Dimensioning & Tolerancing Principles for Gages & Fixtures Part 3 (Tolerancing Policies)

(to ASME Y14.43-2003)

Bruce A. Harding Mechanical Engineering Technology

Gaging Tolerance Policies

The following slides explain the four gage tolerancing policies, 1) absolute (pessimistic), 2) optimistic, 3) tolerant and 4) practical absolute policies (see PLM Documentation Dimensioning & tolerancing gages & fixturesTerms, for definitions). A gage or fixture designer selects one for specific implementation. Examples are based on this sample workpiece.

Absolute Tolerancing (Pessimistic)

Gage tolerances add material to the gaging element, beginning at the limit [e.g., MMC or virtual condition (MMC concept)] of the feature being gaged. Gages produced in accordance with this policy will accept most part features that are within tolerance, reject all part features not within tolerance, and reject a small percentage of borderline part features that are technically within tolerance.

Optimistic Tolerancing
Applies gagemakers tolerances, wear allowances, measurement un-certainties, and form controls all outside of the workpiece limits of size and geometric control. Gage tolerances subtract material from the gage, beginning at the limit [e.g., MMC or virtual condition (MMC concept)] of the feature being gaged. Gages produced to this policy will accept part features that are within tolerance, reject most features not within tolerance, and accept a small percent of borderline part features that are technically not within tolerance. See next slide too.

Tolerant Tolerancing
is accomplished by applying gagemakers tolerances, wear allowances, measurement uncertainties, and form controls in such a manner that some of the tolerance on the gage is within the workpiece limits of size and geometric control, and some of the tolerance on the gage is outside the workpiece limits of size and geometric control.

Tolerant Tolerancing (Continued)

Gage tolerances both add and subtract material from the gage, beginning at the limit [e.g., MMC or virtual condition (MMC concept)] of the feature being gaged. Gages produced in accordance with this policy will accept most part features that are within tolerance, reject most part features not within tolerance, accept a small percentage of borderline out-of-tolerance features, and reject a small percentage of borderline within-tolerance features.

Practical Absolute Tolerancing

This is accomplished by applying gagemakers tolerances, wear allowances, measurement uncertainties, and form controls in such a manner that all of the tolerance on the size of the gage is inside the workpiece limits of size, but allows geometric tolerance a small infringement on the acceptable virtual condition boundary of the workpiece.

Statistics
Statistical tolerancing can be used to calculate tolerances on parts that are to be gaged. This can increase part yield. However, gages that use the absolute tolerancing method will reject some borderline parts that are technically within drawing tolerances. This is to ensure random interchangeability of mating parts. Statistically toleranced parts commonly use tolerances that allow virtual condition boundaries (MMC concept) to be generated on mating parts that reduce interchangeability. GO and functional gages would then accept some parts with statistically based tolerances that would not assemble in worst-case situations. Actual value distribution is the term associated with the amount a feature has deviated from its perfect geometry. As with the parts being toleranced, it is recommended that gage deviation be studied with respect to a gage features manufacturing process capability and that this be used for analysis and setting of gage tolerances.

Normative References
ASME B4.2, Preferred Metric Limits and Fits ASME B46.1, Surface Texture (Surface Roughness,Waviness, and Lay) ASME B89.6.2, Temperature and Humidity Environment for Dimensional Measurement ASME B89.7.2, Dimensional Measurement Planning ASME Y14.5M-1994, Dimensioning and Tolerancing ASME Y14.5.1M-1994, Mathematical Definition of Dimensioning and Tolerancing Principles

Acknowledgments
The author wishes to acknowledge the support from the Society for Manufacturing Engineers - Education Foundation, SME-EF Grant #5004 for Curriculum Modules in Product Lifecycle Management.