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About iSquare
iSquare
(InterOperability & InterChangeability Solutions) Pune, INDIA
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Focus Areas
CAD Data InterOperability : Consistent representation of 3D CAD data in variety of CAD/CAM/CAE applications and platforms. InterChangeability: Predicting Dimensional Variations, its impact and causes at the product and assembly level at early design stage.
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Relationships
InterOperability: With International TechneGroup Incorporated, USA having more than 20 years of Experience in CAD Data InterOperability technology, solutions and services.
cadfix@isquare-india.com
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Relationships
InterChangeability: With Dimensional Control Systems Inc., USA having more than 15 years of experience in Dimensional Control Techniques, Solutions and Services.
3dcs@isquare-india.com
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Our Offerings
CAD Data InterOperability:
Focused & Customized Training Programs on:
CAD/CAM/CAE Data Exchange : Problems and Solutions from CAD, CAE, CAM Perspective. CAD Model Quality Assessment : CAD Model Quality evaluation from downstream application perspective
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Our Offerings
InterChangeability:
Focused & Customized Training Programs on:
Dimensional Management : Understanding and appreciation of computer aided tools for. Takes participants thru evolution, various approaches and real life problems from their application areas.
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Course Title
Fundamentals and Interpretation of Geometric Dimensioning and Tolerancing (GD&T) as per ASME Y14.5M:1994 Advanced Geometric Dimensioning & Tolerancing (GD&T): Concepts & Applications as per ASME Y14.5M:1994 Tolerance Stack-up Analysis using Co-ordinate System of Dimensioning and GD&T : A practical Approach to Solve Assembly Build Problems CATIA V5 Based GD&T/Tolerance Stack-up Analysis using DCS (Dimensional Control Systems Inc., USA) Software Solutions.
(Covers exposure to 1DCS,DCS-DFC and 3DCS-CAAV5 Analyst)
Duration
24hrs (3 days) 24hrs (3 days) 24hrs (3 days)
Pre-requisite
None
32hrs (4 days)
GD&T and Tolerance Stack-up Analysis for an Automobile: A Practical Approach to Control and Calculate Dimensional Variations Introduction to Dimensioning and Tolerancing Principles for Gages and Fixtures Based on ASME Y14.43:2003 Engineering Limits & Fits with introduction to ANSI B4.2-1978 and ISO-286 Standards Introduction to Digital Product Definition Data Practices (Solid Model Tolerancing) per ASME Y14.41:2003
None
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GD&T
Geometric Dimensioning and Tolerancing
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History
In practice, the parts are produced with some variation to accommodate process capabilities and interchangeability called tolerances Generally, tolerances are specified in plus/minus Plus/minus system worked quite well and even today used in many applications.
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Later, the idea of locating round features such as pins/holes etc, with round tolerance zone rather than traditional square tolerance zone introduced which later caught up and adopted by military standards and late became unified ANSI standard
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Introduction to GD&T
Simple part for own use No need for drawings when designer, inspector and manufacturer are same! Designer often creates an assembly, parts fit together with optimal clearances, He conveys ideal size (nominal dimensions) and shapes to each manufacturer. Volume production?: Impossible to make every part identical Every manufacturing process has unavoidable variations that cause variations in manufactured parts. Designer,with due consideration must analyze how much variation may be allowed in size, form, orientation and location. Then along with nominal dimensions, he must communicate magnitude of such variations or TOLERANCE each characteristics can have and still contribute to functional assembly.
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Often words are inadequate; eg. A note Make this surface a real flat only has meaning where all concerned parties can do following:
Understand English Understand to which surface the note applies and extent of the surface Agree on what Flat means Agree on exactly how flat is Real Flat!!
To overcome miscommunication, throughout 20th century a specialized language based on graphical representations and math has evolved to improve communication. Such language is currently recognized as Geometric Dimensioning and Tolerancing (GD&T)
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ASME Y14.5M-1994 Geometric Dimensioning and Tolerancing ASME Y14.5.1M-1994 Mathematical Definition of Dimensioning and Tolerancing Principals
To avoid confusion, hereafter we will call first standard as Y14.5 and the later as Math Standard Later, we will see differences between other International Standard (more followed in Europe) ISO GD&T and the US dialect. ASME offers no .800. number for help on technical issues and interpretations. At times interpretation could be dispute, so users are advised to refer to text / reference books and your organizations internal staff.
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Designer specifies distance to holes ideal location Manufacturer measures this distance and marks a x spot and drills a hole. The Inspector then measures the actual distance to that hole. ALL THREE PARTIES MUST BE IN PERFECT AGREEMENT ABOUT THREE THINGS: From where to start the measurement? What direction to go? And where measurement ends?
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So,
When measurements are precise to two digits, the slightest difference in interpretation (origin / direction /end )can lead to a usable part or expensive paperweight!! Even if everyone agrees to measure to holes center, a egg shaped hole presents a variety of centers and each center is defensible based on different design considerations You may find claims that GD&T affords more tolerance for manufacturing, but by itself, it doesn't. GD&T affords however much or little tolerance the designer specifies. Just as a common claim that using GD&T saves money, but hardly such claims are accompanied with cost or ROI analyses.
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Drawing of an Automobile Wheel Rotor Has neat and uniform appearance . But leaves many features totally out of control!!
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279.24
139.59
78.79
152.55
68.78 20.80
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Co-ordinate tolerancing is a dimensioning system where a part features are defined by means of rectangular dimensions with given tolerances. Such system has three shortcomings:
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Square or Rectangular Tolerance Zones Fixed Size Tolerance Zones Ambiguous instructions for Inspection
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Mounting face being important for the function of the rotor; has been made flat within 0.1. Later Mounting face assigned as Datum A (foundation for drawing..) Another critical face of Rotor has been made parallel to Datum A within 0.16 The Dia 139 bore has been made Perpendicular to mounting face; therefore directly controlled to our foundation (ie. Datum A) and labeled as Datum B
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Together Datum A and B form a sturdy reference from which dia. 10 bolt holes and other round features can be derived/ located
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Contd
Datum features A and B provide a very uniform and well aligned framework from which a variety of relationships and fits can be precisely controlled. Thus, GD&T provides unique, unambiguous meaning for each control. GD&T then, is simply means of controlling surfaces more precisely and unambiguously. This is fundamental reason for using GD&T. Clear communication assures that manufactured parts will function and that those functional parts will not be rejected later due to misunderstanding / miscommunication. So, fewer arguments Less Scrap.
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Hence, GD&T
Adds clarity over co-ordinate system of dimensioning Eliminates notes on the drawings Depicts designers intent and inspection criteria Most significant difference between GD&T and co-ordinate dimensioning is location of round features. The co-ordinate system had square tolerance zone that rejected some good parts!!
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ROI)
Designers / Manufacturers / Inspectors wasting time to interpret drawings and questioning the designers Rework of manufactured parts due to misunderstanding Inspection deriving meaningless data from parts while failing to check critical relationships. Handling and documentation of functional parts that are rejected! Sorting, reworking, filing, shimming of parts often additional operation. Assemblies failing to operate, failure analysis, Quality problems, Customer complaints, loss of market share, product recall, loss of customer loyalty. Meetings, corrective actions, debates, drawing changes and interdepartmental vendettas resulted from failure! ALL THE ADD UP TO AN ENORMOUS, YET UNACCOUNTED COST. BOTTOM LINE? USE GD&T BECAUSE ITS RIGHT THING TO DO. ITS ALL PEOPLE ALL OVER THE WORLD UNDERSTAND AND IT SAVES MONEY
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Probability. Todays modern precision machine tools have accuracy / repeatability say upto
0.0002mm, therefore, it is assumed that part dimensions should never vary more than that. Further there is no way to predict what process may be used, how many and in what sequence to produce a part. Title Block, or contractual standards. Sometimes, these provide clarification. But often they are very old and inadequate for modern high-precision tools. An example of a title block note is All surfaces to be flat within 0.005
All above laws carries obvious risk. Where designer deems the high risk, GD&T Specifications should be spelled out rigorously .
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Identify part surfaces to serve as origins and provide specific rules explaining how these surfaces establish the starting point and direction for measurement. Convey the nominal (ideal) distances and orientations from origin to other surfaces Establish boundaries and / or tolerance zone for specific attributes of each surface along with specific rules for conformance. Allow dynamic interaction between tolerances (simulating actual assembly possibilities) where appropriate to maximize tolerances.
2.
3.
4.
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Symbols for Limits and fits For example, n12.45LC5 or 30f7 (ANSI B4.1 (inch) or ANSI B4.2 (metric)) Limit dimensioning
12.34 12.30
or
12.45 12.49
24.54+0.35 0.25
or
11.65 0.45
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Millimeter values
When a dimension is less than one mm, zero must precede the decimal point ex. 0.4 NOT .4 When a dimension is a whole number, neither a decimal point nor zero is used ex. 45 NOT 45.00 When a dimension is a whole number and decimal, zero does not follow decimal number ex. 47.5 A dimension does not use a comma or space ex 3450 NOT 3,450 or 3 450 A tolerance for dimension can have more numbers of decimal places than dimension itself. ex. 47`0.34 ` When unilateral dimension is used, no sign be used with zero; ex. 450
+0.76
or
340 0.45
When a bilateral tolerance is used, both; the plus and minus tolerance must have identical number of decimal places ex.
45+0.76 0.45
NOT
34+0.55 0.4
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Millimeter values
54.15
When a limit dimension is used, the decimal places must match. ex:
54.00
NOT
53.15 53
Basic dimension can have any number of decimal places in Feature Control Frame. ex. 50 or 50.35 NOT 50.00
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Few Examples
20.2 means 20.2000 160 means 160.0000 Interpreting 80.5 - 80.2 : -If part measures 80.199 part is rejected - If part measures 80.499 part is accepted
All dimensional limits are absolute. A dimension is considered to be followed by zeros after the last significant digit.
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Exercise 1
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Part Features
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Part Features
Up till now, we used term Surfaces and Features loosely and almost interchangeably. To speak GD&T, we should begin to use terms as defined in Y14.5 Feature is the general term applied to physical portion of a part such as surfaces, pin, tab, hole or a slot. Usually, part feature is a single surface (or a pair of opposed parallel plane surfaces) having uniform shape. You can establish datums from, and apply GD&T controls to features only. There are two general types of features. Those that have built-in dimension of size and those that dont.
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Features of Size
A feature of size is one cylindrical or spherical surface or a set of two opposed elements or opposed parallel surfaces, associated with size dimension. Holes are internal features of size. Pins are external features of size. Features of size are subject to principals of material condition modifiers
(to be discussed later)
Opposed parallel surfaces means the surfaces are designed to be parallel to each other. To qualify as opposed, it must be possible to construct a perpendicular line intersecting both surfaces. Only then, we can make a meaningful measurements of size between them. From now on, we will call this type of feature a width-type feature
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This type of feature is neither a sphere, cylinder, nor width type feature, yet has two opposed elements.
5`0.15 `
12`0.2 `
The D hole for example is called irregular feature of size by some text books. Y14.5s own coverage for this type of feature is limited. Although feature has obvious MMC and LMC boundaries, its arguable whether feature is associated with size dimension For now, well consider this type feature as bounded feature of non size
4.95
11`0.15 `
4.9
=??
5.05
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Material Condition
Material condition is yet another way of thinking about the size of an object considering objects nature.
For example, nature of a pizza is base with topping. If you have exxxtraa topping, its material condition increases and pizza gets bigger and thicker.
The Nature of a cannon is that its void, as erosion decreases its material condition, cannon gets bigger. If a mating feature of size is as small as it can be, will it fit tighter or sloppier? We cant answer until we know whether were talking of internal or external feature (hole / pin), but when you know feature of size has less material, it will fit loosely regardless of its type. In laymans term, Material Condition is features size in the context of its intended function.
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Least Material Condition (LMC l) is the condition in which feature of size contains minimum amount of material within stated limits of size.
One can think of LMC as the condition where the least part material is present at the surface of feature, or where part weighs the least (everything else being same). This translates to largest allowable hole or the smallest allowable pin, relative to specified size limits.
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Basic Dimensions
Basic Dimension is a numerical value used to describe (1) the theoretically exact size, true profile, orientation or (2) a location of feature or a gage information (datum targets). When a basic dimension is used to define part features, it provides nominal location from which permissible variations are established by Geometric Tolerances. Basic dimensions are usually denoted by numerical value enclosed in a rectangle or by addition a general note such as un-toleranced dimensions are basic Basic dimensions must be accompanied by geometric tolerance to specify how much tolerance the part feature may have
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Exercise 2
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GD&T Symbols
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GD&T Symbols
(An attempt to explain Wheel Rotor Drawing w/o GD&T Symbols)
Tedious to Explain requirements, instead use symbols. They are better. Any one can read write symbols Symbols mean exactly same thing to everyone. Symbols are compact and reduce clutter Quicker to draw and CAD softwares can draw them automatically. They can be easily spotted visually. Compare this with GD&Ted Drawing and find all positional callouts !!
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h = size of letter
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Each geometric control for a feature is conveyed on a drawing by a rectangular box called feature control frame. A typical FCF is divided in compartments expressing following sequentially left to right.
Geometric Characteristic Symbol Tolerance Modifying Symbol Geometric Tolerance Value Primary Datum Secondary Datum Datum Material Condition Modifiers Tertiary Datum
1st
2nd
3rd
4th
5th
Compartments
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Attach either side or either end of frame to an extension line from the feature, provided it is a plane surface.
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Attach either side or either end of the frame to an extension of the dimension line pertaining to a feature of size.
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With this, feature control frame shown above is reads as: The Position of this feature shall be within cylindrical tolerance zone of diameter 1 at maximum material condition to primary datum A and to secondary datum B at maximum material condition and to tertiary datum C at maximum material condition Isnt it Easy?
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Summarizing FCFs
FCF is specified to each feature or group of features FCF provides instructions form, orientation and position of features; thus providing setup for mfg and inspection. FCF contain information for proper part orientation in relation to specified Datums
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Four different levels of GD&T control can apply to a feature of size. Each higher level control adds a degree of constraint demanded by features functional requirement; however as we move up the level ladder, the lower level control remain in effect. Thus a single feature may subject to many tolerance simultaneously! Level 1: Controls size and (for cylinders and spheres) circularity at each cross section only Level 2: Adds overall Form Control Level 3: Adds Orientation Control Level 4: Adds Location Control
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Start The
Spine for a cylindrical feature (such as pin / hole) is a simple non-self-intersecting curve in space.
Spine Take
a imaginary steel ball whose diameter = small size limit of the cylindrical feature.
Sweep This
we take another spine and sweep another ball whose diameter = large size limit of the cylindrical feature
This
generates second 3D boundary, this time for the features largest size.
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This shows a cylindrical feature of size conforms to its size limits when its surface can contain the small boundary and be contained within larger boundary.
Under Level 1 Control, the curvatures and relative locations of each spine may be adjusted as necessary to achieve the hierarchy of containments as above; except that the small size boundary shall be entirely contained within large size limit boundary
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As shown in figure left, features of size should achieve clearance fit in an assembly
Designer calculates the size tolerances based on assumption that each feature, internal and external is Straight. In this example, the designer knows that n20.5 max pin will fit in a n20.6 min hole if both are straight.
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Level 2 Control:
20.5
If pin is banana shaped and hole is lazy S shaped, they usually wont go together, because Level 1s size limit boundaries can be curved, they cant assure assemblability. Level 2 adds control of overall geometric shape or form of a feature of size by establishing a perfectly formed boundary beyond which features surface(s) shall not encroach. 20.6
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20.5
19.5 20.5
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Figure above is a drawing for electrical bus bar. Note that cross sectional dimensions have relatively close tolerances, not because bar fits closely inside anything, but rather needed to assure a minimum current carrying capacity without wasting expensive copper. Neither the MMC nor the LMC boundary needed perfectly straight.
However, if bus bar is custom rolled, or machined from a plate, it wont automatically be exempted from Rule #1. In such a case, Rule #1 shall be explicitly nullified by adding a note as shown.
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Rule #1 Arguments
Many experts argue that Rule #1 is actually the exception that fewer than half of all features of size need any boundary of perfect form. Which means, for majority of features of size, Rule #1s perfect form at MMC requirement accomplishes nothing except to drive up costs!! The Solution is that Y14.5 prescribes the perfect form not required note and engineers simply fail to add it more often. Interestingly, ISO defaults to perfect form not required (sometimes called as independency principal) and requires special symbol to invoke the envelope of perfect form at MMC. This is one of the major differences between ISO and Y14.5
Every engineer should consider for every feature of size whether a boundary of perfect form is a necessity or a waste?
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Rule #2
Rule #2 states that in absence of modifier (such as m or l) in tolerance or datum compartment, the tolerance applies on RFS (Regardless of Feature Size) basis. In short, modifier s is no longer used.
15 0.15
0.25
15 0.15
0.25
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Boundaries:
Virtual Condition (Fixed Size) Inner & Outer (Variable Size) Worst Case IB/OB (Fixed Size)
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Virtual Condition is NOT a Control Its a condition of a feature established by collective efforts of Size, Geometric Tolerances and Modifiers Virtual Condition Boundaries can be established for Internal and External Features of size.
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VCB = Hole Size Total Tolerance OR VCB = MMC Size limit Geo Tol
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VCB = Pin Size + Total Tolerance OR VCB = MMC Size limit + Geo Tol
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Tolerance Zone = n0.3 at MMC VCB = MMC + GTol VCB = 12.6 + 0.3 = n12.9 In this case VCB is same as Outer Boundary (worst case)
Tolerance Zone = n0.3 at MMC VCB = MMC - GTol VCB = 13.2 - 0.3 = n12.9 In this case VCB is same as Inner Boundary (worst case)
In either case, controlled feature never encroaches respective VCBs. VCBs lie in air space.
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Tolerance Zone = n0.3 at LMC VCB = LMC - GTol VCB = 12.3 - 0.3 = n12.0 In this case VCB is same as Inner Boundary (worst case)
Tolerance Zone = n0.3 at LMC VCB = LMC + GTol VCB = 13.6 + 0.3 = n13.9 In this case VCB is same as Outer Boundary (worst case)
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In either case, controlled feature never encroaches respective VCBs. VCBs are embedded in material.
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A Worst case Boundary (ie locus) generated by the smallest feature (MMC for Internal Feature and LMC for External feature) minus the stated Geometric Tolerance Value and any additional Geometric Tolerance (if applicable) from the features departure from its specified material condition.
A Worst case Boundary (ie locus) generated by the largest feature (LMC for Internal Feature and MMC for External feature) plus the stated Geometric Tolerance Value and any additional Geometric Tolerance (if applicable) from the features departure from its specified material condition.
It is a general term to refer to the extreme boundary of a FOS that is the worst case for assembly. Depending upon dimensioning method, the WCB can be Inner or Outer or Virtual Condition Boundary.
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OB = n20.15
OB = (n20.15+0.3) = n20.45 n
OB = n20.15
IB = (20 - 0.14)=19.86
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IB = n13.2 - 0.3 = n12.9 OB = n12.6 + 0.3 = n12.9 WCOB = MMC + GTol = n12.9 WCIB = MMC - GTol = n12.9 For External FOS: WCOB = MMC + Geometric Tolerance WCIB = LMC Geometric Tolerance For Internal FOS: WCIB = MMC Geometric Tolerance WCOB = LMC + Geometric Tolerance
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Type of Control
Formula to calculate WCB IB = MMC OB = MMC IB = MMC - GTol OB = MMC + GTol IB = VCB = MMC GTol OB = LMC + GTol + Bonus OB = VCB = MMC + GTol IB = LMC GTol - Bonus IB = MMC GTol Bonus OB = VCB = LMC + GTol OB = MMC + GTol + Bonus IB = VCB = LMC - GTol
FOS with no GD&T FOS with GD&T at RFS FOS with GD&T at MMC
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Bonus Tolerance
Bonus Tolerance is an additional tolerance for geometric control. Whenever a geometric tolerance is applied to FOS and it contains an MMC (m) or LMC (l) modifier in the tolerance portion of FCF, a bonus tolerance is permissible When MMC modifier is used in tolerance portion of FCF, it means the stated tolerance is applies when toleranced FOS is at its maximum material condition. When the actual mating size of feature departs from MMC (towards LMC), an increase in the stated tolerance = amount of departure is permitted. Thus this increase or extra tolerance is called as Bonus Tolerance
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Wide gage (2 plates) Bonus tolerance is an additional tolerance for a geometric control. Bonus tolerance is only permissible when an MMC (or LMC) modifier is shown in the tolerance portion of a feature control frame. Bonus tolerance comes from the FOS tolerance Bonus tolerance is the amount the actual mating size departs from MMC (or LMC)
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Plate Thickness 3.8(mmc) 3.7 3.6 3.5 (lmc)
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Bonus tolerance comes from Size (FOS) Tolerance. In this case, Max bonus=0.2
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In the example at left, pin fitting into a hole. We added a large flange for each part. The requirement is the both flanges shall bolt together and make full contact. This introduces an orientation restraint between two mating features. When flange faces are bolter together tightly, the pin and the hole must be square to their respective flange faces. Though the pin and the hole might each respect their MMC boundaries of perfect form; nothing prevents from boundaries being badly skewed to each other. (see
fig on next page)
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VCB=(n21.5-0.5)=n21
n21
VCB=(n20.5+0.5)=n21
In addition to Level 2 control of perfect form, this new boundary has perfect orientation in all applicable degrees of freedom (360deg) relative to any datum features we select. The shape and size of the virtual condition for orientation are governed by the same rules as for form at Level 2. Again, a single feature of size can subject to multiple levels of control, thus multiple virtual condition boundaries. In figure above, weve restrained virtual condition boundary perpendicular to flange face and shows how matability is assured for any part having a pin that can fit inside its n21 MMC virtual condition boundary and any part having a hole that can contain its n21 MMC virtual condition boundary.
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When flange faces are tightened together with bots and the boss and bore are fitted together, the pin and the hole must each still be very square to their respective flange faces. However the parts can no longer slide freely to optimize the location alignment between the pins and the hole. This necessitates the additional restraint that the pins and holes must be accurately located relative to its respective boss or bore.
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50
For spherical feature, the tolerance is preceded by the Sn symbol and specifies a virtual condition boundary that is sphere. A single feature of size may be subjected to multiple levels of control thus multiple virtual condition boundaries one for each form, orientation, location tolerance applied
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Derived Elements
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Derived Elements
Many Geometric Elements can be derived from any feature. A Geometric tolerance RFS applied to a feature of size controls one of the following:
1. 2. 3. 4. 5.
Derived median line(from a cylindrical feature) Derived median plane (from a width type of feature) Feature center Point (from a spherical feature) Feature Axis (from a cylindrical feature) Feature center plane (from a width type feature)
A Level2 (straightness or Flatness) tolerance nullifies Rule #1s boundary of perfect form at MMC. Instead, a separate tolerance controls overall feature form by constraining a derived median line or derived median plane (according to type of feature)
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Tolerance zone for Straightness control at RFS In above figure, the Straightness tolerance applies RFS by default.This specifies a tolerance zone bounded by two parallel planes, separated by a distance equal to tolerance value, within which the entire derived median plane shall be contained. Both size limits are still in force, but neither the spine for the MMC size boundary nor the spine for LMC size boundary need to be perfectly formed. As you will note, its a difficult deriving a median plane, But where its necessary to control overall form within a tolerance that remains constant, regardless of feature size, there is no simpler options.
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For a cast, forged or rough machined feature to assure stock for cleanup in a subsequent cleanup operation. For a non mating bore, fluid passes etc to protect minimum wall thickness for strength. For a non mating boss around a hole, to protect minimum wall thickness for strength For a gaging features of a functional gage to assure the gage wont clear a non conforming part ..
We dont often see LMC applied to datum features, but consider an assembly where datum features of size pilot two mating parts that must be well centered to each other. LMC applied to both datum features guarantee a minimal offset between the two parts regardless of how the loose the fit. This is a valuable technique for protecting other mating interfaces in the assembly. LMC is an excellent choice for datum references on functional gages.
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Press fits Tapers such as Morse Tapers and countersinks for flat headed screws. Elastic parts, or elastic intermediate parts such as O rings An adjustable interface where an adjusting screw, shim, sleeve etc will be used on assembly to center a mating part.
Certain geometric characteristics, such as run out and concentricity where MMC or LMC are so inappropriate that the rule prohibit material condition modifiers. For these type of tolerances, RFS always applies. RFS principal now apply by default in absence of any material condition modifier. RFS is a poor choice for in clearance fit mating interfaces because it does not allow dynamic tolerance interaction. That means smaller tolerance, usable parts are rejected and higher scarp and costs
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Exercise 3
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Form Tolerances
Straightness Flatness Circularity Cylindricity
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When straightness tolerance FCF is specified as shown in figure above, the tolerance controls only line elements of that feature. The FCF may only appear in a view where the controlled surfaces is represented by a straight line. Tolerance specifies a tolerance zone plane containing a tolerance zone bounded by two parallel lines separated by distance equal to tolerance value. As the tolerance zone plane sweeps the entire feature surface, the surfaces intersection with plane shall anywhere be contained within the tolerance zone (between two lines). Within the plane, the location and orientation of tolerance zone may adjust continuously to part surface while sweeping.
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The tolerance zone applies to surface element The tolerance zone is two parallel lines Rule#1 applies The Outer/Inner Boundary is not affected No tolerance modifiers may be specified The straightness tolerance value specified must be less than the size tolerance. No Datum reference required in FCF The control must be directed to surface elements The straightness control must be applied in the view where the controlled elements are shown as a line
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The tolerance zone applies to the axis or centerplane of the FOS Rule#1 is overridden The Virtual condition or Outer/Inner Boundary of the FOS is affected The MMC Modifiers may be specified in the tolerance portion of the control If tolerance modifiers are specified (MMC), the bonus tolerance applies The straightness tolerance value specified may be greater than the size tolerance. A fixed gage may be used to inspect straightness. No Datum references can be specified in the FCF The control must be associated with a FOS dimension If applied to cylindrical FOS, a diameter symbol n should be specified in the tolerance portion of FCF
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For a width type of feature of size, Rule #1 automatically limits the flatness deviation of each surface. Thus to have any meaning, a separate flatness tolerance applied to either single surface must be less than the total size tolerance. The specified tolerance in the FCF is implied as RFS. MMC/LMC does not apply to flatness control because only surface area is controlled and area have no size
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No Datum references can be specified in the FCF The control must be applied to a planar surface No tolerance Modifiers can be specified in the FCF The tolerance value specified must be less than any other geometric controls that limit the flatness of the surface. The tolerance value specified must be less than the size tolerance.
For a Gasket or a Seal To attach a mating part For better contact of datum feature with datum plane.
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Circularity Tolerance
A circularity tolerance controls a features circularity (roundness) at individual cross section. So, a circularity tolerance may be applied to any type of feature having uniformly circular cross sections, including sphere, cylinders, revolute (cones), tubular shapes, rods, torus shapes. When applied to non-spherical feature, the tolerance specifies a tolerance zone plane containing an annular tolerance zone (ring shaped) bounded by two concentric circles whose radii differ by an amount equal to tolerance value.
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Circularity Application
When Circularity is applied to circular elements:
The diameter must be within its size tolerance The circularity control does not override Rule #1 The circularity tolerance must be less than size tolerance The circularity control does not affect the Boundaries of the FOS No Datum references can be specified in the FCF No Tolerance modifiers can be specified in the FCF The control must be applied to diametrical feature
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Cylindricity Tolerance
A Cylindricity tolerance is a composite control of form that includes circularity, straightness, and taper of a cylindrical feature. A cylindricity tolerance specifies a tolerance zone bounded by two concentric cylinders whose radii differ by an amount equal to the tolerance value. The entire feature surfaces shall be contained within the tolerance zone (between two cylinders). The tolerance zone cylinders may adjust to any diameter, provided their radial separation remains equal to the tolerance value . This effectively removes feature size from cylindricity control. As with the circularity tolerance, a cylindricity tolerance must be less than half the size tolerance to limit multi-lobbed from deviations Since neither circularity nor a cylindricity tolerance can nullify size limits for a feature, there is nothing to be gained by modifying either tolerances to MMC or LMC
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Some designs require form control over a limited length or area of the surface, rather than the entire surface. In such cases, as shown above, draw a thick chain line adjacent to the surface, dimensioned for length and location as necessary. Form tolerance applies only within the limits as indicated by chain line.
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Cylindricity Application
When Cylindricity is applied to cylindrical surfaces:
The diameter must be within its size tolerance The cylindricity control does not override Rule #1 The Cylindricity tolerance must be less than size tolerance The Cylindricity control does not affect the OB of the FOS No Datum references can be specified in the FCF No Tolerance modifiers can be specified in the FCF The control must be applied to cylindrical feature
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Radius Tolerance
A radius is a portion of a cylindrical surface encompassing less than 180o arc length. A radius tolerance denoted by R, establishes a zone bounded by a minimum radius arc and maximum radius arc, within which the entire surface feature shall be contained. By default, each arc shall be tangent to the adjacent part surfaces.
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Where a symbol CR is applied to a radius, the tolerance zone will be as described in previous slide #176. But there are additional requirements for the surface. The surface contour shall be fair curve without any reversals. This means a tangent continuous curve that is everywhere convex or concave.
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Geometric Control
Surface?
FOS?
Use of m or l?
Overrides Rule#1?
Datums referencing?
c e g
No Yes No No
No May* No No
No May* No No
No May* No No
No No No No
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Exercise 4
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Datums
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What is Datum?
A Datum is a theoretically exact point, axis or plane derived from the true geometric counterpart of a specified datum feature. A datum is an origin from which the location or geometric characteristics of features of a part are established. A datum feature is an actual feature of a part that is used to establish a datum. A datum reference is an alphabetic letter specified in a compartment following a Geometric tolerance in a feature control frame. It specifies a datum to which the tolerance zone or acceptance boundary is basically related. A feature control frame may have zero, one,two or three datum references.
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Datum feature begets True geometric counterpart which begets a datum which is building block for Datum Reference Frame, which is the basis of establishing tolerance zone for other features.
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Datum Feature
Recall our session #1, where we said: The first step in GD&T is to identify part surfaces to serve as origins and provide specific rules explaining how these surfaces establish the starting point and direction for measurements Such a part surface is called as datum feature Builders understood the need for a consistent and uniform origin from which to base their measurements. It was a patch of leveled ground once. For precision manufacturing, its a flat surface or a straight and round diameter on a machine part. Although any type of part feature can be a datum feature, selecting one is bit like hiring a CEO who will provide strong moral center and direction for the entire organization. So, what qualifications of CEO should we look for?
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Functional Hierarchy
Its tough to judge leadership from void Spot it intuitively when you see how a prospect (parts and features) relates to each other In the assembly figure left for a car engine, consisting of three parts : Engine block, Cylinder Head and Rocker Arm cover, we intuitively rank the dependencies as: Engine block makes a foundation, to which we bolt on the cylinder head to which in turn we bolt rocker arm cover.
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Each datum feature shall be identified with a different latter of alphabet (except I, O, Q). When alphabets are exhausted, double letters (AA through AZ, BA through BZ etc) are used and compartment is stretched to fit.
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A Datum feature symbol is applied to concerned feature surface outline, extension line, dimension line, or feature control frame (FCF) as follows: (a) Placed on the outline of a feature surface, or on an extension line of feature outline, clearly separated from dimension line, when the datum feature is surface itself.
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(b) Placed on an extension of a dimension line of a feature of size when datum is an axis or center plane. If there is insufficient space for two arrows, one of the arrow may be replaced with datum feature triangle
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( c ) Placed on the outline of a cylindrical feature surface, or the extension of the the feature outline, separated from the size dimension, when the datum is the axis. The triangle may be drawing tangent to the feature
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(d) Placed on a dimension leader line to the feature size dimension, where no geometric tolerance and feature control frames are used.
(e) Placed above or below and attached to the feature control frame when the feature (or a group of features controlled is the datum axis or datum center plane
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Go Slide 302
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Case b
Once datum feature A is simulated, it decides orientation of part. The axis of two small holes shall be parallel to datum A, and perpendicular to datum feature simulator for B Note that small holes axis is not perpendicular to datum feature B No relative movement allowed between datum feature A and its simulator.
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Case c
The axis of two small holes shall be perpendicular to datum feature B To simulate datum feature A, an adjustable gage/fixture is required. No relative movement allowed between datum feature A and its simulator.
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Case d
To simulate datum feature A, a fixed gage/fixture of dia 16.0 is required. relative movement allowed between datum feature A and its simulator. Such relative movement could cause the two small holes to shift more wrt to datum axis A
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TGC Types
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TGC Types
As we have already seen, each type of datum feature has corresponding TGC. Each TGC has either no size, adjustable size or fixed size depending upon type of datum feature and referenced material condition. Also, TGC is either restrained or unrestrained depending on datum precedence
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Adjustable Chuck to Simulate datum feature A Datum Axis A. Same as axis of chuck Stepped Shaft Example
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Datum axis F Expandable mandrel to simulate datum feature F Expandable width to simulate datum feature G
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For features of size and bounded features referenced as datums at MMC or LMC, the TGCs include MMC and LMC boundaries of perfect form, MMC and LMC virtual boundaries, and MMC and LMC profile boundaries.
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Datum shift can result in an additional tolerance for a geometric control Datum shift is only permissible when a modifier is shown in datum compartment of a feature control frame Datum shift results when the AME of the datum feature departs from given material condition (in this case MMC The maximum allowable datum shift is the difference between the gage size (for the datum feature) and LMC size of the datum feature.
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When a special-case FOS datum is referenced at MMC, datum shift may be possible when the datum feature is at MMC
Datum Shift = Fixed gage size AME of Datum feature 340
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A gage pin of dia = VCB of datum feature F = MMCGTol = (58.73 - 0.25) - 0.2 = 58.28
A gage block of width = VCB of datum feature G = MMC-GTol = (18.76 - 0.25) 0.2 = 18.31
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Both the simulators will be perpendicular to datum E. Center plane of G will align with datum axis F
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A B
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Orientation Tolerance
Perpendicularity Angularity Parallelism
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Orientation is features angular relationship to a DRF. An Orientation tolerance controls this relationship without meddling in location control. Thus, an orientation tolerance is useful for relating one datum feature to another and for refining the orientation of a feature already controlled with a positional tolerance.
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An orientation tolerance is specified using a feature control frame one of the three orientation characteristic symbols. The symbol used depends on the basic orientation angle as follows: 0o or 180o parallelism symbol 90o or 270o Perpendicularity Symbol Any other angle Angularity Symbol All three symbols work exactly same. The only difference is that where angularity symbol is used, basic angle should be explicitly specified. Where the parallelism or perpendicularity is used, the basic angle is implied by the drawing view that shows parallel or perpendicular relationship. The feature control frame includes the orientation tolerance value followed by one or two datum references.
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Concentricity Symmetry
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Concentricity Tolerance
Concentricity is that condition where median points of all diametrically opposed elements of figure of revolution (or correspondingly located elements of two or more radially disposed features) are congruent with the axis (or center point) of a datum feature. Concentricity tolerance is a cylindrical (or spherical) tolerance zone whose axis (or center point) coincides with the axis (or center point) of datum feature(s) The median points of all correspondingly located feature(s) being controlled, regardless of feature size, must lie within the cylindrical (pr spherical) tolerance zone. The specified tolerance and datum references can apply on Irregularities in the form of a actual feature to be inspected may make it RFS basis only. difficult to establish the location of that features median point. For Concentricity tolerance requires the establishment example a nominally cylindrical surface of revolution may be bowed or out and verification of features median points of round in addition to being displaced from its datum axis, in such cases
finding median point may be very time consuming. Therefore unless there is definite need to establish median points, it is recommended to use position or runout tolerance. 458
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This is the one part configuration acceptable under concentricity control. While parts as shown in previous slide may get rejected when inspected from concentricity viewpoint, if their median points do not lie in 0.4 central tolerance zone cylinder. Note that there are no material modifiers specified for tolerance value as well as for datum feature reference.
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Symmetry Tolerance
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Symmetry control is same as Concentricity control. The difference is that while concentricity is used on surface of revolution, symmetry is used on planar feature of Size
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Runout Tolerance
Circular Runout Total Runout
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Runout Tolerance
Runout is the oldest and simplest concepts used in GD&T Runout is a composite form, location and orientation control of permissible error in the desired part surface during a complete revolution of part around datum axis
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In precision assemblies runout causes misalignment and/or alignment problems. As shown in figure at left, runout of ring groove diameters relative to pistons diameter may cause rings to squeeze unevenly around the piston or force the piston off center in its bore. A motor shaft that runs out relative to its bearing journals will cause motor to run out of balance shortening its working life. A designer can control such wobble by specifying runout control. There are two levels of runout : Circular Runout Total Runout
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Circular runout tolerance can also be applied to a face or a face groove that is perpendicular to datum axis.Here, the surface elements are circles of various diameters, each concentric to the datum axis and each evaluated separately from the others.
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Profile Tolerance
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Profile Control
What is Profile?
A profile is outline of an object in a given plane (2D figure) Profiles are formed by projecting a 3D figure onto a plane or by taking cross sections through the figure. Such profile can contains straight lines, arcs, curves. If the drawing specifies individual tolerances for elements or points of a profile, these elements or points need individual verification
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Profile Tolerancing
The profile tolerance specifies a uniform boundary along the true profile within which the elements of surface must lie. It is used to control form or combination of size, form, orientation or location. Where used as refinement of size, the profile tolerance must be contained within the size limits. Depending upon design requirements, the tolerance may be divided bilaterally to both sides of true profile or applied unilaterally to both sides of profile. When an equally disposed bilateral tolerance is needed, its necessary to show only FCF with leader directed to surface. For an unequally disposed or unilateral tolerance, phantom lines are drawn parallel to true profile to indicate tolerance zone boundary Phantom line should extend only a sufficient distance to make its application clear.
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Profile Tolerancing
Where a profile tolerance applies all around the profile of a part, the symbol used to designate all around is placed on the leader from the FCF.
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Profile Tolerancing
Where segments of profile have different tolerances, the extent of each profile tolerance may be indicated by the use of reference letters to identify the extreme positions or limits of each requirement.
If some segments of profile are controlled by a profile tolerance and other segments by individually toleranced dimensions, the extend of profile tolerance must be indicated.
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In this case, a part with profile of line tolerance where size is controlled by a separate tolerance. Line elements of the surface along the profile must lie within the profile tolerance zone and within a size limiting zone.
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Where two or more surfaces are involved, it may be desirable to identify specific surface(s) to be used as datum feature(s). Datum feature symbol is applied to these surfaces with appropriate tolerance for their relationship with each other. Datum reference letters are added to the FCF for the features being controlled. The tolerance zone thus established applies to all coplanar surfaces including datum surfaces
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Profile tolerance may be used to control form and orientation of plane surfaces. In this case, profile of surface is used to control a plane surface inclined to a datum feature.
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