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Since the 80s, with the introduction of CAD-CAM

software, the need to clearly understand nominal


specifications has been largely solved. Indeed, until this
date, a nominal specification was made up of several 2D
projected geometrical drawings whose consistency was
uncertain. With the advent of 3D CAD-CAM, the
specification becomes a digital result whose consistency is
mathematically certified by the software! This has been a
decisive benefit that explains the worldwide success of this
technology. Although ambiguity of the nominal specification
has all but disappeared, the technical difficulties and
business conflicts are now more apparent due to the
ambiguities of the differences between the nominal
specification and the result. ASME and ISO tolerancing
standards have as a result grown in importance and
tremendously developed through the 80s and 90s.
Nonetheless, they are still topics for research and
development. The tolerance specification language issued
from these standards allows downstream users to define the
admissible limits of the dimensional defects as well as the
shape, orientation and position defects of parts and
assemblies surfaces.
This booklet provides a view on this language,
exemplary both for its clarity and conciseness. It is an
essential tool for the beginner as well as for the experienced
technician.
Professor Emeritus Andr Clment,
CIRP member
2 FOREWORD
FOREWORD
Tolerance standardization on an international scale
for technical objects can be defined with one word: interchan-
geability. Modern times have driven the necessity to share
technological machine features not only because of a failure,
but primarily due to the systematic use of industrial suppliers
to manufacture complex systems.
To get something manufactured, the client has to
first specify their requests. The dimensional description of
the mechanical part to manufacture is identified as the nominal
specification, and the final actual manufactured object is called
the result. The difference between the result and the nominal
specification is a major source of conflict. This difference
needs also to be specified; giving rise to what is called the
tolerance specification, combined with the nominal dimen-
sional specification.
A specification, whatever it may be, must be
comprehensive, consistent and understandable without
interpretation by both the client and supplier.
1 FOREWORD
4 3 3D TOLERANCING IN PRODUCT LIFECYCLE MANAGEMENT
3D TOLERANCING IN PRODUCT LIFECYCLE MANAGEMENT
3D TOLERANCING IN PRODUCT LIFECYCLE MANAGEMENT
Customer
requirements
Maintenance
Functional,
Logical and
Physical
design
Manufacturing
Quality
control
Automotive Aerospace Shipbuilding
Industrial
Equipment
High Tech
Consumer
Goods
LANGUAGE
TOOLS
METHOD
3D Tolerancing is at the core of Product Lifecycle Management from
customer requirements to maintenance.
3D Functional Tolerancing & Annotation is particularly useful in the
following industries.
3D Functional Tolerancing & Annotation 3D FTA
6 5 CONTENTS
GLOSSARY p. 7
DIMENSIONS p. 9
TOLERANCED FEATURE p. 10
DATUM AND DATUM FEATURE p. 11
TOLERANCE ZONE p. 14
GEOMETRIC TOLERANCES p. 15
Form p. 15
Profile p. 17
Orientation p. 19
Location p. 21
Runout p. 25
MAXIMUM AND LEAST MATERIAL CONDITION p. 27
TEST YOUR SKILLS! p. 38
Type Characteristic Example Page
Straightness
15
Circularity
Flatness
Cylindricity
Profile of a line
17
Profile of a surface
Parallelism
19 Perpendicularity
Angularity
Symmetry
21 Concentricity
Position
Circular Runout
25
Total Runout
GEOMETRIC TOLERANCES
GEOMETRIC TOLERANCES
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CONTENTS
8 7
TOLERANCE ZONE P. 14
A portion of space defined by perfect geometry in which the
toleranced feature has to be included to comply with the geo-
metric specification.
MAXIMUM MATERIAL CONDITION (MMC)
LEAST MATERIAL CONDITION (LMC) P. 27-32
The condition in which a feature of size contains the maximum
(respectively least) amount of material within the stated limits
of size; for example, minimum (respectively maximum) hole
diameter, maximum (respectively minimum) shaft diameter.
VIRTUAL CONDITION P. 28, 29
The envelope or boundary that corresponds to the collective
effects of a size features specified MMC or LMC material
condition and the geometric tolerance for that material condition.
GLOSSARY
GLOSSARY
TOLERANCED FEATURE P. 10
An actual feature or a derived feature from an actual feature
of a part which supports a geometric specification (size, form,
profile, orientation, location, runout and roughness).
DATUM FEATURE P. 11, 12
An actual feature of a part (physical plane, physical hole,
physical slot, etc ) which is used to establish a datum.
DATUM P. 11-13
A theoretically perfect geometric feature (exact point, axis, or
plane) derived from the true geometric counterpart of a
datum feature. Datums are used as references from which
geometric tolerances (position, profile, orientation, runout)
are established.
DATUM TARGET P. 11, 12
Apoint, a line or an area of an actual feature of the part which
is used to establish a datum.
GLOSSARY
M L
The following definitions are based on ASME Y14.41-2003.
10 9
When the note n surfaces is mentioned, several surfaces
are considered as a single interrupted or noncontinuous surface.
The control is the same applied to a single plane surface.
An actual feature or a derived feature from an actual feature
of a part which supports a geometric specification (size, form,
profile, orientation, location, runout and roughness).
TOLERANCED FEATURES
DIMENSIONS
DIMENSIONS
TOLERANCED FEATURE
COPLANAR SURFACES
Surface selection
Axis selection
Median plane
selection
Unless Perfect Form at MMC not required is mentioned, the limits
of size rule is applied. When only a size dimension is given:
2 the size dimension at any cross section shall be within the
size tolerance,
2 the surface(s) shall not extend beyond the perfect form
defined by the MMC size.
DIMENSIONS
49 ai 50
ANGLE DIMENSIONS
Toleranced Feature
34.7 di 35.3
L
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12 11 DATUM DATUM
DATUM
Datum Association Criteria
Point
Line
Plane
Plane:
Complex
surface
A theoretically perfect geometric feature (exact point, axis, or plane)
derived from the true geometric counterpart of a datum feature.
Datums are used as references from which geometric tolerances
(position, profile, orientation, runout) are established.
Single Datum
Multiple Datum
Datum Reference Frame
Datum Target
The datum triangle is placed on a feature
surface or on an extension line of the feature
outline. When the Datum Feature is the line
or surface itself, the triangle must be separated
from the dimension line.
The datum triangle is placed on the extension of a dimension arrow
when the datum feature is the axis or the median plane. The datum
triangle can replace a dimension arrow if there is not enough room.
Center of
the smallest
circumscribed
sphere
Center of
the largest
inscribed
sphere
Axis of
the largest
inscribed
cylinder
Axis of
the smallest
circumscribed
cylinder
Tangent plane closest to the
actual surface / Least squares
plane / etc...
Median plane of the
largest circumscribed
parallel planes / etc...
Datum feature Datum
L
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d
14 13 DATUM TOLERANCE ZONE
TOLERANCE ZONE
As seen in this example, the order in which the datums are placed
in the tolerance frame is very important. On a functional perspective,
these two ways of annotating are totally different.
A portion of space defined by perfect geometry in which the toleranced
feature has to be included to comply with the geometric specification.
A geometric tolerance is expressed on the model by:
2 an arrow indicating the toleranced feature,
2 a tolerance frame containing the tolerancing characteristics.
Here are some tolerance zones:
Some tolerance zones are not fixed into space; they have the possibility
to move along different directions or rotate around several axes (DOF:
Degree Of Freedom).
This compass indicates which move is possible for each tolerance zone:
DATUM
CASE OF A SPECIFIED DATUM SYSTEM
A B B A DIFFERENCE BETWEEN AND
Datum plane A
Actual surface A
Datum Axis B
Actual
surface B
Free
rotations
Locked
translations
Free
translations
Locked
rotations
16 15 FORM FORM
FORM
Toleranced Feature Tolerance Zone
L
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d
Straightness
Circularity
Flatness
Cylindricity
18 17 PROFILE PROFILE
PROFILE
Profile
of a line
Profile
of a surface
Profile
of a surface
Toleranced Feature Datum feature Datum Tolerance Zone
L
e
g
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n
d
20 19 ORIENTATION ORIENTATION
ORIENTATION
Parallelism
Perpendicularity
Perpendicularity
Angularity
Toleranced Feature Datum feature Datum Tolerance Zone
L
e
g
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n
d
22 21 LOCATION LOCATION
LOCATION
Concentricity
Symmetry
Position
Toleranced Feature Datum feature Datum Tolerance Zone
L
e
g
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n
d
24 23 LOCATION LOCATION
LOCATION
Position
Position:
a composite
tolerance
0.2 A B
0.1 A B
0.2 A B
0.1 A B
x2
x2
Toleranced Feature Datum feature Datum Tolerance Zone
L
e
g
e
n
d
26 25 RUNOUT RUNOUT
RUNOUT
Circular runout
Total runout
AXIAL
Toleranced Feature Datum feature Datum Tolerance Zone
L
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n
d
RADIAL
28 27 MAXIMUM AND LEAST MATERIAL CONDITION
MAXIMUM AND LEAST MATERIAL CONDITION
MAXIMUM AND LEAST MATERIAL CONDITION
CLASSIC TOLERANCING WITHOUT MMC
Maximum and Least Material Condition are powerful tolerancing
tools allowing the user to transcribe easily and rapidly some of the
functional aspects of assembly parts. They are also of great value
during conception, manufacturing and inspection stages.
MMC is used to ensure interchangeability.
This male part is rejected because it exceeds the specifications limits
( L = 19.94 mm and = 0.23 mm ). However, it can still be
assembled with conform female parts and it answers to the factor G 0.
The tolerancing for this function isnt adapted.
Is it possible to respect to the assembly function G 0 without over-
constraining the parts geometry?
It can indeed be done by respecting the virtual condition. The virtual
condition is the perfect geometric feature centered around the assembly
function binding complementary parts which must be put together:
Gmin = (20 + 0.2) (20.5 - 0.3) = 0 mm
Gmax = 20.6 - 19.9 = 0.7 mm
part 1
part 2
In this example, part 1 and part 2 form a rigid joint.
There is a functional condition (Gap) for the assembly: G 0
M L
M
L
0.2
0.23
19.9
19.94
20.0
Tolerancing
area
30 29 MAXIMUM AND LEAST MATERIAL CONDITION
MAXIMUM AND LEAST MATERIAL CONDITION
MAXIMUM AND LEAST MATERIAL CONDITION
The male part is the only one dealt
with in this section; the process is
the same with the female one.
It is possible to go on with this transfer by exclusively putting the tolerance
value on the dimension and to reach tolerance zero with the geometric
tolerance:
20 and 0.2 20 and 0
If the Maximum Material Condition is not dimensionally reached, it is
possible to transfer the margin (difference between the tolerance size
and the actual size) on the geometric specification (and vice versa).
The Maximum Material Condition must not be exceeded.
Virtual Condition: The envelope or boundary that corresponds to the
collective effects of a size features specified MMC or LMC material
condition and the geometric tolerance for that material condition.
M L
L
0.2
0.3
19.9
Tolerancing
area
20.0
Virtual L = Lmin - max
= 20.5 - 0.3
= 20.2
Virtual L = Lmax + max
= 20 + 0.2
= 20.2
L
0.2
0.3
19.9
Tolerancing
area
20.0 20.2
0
-0.1
+0.2
-0.1
TOLERANCING WITH MMC M TOLERANCING WITH MMC AT TOLERANCE ZERO M
32 31 MAXIMUM AND LEAST MATERIAL CONDITION
MAXIMUM AND LEAST MATERIAL CONDITION
MAXIMUM AND LEAST MATERIAL CONDITION
CONCLUSION OF MMC
LEAST MATERIAL CONDITION
The Least Material Condition is also used to facilitate the fabrication
process. It can be used to maintain a critical wall thickness to avoid
ruptures or to guarantee a maximal value to a defect. This exigency
allows greater control of the precision of a mechanical guide
(example: prismatic joint ensured by two complementary components)
ensuring not to exceed the virtual state at least material.
As seen in the diagram above with MMC, the concept of expanding
the range of acceptable components can also be applied for LMC.
M
M
L
L
0.2
0.3
19.9
Tolerancing
area
20.0
L
0.2
0.3
19.9
Tolerancing
area
20.0 20.2
L
0.2
19.9 20.0
L
Tolerancing
area
Decrease cost
34 33 3D FUNCTIONAL TOLERANCING AND ANNOTATION
3D FUNCTIONAL TOLERANCING AND ANNOTATION
3D FUNCTIONAL TOLERANCING AND ANNOTATION
CATIA 3D Functional Tolerancing and Annotation is a new-generation
CATIA product addressing the easy definition and management of
tolerance specifications and annotations of 3D parts and assemblies.
FTA is fully compliant with the ASME Y14.41-2003 standard.
The intuitive interface of CATIA 3D Functional Tolerancing and
Annotation product provides an ideal solution for new CATIA customers
in small and medium size industries, looking to reduce reliance on 2D
drawings and increase the use of 3D as the master definition.
Define in the 3D model all what is used to be defined in a 2D drawing:
2 toleranced dimensions, datums, geometrical tolerances,
2 roughness, partial surfaces,
2 notes, symbols,
Enhance the quality of the product definition by removing
inconsistencies between 3D definition and 2D Drawing definition.
Validate the Dimensioning and Tolerancing specifications:
2 assist the user in the correct definition of Dimensioning &
Tolerancing specifications (Tolerancing Advisor capabilities).
2 check the validity (according to ASME or ISO standards rules) of
Dimensioning &Tolerancing specifications:
for all the geometric modifications,
for all the tolerancing scheme modifications.
Enhance the quality of the product definition by checking
full compliance to ASME or ISO standards.
FTA
36 35 DELMIA
3D FTA - CATIA 3D FTA - DELMIA
CATIA
REUSE OF FTA BY DOWNSTREAM APPLICATIONS
METROLOG V5
MACHINING
TOLERANCING
ASSISTANT
DELMIAcan read and re-use FTAinformation in different workbenches
as in:
2 DELMIA Machinining Tolerancing Assistant (MTT): MTT is an
add-on product to DPM Machining Process Planner that will allow
manufacturing process planner to create in-process manufacturing
tolerances on the unique in-process model generated from DPM
Machining. MTT is a tolerance stack-up analysis tool that will enable
planners to analyze the stack-up distribution with respect to the FTA
defined tolerances.
2 Metrologic Inspection: FTA tolerances can also be reused in the
off-line & on-line inspection application developed by DELMIA partners
Metrologic. Metrologic software is native to V5 & reads all FTA defined
tolerances & automatically creates an inspection plan.
Manufacturing,
Assembly Process
Planning
Tolerance Analysis
(Manufacturing
context)
Inspection
Assembly Design
(Functional
Requirements)
Part Design
(Functional
Specifications)
Functional
Tolerance
Analysis
(Design context)
FTA
37 CERTIFICATION
About Virtools
Acquired by Dassault Systmes in mid-2005, Virtools is the leading provider of comprehensive software solutions for building
highly interactive 3D life-like applications. Virtools 3D real-time technologies and solutions are used in a wide variety of
applications such as simulation of product usage, ergonomic testing, creating the shopping experience, training scenarios,
right through to branding, advertising and web marketing applications.
For more information, visit www.virtools.com
About Dassault Systmes
As a world leader in 3D and Product Lifecycle Management (PLM) solutions, Dassault Systmes brings value to more than
100,000 customers in 80 countries. A pioneer in the 3D software market since 1981, Dassault Systmes develops and
markets PLM application software and services that support industrial processes and provide a 3D vision of the entire lifecycle
of products from conception to maintenance. The Dassault Systmes portfolio consists of CATIA for designing the virtual
product - SolidWorks for 3D mechanical design - DELMIA for virtual production - SIMULIA for virtual testing and ENOVIA
for global collaborative lifecycle management, including ENOVIA VPLM, ENOVIA MatrixOne and ENOVIA SmarTeam.
Dassault Systmes is listed on the Nasdaq (DASTY) and Euronext Paris (#13065, DSY.PA) stock exchanges. For more
information, visit http://www.3ds.com
Trademarks
CATIA, DELMIA, ENOVIA, SIMULIA and SolidWorks are registered trademarks of Dassault Systmes or its subsidiaries in
the US and/or other countries.
ASME is the registered trademark of The American Society of Mechanical Engineers.
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