Datum reference frame
Position and shape tolerances
Tolerance analysis
Šimon Kovář
Datum reference frame
Datum reference frames are typically for 3D. A typical
datum reference frame is made up of three planes. For
example, the three planes could be one "face side" and
two "datum edges". These three planes are marked A, B
and C, where A is the face side, B is the first datum edge,
and C is the second datum edge. In this case, the datum
reference frame is A/B/C. A/B/C is shown at the end of
feature control frame to show from where the
measurement is taken.
Design Methodology | 2016
Datum reference frame
The engineer selects A/B/C based on the dimensional
function of the part. Typically, a part is required to fit with
other parts. The functional datums are chosen based on
how the part attaches.
Typically, the functional datums are not used to
manufacture the part. The manufacturing datums are
typically different from the functional datums to save cost,
improve process speed, and repeatability. A tolerance
analysis may be needed in many cases to convert between
the functional datums and the manufacturing datums.
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Datum reference frame
There are typically 6 degrees of freedom that need to be
considered by the engineer before choosing which feature is
A, B,or C. For this example, A is the primary datum, B is the
secondary, and C is the tertiary datum. The primary datum
controls the most degrees of freedom. The tertiary datum
controls the least degrees of freedom. For this example, of a
block of wood, Datum A controls 3 degrees of freedom, B
controls 2 degrees of freedom, and C controls 1 degree of
freedom. 3+2+1 = 6, all 6 degrees of freedom are considered.
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Datum reference frame
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Datum reference frame
B
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Datum reference frame - example
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Datum reference frame
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Datum reference frame
Conversion of Position (Cylindrical) Tolerance Zones to/from Coordinate Tolerance Zones
tolerance zone tolerance zone
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Position and shape tolerance
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Position and shape tolerance
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Position and shape tolerance
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Position and shape tolerance
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Position and shape tolerance
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Position and shape tolerance
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Geometric Characteristic Symbols
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An example of the application of maximum material
requirement to coaxiality is illustrated in the figure below
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An example of the application of minimum
material requirement
The feature control frame indicates that the 0.8 tolerance applies when
the hole is at its least material condition, or at size 13.5. At size 12.5, the
available geometric tolerance would be 0.8 “stated tolerance” + (13.5-
12.5 or 1.0 “bonus” tolerance) = 1.8 mm.
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Geometric Characteristic Symbols
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Tolerance Zone
If the zone is identified as a diameter, the
zone is a cylinder.
If there is no zone description, it is
parallel to the surface or a uniform
boundary in the shape of the desired
form.
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Positional tolerancing of holes
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Positional tolerancing of holes
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Profile tolerance
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Profile tolerance
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Concentricity & Symmetry Tolerances
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Angularity & Perpendicularity
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Parallelism & Straightness
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Tolerance analysis
Is the general term for activities related to the study of accumulated variation in
mechanical parts and assemblies. Its methods may be used on other types of
systems subject to accumulated variation, such as mechanical and electrical
systems. Engineers analyze tolerances for the purpose of evaluating geometric
dimensioning and tolerancing.
The choice of method of calculation of tolerances and limit deviations of
dimensional chain components affects manufacturing accuracy and assembly
interchangeability of components. Therefore, economy of production and
operation depends on it. To solve tolerance relations in dimensional chains,
engineering practice uses three basic methods:
• arithmetic method of calculation WC
• statistical method of calculation RSS
• method of group interchangeability
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Other tolerance analysis are
• Analysis of a dimensional chain deformed as a result of temperature
change.
• Extended statistic analysis of dimensional chain using the "6 Sigma„
method.
• Tolerance analysis of a dimensional chain during selective assembly
including optimization of the number of assembled products.
All solved tasks enable work with standardized tolerance values, both
in designing and in optimization of the dimensional chain.
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Theory
A linear dimensional chain is a set of independent parallel dimensions
which continue each other to create a geometrically closed circuit. They
can be dimensions specifying the mutual position of components on one
part (Fig. 1) or dimensions of several parts in an assembly unit (Fig. 2).
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Theory
A dimensional chain consists of separate partial components (input dimensions) and
ends with a closed component (resulting dimension). Partial components (A, B, C,…) are
dimensions either directly dimensioned in the drawing or following from previous
manufacturing, possibly assembly operations. The closed component (Z) in the given
chain represents the resulting manufacturing or assembly dimension, which is the result
of combining partial dimensions as a scaled manufacturing dimension, possibly assembly
clearance or interference of a component. The size, tolerance and limit deviations of the
resulting dimension depend directly on the size and tolerance of partial dimensions.
Depending on how the change of partial component affects the change of the closed
component, two types of components are distinguished in dimensional chains:
- increasing components - partial components, the increase of which results in an
increase of the closed component
- decreasing components - partial components, the increase of which results in a
decrease of the closed component
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Theory
When solving tolerance relations in dimensional chains, two types of problems
occur:
• Tolerance analysis - direct tasks, control. Using known limit deviations of all partial
components, the limit deviation of the closed component is set. Direct tasks are
nambiguous in calculation and are usually used for checking components and
assembly units manufactured according to the specific drawing.
• Tolerance synthesis - indirect tasks, designing. Using known limit deviations of a
closed component given by the functional demands, limit deviations of partial
components are designed. Indirect tasks are solved when designing functional
groups and assemblies.
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Tolerance analysis
Worst-case
Worst-case tolerance analysis is the traditional type of tolerance
calculation. The individual variables are placed at their tolerance limits in
order to make the measurement as large or as small as possible. This
model predicts the maximum expected variation of the measurement.
Designing to worst-case tolerance requirements guarantees 100 % of the
parts will assemble and function properly, regardless of the actual
component variation. The major drawback is that the worst-case model
often requires very tight individual component tolerances. The obvious
result is expensive manufacturing and inspection processes and/or high
scrap rates. Worst-case tolerancing is often required by the customer for
critical mechanical interfaces and spare part replacement interfaces.
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Worst-case – base example
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Tolerance analysis
Statistical variation RSS (Root Sum Squares)
The statistical variation analysis model takes advantage of the principles
of statistics to relax the component tolerances without sacrificing quality.
Each component’s variation is modeled as a statistical distribution and
these distributions are summed to predict the distribution of the
assembly measurement. Thus, statistical variation analysis predicts a
distribution that describes the assembly variation, not the extreme
values of that variation. This analysis model provides increased design
flexibility by allowing the designer to design to any quality level, not just
100 percent.
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Tolerance analysis
RSS (Root Sum Squares) method
This method of calculation is a traditional as well as the most
widespread method of statistical calculation of dimensional chains. The
RSS method is based on the assumption that individual partial
components are manufactured with the level of process capability
(quality) 3.
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6 Sigma method
(selective assembly)
In general engineering, the manufacturing process was traditionally considered satisfactorily efficient
on level 3. That means an estimated 2700 rejected products per one million produced. Although
such portion of off-size products seems very good at first sight, it is considered ever more and more
insufficient in some spheres of production. Besides, it is almost impossible to keep the mean value of
the process characteristic curve exactly in the middle of the tolerance field in the long term.
In case of large production volumes, the
mean value of the process characteristic
shifts in the course of time due to the
influence of various factors (erroneous
set-up, wear of tools and jigs, temperature
changes, etc.). A shift of 1.5 from the
ideal value is typical. In case of
traditionally approached processes with
3 level of capability, that represents an
increase of the off-size product ratio to
approx. 67000 per one million produced.
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Group interchangeability method
(selective assembly)
The selective assembly method is used in mass and large-lot
production of precise products which do not require working
interchangeability of components inside the product. The assembly of
the product is preceded by sorting of individual components into
tolerance subsets. Manufacturing dimensions of components may be
prescribed with a larger tolerance. The narrowed resulting dimensional
tolerance is achieved by the functional matching (combination) of
sorted subsets.
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Group interchangeability method
(selective assembly)
The selective assembly method is a very effective method of solving
dimensional chains, enabling a substantial increase in
manufacturing tolerances of partial components and thus a
significant reduction in manufacturing costs. On the other hand,
application of this method places increased demands on product
assembly. Operating costs will also increase, as it is usually
necessary to replace the whole assembled component in case of
wear or damage of a partial component.
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