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Geometrical
Dimensioning and
Tolerancing for
Mechanical Design
P. MALLINATHAN
ASSISTANT MANAGER TRAINING GTTI,CBE

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Dimension basics
There are two types of dimension:
1. Toleranced
2. Basic
The geometric tolerance applies to the
feature, not to the basic dimension.
Dimensions that are toleranced may be
toleranced on the field of the drawing, in a
general note or a supplemental block of the
drawing format. Basic dimensions are
toleranced indirectly with geometric tolerances

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What is GD&T ?
Geometric dimensioning and Tolerancing is:
1. A symbolic Language
2. Is a design tool
3. Communicate design objective


GD&T is a means of dimensioning & tolerancing a
drawing which considers the function of the part
and how this part functions with related parts.

This allows a drawing to contain a more defined
feature more accurately, without increasing
tolerances
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Why GD&T
GD&T has increased in practice in last 15 years
because of ISO 9000.
ISO 9000 requires not only that something be
required, but how it is to be controlled. For example,
how round does a round feature have to be?
Some international standards are:
1. ISO 1101-2004 ( Geometric Product Specifications-
GPS official name but it is also known as GD&T,
2. ASME Y14.5M- 1994, ASME Y14.41-2003
Dimensioning and Tolerancing)
3. DIN ISO 1101 (1985-03)
4. CAN/CSA B78.2-M91(Dimensioning and
Tolerancing of technical drawings)


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How it is different from coordinate
Tolerancing


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How it is different from coordinate
tolerancing


The tolerated inclined surface must lie between two parallel planes,
inclined to the datum axis A and spaced apart a distance 0f 0.4mm.
The geometrically ideal angle must be 30.
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Position Tolerance GD&T Way
The actual hole position centre must lie in
a circle of diameter of 0.2mm, whose
centre agrees with the theoretically exact
point.

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Coordinate Tolerancing
Analyzed
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Coordinate Tolerancing creates
rectangular tolerance zone
0.1
0.1
Dimensions
create squre
tolerences
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Rectangular tolerance zone


0.1
Dimensions
create squre
tolerences
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Coordinate Tolerancing is not logical. It
gives more tolerance diagonally than flats


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Advantages of GD & T
1. The cylindrical tolerance zone-provides
uniform distance
2. The maximum material condition-
Provides bonus tolerance
3. Datum specified in order of preference-
Primary, secondary, tertiary and so on
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GD&T creates cylindrical tolerance zone


2
0
.
0
0
20.00
2
8
.
6
4
0286 . 0 02 . 0 02 . 0
2 2
Tolerance
Advantage No1 : A cylindrical tolerance zone provides a uniform distance
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57% more tolerance


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What is MMC?
The condition in which a feature of
size contains the maximum amount of
material with the stated limits of size, -
fore example, minimum hole diameter and
maximum shaft diameter.

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The Maximum Material Condition -
MMC


Advantage No2 : MMC Increases available Tolerance
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Advantages of Tolerance specified
at MMC


As the hole diameter increases the location tolerance is also
increased. For Example:
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Advantage No3 : Datum can be specified in order of preference


Datum specification
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INDIVIDUAL (No
Datum
Reference)
INDIVIDUAL or
RELATED FEATURES
RELATED
FEATURES
(Datum
Reference
Required)
Basic Symbols for Geometric Characteristics
TYPE OF
FEATURE
TYPE OF
TOLERANCE
CHARACTERISTIC SYMBOL
SYMMETRY
FLATNESS
STRAIGHTNESS
CIRCULARITY
CYLINDRICITY
LINE PROFILE
SURFACE PROFILE
PERPENDICULARITY
ANGULARITY
PARALLELISM
CIRCULAR RUNOUT
TOTAL RUNOUT
CONCENTRICITY
POSITION
FORM
PROFILE
ORIENTATION
RUNOUT
LOCATION
14 characteristics that may be controlled
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Why use GD&T
Manufacturers have been dimensioning and tolerancing for
decades using engineering drawings (blueprints or CAD files) to
communicate sizes, locations, angles, and shapes from designer to
manufacturer to inspector. However, there has been lot of problems
between the sender and receiver. Symbols and notes are
interpreted differently by product design, manufacturing, and quality,
who typically approach the engineering drawing with different levels
of understanding. Design, manufacturing, and quality typically hold
different assumptions about intended product function,
manufacturing processes, and inspection techniques, which leads to
waste in the form of inconsistent interpretation of dimensions and
tolerances. The results are delayed product introductions, sub-
standard quality, customer dissatisfaction, and increased costs
throughout the life of the product, coupled with frequent frustration,
arguing, and finger-pointing. The symbolic short-hand, rules, and
concepts of GD&T help reduce waste throughout the product
development process.
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Why use GD&T
When GD&T is used, the geometric tolerances apply to
the features - not the dimensions. Therefore when
BASIC dimensions are used with geometric tolerances,
several different dimensioning schemes may be used
without changing the meaning of the drawing. The first
drawing below is an example of baseline dimensioning.
The other two illustrate chain dimensioning. Since the
position tolerance is related to datums A, B and C, all
three drawings have the same meaning even though the
dimensioning is different. This would not be true if the
dimensions locating the holes were toleranced rather
than BASIC. Because the meaning of these drawings is
the same, the designer should consider the needs of
those who will read the print when placing dimensions.
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Imagine these dimension were toleranced rather
than BASIC
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Disadvantages of Coordinate
Tolerancing
1. The coordinate drawing shows two ways in which that
dimensioning is inadequate for defining hole locations. First,
coordinate dimensioning uses square tolerance zones which
allow more tolerance for hole centers diagonally than vertically or
horizontally(Tolerance is not uniform). A more logical and
functional approach is to allow the same tolerance for the hole
center in all directions, creating a round tolerance zone
(Tolerance is uniform).
2. Secondly coordinate dimensioning requires the tolerance zone for
hole location to remain fixed in size, regardless of hole size. When
part function is considered more logically, however, it is clear that
the hole location tolerance zone is most critical when the hole size
is smallest. When the hole size is larger, its location tolerance can
be correspondingly larger without affecting part function. Square
tolerance zones and fixed-size location tolerance zones cause
thousands of functional parts to be needlessly scrapped, whereas
geometric tolerancing allows them to be used
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GD&T vs Coordinate Dimensioning
3. Can be interpreted differently. For example consider
Counterbore location. The geometric tolerancing
version specifies counterbore diameter, depth, and
location. The coordinate version specifies only bore
diameter and depth, allowing the user to choose
between two conflicting location interpretations: Follow
the location of the small diameter or locate by the
toleranced dimension for both diameters Both are
logical interpretations, but only one is intended by the
designer. The geometric tolerancing drawing
eliminates this assumption by including a position,
symbol under the counterbore specifying that its
location is relative to the small diameter.

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GD&T vs Coordinate Dimensioning
4. Lack of maximum material concept
5. Lack of specified datums preferences.Since
coordinate dimensioning makes no provision
for datums and sequences, an additional note
is required to make that drawing communicate
the information in the geometric tolerancing
version: "For part inspection, mount the part in
a set of three mutually perpendicular planes.
Surface A contacts one plane first, surface B
contacts the planes second, and surface C,
third."


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GD&T vs Coordinate Dimensioning
6. Manufacturing does not use tolerance,
they place holes exactly as the
dimension dictates. Inspection process
actually determines the location

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WHY IS GD&T EVEN MORE IMPORTANT?
Saves money
For example, if large number of parts are being
made GD&T can reduce or eliminate inspection of
some features.
Provides bonus tolerance
Ensures design, dimension, and tolerance
requirements as they relate to the actual function
Ensures interchangeability of mating parts at the
assembly
Provides uniformity
It is a universal understanding of the symbols instead
of words
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WHEN TO USE GD&T?
When part features are critical to a function or
interchangeability
When functional gaging is desirable
When datum references are desirable to insure
consistency between design
When standard interpretation or tolerance is not
already implied
When it allows a better choice of machining
processes to be made for production of a part

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TERMINOLOGY

Tolerance: Difference between MMC and
LMC limits of a single dimension.
Allowance: Difference between the MMC
of two mating parts. (Minimum clearance
and maximum interference)
Basic Dimension: Nominal dimension
from which tolerances are derived.
Envelop Principle: Defines the size and
form relationships between mating parts.

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LIMITS OF SIZE


THIS MEAN?
WHAT DOES
SIZE DIMENSION
2.007
2.003
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LIMITS OF SIZE
A variation in form is allowed between the least material condition (LMC) and
the maximum material condition (MMC). Envelop Principle defines the
size and form relationships between mating parts.

SIZE DIMENSION
MMC
LMC
ENVELOPE OF SIZE
(2.003)
(2.007)
ENVELOPE PRINCIPLE
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LIMITS OF SIZE


ENVELOPE PRINCIPLE
LMC
CLEARANCE
MMC
ALLOWANCE
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LIMITS OF SIZE
No portion of the feature may be outside a
perfect form barrier at maximum material
condition (MMC).
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Other Factors
I.e., Parallel Line Tolerance Zones


PARALLEL PLANES
PARALLEL PLANES PARALLEL PLANES CYLINDER ZONE
GEOMETRIC DIMENSIONING TOLERANCE ZONES
PARALLEL LINES PARALLEL LINES PARALLEL LINES
PARALLEL PLANES PARALLEL PLANES
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INDIVIDUAL (No
Datum
Reference)
INDIVIDUAL or
RELATED FEATURES
RELATED
FEATURES
(Datum
Reference
Required)
Basic Symbols Revisited
TYPE OF
FEATURE
TYPE OF
TOLERANCE
CHARACTERISTIC SYMBOL
SYMMETRY
FLATNESS
STRAIGHTNESS
CIRCULARITY
CYLINDRICITY
LINE PROFILE
SURFACE PROFILE
PERPENDICULARITY
ANGULARITY
PARALLELISM
CIRCULAR RUNOUT
TOTAL RUNOUT
CONCENTRICITY
POSITION
FORM
PROFILE
ORIENTATION
RUNOUT
LOCATION
14 characteristics that may be controlled
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How to remember the 14 Geometric
symbols?
FOPRL:2D-3D-2D-3D PAP LS CT PSC
What is FOPRL?: 2D-3D-2D-3D PAP Less Character Test at Public
Selection Commission

There are 5 kinds of geometric tolerances. It can be easily
remembered by the acronym FOPRL which stands for:
1. Form
2. Orientation
3. Profile
4. Run out
5. Location

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1.Form controls
Form controls control the acceptable
variance in the shape of the feature.
There are 4 kinds of form controls which can
be easily remembered as by saying 2D-
3D-2D-3D
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Form
1.Straightness
A Geometry which is 2 Dimensional and
linear is called a straight line. The control
of straight line is called Straightness.

The symbol used to represent a straight line
is ___.

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Form
2.Flatness
A Geometry which is 3 Dimensional and
linear is called a flat plane. The control of
a flat plane is called Flatness.

So the symbol used to represent a flat plane
is

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Form
3.Circularity
A Geometry which is 2 Dimensional and
rotary in nature is called a circle. The
control of circle is called Circularity.

So the symbol used to represent Circularity

is a
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Form
4.Cylindricity
A Geometry which is 3 Dimensional and
rotary in nature can be a cylinder. The
control of the cylinder is called Cylindricity.

So the symbol used to represent Cylindricity
is

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Examples


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Tolerance of Form - Straightness


19.89
19.76
0.03
0.03 Tolerance Zone
What it means -
This cylinder must be straight
within 0.03 mm.
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Concentricity Tolerance Note


XX
A
YY
.007 A
This cylinder (the right cylinder) must be concentric
within .007 with the Datum A (the left cylinder)
as measured on the diameter
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Orientation Control
Orientation control controls the acceptable
difference in the direction of the feature
There are 3 kinds of orientation controls
(acronym-PAP) namely:
1. Parallelism
2. Angularity
3. Perpendicularity

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Orientation Control
Parallelism

Orientation required at zero degree
from the reference is known as
Parallelism.
The symbol used to represent parallelism is
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Orientation Control
Angularity
Orientation required at any arbitrary angle
is known as Angularity
The symbol used to represent Angularity
Is
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Orientation Control
Perpendicularity
Orientation required at right angle to the
reference is known as perpendicularity.
The symbol used to represent
Perpendicularity is
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Profile controls
Profile controls control the acceptable
differences in the profile of a feature.
There are 2 types of profile controls:
1. Line
2. Surface

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Profile controls
Line
When 2 Dimensional profile control the
shape it is known as line profile or profile
of a line.
The line can be of any shape or any
number of lines, arcs or spines.
The symbol used to represent is
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Profile controls
Surface
When 3 Dimensional profile control the
shape it is known as surface profile or
profile of a surface.
The line can be of any shape or any
number of planes, arcs or surfaces.
The symbol used to represent is
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Run out controls
Run out controls control the acceptable
differences in a revolved feature.
There are two kinds of run out control:
1. Circular run out
2. Total run out
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Run out controls
Circular run out
We call the 2 Dimensional run out
control as Circular run out.
The symbol used to represent circular
run out is
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Run out controls
Total run out
We call the 3 Dimensional run out
control as Total run out.
The symbol used to represent Total
run out is
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Location control
The last kind of Geometric control is the
location control.
They control the acceptable differences in
the location of the feature. There are
three kinds of location control:
1. Position
2. Symmetry
3. Concentricity
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Location control
Position
A position tolerance is the total
permissible variation in the location of a
feature about its exact true position.
The symbol used to represent position is
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Location control
Symmetry
The center plane of the feature must fit in
the space between two parallel planes.
The symbol used to represent two thing to
should be symmetric is
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Location control
Concentricity
Concentricity Tolerance controls When two
features should have the same centre
axis.
The symbol used to represent concentricity
is
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Feature of size
Feature:Any distinctive portion of a part that
might be dimensioned is known as feature.
ActualSize: This is what you measure on a
part
Limit of size: The specified minimum and
maximum sizes.
Nominal size: The designation used for the
pupose of general identification

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Feature control frame


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Modifiers or supplementary
symbols

Geometric tolerances for feature of size
can be modified according to the size of
the feature. They are called modifiers.
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Supplementary symbols
for Geometric Characteristics


At maximum material condition
At Least material condition
Projected tolerance zone
Regardless of Feature size
Basic Dimension
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Supplementary symbols
for Geometric Characteristics


Datum Feature

Datum Target

Tangent Plane
Diameter
Spherical Diameter s
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Supplementary symbols
for Geometric Characteristics


Radius

R
Spherical Radius

SR
Reference ( )
Arc length
Free State variations

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Supplementary symbols described
Maximum Material Condition (MMC): When a feature or
part is at the limit of size which results in its containing
the maximum amount of material, it is said to be at
MMC. Thus it is the maximum limit of size for an external
feature, such as shaft, or the minimum limit of size for an
internal feature, such as a hole.
Least Material Condition (LMC): This term refers to that
size of feature that results in the part containing the
minimum amount of material. This is the minimum limit of
size for an external feature such as a shaft, or the
maximum limit of size for an internal feature such as a
hole.

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Supplementary symbols cont.
Regardless of feature size (RFS): This term
indicates that a geometric tolerance applies to
any size of a feature that lies with in its size.
Projected tolerance zone: This symbol applies to
hole in which a pin, stud, screw etc is to be
inserted. It controls the perpendicularity of the
hole to the extend of the projection from the hole
as it relates to the mating part clearance. The
projected tolerance zone extends to the
functional length of the pin above the surface of
the part. (Theoretically exact dimension in ISO)
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Supplementary symbols cont.
Tangent plane: A plane contacting the high points
of the surface.
Free state variations: It is a term used to describe
the distortion of the part when the applied force
is removed.
Basic Dimension : Used to describe the exact size,
profile, orientation or location of a feature. A
basic dimension is always associated with a
feature control frame or datum target.
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Supplementary symbols cont.
Reference Dimension : A dimension
usually without tolerance, used for
information purposes only. It does not
govern production or inspection
operations. (Auxiliary dimension in ISO)
Datum Target: It is a specified point, line, or
area on a part that is used to establish the
Datum Reference Plane for manufacturing
and inspection operations.
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Feature Control Frame


Reads as: The position of the feature must be within a .003 diametrical
tolerance zone at maximum material condition relative to datums A, B, and C.
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Application Of Feature Control
Frame


.007 M B
Geometric
Characteristic
Symbol
Tolerance
Material condition
Datum
Reference
B
.007
This feature must be parallel to Datum B within .007 at MMC (largest
cylinder) as measured on the diameter
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Feature Control Frame


Uses feature control frames to
indicate tolerance





Reads as: The position of the
feature must be within a .003
diametrical tolerance zone at
maximum material condition
relative to datums A at
maximum material condition
and B.
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Some sample drawings
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Notes on Drawing
GD&T has greatly reduced notes on
drawing but still you need some notes.
The following is a table of the notes found
in the standard.
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Purpose of Note Sample Note
For parts that are plated or coated,
it is required that a note appears
on the drawing stating when the
dimensional limits apply.
Examples: DIMENSIONAL LIMITS
APPLY AFTER PLATING
DIMENSIONAL LIMITS APPLY
BEFORE PLATING
To override Rule #1 PERFECT FORM AT MMC NOT
REQD
To establish a boundary of perfect
form at MMC to control the
relationship between features.
PERFECT ORIENTATION (or COAXIALITY
or LOCATION OF SYMMETRICAL
FEATURES) AT MMC REQUIRED FOR
RELATED FEATURES
To designate the specific feature of
a thread, gear, spline, etc. which a
geometric tolerance applies
MAJOR DIA
PITCH DIA
MINOR DIA
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Purpose of Note Sample Note
Sample note that must appear on a
drawing when the symbol is applied.
FEATURES IDENTIFIED AS
STATISTICALLY TOLERANCED
SHALL BE PRODUCED WITH
STATISTICAL PROCESS
CONTROLS, (OR TO THE MORE
RESTRICTIVE ARITHEMETIC
LIMITS)
When it is necessary to relate linear
and angular dimensions to a datum
reference framework. This is not a
substitute for datum references in a
feature control frame.
UNLESS OTHERWISE SPECIFIED,
DIMENSIONS ARE RELATED TO
DATUM A (PRIMARY), DATUM B
(SECONDARY), AND DATUM C
(TERTIARY)
To override simultaneous
requirements.
SEP REQT
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Purpose of Note Sample Note
To override a separate requirements
note or to invoke simultaneous
requirements for the lower segment of
multiple composite feature control
frames.
SIM REQT
To avoid having to apply the basic
dimension symbol to each basic
dimension.
DIMENSIONS LOCATING TRUE
POSITION ARE BASIC
To indicate that a feature control frame
applies to multiple holes shown on a
common axis.
TWO COAXIAL HOLES
Placed beneath a feature control
frame to invoke the Boundary concept.
BOUNDARY
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Purpose of Note Sample Note
To avoid having to apply the basic
dimension symbol to each basic
dimension.
UNTOLERANCED DIMENSIONS ARE
BASIC.
Placed below a feature control frame
to indicate that the profile of a surface
control applies to the entire part. .
ALL OVER
To control only an individual line
element of a surface.
EACH ELEMENT or EACH RADIAL
ELEMENT
To specify where a tolerance
applies. This permits closer control
of a feature at one surface.
AT SURF D
Used on repetitive patterns to reduce
the number of different datums
identified. .
INDIVIDUALLY
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The key Message
Use GD&T to effectively communicate
product specifications to ensure the
part drawn, is the part made.

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