A nominal specification was made up of several 2D projected geometrical drawings. With the advent of 3D CAD-CAM, the specification becomes a "digital result" the difference between the result and the nominal specification is a major source of conflict.
A nominal specification was made up of several 2D projected geometrical drawings. With the advent of 3D CAD-CAM, the specification becomes a "digital result" the difference between the result and the nominal specification is a major source of conflict.
A nominal specification was made up of several 2D projected geometrical drawings. With the advent of 3D CAD-CAM, the specification becomes a "digital result" the difference between the result and the nominal specification is a major source of conflict.
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 F o r m P r o f i l e O r i e n t a t i o n L o c a t i o n R u n o u t 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 e g e n d 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 e g e n 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 e g e n 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 e n d 20 19 ORIENTATION ORIENTATION ORIENTATION Parallelism Perpendicularity Perpendicularity Angularity Toleranced Feature Datum feature Datum Tolerance Zone L e g e n d 22 21 LOCATION LOCATION LOCATION Concentricity Symmetry Position Toleranced Feature Datum feature Datum Tolerance Zone L e g e 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 e g e 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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Geometrical Dimensioning and Tolerancing for Design, Manufacturing and Inspection: A Handbook for Geometrical Product Specification Using ISO and ASME Standards