Geometric Dimensioning and ‘Tolerancing for Mechanical Design A SELF-TEACHING GUIDE TO THE ASME Y14.5M-1994 STANDARD © Interprets and apples the ASME Y14.5M-1994 Standard © Covers datum and form orientation, and profile control: V Detailed explanation of the ening applications of the poxition contrat + Practice questions and problems at the and of each chapter Gene R. CogarnoGeometric Dimensioning and Tolerancing for Mechanical Design Gene R. Cogorno McGraw-Hill New York Chicago SanFrancisco Lisbon London Madrid Mexico City Milan New Delhl San Juan Seoul ‘Singapore Sydney Torontoa) Professional JQ) Want to learn more? ae We hope you enjoy this McGraw-Hill eBook! If you'd like more information about this book, its author, or related books and websites, please click here.Geometric Dimensioning and Tolerancing for Mechanical Design‘This page intentionally tet blankCopyright © 2006 by Gene R. Cogomo, All rights reserved. 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Underno circumstances shall MeGraw-Hill andor its licensors be liable for any indieect, incidental, special, punitive, consequential or similar damages that result from the use of or inability to use the work, even iff any of them has been advised ofthe possibilty of such damages. Ths limitation of liaility shall apply to any claim or cause what- soever whether such claim or cause arises in contract, tortor otherwise. DOF: 10.1936/0071460705For more information about this title, click here Contents Preface ix Acknowledgments xi Chapter 1. Introduction to Geometric Dimensioning and Tolerancing Chapter Objectives What Is GD&T? When Should GD&T Be Used? Advantages of GD&T over Coordinate Dimensioning and Tolerancing ‘Summary Chapter Review Chapter 2, Dimensioning and Tolerancing Fundamentals Chapter Objectives: Fundamental Drawing Rules Units of Linear Measurement Units of Angular Measurement ‘Types of Dimensions ‘Specitying Linear Tolerances Specifying Angular Tolerances Interpreting Dimensional Limits Dimensioning and Tolerancing for CAD/CAM Database Models ‘Summary ‘Chapter Review Chapter 3. Symbols, Terms, and Rules Chapter Objectives ‘Symbols Terms Rules ‘Summary Chapter Review Problems: @ooenns 10 1" n 12 13 4 14 15 15 17 7 7 30 33 38 39wi Contents Chapter 4. Datums a Chapter Objectives aT Definitian 48 Immobilization of a Part 49 Application of Datums 49 Datum Feature Selection a1 Datuin Feature Identification 54 Inclined Datum Features 52 Cylindrieal Datum Features 52 Establishing Datums 53 Multiple Datum Features 81 A Partial Surface as a Datum Feature 58 Datum Targets 59 Summary 62 Chaptar Review 69 Prablem 86 Chapters. Form eo Chapter Objactives 69 Flatnase 89 Straiahiness 72 Circularity 78 Cylindrieity 2 Froe-State Variation 78 Summary 80 Chapter Review 80 Problems 24 Chapter6. Orientation a Chapter Objectives 87 Parallelism 88 Perpendicutariny 90 Angularity 93 Summary 97 Chaptar Review 7 Problems 400 Chapter 7. Position, General 108 Chapter Objectives 409 Definitian 403 Specitying the Pasition Tolerance 104 Recardless af Feature Size 408 ‘Maxi murh Material Condition 407 Shit Tolerance 409 Least Matarial Condition 112 Boundary Conditions 418Zero Positional Tolerance at MMC Summary Chapter Review Problem = Chapter 8. Position, Location Chapter Objectives Floating Fasteners Fixed Fasteners Projected Tolerance Zones Iultiple Patterns of Features Composite Positional Tolerancing Two Single-Seament Feature Gortrol Frames Nonparallel Holes Countarbored Holes Noncircular Features st Nic Sym metrical Features at MMC Summary Chapter Review Probleme Chapter9. Position, Coaxiality Chapter Objectives Defirition Comparison Between Position, Runout, and Concentricity Specifying © omality at MMC Composita Positional Control of Coaxial Features Tolerancing a Plug and Socket Summary Chapter Review Problem Chapter 10. Concentricity and Symmetry Chapter Objectives Concentricity Sym metry Summary Chapter Review Problem = Chapter 11. Runout Chapter Objectives Definition Cireular Bunout Total Runout Specifying Runout and Partial Punout Multiple Datum Features Camerts vil 446 148 aa 424 125 125 426 428 490 492 498 198 499 498 a 142 146 447 449 1 487 187 189 48g 460 482 162 469 a4 167 4187 487 470 472 473 475 WF a7 v7 a 478 479 478vil Contents Face and Diameter Datum s Geometric Controls ta Refine Datum Features Surface Relationships Betwoon Features Inspecting Runout Summary Chapter Review Problems Chapter 12. Profile Chapter Objectives Definition Specifying Profile Tha Application of Datums A Radius Refinement with Profile Combing Profile Tolerances with Other Geometric Controls Coplanarity Profile of a Conical Feature Com posita Profile Summary Chapter Review Problems Chapter 12. Graphic Analysis Chapter Objectives Advantages of Graphic Analysis Tha Accuracy of Graphic Analysis Analysis of a Composite Geometric Tolerance Analysis of a Pattem of Features Controlledto a Datum Feature of Size Summary Chapter Review Problems. Chapter 14. A Strategy for Tolerancing Parts Chapter Objectives Size Faatures Located to Plane Surface Featuras Size Features Located to Size Features ‘A Pattern of Features Located to a Second Pattern of Features Summary Chapter Fleview Probleme Appendix Incex 473 184 494 4182 499 184 495 187 487 487 498 190 190 191 192 194 195 198 200 208 207 207 207 208 209 249 ony 248 220 225 225 226 294 236 240 244 Daa aa 253Preface This book is written primarily for the learner who is new to the subject of geometric dimensioning and toleraneing (GD&T). The primary purpose ofthis book is to teach the graphic language of GD&T tn a way that the learner can understand and use it in practical applications. It is intended as a textbook to be used in colleges and universities and asa training manual for corporate training programsthatteach engineering, design, drafting, manufacburing, and quality professionals. This book is also appropriate for a self-study course. ‘The material in this book is written in aceordance with the latest revision ofthe geometric dimensfoning and bolerancing standard, ASME Y14.6M-1994. GD&T is a graphic language. To facilitate understanding, there is at least one drawing for each eoneept discussed. Drawings in this text are for illustration purposes only. In order to avoid confision, only the concepts being discussed are eomplebely toleranced. All of the drawings in this book are dimensioned and toleranced with the inch systern of measurement because most drawings produced in the United States are dimensioned with this system. You should be skilled ab reading engineering drawings. Organtzation The discussion of each control starts with a definition, and continues with how the control is specified, interpreted, and inspected. There is a review at the end of each chapter to emphasize key coneapts and ta serve asa self-test. This books is logically ordered so that it can be used as a reference text. A Note to the Learner To optimize the learning process, preview the chapter objectives, the subtitles, the drawing captions, and the summary. Next, review the chapter once again focusing attention on the drawings and at the same time formulating questions about the material. Finally, read the chapter completely, searching for answers to the questions. Comprehending new information from the printed page is only part of the learning process. Retaining it in long-term memory is just as important. Copytight ©2006 hy Gene R. Cagoma. Click hee for tems of use,x Proface ‘Do optimize the learning process an to drive the information into long-term memory, review all new information at the end of the day; raview it again the next day, the nexb week, and the next month, Review is more than just look- ing at the information, Review includes rereading the material, spealking it out loud, or writing it. Some learners leam best with their eyes, others with their ears, and still others learn best by doing. Everyone learns differently, and some students may learn best by doing a combination of these activities or all three. Learners can experiment to determine their own best method of learning. A Note tothe Instructor An instructor's guide is available. The instructor's guide includes teaching strategies, midterm examinations, a final examination, and all ofthe answers, Also, this book is organized in such a way that the instructor ean select ap- propriate material for a more abbreviated course. This text can also be used as supplementary material for other courses, such as mechanical engineering, tan] design, drating, machining practices, and inspection. Using this text and the instructor's guide will greatly facilitate the administration ofa course inGD&T Gene R. CogornoAcknowledgments ‘The author wishes to express partiaular gratitude to his wife, Marianne, forher support of this project and for the many hours she spent reading and editing the mamuseript; also, thanks go to his son Steven, wha devoted considerable time and effort toward shpaing the style of this bodk. The author also wishes to express his thanks to Anthony Teresi and John Jensen for their engineering expertise and editorial comments. Acknowledgments also go to the MeGraw- Hill Professional staff for their technical contributions and editorial comments, A special thanksgoesto.JamesM eadows, the author's first GD &T instructor, for his guidance and support throughout the years. Finally, thanksto the American Society of Mechanical Engineers for permission to reprint excerpts from ASME Y1A.5 M-1994 (R204): all rights reserved. Copytight ©2006 hy Gene R. Cagoma. Click hee for tems of use,‘This page intentionally tet blank‘Source: Geometric Dimensioning and Tolerancing for Mechanical Design Chapter Introduction to Geometric Dimensioning and Tolerancing For many in the manufacturing sector, geometric dimensioning and tolerancing (GD&T}is a new subject. During World War II, the United States manufactured and shipped spare parts overseas for the war effort. Many of these parts were made to specifications but would not assemble. The military recognized that producing parts that do not properly fit or function is a serious problem since lives depend on equipment that functions properly. After the war, a committee representing government, industry, and education spent considerable time and effort investigating this defective parts problem; this group needed to find a way to insure that parts would properly fit and function every time. The result, was the development of GD&T: Ultimately, the USASI Y14.5-1966 (United States of America Standards Institute—predecessor to the American National Standards Institute) docu- ment was produced on the basis of earlier standards and industry practices. ‘The following are revisions to the standard: = ANSI Y14.5-1973 (American National Standards Institute) = ANSI Y14.5M-1982 = ASME Y14.5M-1994 (American Society of Mechanical Engineers) The 1994 revision is the current, authoritative reference document that spec- ifies the proper application of GD&T. Most government contractors are now required to generate drawings that are toleranced with GD&T. Because of tighter tolerancing requirements, shorter time to production, and the need to more accurately communicate design intent, many companies other than military suppliers are recognizing the importance of tolerancing their drawings with GD&T: Downloaded from Digital Engingering Library @ McGraw (wwyigitalengineeringbrarycom) ‘Copyright © 2006 The McGraw-Hill Companies. All ights reserved. ‘Any Use is subject to the Terms of Use as given at the website.2 Introduction to Geometric Dimensioning and Tolerancing Chapter One Conventional tolerancing methods have been in use since the n 1800s, These methods do a good job of dimensioning and tolerancing size fea- tures and are still used in that eapacity today, but they doa poor job of locating and orienting size features. GD&T is used extensively for locating and orient- ing size features and for many other tolerancing applications, Tolerancing with GD&T has a number of advantages over conventional tolerancing methods; three dramatic advantages are illustrated in this introduction. ‘The purpose of this introduction is to provide an understanding of what GD&Tis, why it was developed, when to use it, and what advantages it has over conventional tolerancing methods. With this understanding of GD&T, techni- cal practitioners will be more likely to effectively learn the skill of toleraneing with GD&T. With this new skill, they will have a greater understanding of how parts assemble, do a better job of communicating design intent, and ul- timately be able to make a greater contribution to their companies’ bottom line. Chapter Objectives After completing this chapter, you will be able to * Define GD&T = Explain when to use GD&T * Identify three advantages of GD&T over coordinate toleraneing What Is GD&T? GD&T isa symbolic language. It is used to specify the size, shape, form, orienta- tion, and location of features on a part. Features toleranced with GD8&T reflect the actual relationship between mating parts. Drawings with properly applied geometric tolerancing provide the best opportunity for uniform interpretation and cost-effective assembly. GD&T was created to insure the proper assembly of mating parts, to improve quality, and to reduce cost. GD&T is a design tool. Before designers ean properly apply geometric toler- ancing, they must carefully consider the fit and function of each feature of every part. GD&T, in effect, serves as a checklist to remind the designers to consider all aspects of each feature. Properly applied geometric tolerancing insures that every part will assemble every time, Geometric tolerancing allows the design- ers to specify the maximum available tolerance and, consequently, design the most economical parts. GD&T communicates design intent. This tolerancing scheme identifies all applicable datums, which are reference surfaces, and the features being con- trolled to these datums. A properly toleranced drawing is not only a picture that communicates the size and shape of the part, but it also tells a story that explains the tolerance relationships between features Downloaded from Digital Engingering Library @ McGraw (wwyigitalengineeringbrarycom) ‘Copyright © 2006 The McGraw-Hill Companies. All ights reserved. ‘Any Use is subject to the Terms of Use as given at the website.Introduction to Geometric Dimensioning and Tolerancing Introduction to Geometric Dimensioning and Tolerancing 3 When Should GD&T Be Used? Many designers ask under what circumstances they should use GD&T. Because GD&T was designed to position size features, the simplest answer is, locate all size foatures with GD&T controls. Designers should tolerance parts with GD&T when = Drawing delineation and interpretation need to be the same = Features are critical to function or interchangeability = It is important to stop scrapping perfectly good parts = It is important to reduce drawing changes = Automated equipment is used d = It is important to increase productivity = Functional gaging is req) = Companies want across-the-board savings Advantages of GD&T over Coordinate Dimensioning and Tolerancing Since the middle of the nineteenth century, industry has been using the plus or minus tolerancing system for tolerancing drawings. This system has several limitations: = The plus or minus tolerancing system generates rectangular tolerance zones. A tolerance zone, such as the example in Fig. 1-1, is a boundary within which the axis of a feature that is in tolerance must lie. Rectangular tolerance zones do not have a uniform distance from the center to the outer edge. In Fig. 1-1, from left to right and top to bottom, the tolerance is + .005; across the diag- onals, the tolerance is + ,007. Therefore, when designers tolerance features with + .005 tolerance, they must tolerance the mating parts to accept + .007 tolerance, which exists across the diagonals of the tolerance zones. = Size features can only be specified at the regardless of feature size condition. Regardless of feature size means that the location tolerance remains the same no matter what size the feature happens to be within its size tolerance. If a hole, like the one in Fig. 1-1, increases in size, it has more location tolerance, but there is no way to specify that additional tolerances with the plus or minus tolerancing system. = Datums are usually not specified where the plus or minus tolerancing system is used. Consequently, machinists and inspectors do not know which datums apply or in what order they apply. In Fig. 1-1, measurements are taken from the lower and left sides of the part. The fact that measurements are taken from these sides indicates that they are datums. However, since these datums are not specified anywhere, they are called implied datums. Where datums are Downloaded from Digital Engingering Library @ McGraw (wwyigitalengineeringbrarycom) ‘Copyright © 2006 The McGraw-Hill Companies. All ights reserved. ‘Any Use is subject to the Terms of Use as given at the website.Introduction to Geometric Dimensioning and Tolerancing 4 Chapter One © 3.000-3.030 — 2,000 +005 Figwe 14 The traditional plus or minus tolerancing system. (The axis of the 8-inch hole must fall inside of the .010-ineh square tolerance zone.) implied, the designer has not indicated which datum is more important and has not specified whether or not a third datum is included. Tt would be logical to assume that a third datum does exist because the datum reference frame consists of three mutually perpendicular planes, but this is not specified ‘When locating features with GD&T, there are three important advantages over the coordinate tolerancing system: = The cylindrical tolerance zone = The maximum material condition = Datums specified in order of precedence The cylindrical tolerance zone The cy drical tolerance zone is located and oriented to a specified datum ref- erence frame. In Fig. 1-2, the tolerance zone is oriented perpendicular to datum plane A and located, with basic dimensions, to datum planes B and C. Ba- sic dimensions have no tolerance directly associated with the dimension, thus, eliminating undesirable tolerance stack-up. The full length of the axis through the feature is easily controlled because the cylindrical tolerance zone extends through the entire length of the feature. Unlike the rectangular tolerance zone, the cylindrical tolerance zone defines a uniform distance from true position, the center, to the tolerance zone boundary. When a.014 diameter cylindrical tolerance zone is specified about true position, Downloaded from Digital Engingering Library @ McGraw (wwyigitalengineeringbrarycom) ‘Copyright © 2006 The McGraw-Hill Companies. All ights reserved. ‘Any Use is subject to the Terms of Use as given at the website.Introduction to Geometric Dimensioning and Tolerancing Introduction to Geometric Dimensioning and Tolerancing 5 © 3.000-3.030 ES CMILIOLE | @014@ MMC J esis Terence Zone 8 “The rectangular tolerance zane is \— 2 "Qosin the heonizortal and vertical ‘ireotions, Figure 1-2 A cylindrical tolerance zone compared with a rectangular tolerance zone. there is a tolerance of .007 from true position in all directions. A cylindrical tolerance zone circumscribed about a square tolerance zone, like the one in Fig. 1-3, has 57% more area than the square, in which the actual axis of the feature may lie Figuro 1-3 A cylindrical tolerance zone provides a uniform distance from the axis to the edge, Downloaded from Digital Engingering Library @ McGraw (wwyigitalengineeringbrarycom) ‘Copyright © 2006 The McGraw-Hill Companies. All ights reserved. ‘Any Use is subject to the Terms of Use as given at the website.Introduction to Geometric Dimensioning and Tolerancing 6 — Chapter One Figure 1-4 ‘The size, size tolerance, and feature con~ trol frame for the hole in Fig. 1-2. The maximum material condition ‘The maximum material condition symbol (circle M) in the feature control frame is a modifier. It specifies that as the hole in Fig. 1-2 inereases in size, a bonus tolerance is added to the tolerance in the feature control frame. ‘The limit tolerance in Fig. 1-4 indicates that the hole size can be as small as ® 3.000 (maximum material condition) and as large as @ 3.030 (least material condition). The geometric tolerance specifies that the hole be positioned with a cylindrical tolerance zone of .014 in diameter when the hole is produced at its maximum material condition. The tolerance zone is oriented perpen- dicular to datum A and located with basic dimensions to datums B and C. As the hole size in Fig. 1-2 departs from the maximum material condition toward the least material condition, additional location tolerance, called bonus tolerance, is allowed in the exact amount of such departure. If the hole specified by the feature control frame in Fig. 1-4 is actually produced at a diameter of 3.020, the total available tolerance is a diameter of .034 of an inch. Actual feature size ‘Minus the maximum material condition Bonus tolerance Plus the geometric tolerance Total tolerance ‘The maximum material condition modifier allows the designer to capture all of the available tolerance, Datums specified in order of precedence When drawings are toleranced with the coordinate dimensioning system, da- tums are not specified. The lower and left edges on the drawing in Fig. 1-5 are implied datums because the holes are dimensioned from these edges. But which datum is more important, and is a third datum plane included in the datum reference frame? A rectangular part like this is usually placed in a da- tum reference frame consisting of three mutually perpendicular planes. When datums are not specified, machinists and inspectors are forced to make assump- tions that could be very costly. ‘The parts placed in the datum reference frames in Fig. 1-6 show two interpre- tations of the drawing in Fig. 1-5. With the traditional method of toleraneing, Downloaded from Digital Engingering Library @ McGraw (wwyigitalengineeringbrarycom) ‘Copyright © 2006 The McGraw-Hill Companies. All ights reserved. ‘Any Use is subject to the Terms of Use as given at the website.Introduction to Geometric Dimensioning and Tolerancing Introduction to Geometric Dimensioning and Tolerancing 7 [, 2X @ .510-.530 Unless Othensise Specified X= E01 ANGLES: = £1° Figuo1-5 No datums aro specified on this drawing. it is not clear whether the lower edge of the part should be resting against the horizontal surface of the datum reference frame as in Fig. 1-64 or whether the left edge of the part should be in contact with the vertical surface of the datum. reference frame as in Fig. 1-6B. Manufactured parts are not perfect. It is clear that, when drawings are di- mensioned with traditional tolerancing methods, a considerable amount of in- formation is left to the machinists’ and inspectors’ judgment. If a part is to be inspected the same way every time, the drawing must specify how the part is to fit in the datum reference frame. All of the datums must be specified in order of precedence. Figuo 1-6 Poseible datum interpretation. Downloaded from Digital Engingering Library @ McGraw (wwyigitalengineeringbrarycom) ‘Copyright © 2006 The McGraw-Hill Companies. All ights reserved. ‘Any Use is subject to the Terms of Use as given at the website.