerance Zone - More logically, less than or equal to half of the size
tolerance
 MMC or LMC modifier or RFS principle can not be applied since the
flatness is always applied to planar surface.
 Flatness can not override Rule 1. Rule 1 is applied for boundary
conditions. Whenever Rule 1 is applied to FOS, an automatic indirect
flatness control exists for the both the surfaces.

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Form Controls
Flatness:
 In Flatness application, three separate part requirements
must be verified: the size tolerance, the Rule 1 boundary
and the flatness requirements.

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Form Controls
Flatness Example:

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Form Controls
Legal Specification Test for a Flatness Control:
 No datum references is specified in the Feature Control Frame
 No modifiers specified in the Feature Control Frame
 The control is applied to a planer surface
 The flatness control tolerance is less than any other geometric control that
limits the flatness of the surface
 The flatness control tolerance value is less (often less than half) than the
size tolerance associated with the surface.

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Form Controls
Straightness as an surface element control:
 The condition where each line element (or axis or centre plane) is
straight line
 Tolerance Zone - More logically, less than or equal to half of the
size tolerance
 MMC or LMC modifier or RFS principle can not be applied since the
Straightness is always applied to surface elements.
 Straightness can not override Rule 1. Whenever Rule 1 is applied to FOS, an
automatic indirect straightness control exists for the surface line elements.

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Form Controls
Straightness:
 In Straightness application, three separate part
requirements must be verified: the size tolerance, the Rule
1 boundary and the straightness requirements.

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Form Controls
Straightness Example:

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Form Controls
Legal Specification Test for a Straightness Control:
 No datum references is specified in the Feature Control Frame
 No modifiers specified in the Feature Control Frame
 The control is applied to a surface elements
 The Straightness control tolerance is less than any other geometric control
that limits the form of the surface
 The straightness control tolerance value is less (often less than half) than the
size tolerance associated with the surface.

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Form Controls
Straightness as an axis or centerplane control:
 Straightness control is the only form control that can be applied to either a surface
or a feature of size. The interpretation of a straightness control applied FOS is
significantly different from a straightness control applied to a surface.
 When a straightness control is applied to a FOS the following conditions apply:
- Tolerance Zone applies to the axis or centerplane of the FOS
- Rule 1 is overridden
- The virtual condition or outer / inner boundary of the FOS is affected
- MMC or LMC may be used
- The tolerance value specified may be greater than the size tolerance

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Form Controls
Straightness as an axis or centerplane control (at MMC)
 The FOS must also be within its size tolerance
 The Straightness control specifies a tolerance zone within which the
axis or centerplane must lie
 Rule No 1 is overridden
 A bonus tolerance is permissible
 The virtual condition of FOS is affected
 Fix gauge may be used to verify the straightness

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Form Controls
Indirect Straightness Controls:

 There are several geometric controls which can indirectly affect the
straightness of an axis or centreplane. They are cylindricity, Total runout,
and in some cases, profile of a surface. When these controls are used,
they may affect the straightness of an axis or centerplane of a FOS.

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Form Controls
Straightness control of an axis (MMC):

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Form Controls
Legal Specification Test for a Straightness applied to a FOS:
 No datum references can be specified in the Feature Control Frame
 The control must be associated with a feature of size dimension
 If applied to a cylindrical FOS, a diameter symbol should be specified in the
tolerance portion of the feature control frame.
 The Straightness control cannot contain the projected tolerance zone or tangent
plane modifier.
 The straightness control tolerance value should be a refinement of other
geometric tolerances that control the straightness of the feature.

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Form Controls
Circularity (Roundness) :
 The condition where all points of a surface of revolution at any section
perpendicular to common axis are equidistant from that axis. Circularity can be
applied to any part feature with a diametrical (round) cross section.
 Tolerance Zone - More logically, less than or equal to half of the size tolerance
 MMC or LMC or RFS principle, diameter, projected tolerance zone, or tangent
plane modifiers are not used since the circularity is always applied to a surface.
 Circularity can not completely override Rule 1. Rule 1 is applied for boundary
conditions. Whenever Rule 1 is applied to FOS with a diametrical cross section,
an automatic indirect circularity control exists for the surface.

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Form Controls
Indirect Circularity Controls:
 There are several geometric controls that can indirectly affect the circularity
of a diameter. They are Rule 1, cylindricity, profile and runout. When any of
these controls are used on a diameter, they also limit the circularity error of
the diameter. However the indirect circularity controls are not inspected. If a
circularity control is specified, its tolerance value must be less than the
tolerance value of any indirect circularity control that affects the diameter.

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Form Controls
Circularity Example:

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Form Controls
Legal Specification Test for a Circularity Control:
 No datum references is specified in the Feature Control Frame
 No modifiers specified in the Feature Control Frame
 The control is applied to a diametrical feature.
 The Circularity control tolerance value is less than any other
geometric control that limits the circularity of the feature

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Form Controls
Cylindricity :
 The condition of a surface of revolution in which all the points of the surface are
equidistant from common axis. Cylindricity tolerance specifies a tolerance zone of
two co-axial cylinders within which all points of the surface must lie.
 Tolerance Zone - More logically, less than or equal to half of the size tolerance
 MMC or LMC or RFS principle, diameter, projected tolerance zone, or tangent
plane modifiers are not used since the cylindricity is always applied to a surface.
 Cylindricity can not completely override Rule 1. Rule 1 is applied for boundary
conditions. Whenever Rule 1 is applied to FOS , an automatic indirect circularity
control exists for the surface.

17.06.2018 Designed by Mr. Vishwanathan K.@3a 79

Form Controls
Indirect Cylindricity Controls:
 There are several geometric controls that can indirectly affect the circularity
of a diameter. They are Rule 1, profile of a surface, and total runout. When
any of these controls are used on a diameter, they also limit the cylindricity of
the diameter. However the indirect cylindricity controls are not inspected. If a
cylindricity control is specified, its tolerance value must be less than the
tolerance value of any indirect cylindricity control that affects the diameter.

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Form Controls
Cylindricity Example:

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Form Controls
Legal Specification Test for a Cylindricity Control:
 No datum references is specified in the Feature Control Frame
 No modifiers specified in the Feature Control Frame
 The control is applied to a cylindrical feature.
 The Cylindricity control tolerance value is less than any other
geometric control that limits the cylindricity of the feature

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Group Work – 3 (1hr Max)

Time: 30 min (Group activity)
Time: 30 min (Max) for Group
Presentation & clarification by
Trainer

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Group Work - 3

Dia WC Max Circularity Max line element Error Max Bend Rule – 1
B error possible Possible possible (Y/N)
A
B
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Home Work - 1

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Home Work – 1 (Questions)

1. Maximum Size Variation possible?
2. Max Taper (Straightness) possible?
3. Max Ovality (Circularity) Possible?
4. Max Shape / Form Variation Possible?
5. Max Shape / Form Variation possible at MMC ?
6. Rule 1 or 2 applied?
7. Bonus Tolerance Applicable? How much if applicable?
8. In Worst Case, What is the value of boundary condition
(Envelope)?

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Section: 5 Datum

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Datums
Contents:
 Definition of Datum System
 3 benefits of Datum System
 Implied Datum – Disadvantages
 Definition of a Datum
 Datum Targets

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Datums
Datum System:
 The Datum system is a set of symbols and rules that communicates to the
drawing user how dimensional measurements are to be made.
 The datum system is used for two reasons: 1) the datum system allows
the designer to specify in which sequence the part is to contact the
inspection equipment for the measurement of a dimension. 2) It allows the
designer to specify which part surfaces are to contact the inspection
equipment for the measurement of a dimension.

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Datums
Benefits of Datum System:
 Aids in making repeatable dimensional measurements
 Aids in communicating part functional relationships
 Aids in making the dimensional measurement as intended
by the designer

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Datums
Disadvantages of Implied Datum:
 No clear communication to the drawing user which surface should
contact the inspection equipment.
 No clear communication to the drawing user in which sequence the
part should be brought into contact with the inspection equipment.
 Use of implied datum results in two consequences: 1) Good parts are
rejected, 2) Bad parts are accepted

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Datums
Datum:
 A datum is a theoretically exact plane, point or axis
from which a dimensional measurement is made.
 A datum feature is a part feature that contacts a datum.

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Datums
Categories of Datum:
 Primary, secondary & Tertiary datum
 Primary: The first datum plane that the part contacts. Established through 3 point
contact to restrict the movement along the z axis, rotation around x axis and y
axis.
 Secondary: The second datum plane that the part contacts. Established through 2
point contact to restrict the rotation around z axis and movement along the y axis.
 Tertiary Datum: The third datum plane that the part contacts. Established through
one point contact to restrict remaining possible movement along x axis

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Datums
Categories of Datum:

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Datums
Datum Targets:
 Datum targets are symbols that describe the shape, size and location of gage
elements that are used to establish datum planes or axis.
 Datum targets are shown on the part surfaces on a drawing, but they actually
don’t exist on the part.
 Datum targets describe the gage elements.
 Few examples of usage of Datum targets: Casting, Forging, irregularly shaped
parts, plastic parts and weldments. These type of parts don’t have planar datum
feature normally. And also the datum feature is likely to warp or get bowed,
wobbled (not resting in the same position on a full datum plane) resulting in
unsuitable contact with a full datum plane.

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Datums
Datum Targets:

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Section: 6 Orientation Controls

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Orientation Controls
Contents:
 Definition & Application of Perpendicularity control
 Definition & Application of Angularity control
 Definition & Application of Parallelism control
 Legal Specification Test for Perpendicularity, Angularity &
Parallelism

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Orientation Controls
Perpendicularity:
 Perpendicularity is the condition that results when a surface,
axis or centerplane is exactly 90 deg to datum
 Two common tolerance zone 1) Two Parallel Planes &
2) A cylinder
 Perpendicularity applied to a surface, Planar FOS & Cylinder
FOS.

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Orientation Controls
Perpendicularity – Conditions when applied to surface:
1) Shape of the Tol Zone is two parallel planes that are perpendicular to the datum plane
2) The tolerance value of the perpendicularity control defines the distance between the
tolerance zone planes
3) All the elements of the surface must be within the tolerance zone
4) The perpendicularity tolerance zone limits the flatness of the toleranced feature

Perpendicularity - conditions when applied to non-cylindrical and

cylindrical FOS (at MMC application)
1) A bonus tolerance is permissible
2) Fixed gauge may be used to verify the perpendicularity control
And all the above 4 points also applicable.

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Orientation Controls
Legal Specification Test for Perpendicularity control:
 A datum must be referenced in the feature control frame
 If it is applied to a surface, the projected tolerance zone, diameter,
MMC, LMC modifiers may not be used in the tolerance portion of
the feature control frame. If it is applied to a FOS, modifiers may be
used
 The tolerance value specified must be less than any other
geometric tolerances that control the perpendicularity of the feature
(for example, tolerance of position, total runout, concentricity, and
profile)

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Orientation Controls
Perpendicularity control example:

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Orientation Controls
Angularity:
 Angularity is the condition of a surface, centerplane or axis being exactly
specified angle. An angularity control is a geometric tolerance that limits
the amount of surface, axis or centreplane is permitted to vary from its
specified angle.
 Two common tolerance zones: 1) Two Parallel Planes, 2) A Cylinder
 Angularity applied to a surface and cylindrical FOS

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Orientation Controls
Angularity example:

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Orientation Controls
Angularity – Conditions when applied to a surface :
 Shape of the tolerance zone is two parallel planes
 Tol zone is oriented relative to the datum plane with a
basic angle
 All of the elements of the surface must be within the
tolerance zone
 Angularity tol zone also limits the flatness of the
toleranced surface

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Orientation Controls
Angularity – Conditions when applied to a dia :
 Shape of the tolerance zone is cylinder
 Tol zone is oriented relative to the datum plane with a
basic angle
 Axis of toleranced feature must be within the tolerance
zone
 Angularity control tolerance value defines the dia of the
tolerance cylinder.

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Orientation Controls
Legal Specification Test for Angularity control:
 One or more datum planes, a datum axis, or centerplane must be referenced in
the feature control frame
 If it is applied to a surface, the projected toleranced zone, diameter, MMC and
LMC modifiers may not be used in the tolerance portion of the feature control
frame (IF it is applied to a FOS, modifiers may be used)
 A basic angle must be specified relative to the datums referenced
 The tolerance value specified must be a refinement of any other geometric
tolerances that control the angularity of the feature (for example, tolerance of
position, runout, an profile)

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Orientation Controls
Parallelism:
 Parallelism is the condition that results when a surface, axis or
centerplane is exactly parallel to a datum
 Two common tolerance zone: 1) Two Parallel Planes, 2) A
cylinder
 Parallelism is applied to a surface & a dia (MMC)

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Orientation Controls
Parallelism example:

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Orientation Controls
Parallelism – condition when applied to a surface:
 Tolerance zone is two parallel planes that are parallel to the
datum plane
 Tol zone is located within the limits of the size dimension
 Tol value of the parallelism control defines the distance between
the tol zone planes
 All elements of the surface must be within the tolerance zone
 Parallelism tol zone limits the flatness of the toleranced feature

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Orientation Controls
Parallelism – condition when applied to a dia and
contains MMC modifier:
 Bonus tolerance is permissible
 Fixed gauge may be used to verify the parallelism control.

(all the conditions under “Parallelism applied to a surface” are

applicable here also)

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Orientation Controls
Parallelism – condition when applied to a tangent
plane modifier:
 Tol Zone is two parallel planes
 Tangent Plane established by the high points of the surface
must be within 0.1 parallelism tol zone.

(all the conditions under “Parallelism applied to a surface” are

applicable here also)

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Orientation Controls
Legal Specification Test for Parallelism control:
 One or more datum planes, a datum axis, or centreplane must be
referenced in the feature control frame.
 If it is applied to a surface, the LMC or MMC modifiers may not be
used in the tolerance portion of the feature control frame.
 The tolerance value specified must be less than any other
geometric tolerances that control the parallelism of the feature (for
example, tolerance of position, runout and profile)

17.06.2018 Designed by Mr. Vishwanathan K.@3a 113

Group Work – 4 (1hr Max)

Time: 30 min (Group activity)
Time: 30 min (Max) for Group
Presentation & clarification by
Trainer

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Group Work - 4

Letter identified as If FOS dimension is identified If FCF is identified

Letter FOS Non FOS FCF Rule 1 applied Rule 1 not Applied WCB Feature FOS BT
A

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Section: 7 Positional Tolerances

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Positional Tolerance
Contents:
 Positional Tolerance Definition
 Advantage of Positional Tolerance
 Controlling 4 types of part relationship
 Positional tolerance MMC & RFS comparison
 Fixed and Floating Fasteners – definition & formula for positional
tolerance
 Legal Specification Test

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Positional Tolerance
Definition:
 Positional tolerance control is a geometric tolerance that defines the location
tolerance of a FOS from its true position.
 When specified on an RFS basis, a positional tolerance control defines a
tolerance zone that the center, axis, or centreplane of the actual mating
envelope of a FOS must be within.
 When specified on an MMC or LMC basis, a positional tolerance defines a
boundary – often referred to as the virtual condition – that may not be violated
by the surface or surfaces of the considered feature.

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Positional Tolerance
Advantage of Positional Tolerance:
 Provides larger tolerance zone i.e. Cylindrical tolerance zone are
57% larger than square tolerance zone.
 Permits additional tolerance – bonus & datum shift
 Prevents Tolerance accumulation
 Permits the use of functional gages
 Protects the part function
 Lowers the manufacturing cost

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Positional Tolerance
Used to Control 4 types of part relationship:
 The distance between features of size such as holes, bosses,
slots, tabs, etc.
 The location of feature of size such as holes, bosses, slots,
tabs, etc.
 Co- axiality between feature of size
 Symmetrical relationship between feature of size

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Positional Tolerance
Positional tolerance – MMC & RFS comparison

MMC RFS
Tolerance Zone A boundary Zone An axis Zone

Bonus Tolerance Yes No

permissible
Gaging Functional Variable

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Positional Tolerance
Positional tolerance example –coordinate tolerance system

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Positional Tolerance
Positional tolerance example – GD&T

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Positional Tolerance
Fixed and Floating Fastener Assemblies:
 A fixed fastener assembly is where the fastener is held in place
into one of the components of the assembly. Often the hole in
one component of the assembly are clearance holes and holes in
other component are threaded hole (press fit like a dowel hole).
This type of assembly is called a fixed fastener assembly
because the fastener is fixed in the assembly.

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Positional Tolerance

Fixed and Floating Fastener Assemblies – contd..:

 A floating fastener assembly is where the fastener is held
together with fasteners (such as bolts and nuts) and both the
components have the clearance holes for the fasteners. This type
of assembly is called a floating fastener assembly because the
fastener can float (move) in the holes of each part.

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Positional Tolerance
Fixed and Floating Fastener Assemblies – contd..:
 Fixed Fastener Formula for positional tolerance dia =
T = H – F or H = F + 2T
2

 Floating Fastener Formula for Positional Tolerance =

T=H–F
Where H = MMC of the clearance hole & F = MMC of the Fastener

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Positional Tolerance
Legal Specification Test for Positional Tolerance:
 The Positional Tolerance must be applied to a FOS
 Datum references are required. The datum references must
ensure repeatable measurements of the toleranced FOS.
 Basic Dimensions must be used to establish the true position
of the toleranced FOS from the datums referenced (and
between features of size in a pattern)

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Section: 8 Concentricity & Symmetry

controls

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Concentricity & Symmetry Controls

Contents:
 Concentricity definition
 Concentricity Application
 Concentricity condition
 Legal Specification test for concentricity control
 Symmetry definition
 Symmetry Application
 Symmetry condition
 Legal specification test for symmetry

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Concentricity & Symmetry Controls

Concentricity - definition:
 Is the condition where the median points of all diametrically
opposed elements of a cylinder (or surface of revolution) are
congruent with the axis of datum feature. A median point is the
midpoint of a two point measurement.

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Concentricity & Symmetry Controls

Concentricity Application:
 Concentricity is used when a primary consideration is precise
balance of the part, equal wall thickness, or another functional
requirement that calls for equal distribution of mass.
 The toleranced FOS may contain flats or be lobed and still be
concentric.
 Before using concentricity control, the use of tolerance of position
or runout should be considered.

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Concentricity & Symmetry Controls

Concentricity example:

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Concentricity & Symmetry Controls

Concentricity example:

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Concentricity & Symmetry Controls

Concentricity condition:
 The diameter must meet its size and Rule 1 requirements
 The concentricity control tolerance zone is a cylinder that is
coaxial with a datum axis
 The tolerance value defines the diameter of the tolerance
zone.
 All median points of the toleranced diameter must be within the
tolerance zone.

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Concentricity & Symmetry Controls

Legal Specification Test for Concentricity Control:
 The feature control frame must be applied to a surface of
revolution that is coaxial to the datum axis.
 Datum references are required. The datum references must
ensure that a legal datum axis is established
 The diameter symbol must be shown in the tolerance portion of the
feature control frame
 The MMC, LMC, Tangent Plane, Projected Tolerance zone
modifiers may not be used in the feature control frame.

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Concentricity & Symmetry Controls

Symmetry control:
 Symmetry is similar to concentricity.
 The concentricity is used on surface of revolution, symmetry is used on planar
feature of size.
 A symmetry control is a geometric tolerance that limits the symmetry error of a part
feature.
 When using a symmetry control, the specified tolerance and the datum references
must always be applied on an RFS basis.

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Concentricity & Symmetry Controls

Symmetry Application:
 Symmetry is used when a primary consideration of
symmetrical features is precise balance of the part,
equal wall thickness, or another functional requirement
that calls for equal distribution of mass.

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Concentricity & Symmetry Controls

Symmetry Example:

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Concentricity & Symmetry Controls

Symmetry Example:

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Concentricity & Symmetry Controls

Symmetry Condition:
 When symmetry is applied to a slot, the following conditions apply:
- The slot must meet its size and Rule 1 requirements
- The symmetry control tolerance zone is two parallel planes that are centered
about the datum centerplane.
- The tolerance value of the symmetry control defines the distance between the
parallel planes.
- All the median points of the toleranced slot must be within the tolerance zone.

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Concentricity & Symmetry Controls

Legal Specification Test for Symmetry Control:
 The feature control frame must be applied to a planar FOS
that is symmetrical about the datum centerplane.
 Datum references are required. The datum references must
ensure that a legal datum centerplane is established
 No modifiers may be used in the feature control frame.

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Section: 9 Run out Controls

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Runout Controls
Contents:
 Definition of Circular and Total Runout
 WCB calculation in circular & Total runout application
 Legal Specification Test for Circular and Total Runout
 Verification method for Total and Circular Runout

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Runout Controls
Runout – concept:
 Runout is a composit control. A composite control controls the form,
location, and orientation of a part feature simultaneously (in a single
gage reading).
 Runout controls are often used to control the coaxiality of diameters.
 Runout control always requires a datum axis.
 There are two types of runout controls. Circular runout and total runout.

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Runout Controls
Circular Runout – Definition:
 Circular runout is a composite control that affects the
form, orientation, and location of circular elements
(individually) of a part feature relative to datum axis.
 Circular runout applies independently to each circular
element of a diameter.

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Runout Controls
Circular Runout – Application:
 The dia must meet its size requirements
 The worst case boundary is affected
 The runout control applies RFS
 Runout applies at each circular element of the toleranced diameter
 The runout tolerance zone is two coaxial circles

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Runout Controls
Circular Runout –Example:

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Runout Controls
Total Runout – Definition:
 Total runout is a composite control that affects the form,
orientation, and location of circular elements (simultaneously)
of a diameter (or surface) relative to datum axis.
 Total runout applies to the entire length of a diameter
simultaneously.

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Runout Controls
Total Runout – Application:
 The dia must meet its size requirements
 The worst case boundary is affected
 The runout control applies RFS
 Runout applies simultaneously to all element of the diameter.
 The runout tolerance zone is two coaxial cylinders

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Runout Controls
Total Runout – Example:

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Runout Controls
Legal Specification Test for Runout controls:
 A datum must be referenced in the feature control frame
 Datums referenced must specify a proper datum axis
 A runout control must be applied to a surface element that surrounds or
is intersected by the datum axis
 The runout control must be applied on an RFS basis
 The runout control must not include any modifiers

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Section: 10 Profile Controls

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Profile Controls
Contents:
 Profile Terminology
 Profile Tolerance Zone
 Advantages of Profile
 Profile of a surface application
 Profile of line control
 Verifying the profile control
 Legal Specification Test for profile control applications

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Profile Controls
Profile Terminology:
 A unique aspect of profile controls is that they can be
specified with a datum (as a datum-related control) or
without a datum (as a form control). When datums are
referenced, the profile tolerance zone is related to the datum
reference frame. When no datums are referenced, the profile
tolerance zone applies where the part surface actually
exists.

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Profile Controls
Profile Terminology – continued:
 A profile control is a geometric tolerance that specifies a uniform boundary
along the true profile that the elements of surface must lie within.
 A profile control can be used to control four part characteristics: Size,
location, orientation, or form of part feature. It can be applied to single or
multiple features. Several profile controls may be applied to single feature.
There are two types of profile controls: Profile of a surface & Profile of a
line.

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Profile Controls
Profile Terminology – continued:
 Profile of a surface can be used to control the size,
location, orientation, and form of a part feature. Profile of
a surface or line can be used to tolerance planer
surfaces, cylinders, cones, curves, and irregular curves.

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Profile Controls
Profile Tolerance Zone :
 The tolerance zone is a uniform boundary (3-D tolerance zone)
when a profile of a surface control is specified. It applies for full
length, width, and depth of the surface.
 When a profile of a line control is specified, the tolerance zone is
two uniform lines ( 2-D tolerance zone). It applies for full length
of the surface.

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Profile Controls
Profile Tolerance Zone :
 When using profile controls (surface or line), four categories
of tolerance zone are permissible:
1) Bilateral tolerance zone with equal distribution
2) Bilateral tolerance zone with unequal distribution
3) Unilateral tolerance zone (outside)
4) Unilateral tolerance zone (inside)

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Profile Controls
Three ways to extend the coverage of profile control:
 A note associated with the profile control
 The between symbol
 The all around symbol

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Profile Controls
Three advantages of profile tolerancing when compared
to Coordinate tolerancing:
 Provides clear definition of the tolerance zone
 Communicates the datums and datum sequence
 Eliminates accumulation of tolerances

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Profile Controls
Profile of a surface application:
 Is a geometric tolerance that limits the amount of error a surface can
have relative to its true profile. Common application for profile of a
surface controls include controlling – either independently or in
combination – the size, location, orientation and form of – Planar,
curved or irregular surfaces, polygon, cylinders, surfaces of
revolution or cones, coplanar surfaces

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Profile Controls
Profile of a surface example:

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Profile Controls
Profile of a surface example:

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Profile Controls
Profile of a line application:
 The basic concepts of profile a surface and profile of a line are
similar. The primary diff is the tolerance zone. For profile of a
surface, 3 Dimensional & For profile of line, 2 Dimensional.
 Profile of a line control is a geometric tolerance that limits the
amount of error of line elements relative to their true profile.

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Profile Controls
Profile of a line example:

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Profile Controls
Legal specification test for profile of a surface:
 The true profile must be defined with basic dimensions or be a planer
surface (or co-planer surfaces)
 No modifiers may be displayed in the tolerance portion of the feature control
frame.
 If the true profile is located with toleranced dimensions, the profile tolerance
must be a refinement of the tolerance value of the dimensions.

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Section: 11 Tolerance Stacks

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Tolerance Stacks
Contents:
 Definition & importance of Tolerance Stack
 Tolerance Stacks using Positional Tolerance at RFS
 Tolerance Stacks using Runout
 Group Work

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Tolerance Stacks
Definition & Importance of Tolerance Stack:
 Tolerance Stack is a calculation to find an extreme max or min distance on a
part.
 When calculating the extreme max or min, all of the part tolerances (including
applicable geometric tolerancing) must be included.
 This is normally done before freezing the design (as part of Design review) to
ensure that the part specification is met even after the accumulated effect due to
tolerances. Few issues faced by some companies due to non-consideration of
accumulated effect on the part like Hole Puncture (since less wall thickness in
extreme conditions), Total length not matching when individual lengths are as per
the tolerance specified, etc.)

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Tolerance Stacks
Tolerance Stacks using positional Tolerance at RFS – Example:

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Tolerance Stacks
Tolerance Stacks using positional Tolerance at RFS – Example:

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Tolerance Stacks
Tolerance Stacks using Runout – Example:

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Tolerance Stacks
Tolerance Stacks using Runout – Example:

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Group Work - 5

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Group Work – 5 (1hr Max)

Time: 30 min (Group activity)
Time: 30 min (Max) for Group
Presentation & clarification by
Trainer

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Group Work - 5

Distance Maximum Minimum

A
B
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Group Work – 1 Key

Letter FOS Non - FOS
A Yes
B Yes
C Yes
D Yes
E Yes
F Yes
G Yes
H Yes
I Yes
J Yes
K Yes

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Group Work – 2 Key

Letter FOS Non - FOS Does Not Apply
A Yes
B 70.5 69.5
C Yes
D Yes
E Yes
F Yes
G Yes
H 3.8 4.2
I Yes
J Yes
K 52.5 51.5

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Group Work – 3 Key

Dia WCB Max Max St. of Max St. of Rule – 1
Circularity axis error line error (Y / N)

9.8 0.8 0.8 0.8 Y

A

14.9 0.2 0.9 0.9 N

B

10.4 0.08 0.08 0.08 Y (1.2)

C

20.7 0.1 0.3 0.3 N

D

5.8 0.2 0.5 0.5

E N

18.6 0.04 0.4 0.4

F Y

Note: All Values are in diametrical basis (mm)

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Group Work – 4 Key

FOS Non FCF Rule 1 WCB FCF BT
Letter FOS (Y / N) Applied
A -- -- Yes -- -- Feature NA
B Yes -- -- Yes 63 -- --
C -- -- Yes -- -- Feature NA
D -- -- Yes -- -- Feature NA
E Yes -- -- Yes 4.0 -- --
F -- -- Yes -- -- FOS 0.4
G -- Yes -- -- -- -- --
H -- -- Yes -- -- Feature NA
I Yes -- -- No 37.0 -- --
J -- -- Yes -- -- FOS 0.6
K Yes -- -- Yes 29.1 -- --
L -- -- Yes -- -- FOS 1.0

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Group Work – 5 Key

Letter MAX MIN

A 2.75 1.25

B 2.60 1.50

C 3.10 1.10

D 1.10 0.85

E 2.15 1.05

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Thank You

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