QuickTime and a TIFF (LZW) decompressor are needed to see this picture.

Geometric Dimensioning and Tolerancing for Mechanical Design

Instructors' Guide

Contents
1. 2. 3. 4. 5. Course Calendar Lecture Topics Study Guide and Problem Answers Midterm and Final Exam Midterm and Final Exam answers

Geometric Dimensioning and Tolerancing for Mechanical Design

2

Instructors Guide

Course Calendar
Week 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Week 1 2 3 4 5 6 7 8 9 10 Date Date 1st Weekly Meeting
Admin. & Overview Lecture 3 Lecture 6 Lecture 9 Lecture 12 Lecture 15 Ch. 3 Ch. 4 Ch. 5 Ch. 5 Ch. 6

2nd Weekly Meeting

Lecture 1 Lecture 4 Lecture 7 Lecture 10 Lecture 13 Lecture 16 Lecture 17 Lecture 20 Lecture 23 Lecture 26 Lecture 27 Lecture 30 Lecture 33 Lecture 36 Ch. 1 Ch. 3 Ch. 4 Ch. 5 Ch. 5 Ch. 6 Ch. 7 Ch. 7 Ch. 8 Ch. 9 Ch. 10 Ch. 11 Ch. 13 Ch. 14

3rd Weekly Meeting

Lecture 2 Lecture 5 Lecture 8 Lecture 11 Lecture 14 Ch. 2 Ch. 3 Ch. 4 Ch. 5 Ch. 6

First Midterm Exam Lecture 18 Lecture 21 Lecture 24 Ch. 7 Ch. 8 Ch. 8

Midterm Review Lecture 19 Lecture 22 Lecture 25 Ch. 7 Ch. 8 Ch. 9

Second Midterm Exam Lecture 28 Lecture 31 Lecture 34 Lecture 37 Ch. 10 Ch. 12 Ch. 13 Ch. 14

Midterm Review Lecture 29 Lecture 32 Lecture 35 Ch. 11 Ch. 12 Ch. 14

Final Preview

Final Preview

Final Preview

1st Weekly Meeting

Admin. & Overview Lecture 3 Lecture 6 Lecture 9 Ch. 3 Ch. 4 Ch. 6

2nd Weekly Meeting

Lecture 1 Lecture 4 Lecture 7 Lecture 10 Ch. 1 Ch. 3 Ch. 5 Ch. 6

3rd Weekly Meeting

Lecture 2 Lecture 5 Lecture 8 Lecture 11 Lecture 12 Lecture 15 Lecture 18 Lecture 21 Lecture 24 Ch. 3 Ch. 4 Ch. 5 Ch. 6 Ch. 7 Ch. 8 Ch. 8 Ch.11 Ch.12

Midterm Exam Lecture 13 Lecture 16 Lecture 19 Lecture 22 Lecture 25 Ch. 7 Ch. 8 Ch. 9 Ch.11 Ch. 14

Midterm Review Lecture 14 Lecture 17 Lecture 20 Lecture 23 Ch. 7 Ch. 8 Ch.9 Ch.12

Final Preview
3

Final Preview
Instructors Guide

Geometric Dimensioning and Tolerancing for Mechanical Design

Geometric Dimensioning and Tolerancing for Mechanical Design

Lecture Topics
No.
1. Introduction A. B. C. What is Geometric Dimensioning and Tolerancing When should GD&T be used? Advantages of GD&T over coordinate dimensioning and tolerancing 1.The cylindrical tolerance zone 2.The maximum material condition 3.Datums specified in order of precedence

Topics

2. Dimensioning and Tolerancing Fundamentals A.Fundamental drawing rules B.Units of angular measurement C.Types of dimensions D.Specifying linear tolerances E.Specifying angular tolerances F.Interpreting dimensional limits G.Dimensioning and Tolerancing for CAD/CAM database models 3. Symbols, Terms, and Rules A. Geometric characteristic symbol B. Datum feature symbol C. Feature control frame D. Material conditions E. Other symbols used with geometric tolerancing F. Terms G. General rules 1.Rule #1 2.Rule #2 3.Pitch diameter rule 4.Virtual condition rule Datums A. Definition B. Immobilization of a part C. Application of datums D. Datum feature selection E. Datum feature identification
Instructors Guide 4

3 4 5

4. 6

Geometric Dimensioning and Tolerancing for Mechanical Design

8 5. 9

F. G. H. I. J. K. L. M. N.

Inclined datum features Cylindrical datum features Establishing datums Datum features of size Multiple datum features A partial surface as a datum feature Datum targets Datum targets established on a cylindrical part Step and equalizing datums

10

11

12

13 6. 14

Form controls A. Flatness 1. Definition 2. Specifying flatness tolerance 3. Interpretation 4. Unit flatness 5. Inspection B. Straightness 1. Definition 2. Specifying straightness of a surface tolerance 3. Interpretation 4. Inspection 5. Specifying straightness of a median line and median plane 6. Interpretation 7. Inspection C. Circularity 1. Definition 2. Specifying Circularity Tolerance 3. Interpretation 4. Inspection D. Cylindricity 1. Definition 2. Specifying Cylindricity Tolerance 3. Interpretation 4. Inspection E. Free state variation 1. Free state 2. Restrained condition Orientation A. Parallelism 1. Definition 2. Specifying parallelism of a flat surface 3. Interpretation 4. Inspection 5. Specifying parallelism of an axis

Geometric Dimensioning and Tolerancing for Mechanical Design

5

Instructors Guide

B. 15

C. 16

Perpendicularity 1. Definition 2. Specifying perpendicularity of a flat surface 3. Interpretation 4. Tangent plane 5. Inspection 6. Specifying perpendicularity of an axis Angularity 1. Definition 2. Specifying angularity of a flat surface 3. Interpretation 4. Inspection 5. Specifying angularity of an axis

7. 17

18 19 20 8. 21 22 23 24

Position, General A. Specifying the position tolerance B. Interpretation C. Inspection D. Regardless of feature size E. Maximum material condition F. Shift tolerance G. Least material condition H. Boundary conditions I. 0 positional tolerancing at MMC Position, Location A. Floating and fixed fasteners B. Projected tolerance zones C. Multiple patterns of features D. Composite positional tolerancing E. Two single-segment feature control frames F. Nonparallel holes G. Counterbored holes H. Noncircular features at MMC I. Symmetrical features at MMC Position, Coaxiality A. Definition B. Comparison between position, runout, & concentricity C. Specifying coaxiality at MMC D. Composite control of coaxial features E. Tolerancing a plug and socket

9. 25 26

Geometric Dimensioning and Tolerancing for Mechanical Design

6

Instructors Guide

27

28

10. Concentricity & Symmetry A. Concentricity 1. The definition of concentricity 2. Specifying concentricity 3. Interpretation 4. Inspection 5. Applications of concentricity B. Symmetry 1. The definition of symmetry 2. Specifying symmetry 3. Interpretation 4. Inspection 5. Applications of symmetry 11. Runout A. Definition B. Circular runout C. Total runout D. Specifying runout and partial runout E. Multiple datum features F. Face and diameter datums G. Geometric control to refine datum features H. Surface relationship between features I. Inspecting runout 12. Profile A. Definition B. Specifying profile C. The application of datums D. A radius refinement with profile E. Combining profile tolerances with other geometric controls F. Coplanarity G. Profile of a conical feature H. Composite profile 13. Graphic Analysis A. Advantages of graphic analysis B. The accuracy of graphic analysis C. Analysis of a composite geometric tolerance D. Analysis of a pattern of features controlled to a datum size feature 14. A Strategy for Tolerancing Parts A. Size features located to plane surface features B. Size features located to size features C. Size features located to a pattern of features

29

30

31

32

33 34 35 36 37

Geometric Dimensioning and Tolerancing for Mechanical Design

7

Instructors Guide

Chapter 1 Introduction to Geometric Dimensioning and Tolerancing

Chapter Review
Page 8 1. Geometric Dimensioning and Tolerancing is a symbolic language used to specify the

size
and

shape

form

orientation

location

of features on a part.

2. Features toleranced with GD&T reflect the between mating parts.

actual relationship

3. Geometric Dimensioning and Tolerancing was designed to insure the proper assembly of

mating parts

, to improve

quality

, and reduce

cost

4. Geometric tolerancing allows the maximum available the most 5.

tolerance

and, consequently,

economical ASME Y14.5M1994

parts. is the current, authoritative reference document

that specifies the proper application of Geometric Dimensioning and Tolerancing. 6. Plus or minus tolerancing generates a 7.

rectangular

shaped tolerance zone.

GD&T

generates a cylindrical shaped tolerance zone to control an axis.

8. If the distance across a square tolerance zone is .005 or a total of .010, what is the approximate distance across the diagonal?

.007 or .014
Instructors Guide 8

Geometric Dimensioning and Tolerancing for Mechanical Design

9. Bonus tolerance equals the difference between the actual feature size and the

maximum material condition

10. While processing, a rectangular part usually rests against a

datum

reference frame

consisting of three mutually perpendicular planes.

Chapter 2 Dimensioning and Tolerancing Fundamentals

Chapter Review
Page 15 1. Each dimension shall have a

tolerance

except those dimensions

specifically identified as reference, maximum, minimum, or stock. 2. Each feature shall be

fully dimensioned

and

toleranced

so that there is a complete description of the characteristics of each part. 3. 4. Each dimension shall not be subject to more than one The drawing should method of 5. A

interpretation

define

the part without specifying a particular . applies where center lines and lines representing

manufacturing

90 angle

features on a drawing are shown at right angles and no angle is specified. 6.

A basic 90 angle

applies where centerlines of features in a pattern

or surfaces shown at right angles on a drawing are located or defined by basic dimensions and angles are not specified.
Geometric Dimensioning and Tolerancing for Mechanical Design
9 Instructors Guide

7.

All dimensions are to be measured at

68F (20C)

unless otherwise specified.

Measurements made at other temperatures may be adjusted mathematically. 8. 9. All dimensions apply in the All geometric tolerances apply for the

free state condition full depth full width

except for non-rigid parts. , of the feature unless otherwise

full length
specified.

, and

10. Dimensions and tolerances apply only at the specified.

drawing level

where they are

11. Units of linear measurement are typically expressed either in the

inch

system or the

metric

system.

12. Angular units of measurement are specified either in

degrees and decimal parts of a

.

degree

or

degrees, minutes, and seconds

13. What two dimensions are not placed on the field of the drawing?

The 90 angle and a zero distance

14. What are the two types of direct tolerancing methods?

Limit dimensioning and plus and minus dimensioning

15. For decimal inch tolerances, a than one inch. 16. For decimal inch tolerances, a dimension is specified with the same number of decimal places as its

zero

is never placed before the decimal point for values less

tolerance
Geometric Dimensioning and Tolerancing for Mechanical Design
10

17. For decimal inch tolerances, when a unilateral tolerance is specified and either the plus or minus limit is
Instructors Guide

zero, its zero value will have as the other limit and the appropriate

the same number of plus and minus signs

decimal places
.

18. For decimal inch tolerances, where bilateral tolerancing or limit dimensioning and tolerancing is used, both values

have the same number of decimal places

19. Where basic dimensions are used, the basic dimension values are expressed with

the same number of decimal places as the associated tolerances

20. Dimensional limits are used as if the last digit after the decimal point. 21. If CAD/CAM database models are used and they do not include tolerances, then tolerance must be expressed

. followed

an infinite number of zeros

outside of the database to reflect design requirements.

Geometric Dimensioning and Tolerancing for Mechanical Design

11

Instructors Guide

Chapter 3 Symbols, Terms, and Rules

Chapter Review
Page 39 1. 2. 3. 4. The second compartment of the feature control frame is the What type of geometric controls has no datums?

tolerance

compartment.

Form controls Flattness

Which of the location controls is the most common?

What type of geometric controls indicates an angular relationship with specified datums?

Orientation controls
5. What is the name of the symbol that must identify physical features of a part and shall not be applied to centerlines, center planes, or axes? 6. 7.

Datum feature symbol I, O, & Q

Datum identifying letters may be any letter of the alphabet except what letters?

If the datum feature symbol is placed in line with a dimension line or on a feature control frame associated with a size feature, then the datum is what?

A size feature
8. One of the 14 geometric characteristic symbols always appears in the compartment of the feature control frame.

first

Geometric Dimensioning and Tolerancing for Mechanical Design

12

Instructors Guide

Pertains to

Typeof Tolerance

Geometric Characteristics STRAIGHTNESS

Symbol

Individual Feature Only

FLATNESS Form CIRCULARITY CYLINDRICITY

Individual Feature or Related Features

PROFILEOF A LINE Profile PROFILEOF A SURFACE ANGULARITY Orientation PERPENDICULARITY PARALLELISM

Related Features Location

POSITION CONCENTRICITY SYMMETRY CIRCULAR RUNOUT Runout TOTAL RUNOUT

Fig. 3-23 Geometric characteristic symbols 9. Write the names and geometric characteristic symbols where indicated in Fig. 3-23.
Instructors Guide 13

Geometric Dimensioning and Tolerancing for Mechanical Design

10. The tolerance is preceded by a diameter symbol only if the tolerance zone is 11. Datums are arranged in order of

cylindrical

. .

precedence or importance

12. Write the name, abbreviation, and symbol for the three material condition modifiers.

Material Condition
Regardless of Feature Size Maximum Material Condition Least Material Condition

Abbreviation
RFS MMC LMC

Symbol
None

M L

13. Which modifier specifies that the tolerance is the same no matter what size the feature is within its size limits?

Regardless of Feature Size (RFS)

14. The maximum material condition modifier specifies that the tolerance applies at the

maximum

material

condition

of the feature.

15. The maximum material condition modifier specifies that as the actual size of the feature departs from maximum material condition toward least material condition, a

bonus

tolerance

is achieved in the exact amount of such departure.

16. The bonus tolerance equals the difference between the

actual feature size and MMC

17. The total positional tolerance equals the sum of the tolerance and the

bonus
tolerance.

geometric tolerance

Geometric Dimensioning and Tolerancing for Mechanical Design

14

Instructors Guide

.515-.540 Hole

.495-.500

Pin

C
1.000

1.000

1.000

Fig. 3-24 refer to this drawing for questions 18 through 25.

Hole
18. 19. 20. 21. 22. 23. What is the MMC? What is the LMC? What is the geometric tolerance? What material condition modifier is specified? What datum(s) control(s) perpendicularity? What datum(s) control(s) location?

Pin .500 .495 .005 MMC A B&C

.515 .540 .010 MMC A B&C

24. Complete the table below.

Internal Feature (Hole)

Actual Feature Geometric
15

Total Positional
Instructors Guide

Geometric Dimensioning and Tolerancing for Mechanical Design

Size MMC.515 .520 .525 .530 .535 LMC .540

MMC

Bonus

Tolerance

Tolerance

.515 .515 .515 .515 .515 .515

.000 .005 .010 .015 .020 .025

.010 .010 .010 .010 .010 .010

.010 .015 .020 .025 .030 .035

Table 3-3 Bonus tolerance for holes 25. Complete the table below.

External Feature (Pin)

Actual Feature Size MMC .500 .499 .498 .497 .496 LMC .495 Geometric Tolerance Total Positional Tolerance

MMC

Bonus

.500 .500 .500 .500 .500 .500

.000 .001 .002 .003 .004 .005

.005 .005 .005 .005 .005 .005

.005 .006 .007 .008 .009 .010

Table 3-4 Bonus tolerance for pins Using the drawing in Fig. 3-23, complete tables 3-3 and 3-4 above.

26. The all around and between symbols are used with what control?

Profile

27. What is the name of an actual feature on a part used to establish a datum?

A datum feature
28. A numerical value used to specify the theoretically exact size, profile, orientation, or location of a feature
Geometric Dimensioning and Tolerancing for Mechanical Design
16 Instructors Guide

is called?

Basic dimension

29. What is the theoretically exact point, line, or plane derived from the true geometric counterpart of a specified datum feature called?

Datum

30. What is a real surface with a sufficiently precise form, such as a surface plate or machine table, used to contact datum features to establish simulated datums called?

A simulated datum

Name All Around

Symbol

Name Free State

Symbol

F P T
r c

) Between Number of Places Counterbore/Spotface % Countersink ^ Depth/Deep Diameter Dimension, Basic Dimension, Reference Spherical Radius Radius, Controlled Projected Tolerance Zone

X
$

Tangent Plane Radius

y z
Spherical Diameter

1.000

&
Square

(60)

s
Statistical Tolerance

Geometric Dimensioning and Tolerancing for Mechanical Design

17

Instructors Guide

! Dimension Origin Datum Target

.500 A1

Arc Length Conical Taper

110
@

Target Point # Slope

Fig. 3-25 Geometric tolerancing symbols 31. Draw the indicated geometric tolerancing symbols in the spaces on Fig. 3-23. 32. What is the name of a physical portion of a part, such as a surface, pin, hole, tab, or slot?

A feature
33. What is the name of a feature that has a dimension such as a cylindrical surface or two opposed parallel surfaces?

A feature of size (size feature) A feature of size

34. What kind of features always apply at MMC, LMC, or RFS?

35. What is the maximum amount of material within the stated limits of size of a size feature called?

Maximum material condition

36. What is a feature of size with the least amount of material within the stated limits of size called? ?

Least material condition

37. What is the term used to indicate that a specified geometric tolerance or datum reference applies at each increment of size of a feature within its limits of size? ?

Regardless of feature size

38. What is the theoretically exact location of a feature established by basic dimensions called?
Geometric Dimensioning and Tolerancing for Mechanical Design
18 Instructors Guide

True position

39. What is a constant boundary generated by the collective effects of the MMC limit of size of a feature and the applicable geometric tolerance called?

Virtual condition
40. Where only a tolerance of size is specified, the limits of size of an individual feature prescribe the extent to which variations in its geometric form, as well as size, are allowed. This statement is the essence of

Rule #1
41. The form tolerance increases as the actual size of the feature departs from toward

MMC

LMC

42. If features on a drawing are shown coaxial, or symmetrical to each other and not controlled for

location

, the drawing is incomplete.

43. If there is no orientation control specified for a rectangle on a drawing, the perpendicularity is controlled, not by the size

tolerance

, but by the tolerance. automatically applies,

title block angularity tolerance

44. Rule #2 states that

regardless of feature size (RFS)

to individual tolerances of size features and to datum features of size. 45. Each geometric tolerances or datum reference specified for screw threads applies to the axis of the thread derived from the

pitch diameter

46. Each geometric tolerance or datum reference specified for gears and splines must designate the specific feature at which each applies such as
Geometric Dimensioning and Tolerancing for Mechanical Design
19 Instructors Guide

MAJOR DIA, PITCH DIA, or MINOR DIA

47. Where a datum feature of size is controlled by a geometric tolerance and is specified as a secondary or tertiary datum, the datum applies at with respect to orientation.

virtual condition

Problems
Page 44

A
Fig. 3-26 Material condition symbols: Problem 1 1.

Read the complete tolerance in each feature control frame in Fig. 3-25, and write them below (Datum A is a size feature). A.

Locate the feature (s) with a cylindrical tolerance zone .005 in diameter to datum A.

B.

Locate the feature (s) with a cylindrical tolerance zone .005 in diameter at MMC to datum A at MMC.

Geometric Dimensioning and Tolerancing for Mechanical Design

20

Instructors Guide

A 2X 1.375-1.390

B D C E

C 2.000-2.020 1.000 A

1.000

4.000 6.000-6.020

B F H

Fig. 3-27 Definitions: Problem 2 1. Place the letters of the items on the drawing in Fig. 3-24 next to the terms below. Make a dash next to the terms not shown.

F A B

Datum MMC LMC

G C E

Basic Dimension Feature Feature of Size

I D H

Feature control frame True Position Datum feature symbol

Geometric Dimensioning and Tolerancing for Mechanical Design

21

Instructors Guide

 4.25

8X .514-.540

A A

.500-.510 2.500 C A 8X 45 1.255-1.265 .75 SECTION AA

Unless Otherwise Specified: .XX = .01 ANGLES = 1

Fig. 3-28 Virtual condition rule: Problem 3 3. When inspecting the eight-hole pattern: A. Does the center hole, datum B, apply at MMC or virtual condition?

Virtual condition
If the center hole were produced at 1.260, how much shift tolerance would be available from the center hole?

A cylindrical tolerance of .010 in diameter Virtual condition (In this

B. Does the keyseat, datum C, apply at MMC or virtual condition?

case, virtual condition is the same as MMC.)

If the keyseat were produced at .505, how much shift tolerance would be available from the keyseat?

The tolerance between two parallel planes .005 apart

Geometric Dimensioning and Tolerancing for Mechanical Design
22 Instructors Guide

Chapter 4 Datums
Chapter Review
Page 63 1. Datums are theoretically perfect Datums establish the

points, lines, and planes

2.

origin

from which the location or geometric characteristic of

features of a part are established. 3. Datums exist within a structure of three mutually perpendicular intersecting planes known as a

datum reference frame

4.

To properly position a part with datum features that are plane surfaces in a datum reference frame, the datum features must be specified in order of

precedence three

5.

The primary datum feature contacts the datum reference frame with a minimum of points of contactnot in a straight line.

6. 7. 8. 9.

Datums are assumed to exist in and be simulated by the

processing equipment the feature control frame.

Datums are specified in order of precedence as they appear in Datums need not be in

alphabetical

order.

When selecting datum features, the designer should consider features that are:

Functional surfaces, mating surfaces, readily accessible surfaces, and surfaces that allow repeatable measurements .
Geometric Dimensioning and Tolerancing for Mechanical Design
23 Instructors Guide

10. The primary datum controls

the orientation of the part physical features

11. The datum feature symbol is used to identify of a part as datum features. 12. Datum feature symbols shall not be applied to

centerlines, center planes, or axes

13. One method of tolerancing datum features at an angle to the datum reference frame is to place a datum feature symbol on the

inclined surface

and control that

surface with an angularity tolerance and a basic angle. 14. A

cylindrical datum feature

is always

intersected by two theoretical planes meeting at right angles at its datum axis. 15. The two kinds of features specified as datums are:

Features not subject to size variations Features subject to size variations

16. Size features may apply at

regardless of feature size or maximum material

.

condition
17. When size features are specified at RFS, the processing equipment must make

physical contact

with the datum features.

18. When size features are specified at MMC, the size of the processing equipment has a

constant boundary

Geometric Dimensioning and Tolerancing for Mechanical Design

24

Instructors Guide

2X .510-.530

6.000-6.020
B Fig. 4-18 Datum feature of size drawing for questions 19 - 24 19. The 2-hole pattern is perpendicular to what datum? 20, The 2-hole pattern is located to what datum?

Datum A Datum B 6.030 2X .500

21. If inspected with a gage, what is the datum B diameter of the gage?

22. If inspected with a gage, what is the diameter of the 2 pins on the gage?

23. If datum B had been specified at RFS, explain how the gage would be different.

Datum B would have to be a variable diameter like a chuck to make physical contact with the outside diameter.
Geometric Dimensioning and Tolerancing for Mechanical Design
25 Instructors Guide

24. If datum B had been specified as the primary datum at RFS, explain how the gage would be different.

Datum B would not only have to be a variable diameter, such as a chuck, to make physical contact with the outside diameter, but the outside diameter, datum B, would align with the gage as well.
25. If a datum feature symbol is in line with a dimension line, the datum is the

size feature

measured by the dimension.

26. When cylinders are specified as datums at regardless of feature size, the entire surface is considered to be the

datum feature

27. When more than one datum feature is used to establish a single datum, the

datum reference letters

and appropriate

modifiers

are separated by a dash and specified in one compartment of the feature control frame. 28. If only a part of a feature is required to be the datum feature, then a

heavy chain

line

is drawn adjacent to the surface profile and dimensioned with basic dimensions.

29. Datum targets may be used to immobilize parts with 30. Costly manufacturing and inspection datum targets.

uneven or irregular surfaces

tooling

is required to process

Geometric Dimensioning and Tolerancing for Mechanical Design

26

Instructors Guide

Problems
Page 66

A B
1.997-2.000 4X 1.010-1.030
(+) See below

4.000

Fig. 4-19 Datums at MMC and RFS: Problem 1 1. Complete the feature control frames with datums and material condition symbols to reflect the drawing in Fig. 4-19.

Geometric Dimensioning and Tolerancing for Mechanical Design

27

Instructors Guide

4X .760 -.790

or
3.500 1.500

C
1.500

2.500

1.500

3.000

A B
1.000 - 1.030

or
D

Fig. 4-20 Specifying datums and datum feature symbols: Problem 2 2. Provide the appropriate datum feature symbols on the drawing and datums in the feature control frames in the datum exercise above.

(Two solutions suggested.)

Geometric Dimensioning and Tolerancing for Mechanical Design

28

Instructors Guide

4X .514-.590

3.970 2.500

.500.515

4.2004.230

A B

Fig. 4-21 Specifying datums and datum feature symbols: Problem 3 3. Specify the appropriate datums feature symbols and datums in the drawing in Fig. 4-21.

(One solution. Explore other possibilities.)

Geometric Dimensioning and Tolerancing for Mechanical Design

29

Instructors Guide

Chapter 5 Form
Chapter Review
Page 80 1. 2. 3. Form tolerances are independent of all No

other features

. apply to form tolerances.

datums

The form of individual features is automatically controlled by the

size tolerance, rule #1

4. A form tolerance may be specified as a refinement when

the size tolerance does not adequately control the form of a feature
5. All form tolerances are surface controls except for

straightness of a median line and straightness of a median plane

6. No

cylindrical tolerance zones

or

material conditions

are appropriate for surface controls. 7. Flatness of a surface is a condition where all line elements of that surface are in one

plane
8. In a view where the surface to be controlled with a flatness tolerance appears as a

line

Geometric Dimensioning and Tolerancing for Mechanical Design

30

Instructors Guide

a feature control frame is attached to the surface with a 9. The feature control frame controlling flatness contains a and a

leader or extension line flatness symbol

numerical tolerance two parallel planes

10. The surface being controlled for flatness must lie between

separated by the flatness tolerance. In addition, the feature must fall within the

size tolerance
11. The flatness tolerance zone does not need to be 12. The size feature may not exceed the

parallel

to any other surface.

boundary of perfect form at MMC

1.000-1.020
Fig. 5-12 Specifying flatness 13. Specify the flatness of the top surface of the part in Fig. 5-12 within .006 in a feature control frame. 14. Draw a feature control frame with an overall flatness of .015 and a unit flatness of .001 per square inch.

15. To measure the flatness of a feature, first, the size feature is measured to verify that it falls within the

size limits
Geometric Dimensioning and Tolerancing for Mechanical Design
31

.
Instructors Guide

16. The surface is adjusted with jackscrews to remove any

parallelism all directions

error. .

17. Then, flatness verification is achieved by measuring the surface in 18. Straightness is a condition where a line element of a

surface, a median line, or a line

is a straight line.

element of a median plane

19. In a view where the line elements to be controlled appear as a a feature control frame is attached to the surface with a 20. Straightness tolerance is a refinement of the and must be less than the

line

leader or extension line

, .

size tolerance, rule #1

size tolerance

Actual Part Size 1.020 1.018 1.016 1.014 1.010 1.005 1.000 Table 5-5 Problem 21

Straightness Tolerance

Controlled By

.000 .002 .004 .004 .004 .004 .004 Straightness Tolerance Rule #1

21. Complete Table 5-5 specifying the straightness tolerance and what controls it for the drawing in Fig. 5-4. 22. The measurement of surface variation for straightness is performed similar to the measurement for

flatness
Geometric Dimensioning and Tolerancing for Mechanical Design
32

.
Instructors Guide

23. Each line element is

independent

of every other line element.

24. When a feature control frame with a straightness tolerance is associated with a size dimension, the straightness tolerance

applies to the median line or

a median
.

plane
25. While each actual local size must fall within the size

tolerance

the feature controlled with straightness of a median line or median plane may exceed the

exceed the boundary of perfect form

at maximum material condition. 26. A straightness control of a median line or median plane will allow the feature to violate

Rule #1

27. If specified at MMC, the total straightness tolerance of a median line or median plane equals the tolerance in the feature control frame plus any

bonus tolerance

Cylindrical Feature (Straightness of a Median Line) Feature Size 1.020 MMC 1.015 1.010 1.005 1.000 LMC

.006 .006 .006 .006 .006

.006 .011 .016 .021 .026

Instructors Guide 33

Geometric Dimensioning and Tolerancing for Mechanical Design

28. Complete the table above specifying the appropriate tolerances for the sizes given. 29. Straightness verification of a size feature specified at MMC can be achieved by

placing the part in a full form functional gage

30. Straightness verification of a size feature specified at

RFS

cannot be achieved by placing the part in a full form functional gage. 31. Circularity tolerance consists of two in which the

concentric circles

radial distance

between them is equal to the tolerance specified in the feature control frame. 32. For circularity verification the feature must first be measured at each cross section to determine that it satisfies the

limits of size

and

rule #1

. .

33. Circularity can be accurately inspected on a

circularity inspection machine

34. Cylindricity is a condition if the surface of a cylinder where all points of the surface are

equidistant from the axis

35. The cylindricity tolerance consists of two the

coaxial cylinders

in which

radial feature control frame composite

between them is equal to the tolerance . form tolerance that simultaneously controls of cylindrical features.

specified in the 36. Cylindricity is a

circularity, straightness of a surface, and taper

Geometric Dimensioning and Tolerancing for Mechanical Design
34

Instructors Guide

Size Feature 1. Datums do not apply to these controls 2. This tolerance violate rule #1 3. This is a size feature control 4. This control is associated with the dimension 5. This tolerance may exceed the size tolerance 6. Rule #1 applies to this tolerance 7. This tolerance is a surface control 8. This control is specified with a leader 9. This tolerance is a refinement of Rule #1 10. The , circle M, and circle L symbols may be used Table 5-7 Problem 37 37. Place an X in the row and under the control that agrees with the statement. 38. Free state variation is a term used to describe the distortion of a part after the removal of forces applied during the

X X X X X

X X X X

X X X X X

X X X X

X X

manufacturing process

39. Where a form or location tolerance is specified for a feature in the free state, the free state symbol is placed inside the

feature control frame

.

following the

tolerance and any modifiers

40. A minimum of

four measurements

must be taken to insure

the accuracy of an average diameter. 41. The restrained condition should simulate

actual assembly conditions

Geometric Dimensioning and Tolerancing for Mechanical Design

35

Instructors Guide

Problems
Page 84

OR

1.000

3.000
.XXX= .010 ANGLES = 1

Fig. 5-13 Flatness: Problem 1 1. Specify a flatness control of .005 for the top surface of the part in Fig. 5-13.

(Either a leader or an extension line can be used)

2. Below, draw a feature control frame with a unit flatness of .003 per square inch and an overall flatness of .015.

Geometric Dimensioning and Tolerancing for Mechanical Design

36

Instructors Guide

Fig. 5-14 straightness of a surface: Problem 3 3. Specify straightness of a surface of .002 on the cylinder in the drawing in Fig. 5-14.

(Either a leader or an extension line can be used)

Fig. 5-15 straightness of a median line: Problem 4 4. Specify straightness of a median line of .010 at MMC on the cylinder in the drawing in Fig. 5-15.

(The feature control frame must be associated with the dimension.)

Geometric Dimensioning and Tolerancing for Mechanical Design

37

Instructors Guide

Fig. 5-16 Circularity: Problems 5 and 6 5. 6. Specify a circularity tolerance of .002 on the come in the drawing in Fig. 5-16. Specify a cylindricity tolerance of .0005 on the cylinder in the drawing in Fig. 5-16.

Chapter 6 Orientation
Chapter Review
Page 97 1. 2. Orientation is the general term used to describe the Orientation controls include

angular

relationship between features.

parallelism, perpendicularity, angularity, and in

some cases, profile

3. All orientation controls must have

datums
38

.
Instructors Guide

Geometric Dimensioning and Tolerancing for Mechanical Design

4.

In a view where the surface to be controlled appears as a line, a feature control frame is attached to the surface with a

leader or extension line

5.

The feature control frame for parallelism of a surface must at least contain

a parallelism symbol, a numerical tolerance, and at least one datum

6. 7. The datum feature is identified with a

. .

datum feature symbol

Parallelism tolerance of a flat surface is a refinement of the size tolerance and must be less than the

size tolerance
8. 9. Size features may not exceed the

maximum material condition boundary

A surface being controlled with a parallelism tolerance must lie between

two parallel planes

separated by the parallelism

tolerance specified in the feature control frame. The tolerance zone must also be

parallel
10. The controlled surface may not exceed the

to the datum plane.

boundary of perfect form at maximum

.

material condition
11. Parallelism is the only orientation control that where applied to a flat surface requires a perfect angle (Parallelism is a 0 angle.) at

maximum material condition

Geometric Dimensioning and Tolerancing for Mechanical Design

39

Instructors Guide

2.00 1.00 1.00 7.00

.XX = .01 ANGLES = 1
Fig. 6-15 Specifying parallelism 12. Supply the appropriate geometric tolerance on the drawing to control the top surface of the part in Fig. 615 parallel to the bottom surface within .010.

(Either a leader or an extension line can be used)

13. When controlling the parallelism of a size feature, the feature control frame is associated with the

size dimension

of the feature being controlled.

14. If the size feature is a cylinder, the numerical tolerance is usually preceded by a 15. A surface being controlled with a perpendicularity tolerance must lie between

two parallel planes

separated by the perpendicularity

tolerance specified in the feature control frame. The tolerance zone must also be

perpendicular

to the datum plane.

16. A Tangent Plane symbol (circle T) in the feature control frame specifies that the tolerance applies to the
Geometric Dimensioning and Tolerancing for Mechanical Design
40 Instructors Guide

precision plane contacting the

high points

of the surface.

17. When controlling the perpendicularity of a size feature, the feature control frame is associated with the

size dimension

of the feature being controlled.

18. If the tolerance in the feature control frame applies to a size feature and no material condition symbol is specified,

RFS bonus

applies. tolerance exists.

19. If the tolerance applies at MMC then a possible

3.00

4.00

2.00

A .XX = .01 ANGLES = 1

Fig. 6-16 Specifying perpendicularity of a surface 20. Supply the appropriate geometric tolerance on the drawing in Fig. 6-16 to control the 3.00-inch vertical surface of the part in Fig. 6-16 perpendicular to the bottom surface within .005.

(Either a leader or an extension line can be used)

Geometric Dimensioning and Tolerancing for Mechanical Design

41

Instructors Guide

 1.000-1.010

2.00

A
Fig. 6-17 Specifying perpendicularity of a size feature 21. Supply the appropriate geometric tolerance on the drawing in Fig. 6-17 to control the 1.00-inch vertical pin perpendicular to the bottom surface of the plate within .005 at RFS.

Fig. 6-18 Perpendicularity specified at MMC 22. If the pin in Fig. 6-17 were produced at a diameter of 1.004 and toleranced with the feature control frame in Fig. 6-18, what would the total perpendicularity tolerance be?

.008

23. The numerical tolerance for angularity of a surface is specified as a linear dimension because it generates a

uniform shaped tolerance

zone.

24. A plus or minus angularity tolerance is not used because it generates a

Geometric Dimensioning and Tolerancing for Mechanical Design
42 Instructors Guide

nonuniform, fan

shaped tolerance zone.

25. When controlling the angularity of a size feature, the feature control frame is associated with the

size dimension

of the feature being controlled.

26. If the diameter symbol precedes the numerical tolerance, the axis is controlled with a

cylindrical tolerance

zone.

27. When maximum material condition or least material condition is desirable, it might be more appropriate to specify angularity and location at the same time with the

position control
Axes & Ctr. Planes X X X

Plane Surfaces Datums are required Controls flatness if flatness is not specified Circle T modifier can apply Tolerance specified with a leader or extension line May not exceed boundary of perfect form at MMC Tolerance associated with a dimension Material condition modifiers apply A virtual condition applies Table 6-2 Orientation problem X X X X X X X X X X X X X

X X X

X X X

X X X

28. In Table 6-2, mark an X in the box that indicates the control applies to the statement at the left.

Geometric Dimensioning and Tolerancing for Mechanical Design

43

Instructors Guide

Problems
Page 100

.004 1.00

2.00 1.00 4.00 A

.XX = .01 ANGLES = 1
Fig. 6-19 Parallelism of a plane surface: Problem 1 1. In Fig. 6-19, specify the top surface of the part parallel to the bottom surface within a tolerance of .004. Draw and dimension the tolerance zone.

2.00

Geometric Dimensioning and Tolerancing for Mechanical Design

44

Instructors Guide

.010

B
3.00

4.00

2.00

A
Fig. 6-20 Perpendicularity of a plane surface: Problem 2 2.

.XX = .01 ANGLES = 1

In Fig. 6-20, specify the 3.00-inch surface of the part perpendicular to the bottom and back surfaces within a tolerance of .010. Draw and dimension the tolerance zone.

Geometric Dimensioning and Tolerancing for Mechanical Design

45

Instructors Guide

 .998-1.000

1.015

Gage

1.50

A
.XX = .01 ANGLES = 1

Fig. 6-21 Perpendicularity of a pin to a plane surface: Problem 3 3. In Fig. 6-21, specify the 1.00-inch pin perpendicular to the top surface of the plate within a tolerance of . 015 at MMC. On the drawing, sketch and dimension a gage used to inspect this part.

.0 0 3 2 0 2 .5 7 1 .0 0 6 .0 0

A
Fig. 6-22 Angularity of a plane surface: Problem 4 4.

.X =1 X . 0 AL N S =1 G E

In Fig. 6-22, specify the top surface of the part to be at an angle of 20 to the bottom surface within a tolerance of .003. Draw and dimension the tolerance zone.

Geometric Dimensioning and Tolerancing for Mechanical Design

46

Instructors Guide

.980-.990

1.015-1.030

MMC Geometric Tolerance Virtual Condition

Fig. 6-23 Orientation: Problem 5 5.

.990 +.010 1.000

1.015 .015 1.000

Complete the feature control frames in Fig. 6-23 so that the two parts will always assemble, datums A & B will meet, and the part can be produced using the most cost effective design. The pin is machined in a lathe and the hole is drilled.

(There are several possible solutions to this problem. The virtual conditions should be equal to insure assembly and to provide maximum tolerance. Typically, for this method of manufacturing, more tolerance is given to the hole.)

Geometric Dimensioning and Tolerancing for Mechanical Design

47

Instructors Guide

Chapter 7 Position, General

Chapter Review
Page 119 1. Position is a composite tolerance that controls both the of size features at the same time. 2. The tolerance of position may be viewed in either of two ways:

location and the orientation

A theoretical tolerance zone located at true position of the toleranced feature within which the center point, axis, or center plane of the feature may vary from true position
.

A virtual condition boundary of the toleranced feature, when specified at MMC or LMC and located at true position, which may not be violated by its surface or surfaces
.

3.

Since the position tolerance only controls size features such as pins, holes, tabs, and slots, the feature control frame is always associated with a

size dimension

4.

The location of true position, the theoretically perfect location of an axis, is specified with

basic dimensions
5. Once the feature control frame is assigned, an imaginary

from the datums indicated.

tolerance zone
is defined and located about true position.

Geometric Dimensioning and Tolerancing for Mechanical Design

48

Instructors Guide

5. 6.

Datum surfaces have

datum feature symbols datum reference frame processing

identifying them. ; .

Datums A, B, and C identify a,

consequently, they describe how the part is to be held for 7.

To inspect a hole, the largest pin gage to fit inside the hole is used to simulate the

actual mating envelope

8.

The measurement from the surface plate to the top of the pin gage minus half of the diameter of the pin gage equals the distance from

datum B to the actual axis of the hole RFS

. modifier

9.

If no material condition symbol is specified in the feature control frame, the automatically applies to the tolerance of the feature.

10. When the maximum material condition symbol is specified to modify the tolerance of a size feature, the following two requirements apply: The specified tolerance applies

at the maximum material condition of the feature.

As the size of the feature departs from maximum material condition toward least material condition,

a bonus tolerance is achieved in the exact amount of such departure.

11.

Bonus tolerance

equals the difference between the actual feature size and MMC.

12. Bonus plus the geometric tolerance equals

the total positional tolerance

.510 .550
Fig. 7-13 Geometric tolerance 13. If the tolerance in Fig. 7-13 is for a pin .530, what is the total tolerance?
Geometric Dimensioning and Tolerancing for Mechanical Design
49

.030
Instructors Guide

14. What would be the size of the hole in a functional gage to inspect the pin above? 15. If the tolerance in Fig. 7-13 is for a hole .540, what is the total tolerance?

.560

.040 .500

16. What would be the size of the pin on a functional gage to inspect the hole above?

.510 .560
Pin Fig 7-14 Zero positional tolerance conversion

.500 .550
Hole

17. Convert the tolerance in Fig. 7-13 to the zero positional tolerances in Fig. 7-14. 18. Shift tolerance is allocated to a feature or pattern of features, as a group, and equals the amount a datum feature of size departs from or

maximum material condition

.

virtual condition toward least material condition

19. When a datum feature of size is specified with a maximum material condition symbol: the

datum feature of size

applies at its MMC condition or virtual condition.

As the actual size of a datum feature departs from maximum material condition toward least material condition, a

shift tolerance

, of the pattern as a group, is allowed in the exact

amount of such departure. 20. The

virtual condition rule

states that, where a datum feature of size

is controlled by a geometric tolerance and is specified as a secondary or tertiary datum, the datum applies at its virtual condition with respect to orientation.

Geometric Dimensioning and Tolerancing for Mechanical Design

50

Instructors Guide

Problems
Page 121

1.010 - 1.025

3.500
C

1.500

1.500 2.500 1.500

3.000 4X .510 -.525

Fig. 7-15 Design a gage to inspect for shift tolerance: Problem 1 1. On a gage designed to control the 4-hole pattern in Fig. 7-15, what size pin must be produced to inspect the center hole (datum D)?

1.000

On the same gage, what is the diameter of the four pins locating the hole pattern?

.500

Geometric Dimensioning and Tolerancing for Mechanical Design

51

Instructors Guide

2.500 .020

2.000 .020

4.059 .003

Fig. 7-16 A hole specified at LMC: Problem 2 2. Calculate the minimum wall thickness between the inside diameter and datum B in Fig. 7-16.

Datum B @ LMC I. D. @ LMC Tolerance @ LMC

2.480 2.020 .020 .440

The wall thickness equals half of the differences in diameters or .220. (Calculating diameters and diving the final diameter in half minimize Errors.)

Geometric Dimensioning and Tolerancing for Mechanical Design

52

Instructors Guide

 .998-1.000 C

1.000-1.006

1.000

B
1.500 3.000 6.00

.XX = .01 ANGLES = 1

Fig. 7-17 Boundary conditions: Problem 3 3. First calculate the virtual conditions and resultant conditions for the pin and hole. Then calculate the maximum and minimum distances for dimensions X and Y in Fig. 7-17. The Virtual Condition of the PIN. The Virtual Condition of the HOLE.

VCp = MMC + Geo. Tol. VCp = 1.000 + .004 = 1.004 VCp/2 = .502
Resultant Condition of the PIN.

VCh = MMC Geo. Tol. VCh = 1.000 .004 = .996 VCh/2 =.498
Resultant Condition of the HOLE.

RCp = LMC Geo. Tol. Bonus RCp =.998 .004 .002 = .992 RCp/2 = .496 XMax = Dist. RCp/2 VCh/2 = XMax =3.000 .496 .498 = XMax = 2.006 YMax =Dist. @ MMC VCh/2 = YMax =6.010 .498 = YMax =5.512

RCh = LMC + Geo. Tol. + Bonus RCh =1.006 +.004 +.006 =1.016 RCh/2 =.508 XMin = Dist. VCp /2 RCh /2 = XMin = 3.000 .502 .508 XMin =1.990 YMin = Dist. @ LMC RCh/2 = YMin = 5.990 .508 = YMin =5.482
Instructors Guide 53

The maximum and minimum distances for dimension X:

The maximum and minimum distances for dimension X:

Geometric Dimensioning and Tolerancing for Mechanical Design

.998 1.004
Pin

.996 1.006
Hole

Fig 7-18 Zero positional tolerance conversion: Problem 4 4. Convert the tolerance in Fig. 7-17 to the zero positional tolerances in Fig. 7-18. Zero tolerance is not used when the tolerance applies at tolerance is available as in a tolerance specified for

RFS

, or when no bonus

threads or press fit pins.

Chapter 8 Position, Location

Chapter Review
Page 147 1. The floating fastener formula is:

T=HF
2. T = Tol.

or

H=F+T
H=

at MMC

Hole at MMC

F=

Fastener at MMC
. .

3. 4. 5.

The LMC clearance hole can be calculated by The fixed fastener is fixed by one or more of the

H @ LMC = (F +F head) / 2 members being fastened

A fastener fixed at its head in a countersunk hole and in a threaded hole at the other end is called what?

A double fixed fastener

Geometric Dimensioning and Tolerancing for Mechanical Design

54

Instructors Guide

6.

The formula for fixed fasteners is:

t1 + t2 = H F

or

H = F + t1 + t2

7. The tolerance for both the threaded hole and the clearance hole must come from the difference between the size of the clearance hole and the size of the 8. 9.

fastener the fasstener threaded threaded

Total possible tolerance equals clearance Hole size @ LMC minus It is common to assign a larger portion of the tolerance to the

hole. hole.

10. As much as 60% of the tolerance may be assigned to the

11. When specifying a threaded hole or a hole for a press fit pin, the orientation of the

hole

determines the orientation of the mating pin.

12. The most convenient way to control the orientation of the pin outside the hole is to the tolerance zone into the mating part. 13. The height of the projected tolerance zone is equal to or greater than the thickest

project

mating
after installation.

part

or tallest

stud or pin

14. The dimension of the projected tolerance zone height is specified as a

minimum

15. Two or more patterns of features are considered to be one composite pattern if they

are located with basic dimensions, to the same datums features, in the same order of precedence, and at the same material conditions
16. Datum features of size specified at RFS require

physical contact
Instructors Guide 55

Geometric Dimensioning and Tolerancing for Mechanical Design

between the gagging element and the datum feature.

17. If the patterns of features have no relationship to each other, a note such as

SEP REQT
be inspected separately.

may be placed under each feature control frame allowing each pattern to

18. Composite tolerancing allows the relationship from

feature-to-feature

to be kept to a tight tolerance and the relationship between the

pattern and its datums

19. A composite positional feature control frame has one that applies to the two horizontal

to be controlled to a looser tolerance.

position

symbol that follow.

segments

20. The upper segment of a composite feature control frame, called the

pattern-locating pattern
.

control, governs the relationship between the datums and the

21. The lower segment of a composite feature control frame is called the control; it governs the relationship from

feature-relating
. .

feature-to-feature location

22. The primary function of the position control is to control

23. There is a requirement and a condition for the datums in the lower segment of the composite positional tolerancing feature control frame. They:

are required to repeat the datums in the upper segment only control orientation
Geometric Dimensioning and Tolerancing for Mechanical Design
56 Instructors Guide

(For question numbers 24 and 25, assume plane surface datums.) 24. When the secondary datum is included in the lower segment of a composite feature control frame, the tolerance zone framework must remain

Parallel

to the secondary datum plane.

25. The lower segment of a two single segment feature control frame only refines the feature-to-feature relationship

perpendicular

to the primary datum plane and to the secondary datum plane.

located

26. Counterbores that have the same location tolerance as their respective holes are specified by indicating the

hole callout and the counterbore callout followed by the geometric

.

tolerance for both

27. Counterbores that have a larger location tolerance than their respective holes are specified by

separating the hole callout from the counterbore callout

28. When tolerancing elongated holes, no

.
precedes

diameter symbol cylinder

the tolerance in the feature control frame since the tolerance zone is not a The note

BOUNDARY

is placed beneath each feature control frame.

29. The virtual condition boundary is the the elongated hole and equal in size to its 30. A

exact shape virtual condition

of .

size feature

may be located symmetrically to a datum feature of size

Instructors Guide 57

Geometric Dimensioning and Tolerancing for Mechanical Design

and toleranced with a

position control

associated with the size dimension

of the feature being controlled.

Geometric Dimensioning and Tolerancing for Mechanical Design

58

Instructors Guide

Problems
Page 149

2X

1.000

1.000

3.000

Fig. 8-25 Floating fastener drawing: Problems 1 through 4 1. Specify the MMC and LMC clearance hole sizes for #10 (.190) socket head cap screws.

(Many other solutions are possible, but they must satisfy the floating fastener formula.) 2X .220-.246 n]w.030m]A]B]C]
2. each callout. Actual Size MMC Bonus Geo. Tolerance

2X .200-.246 2X .190-.246 n]w.010m]A]B]C] n]w.000m]A]B]C]

If the actual size of the clearance holes in problem 1 is .230, calculate the total positional tolerance for

.230 .220 .010 + .030

59

.230 .200 .030 + .010

.230 .190 .040 + .000

Instructors Guide

Geometric Dimensioning and Tolerancing for Mechanical Design

Total Tolerance 3.

.040

.040

.040

Specify the MMC and LMC clearance hole sizes for 3/8 (.375) hex head bolts.

2X .400-.460 n]w.025m]A]B]C]
4. each callout. Actual Size MMC Bonus Geo. Tolerance Total Tolerance

2X .390-.460 2X .375-.460 n]w.015m]A]B]C] n]w.000m]A]B]C]

If the clearance holes in problem 3 actually measure .440, calculate the total positional tolerance for

.440 .400 .040 + .025 .065

2X

.440 .390 .050 + .015 .065

.440 .375 .065 + .000 .065

1.000

1.000

3.000

Fig. 8-26 Fixed fastener drawing: Problems 5 through 8

5. Specify the MMC and LMC clearance hole sizes for #8 (.164) socket head cap screws.
2X .164 (#8)-32 UNF-2B 2X .164 (#8)-32 UNF-2B 2X .164 (#8)-32 UNF-2B

n]w.025m]A]B]C] .199 .213 n]w.010m]A]B]C]

n]w.025m]A]B]C] n]w.025m]A]B]C] .194 .213 .189 .213 n]w.005m]A]B]C] n]w.000m]A]B]C]

Geometric Dimensioning and Tolerancing for Mechanical Design

60

Instructors Guide

6.

If the clearance holes in problem 5 actually measure .205, calculate the total positional tolerance for each callout.

Actual Size MMC Bonus Geo. Tolerance Total Tolerance

.205 .199 .006

+ .010

.205 .194 .011 + .005 .016

.205 .189 .016 + .000 .016

.016

7. Specify the MMC and LMC clearance hole sizes for the 1/2 hex head bolts.
2X .500-20 UNF-2B 2X .500-20 UNF-2B 2X .500-20 UNF-2B

n]w.060m]A]B]C] 2X .580 .612 n]w.020m]A]B]C]

8. each callout. Actual Size MMC Bonus Geo. Tolerance Total Tolerance

n]w.060m]A]B]C] n]w.060m]A]B]C] 2X .570 .612 2X .560 .612 n]w.010m]A]B]C] n]w.000m]A]B]C]

If the clearance holes in problem 5 actually measure .585, calculate the total positional tolerance for

.585 .580 .005 + .020 .025

.585 .570 .015 + .010 .025

.585 .560 .025 + .000 .025

Geometric Dimensioning and Tolerancing for Mechanical Design

61

Instructors Guide

n]w.040mp]A]B]C]
C

2X .500-20 UNF-2B

2.00 1.000
B

6.00

1.51 MIN

Mating Part

1.50

.50

1.000

4.000

.XX = .01 .XXX = .005 ANGLES = 1

Fig. 8-27 Projected tolerance zone: Problem 9 9. Complete the drawing in Fig. 8-27. Specify a .040 tolerance at MMC with the appropriate projected tolerance.

Geometric Dimensioning and Tolerancing for Mechanical Design

62

Instructors Guide

2X .500-20 UNF-2B

n]w.050mp2.13]A]B]C] C

2.00 1.000

B
6.00

Two Studs

2.12

Mating Part

1.50

1.25

1.000

4.000

.XX = .01 .XXX = .005 ANGLES = 1

Fig. 8-28 Projected tolerance zone: Problem 10 10. Complete the drawing in Fig. 8-28. Specify a .050 tolerance at MMC with the appropriate projected tolerance.

Geometric Dimensioning and Tolerancing for Mechanical Design

63

Instructors Guide

2X .500-.580

2X 1.010-1.045

2.500

.50

Fig. 8-29 Multiple patterns of features: Problems 11 through 13 11. Position the small holes with .000 tolerance at MMC and the large holes with .010 tolerance at MMC; locate them to the same datums and in the same order of precedence. Use maximum material condition wherever possible. 12. Must the hole patterns be inspected in the same setup or in the same gage explain?

Yes, they must be inspected at the same time. The large hole and small hole patterns are tied together by their datums.
13. Can the requirement be changed, how?

Yes, place a note, SEPT REQT, under each feature control frame.
Geometric Dimensioning and Tolerancing for Mechanical Design
64 Instructors Guide

4X .250-.335

.50

3.00 C
1.000

1.000

1.000

2.000

A B
.XX = .01 .XXX = .005 ANGLES = 1

4.00

Fig. 8-30 Composite tolerancing: Problems 14 and 15 14. The pattern of clearance holes in the part in Fig. 8-30 must be located within a cylindrical tolerance zone of .060 at MMC to the datums specified. The plate is designed to be assembled to the mating part with 1/4-inch bolts as floating fasteners. Complete the drawing. 15. It has been determined that the hole pattern in Fig. 8-30 is required to remain parallel, within the smaller tolerance, to datum B. Draw the feature control frame that will satisfy this requirement.

Geometric Dimensioning and Tolerancing for Mechanical Design

65

Instructors Guide

4X .260-.290 $ .422 .010 ^.395 .010

4.00

2.000

1.000

1.000

2.000 5.00

B A

1.00

Unless Otherwise Specified: .XX = .01 .XXX = .005 ANGLES = 1

Fig. 8-31 Counterbore: Problems 16 and 17 16. Tolerance the holes and counterbores in Fig. 8-31 for four .250 socket head cap screws. The counterbores are .422 .010, the depth is .395 .010, and the geometric tolerance is .010 at MMC.

(Limit tolerances may also be used.)

17. If the geometric tolerance for just the counterbores in Fig. 8-31 can be loosened to .020 at MMC instead of .010, draw the entire callout below.

4X .260-.290 4X$ .422 .010 ^.395 .010

Geometric Dimensioning and Tolerancing for Mechanical Design

66

Instructors Guide

3X .50

.50

3X 1.00
3.00 2.000

C
1.000 1.000 1.000

A B

.500 6X R

4.00

Unless Otherwise .XX = .XXX = ANGLES =

Specified: .01 .005 1

Fig. 8-32 Elongated hole: Problem 18 18. Specify a geometric tolerance of .040 at MMC in the half-inch direction and .060 at MMC in the one-inch direction for the elongated holes in Fig. 8-32.

4.000-4.002 1.990-2.000

Unless Otherwise Specified: .XXX = .005 ANGLES = 1

Geometric Dimensioning and Tolerancing for Mechanical Design

67

Instructors Guide

Fig. 8-33 Symmetry: Problems 19 and 20 19. Control the 2.000-inch feature in Fig. 8-33 symmetrical with the 4.000-inch feature within a tolerance of . 020 at MMC to the datum indicated. Use MMC wherever possible. 20. If the controlled feature in Fig. 8-33 happened to be produced at 1.995 and the datum feature produced at 4.000, what would the total positional tolerance be?

.027

Chapter 9 Position, Coaxiality

Chapter Review
Page 163 1. 2. Coaxiality is that condition where the axes of two or more surfaces of revolution are There is a misconception that centerlines or the tolerance block control the between two cylinders. 3. The

coincident

coaxiality

position

control is the appropriate tolerance for coaxial surfaces of revolution

that are cylindrical and require a maximum or least material condition. 4. A

cylindrical

tolerance zone is used to control the axis of a feature

toleranced with a position or a concentricity control. 5. For position, both the tolerance and the datum(s) may apply at what material conditions?

MMC, LMC, and RFS

6. When a coaxiality tolerance and a datum feature of size are specified at maximum material condition,

bonus and shift

tolerances are available in the exact amount of the departures from

maximum material condition toward least material condition.

Geometric Dimensioning and Tolerancing for Mechanical Design
68 Instructors Guide

7.

The upper segment of a composite feature control frame controls the location of the hole pattern to the

location datums
8. The lower segment of a composite feature control frame controls the coaxiality of holes to

one another within the tighter tolerance

9. The smaller tolerance zone of a composite feature control frame with no datums may float

up and down, back and forth, and at any angle to the datums within the larger tolerance zone
10. A mating plug and socket will assemble every time if they are designed to their virtual .

conditions.

Problems
Page 164

1.000

2.00

Unless Otherwise Specified: .XX = .01 .XXX = .005 ANGLES = 1

Fig. 9-7 Specify coaxiality: Problems 1 through 3 1. What controls the coaxiality of the two cylinders on the drawing in Fig. 9-7?

The way the drawing in Fig. 9-7 is shown, nothing controls coaxiality.
Geometric Dimensioning and Tolerancing for Mechanical Design
69 Instructors Guide

2.

On the drawing in Fig. 9-7, specify a coaxiality tolerance to control the 1.000-inch feature within a cylindrical tolerance zone of .004 to the 2.00-inch feature. Use MMC wherever possible.

3.

Now that you have added the feature control frame to the drawing in Fig. 9-7, if the larger diameter is produced at 2.00 inches and the smaller diameter is produced at 1.000 inch, how much total coaxiality tolerance applies?

.019

2X .500-.520

.750
B

1.000

36.00
Unless Otherwise Specified: .XX = .01 .XXX = .005 ANGLES = 1

Fig. 9-8 Specify coaxiality: Problem 4 4. Locate the two holes in the hinge brackets within .030 at MMC to the datums indicated and specify coaxiality to each other. They must be able to accept a .500 hinge pin. Specify MMC wherever possible.
Geometric Dimensioning and Tolerancing for Mechanical Design
70 Instructors Guide

 .745-.750

.751-.755

1.000 .996

1.004 1.000

.000 @ MMC

.001 @ MMC

Fig. 9-9 Specify coaxiality for the plug and socket: Problem 5 5. Control the coaxiality of both parts so that they will always assemble.

Plug MMC Geo. Tol. Virtual Condition

6.

Socket .751 .001 = .750

.750 + .000 .750

Draw and dimension the tolerance zones at MMC on the drawing.

Geometric Dimensioning and Tolerancing for Mechanical Design

71

Instructors Guide

Chapter 10 Concentricity and Symmetry

Chapter Review
Page 173 1. Both concentricity and symmetry controls are reserved for a few

unique tolerancing applications

2. Concentricity and symmetry both employ the same tolerancing different 3.

concept

; they just apply to .

geometries

Concentricity is that condition where the median points of all diametrically opposed points of a surface of revolution are congruent with

the axis (or center point) of a datum feature

4. Concentricity is a

location

control. It has a

cylindrical shaped
. basis. that also only applies .

tolerance zone that is coaxial with 5. Concentricity tolerance only applies on a It must have at least

the datum axis RFS

one datum

at regardless of feature size

6. For concentricity, the aggregate of all must lie within a

cylindrical the datum feature

tolerance zone .

whose axis is coincident with the axis of

Geometric Dimensioning and Tolerancing for Mechanical Design

72

Instructors Guide

7.

Concentricity can be inspected, for acceptance only, by placing a toleranced surface of revolution and rotating the part about the

dial indicator datum axis

on the .

8.

To reject parts and to inspect features such as regular polygons and ellipses, the traditional method of

differential measurements balance

is employed.

9.

The concentricity tolerance is often used to accurately control for high speed rotating parts.

10. Concentricity is time consuming and expensive, to but less expensive to

inspect

, than the runout tolerance.

manufacture median points

11. Symmetry is that condition where the

of all opposed

or correspondingly located points of two or more feature surfaces are with the 12. Symmetry is a

congruent
of a datum feature. control.

axis or center plane location planes

13. Symmetry has a tolerance zone that consists of two parallel evenly disposed about the center 14. Symmetry tolerance only applies at 15. Symmetry must have at least one 16. The aggregate of all

plane or axis RFS datum

that also only applies at

of the datum feature. .

RFS

median points two parallel planes datum feature

73

must lie within a tolerance zone defined by equally disposed about the center plane of the

.
Instructors Guide

Geometric Dimensioning and Tolerancing for Mechanical Design

17. The symmetry tolerance is independent of both 18. Differential measurement excludes

size and form

size, shape, and form

while controlling the median points of the feature. 19. The symmetry tolerance is often used to accurately control for rotating parts or to insure equal

balance
. to

wall thickness time consuming and expensive

20. Specify symmetry only when it is necessary because it is manufacture and inspect.

Problems
Page 175

7.990-8.000

3.995-4.000

Fig. 10-7 Coaxiality of a cylinder: Problem 1 1. The mass of this high speed rotating part above must be accurately balanced. The form of the surface is sufficiently controlled by the size tolerance. Specify a coaxiality control for the axis of the 4.000-inch diameter within a tolerance of .001 at RFS to datum A at RFS.

Geometric Dimensioning and Tolerancing for Mechanical Design

74

Instructors Guide

Fig. 10-8 Coaxiality of an ellipse: Problem 2 2. The mass of the ellipse shown above must be accurately balanced. Specify a coaxiality control that will locate the median points of the ellipse within a tolerance of .004 at RFS to datum A at RFS.

Geometric Dimensioning and Tolerancing for Mechanical Design

75

Instructors Guide

3X 24.990-25.000

Fig. 10-9 Coaxiality of the hexagon: Problem 3 3. The mass of the hexagon shown above must be accurately balanced. Specify a coaxiality control for the median points of the hexagon within a tolerance of .005 at RFS to datum A at RFS.

4.000

2.000-2.004

Fig. 10-10 Symmetry of the slot: Problem 4 4. The part above rotates at a high speed and the mass must be accurately balanced. Specify a geometric tolerance that will centrally locate the slot in this part within a tolerance of .005 at RFS to datum A at RFS.
Geometric Dimensioning and Tolerancing for Mechanical Design
76 Instructors Guide

Chapter 11 Runout
Chapter Review
Page 184 1. Circular runout applies to every

circular element

on

the surface of a part either constructed around a datum axis or perpendicular to a datum axis as the part is rotated 2.

360

about its datum axis.

Where circular runout is applied to surfaces constructed around a datum axis, it controls a combination of variations in

circularity and coaxiality

3.

Where circular runout is applied to surfaces at a 90 angle to a datum axis, it controls variations in

perpendicularity
4.

of circular elements to its datum axis.

Total runout is a compound control that applies to all elements in the surface of a part either

around its datum axis

as the part is rotated 5.

or

perpendicular to its datum axis

360

about its datum axis.

Total runout tolerance applies simultaneously to all and

circular
measuring position.

profile

6.

Total runout applied to surfaces constructed around a datum axis controls a combination of

coaxiality, circularity, straightness, angularity, taper, and profile

variations of the surface. 7. Total runout applied to surfaces at a 90 angle to a datum axis controls the combination of variations of
Instructors Guide 77

Geometric Dimensioning and Tolerancing for Mechanical Design

perpendicularity to the datum axis and flatness

8. The runout feature control frame consists of

a runout symbol, the numerical tolerance, and at least one datum

9. In many cases, two functional

datum diameters

are used to support a rotating part.

10. Where face and diameter datum surfaces are specified, the surface being controlled must first be perpendicular to the

face

datum.

11. Design requirements may make it necessary to restrict datum surface variations with respect to (other geometric controls) straightness,

flatness, circularity, cylindricity, and parallelism.

12. It may be necessary to include a runout control for individual datum features on a

multiple datum feature reference

13. If two or more surfaces are controlled with a runout tolerance to a common datum reference, the worstcase runout between two surfaces is the

sum of the two individual runout tolerances. toleranced

.

14. If two features have a specific relationship between them, one should be

directly to the other and not through a common datum axis

15. Multiple leaders directed from a runout feature control frame may be specified without

affecting the runout tolerance

Geometric Dimensioning and Tolerancing for Mechanical Design

78

Instructors Guide

Problems
Page 185
4.000-4.005

2X .998-1.000

Fig. 11-8 Runout control: Problem 1 1. On the part in Fig. 11-8, control the four-inch diameter with a total runout tolerance of .002 to both 1-inch diameters.

1.995-2.000

1.000 2X .998-1.000

Fig. 11-9 Partial runout: Problem 2 2. On the drawing in Fig. 11-9, specify a circular runout tolerance of .002 controlling the two-inch diameter to both of the 1-inch diameters. This control is a partial runout tolerance one inch long, starting from the left end of the two-inch diameter. Specify a circular runout of .001 for each of the 1-inch diameters.

Geometric Dimensioning and Tolerancing for Mechanical Design

79

Instructors Guide

1.995-2.000

2X .998-1.000

Fig. 11-10 Datums toleranced with a cylindricity tolerance: Problem 3 3. Tolerance the two-inch diameter with a total runout tolerance of .001 to both of the one-inch diameter shafts. Tolerance each one-inch diameter shaft with a cylindricity tolerance of .0005.

Fig. 11-11 Multiple features tolerance with one feature control frame: Problem 4 4. In Fig. 11-11, which datum, A or B, takes precedence?

Datum A is no more important than datum B, and datum B is no more important than datum A.
5. What is the worst possible runout tolerance between the two largest diameters in Fig. 11-11?

.030
Geometric Dimensioning and Tolerancing for Mechanical Design
80 Instructors Guide

Chapter 12 Profile
Chapter Review
Page 200 1. Profile of a line is the

outline

of an object in a plane as the plane passes through the object. 2. Profile of a surface is the result of

projecting the profile of an object on a plane.

or taking cross sections through the object at various intervals. 3. The true profile may be dimensioned with what kind of dimensions?

With basic size dimensions, basic coordinate dimensions, basic radii, basic angular dimensions, formulas, or undimensioned drawings
4. 5. The feature control frame is always directed to the profile surface with a

leader

What symbols do not apply in the tolerance section of profile feature control frames?

Cylindrical tolerance zones and material conditions

6. When the leader from a profile tolerance points directly to the profile, the tolerance specified in the feature control frame is 7.

equally disposed about the true profile

If the leader from a profile tolerance points directly to a segment of a phantom line extending, outside or inside, parallel to the profile, then

all the tolerance is outside or inside the true

.

profile

Geometric Dimensioning and Tolerancing for Mechanical Design

81

Instructors Guide

8.

Where a profile tolerance applies all around the profile of a part, the

all around symbol

9. Draw the all around symbol.

is specified.

10. If the profile is to extend between two points, the points are and a note using the

labeled

between symbol

is placed beneath the feature control frame.

11. Draw the between symbol. 12. If a part is to be controlled with a profile tolerance over the entire surface of the part, the note

ALL OVER
13. Profile tolerances

is placed

beneath the feature control frame

may or may not

have datums.

14. The profile of a surface control usually requires a datum(s) to properly

orient and locate the surface

15. Datums are generally only

. for profile of a line when is being controlled.

not used

the cross section

16. If the design requires a smaller radius than the radius allowed by the profile tolerance, a note such as,

R.015 MAX or, ALL CORNERS R.015 MAX,

is directed to the radius with a

leader geometric tolerances

17. The profile tolerance may be combined with other to

refine

certain aspects of a surface.

Geometric Dimensioning and Tolerancing for Mechanical Design

82

Instructors Guide

18. Coplanarity is the condition surfaces having all

of two or more elements in one plane

.

19. Coplanarity is toleranced with the profile of a surface feature control frame, connected with a leader , to a

phantom line

connecting the surfaces.

20. Where specifying coplanarity, a note indicating is placed beneath the

the number of coplanar surfaces

.

feature control frame

21. Where coplanar surfaces are used as a datum, it is best to attach the datum feature symbol to

the profile feature control frame include a note specifying the number of coplanar surfaces
22. Conicity may be controlled with a

and . . .

profile tolerance composite positional tolerancing

23. Composite profile tolerancing is very similar to

24. The upper segment of a composite profile feature control frame is called the

profile locating control location relationship between the datums and the profile
25. The lower segment, referred to as the

and it governs the . ,

profile refinement control

is a smaller tolerance than the profile locating control and governs

the size, form, and orientation relationship

26. The feature profile must fall inside

of the profile. .

both profile tolerance zones

Geometric Dimensioning and Tolerancing for Mechanical Design

83

Instructors Guide

27. For composite profile tolerancing, there is a requirement and a condition:

Any datums in the lower segment of the feature control frame are required to repeat the datums in the upper segment. The condition of datums in the lower segment of the feature control frame is that they only control orientation
.

28. A second datum may be repeated in the lower segment of the composite feature control frame that also controls

orientation

29. The lower segment of a two single-segment feature control frame acts just like

any other profile control

30. The upper segment of a two single-segment feature control frame allows the smaller tolerance zone to

translate

relative to the datum not repeated in the lower segment within the larger tolerance.

Geometric Dimensioning and Tolerancing for Mechanical Design

84

Instructors Guide

Problems
Page 202

2.000 A

1.800

1.015.015 3X R .750

Fig. 12-15 Profile of a surface: Problem 1 1. Specify a profile of a surface tolerance of .020, perpendicular to datum A, and all around the part in Fig. 12-15.

R2 0 .0 0 C X R1 0 .0 0 X) Y A

6 0 Y 2 0 .0 0

3 0 .0

Fig. 12-16 Profile of a surface between two points: Problem 2 2. For the curved surface and the angle in Fig. 12-16, specify a profile of a surface tolerance of .030,
Instructors Guide

Geometric Dimensioning and Tolerancing for Mechanical Design

85

located to datums A, B, and C, between points X and Y.

3X R1.000

R 3.500

10.000 5.000

2.500 2.000

2.500

6.000 11.000

Fig. 12-17 Locating a profile of a surface: Problem 3 3. Control the entire surface of the center cavity to the datums indicated within a tolerance of .015 outside the true profile. (Outside the profile is external to the true profile line. Inside the profile is within the profile loop.)

Geometric Dimensioning and Tolerancing for Mechanical Design

86

Instructors Guide

3X R1.000

R 3.500

10.000 5.000

2.500

2.500

6.000 11.000

2.000

Fig. 12-18 Locating a mating profile of a surface: Problem 4 4. Control the entire surface of the punch to the datums indicated within a tolerance of .015 inside the true profile. (Outside the profile is external to the true profile line. Inside the profile is within the profile loop.)

Geometric Dimensioning and Tolerancing for Mechanical Design

87

Instructors Guide

4X .375-.415

2.000

1.000 3.000 2.000

A
Fig. 12-19 Coplanarity: Problem 5 5.

TWO SURFACES

The primary datum is the two lower coplanar surfaces. Specify the primary datum to be coplanar within .004.

Geometric Dimensioning and Tolerancing for Mechanical Design

88

Instructors Guide

3 0- 4 X .5 0.5 0 R .0 10 B 2 2- 6 X .6 56 5

2 R .0 X 90 30 .0 0

70 .0 0

10 .0 0 40 .0 0 2 R .5 X 10 80 .0 0 R6 0 1 .0

A
Fig. 12-20 Profile controlled to size feature datums: Problem 6 6.

.XX = .03 .XXX = .010 Angle = 1

Specify controls locating the hole-patterns to each other and perpendicular to the back of the part. Specify a control locating the profile to the hole-patterns and perpendicular to the back of the part within a tolerance of .060. The holes are for 1/2-inch and 5/8-inch bolts.

Geometric Dimensioning and Tolerancing for Mechanical Design

89

Instructors Guide

4X R .300

A C

2.00 2.000

1.000

1.000

5.000

1.00

Fig. 12-21 Composite profile: Problems 7 through 9 7. Specify a profile tolerance for the center cutout that will control the size and orientation to datum A within .010 and locate it to the datums indicated within .060. Complete the drawing. Complete the drawing in Fig. 12-21 8. Draw a profile tolerance below that will satisfy the requirements for problem 7 and orient the cutout parallel to datum B within .010.

9.

Draw a profile tolerance below that will satisfy the requirements for problem 7 and locate the cutout to datum B within .010.

Geometric Dimensioning and Tolerancing for Mechanical Design

90

Instructors Guide

 .500-.540

.190-.220

4.00
C

3.000 2.000 1.000 1.000 2.000 3.500 5.000 6.000 7.00

X) Z TOP SURFACE Z B

6X .250-.300

2.000
X

A TWO BOTTOM SURFACES

Fig. 12-22 Profile of a sheet metal part: Problem 10 10. Specify the bottom of the lower surface of the sheet metal part in Fig. 12-22 coplanar within .020. Tolerance holes with geometric tolerancing. The smallest tolerance for each hole is the virtual condition for the mating part. Specify the profile of the top surface of the part within .040.

Geometric Dimensioning and Tolerancing for Mechanical Design

91

Instructors Guide

Chapter 13 Graphic Analysis

Chapter Review
Page 218 1. List the advantages of graphic analysis.

Provides functional acceptance Reduces cost and time Eliminates gage tolerance or wear allowance Allows function verification of MMC, RFS, and LMC Allows verification of any shape tolerance zone Provides a visual record for the material review board Minimizes storage required
2. List the factors that affect the accuracy of graphic analysis.

The accuracy of the graphs and overlay gage The accuracy of the inspection data The completeness of the inspection process The drawings ability to provide common drawing interpretations

Geometric Dimensioning and Tolerancing for Mechanical Design

92

Instructors Guide

Refer to the feature control frame above for questions 3 through 7. 3. A piece of graph paper with datums, true positions, tolerance zones, and actual feature locations drawn on it is called a 4.

data graph

A piece of tracing paper with datums, true positions, tolerance zones, and actual feature locations traced or drawn is called a

tolerance zone overlay gage

5.

The upper segment of the composite feature control frame, the drawing, and the inspection data dictates the configuration of the

data graph

6.

The lower segment of the feature control frame, the drawing, and the inspection data dictate the configuration of the

tolerance zone overlay gage tolerance zones

7.

If the tracing paper can be adjusted to include all feature axes within the on the tracing paper, the featuretofeature relationships are in tolerance.

Refer to the feature control frame above for questions 8 through 11. 8. To inspect a datum feature of size, the feature control frame, the drawing, and the inspection data dictate the configuration of the 9.

data graph

Draw the actual location of each feature on the data graph. If each feature axis falls inside its respective tolerance zone, the part is

in tolerance

10. If any of the feature axes fall outside its respective tolerance zone,
Geometric Dimensioning and Tolerancing for Mechanical Design
93

the part still may be

Instructors Guide

acceptable if there is enough shift tolerance to shift all axes into their respective tolerance zones
.

11. If the tracing paper can be adjusted to include all feature axes within the tolerance zones on the data graph and the datum axis contained within its tolerance zone while keeping the pattern parallel to datum B, the pattern of features is

in tolerance

Problems
Page 220

4X .190-.205

4.000

2.000

1.000

1
1.000 2.000 5.000 C

4
1.000 A

Unless Otherwise Specified: .XXX = .005 ANGLES = 1

Fig. 13-12 A pattern of features controlled with a composite tolerance: Problem 1 Feature Feature Feature Feature Departure
94

Datum-to-

Feature-toInstructors Guide

Geometric Dimensioning and Tolerancing for Mechanical Design

Number

Location from Datum C X-Axis 1.002 1.005 3.005 3.003

Location from Datum B Y-Axis 1.003 3.006 3.002 .998

Size

from MMC (Bonus)

Pattern Tolerance Zone Size

Feature Tolerance Zone Size

1 2 3 4

.200 .198 .198 .196

.010 .008 .008 .006

.020 .018 .018 .016

.010 .008 .008 .006

Table 13-3 Inspection data for graphic analysis of problem 1 1. A part was made from the drawing in Fig. 13-12; the inspection data was tabulated in Table 13-3. Perform a graphic analysis of the part. Is the pattern within tolerance?

Yes

Geometric Dimensioning and Tolerancing for Mechanical Design

95

Instructors Guide

4X .166-.180

4.000

2.000

1.000

1
1.000 2.000 5.000 C

4
1.000 A

Unless Otherwise Specified: .XXX = .005 ANGLES = 1

Fig. 13-13 A pattern of features controlled with a composite tolerance: Problem 2 Feature Number Feature Location from Datum C X-Axis 1.004 .995 3.000 3.006 Feature Location from Datum B Y-Axis .998 3.004 3.006 1.002 Feature Size Departure from MMC (Bonus) Datum-toPattern Tolerance Zone Size Feature-toFeature Tolerance Zone Size

1 2 3 4

.174 .174 .172 .176

.008 .008 .006 .010

.018 .018 .016 .020

.010 .010. .008 .012

Instructors Guide

Table 13-4 Inspection data for graphic analysis of problem 2

Geometric Dimensioning and Tolerancing for Mechanical Design
96

2.

A part was made from the drawing in Fig. 13-13; the inspection data was tabulated in Table 13-4. Perform a graphic analysis of the part. Is the pattern within tolerance?

No

(The pattern must remain parallel to datum B because datum B has been repeated in the lower segment of the feature control frame.)
If it is not in tolerance, can it be reworked, if so, how?

The pattern will be in tolerance if

hole numbers 2 and 3 are enlarged by about .004.

4X .270-.285

.505-.530

D
2 3

3.000

3.000

1
4.000 4.000

Fig. 13-14 A pattern of features controlled to a size feature: Problem 3

Geometric Dimensioning and Tolerancing for Mechanical Design

97

Instructors Guide

Feature Number

Feature Location from Datum D X-Axis -1.992 -1.993 2.010 2.010

Feature Location From Datum D Y-Axis -1.493 1.509 1.504 -1.490

Actual Feature Size .278 .280 .280 .282 .520

Departure from MMC (Bonus)

Total Geometric Tolerance

1 2 3 4 Datum

.008 .010 .010 .012

Shift Tolerance =

.008 .010 .010 .012 .020

Table 13-5 Inspection data for graphic analysis of problem 3 3. A part was made from the drawing in Fig. 13-14; the inspection data was tabulated in Table 13-5. Perform a graphic analysis of the part. Is the pattern within tolerance?

Yes

Geometric Dimensioning and Tolerancing for Mechanical Design

98

Instructors Guide

4X .214-.225

.375-.390

D
2 3

3.000

3.000

1
4.000 4.000

Fig. 13-15 A pattern of features controlled to a size feature: Problem 4 Feature Number Feature Location from Datum D X-Axis -1.995 -1.996 2.005 1.997 Feature Location From Datum D Y-Axis -1.495 1.503 1.497 -1.506 Actual Feature Size .224 .218 .220 .222 .380 Departure from MMC (Bonus) Total Geometric Tolerance

1 2 3 4 Datum

.010 .004 .006 .008

Shift Tolerance =

.014 .008 .010 .012 .005

Table 13-6 Inspection data for graphic analysis of problem 4 4. A part was made from the drawing in Fig. 13-15; the inspection data was tabulated in Table 13-6.
Instructors Guide 99

Geometric Dimensioning and Tolerancing for Mechanical Design

Perform a graphic analysis of the part. Is the pattern within tolerance? If it is not in tolerance, can it be reworked, if so, how?

No

The pattern will be in tolerance if

all holes are enlarged to their LMC size.

Chapter 14 A Strategy for Tolerancing Parts

Chapter Review
Page 241
1.005-1.020

C 4.00

2.000

3.000 6.00

2.00

Unless Otherwise Specified: .XX = .03 .XXX = .010 ANGLES = 1

Fig. 14-21 A hole located and oriented to datums A, B, and C for questions 1 through 5 1. What category of geometric tolerances applies to the primary datum in a drawing like the drawing in Fig.14-21? 2.

Form tolerance
Instructors Guide

What geometric tolerance applies to the primary datum in the drawing in Fig.14-21?
100

Geometric Dimensioning and Tolerancing for Mechanical Design

Flatness
3. 4. The primary datum controls

the orientation

of the feature being controlled.

If the feature control frame for the hole in Fig. 14-21 happened to be:

What relationship would the 1.005-inch hole have to datums B & C?

The tolerance zone of the one-inch hole would be parallel to datum B and parallel to datum C and at the same time , located with basic dimensions up from datum B and over from datum C.
5. If the feature control frame for the hole in Fig. 14-21 happened to be:

What relationship would the 1.005-inch hole have to datums A, B & C?

The tolerance zone of the one-inch hole would be perpendicular to datum A, located with basic dimensions up from datum B and over from datum C.
6. Complete the feature control frame below so that it will refine orientation to .000 at MMC.

7.

Draw a feature control frame to control a pattern of holes within .125 at MMC to its datums - datums A. B, & C. Refine the tolerance of the feature-to-feature relationship to a .000 at MMC.

Geometric Dimensioning and Tolerancing for Mechanical Design

101

Instructors Guide

8.

What is the orientation tolerance for the pattern of holes in the answer that you specified for question number 7?

Perpendicular to datum A within a cylindrical tolerance zone of

.000 in diameter at MMC.

9. Keeping in mind that the primary datum controls orientation, explain how you would select a primary

datum on a part.

Key points in selecting a primary datum are:

Select a functional surface Select a mating surface Select a sufficiently large, accessible surface that will provide repeatable positioning in a datum reference frame while processing and ultimately in assembly
10. How would you determine which datum should be secondary and which should be tertiary?

The secondary datum may be more important because it is larger than the tertiary datum or because it is a mating surface.

Geometric Dimensioning and Tolerancing for Mechanical Design

102

Instructors Guide

4X .514-.590

3.970 2.500

.500.515 4.235-4.250 C A B

Fig. 14-22 Pattern of features for questions 11 through 17 11. Select a primary datum and specify a form control for it. 12. Select a secondary datum and specify an orientation control for it. The virtual condition of the mating outside diameter is 4.250. 13. Tolerance the keyseat for a 1/2-inch key. 14. Tolerance the 1/2-inch clearance holes for 1/2-inch floating fasteners. 15. Are there other ways this part can be toleranced? How

Yes, the hole pattern could be datum C, or datum C could be left off entirely.
Geometric Dimensioning and Tolerancing for Mechanical Design
103 Instructors Guide

16. If the outside diameter is actually produced at 4.240, how much shift tolerance is available?

If datum B were perfectly perpendicular to datum A, there would be a .010 cylindrical tolerance zone
17. If the outside diameter is actually produced at 4.240 and the keyseat is actually produced at .505, how much can this part actually shift? Sketch a gage about the part.

If datum B were perfectly perpendicular to datum A, The outside diameter could shift back and forth .010 and up and down .005. The part could rotate some.
3X .250-.285 1.000 1.000

C
1.500

1.000

1.000 2X .510-.540

2.000

Fig. 14-23 Two patterns of features for questions 18 through 21

Geometric Dimensioning and Tolerancing for Mechanical Design
104 Instructors Guide

18. Locate the two-hole pattern to the surface datums with a positional tolerance of .085 at MMC. Locate the two holes to each other and orient them to datum A within a tolerance of .010 at MMC. 19. Locate the three-hole pattern to the two-hole pattern within a .000 positional tolerance. 20. The two-hole pattern is specified as a datum at MMC, at what size do the two holes apply?

Virtual condition .500

21. What is the total possible shift tolerance allowed for the three-hole pattern?

If the holes were

perfectly oriented and located and produced at their largest size .540, there would be .040 cylindrical shift tolerance. At worst case out of orientation and position, there would be no shift tolerance.

Geometric Dimensioning and Tolerancing for Mechanical Design

105

Instructors Guide

Problems
Page 244
4X .223-.246 C

4.00 3.000 A

.500 .500 6.00

Unless Otherwise Specified: .XX = .03 .XXX = .010 ANGLES = 1

4.000

2.00

Fig. 14-24 Tolerancing: Problem 1 1. Dimension and tolerance the four-hole pattern for # 10 cap screws as fixed fasteners. Allow maximum tolerance for the clearance holes and 60% of the total tolerance for the threaded holes in the mating part.

(The .223 MMC clearance hole diameter is subject to good engineering judgment. It might very well have been rounded off to .220.)
How flat is datum surface A?

Within .060 in reality probably within .015 1

How perpendicular are datums B and C to datum A and to each other?

Geometric Dimensioning and Tolerancing for Mechanical Design

106

Instructors Guide

.505-.540

3.500 C

1.500

1.500 1.500

2.500

3.000

4X .250-.260

Fig. 14-25 Tolerancing: Problem 2 2. Tolerance the center hole to the outside edges with a tolerance of .060 at MMC. Refine the orientation of the .500-inch hole to the back of the part within .005. Control the four-hole pattern to the center hole. The four-hole pattern mates with a part having four pins with a virtual condition of .250. Give each feature all of the tolerance possible. At what size does the center hole apply for the purposes of positioning the four-hole pattern?

Virtual condition with respect to orientation .500

If the center hole is produced at a diameter of .535, how much shift of the four-hole pattern is possible?

.035 if datum D is perfectly perpendicular to datum A

Instructors Guide 107

Geometric Dimensioning and Tolerancing for Mechanical Design

2X .510-.525

6X .250-.260

.500 3.00 1.500 .500 1.000 1.00 B 4.00 C

Unless Otherwise Specified: .XX = .03 .XXX = .010 ANGLES = 1

.750 1.000 1.500 1.000

Fig. 14-26 Tolerancing: Problem 3 The location of the hole patterns to the outside edges is not critical; a tolerance of .060 at MMC is adequate. The location between the two .500-inch holes and their orientation to datum A must be within .010 at MMC. Control the six-hole pattern to the two-hole pattern within .000 at MMC. At what size does the two-hole pattern apply for the purposes of positioning the six-hole pattern?

Virtual condition with respect to orientation .500

If the two large holes are produced at a diameter of .540, how much shift of the four-hole pattern is possible?

.040

Geometric Dimensioning and Tolerancing for Mechanical Design

108

Instructors Guide