GD&T Book Complete

TMC
GEOMETRIC
DIMENSIONING
&
TOLERANCING
Level II
Design Engineering
Produced by:
Tony M Consulting Pty. Ltd.
25 Clifton Court,
McLaren Vale
SA 5171
AUSTRALIA
Phone/Fax +61 8 83237893

E-mail: tony_meredith@bigpond.com
ABN: 73 073 348 455
T MC
GEOMETRIC
DIMENSIONING &
TOLERANCING
(GD&T)
Curriculum Outline
&
Introduction
1
Tony M Consulting Pty. Ltd
T MC
PHILOSOPHY OF DESIGN
Roll of design Engineers in Industry

Engineering Structures
Cost Effective Design
How & Why things can Go Wrong
Communications (Role of GD&T)
Function
Myths
The Engineers Crutch
Conventions & National Standards
2
1
T MC
DATUM THEORY
What is a DATUM ?
3-Plane Concept.
Datum Features - Planes

- Cylinders
- Targets
Effect of Size & Form
Gauge/Inspection Datum Set-up
Practical exercises
3
T MC
GEOMETRIC CHARACTERISTICS
Symbols (General Outline).
Detailed Discussion, application techniques,

Interpretations & practical exercises.
a) Flatness, Straightness, Roundness & Cylindricity
b) Profiles of Lines & Surfaces
c) Parallelism, Perpendicularity & Angularity
d) Runout, True Position, Concentricity & Symmetry
e) True Position in depth
4
2
T MC
PRACTICAL TOLERANCING
A] Capturing DESIGN INTENT
B] Application
C] Interpretation
D] Drawing Practice
E] Gauging
F] Significant Characteristics
5
T MC
FMEA & GD&T
Function Matrix
Co-ordination & interaction
WORKSHOP
Critique of drawings
Review of real examples from
your organization
6
3
T MC
T h e R ole o f D esign E n g ineers in Ind u stry
The major function of a Design Engineer in Industry today is to Develop information

which permits an idea or concept to be converted into a physical object or system that
precisely meets the functions of that idea or concept.
The Design Engineer plays a pivotal role in manufacturing

organizations
7
T MC
Design A Definition
The PHYSICALISATION
of the
IMAGINATION
8
4
T MC
Traditional:
The traditional structure in Manufacturing Industries is to have a special
Department with its own hierachy. This is further broken down into specialist engineering
functions, such as Product Design,Manufacturing Engineering, Testing etc.
9
T MC
Modern:
Engineers are incorporated into Multi-Functional teams with specific
project responsibilities. The teams usually have members with different disciplines, ie.
Engineers(their sub-disciplines are dependent on the project ), Manufacturing, Quality,
Marketing, Purchasing, Finance, MIS, etc.
Under this type of structure accountability is through the Team Leader

who may or may not be an Engineer.
The ability of the engineer to communicate accurately, under this structure is even
more demanding than in the traditional structure.
10
5
T MC In order to be able to do his/her job properly the engineer must
be trained to understand the following:
1) Laws of Physics as they apply to the concept
2) Mathematics
3) Mechanical systems, their functions & their environmental

limitations
4) Various materials available, their characteristics & applicability
5) Any Legal or other demands relevant to the application of the

concept
6) Costing
7) Testing methods
8) Performance evaluation techniques (statistics)
9) Manufacturing
10)Using TOOLS Effectively (eg. CAD)
11) Effective Engineering Communications
11
T MC
An Engineer s capability is measured according to how well

he/she applies that training to ensure that the resulting system
efficiently performs the idea/concept s function, ie,
SKILL
In order to demonstrate the above capability the Engineer must

be able to COMMUNICATE his/her system requirements in a
way that can be UNDERSTOOD
12
6
T MC C O S T E F F E C T IV E
D E S IG N
Every COMPONENT drawing in whatever form has a cost
C S
O K
S I
T L
L
No. Made No. Made
C
O
S
T
SKILL
The above curves apply to all enterprises, whether producing components,

works of art or making component drawings.
13
T MC
There are many examples in the World which demonstrate that
poorly executed drawings/specifications of an excellent
concept will create a poor reputation for Manufacturing &
Reliability in the Market place,
While well executed drawings/specifications can make a
mediocre/conservative concept achieve an excellent reputation
for Manufacturing & Reliability etc. in the Market place.
Well executed Drawings/Specifications also minimize

problems & delays in the process from Concept to Production.
14
7
T MC
Things That can Go Wrong
Common Problems in Manufacturing Industry
Example A
A component is submitted for Off Tool Sample approval & found not to
perform properly with its interacting components.
WHY ?
1) The component was not made to drawing because:-
a) The supplier made a mistake
b) The Supplier Mis-interpreted the Drawing
15
T MC
Example A (cont d)
2) The component was made to the Drawing BUT:-
a) The Engineer/Draughtsman made a mistake
b) The Engineer/Draughtsman put INCORRECT information on

the Drawing because he/she did not understand fully the
FUNCTIONAL RELATIONSHIP with its interacting
components.
16
8
T MC
Common Problems in Manufacturing Industry
Example B
A component is submitted for Off Tool Sample approval which(after an

extensive test program) was found to work satisfactorily with its
interacting components, although it does NOT CONFORM to the
Drawing
WHY ?
1) The Supplier process was not capable of producing parts within the
Specified tolerance range & making changes to the tooling would jeopardise
the cost &/or the program timing.
17
T MC
Example B (cont d)
2) The Engineer/Draughtsman did not investigate the TRUE tolerance

allowance for the feature(s) because:-
a) He/she played safe in allocating the tolerance(s)
b) he/she did not understand/investigate the true FUNCTIONAL

VARIABLES of the component with its INTERACTING
components.
18
9
T MC
These examples are intended to illustrate some of the

problems that can affect a Company s relationship
with a Customer or the effective operations within the
Company.
Highlighted are the effects of not understanding or using

the means of communication properly between
Designers, Engineers or Draughtsmen with those
responsible for making the Components/Assemblies.
19
T MC
Cost of correction
Design Prototype Tooling Pilot Prodn. Serial Prodn. In Market Prod. Recall
Error Detection Stage
20
10
T MC
IMPORTANT!
Engineering drawings & specifications are
LEGAL DOCUMENTS
1] In respect to contract between Supplier &

Customer.
2] In respect to Product Liability issues that

can arise from the market place
21
T MC
COMMUNICATIONS
Communications between
Human Beings is by means of
LANGUAGE
22
11
T MC
To UNDERSTAND and, to
ensure that you convey the
true meaning of your
Feelings, Needs, Ideas etc.,
the LANGUAGE MUST BE
LEARNED
23
T MC
All languages have common attributes:-
SOUNDS are used to communicate feelings,

needs, ideas etc. directly to another person or
group who understand the spoken language.
SYMBOLS are used to communicate

feelings, needs, ideas etc. to another person or
group who are remote and understand the
written language.
24
12
T MC
WRITTEN communication is also

NECESSARY when continuous reference is
required to ensure that the information does not
change from one reading to the next.
Reliance on VERBAL communication used in

conveying PRECISE information can lead to many
mistakes & so be sources of conflict.
25
T MC
Geometric Dimensioning & Tolerancing

System
-Is the Language that Engineers use to

communicate their requirements of a
component or an assembly so that the end
product meets the DESIGN INTENT-
26
13
T MC
WHY USE GEOMETRIC DIMENSIONING AND TOLERANCING?
Why is it that we should be so interested in this subject?
FIRST AND FOREMOST ITS USE SAVES MONEY!

It saves money directly by providing for maximum producibility of the
part through maximum production tolerances. It provides "bonus" or extra
tolerances in many cases.
It ensures that design dimensional and tolerance requirements, as they
relate to actual function, are specifically stated and thus carried out.
It adapts to, and assists, computerization techniques in design and
manufacture. It ensures interchangeability of mating parts at assembly.
It provides uniformity and convenience in drawing delineation and
interpretation, thereby reducing controversy and guesswork.
27
T MC
WHY USE GEOMETRIC DIMENSIONING AND TOLERANCING?
Aside from the primary reasons stated before there are others of a more general nature:
The intricacies of today's sophisticated engineering design demand new and better ways of
accurately and reliably communicating requirements. Old methods simply no longer suffice.
Diversity of product line and manufacture makes considerably more stringent demands of
the completeness, uniformity, and clarity of drawings.
It is increasingly becoming the "spoken word" throughout industry, the military, and
internationally, on engineering drawings & documentation. Every engineer or technician
involved in originating or reading a drawing should have a working knowledge of this new
state of the art.
28
14
T MC
FUNCTION
How do we define FUNCTION
There are TWO entities that require consideration

from an engineering aspect:
1) An ASSEMBLY (or Sub-assembly)
2) An individual COMPONENT
29
T MC
FUNCTION
1) An ASSEMBLY (or Sub-assembly)
An Assembly (or Sub-assembly) is a group of components

that are joined together and/or interact, such that for a
given physical INPUT manipulates that input to create an
OUTPUT which achieves a desired objective.
30
15
T MC
FUNCTION
2) An Individual COMPONENT
A COMPONENT is a single piece within an Assembly

(or Sub-assembly) that has essential
characteristics/features which interact with other
components in order that the Assembly (or Sub-
assembly) can reliably perform its design intent.
31
T MC Define the CONDITIONS & EXPECTATIONS for the

Functions
Corrosion Resistance
Temperature/Humidity
Environment
Ageing (Accelerated)
Customer
Number of Cycles
&
Life Expectation
Fatigue Legal
Requirements
Interacting Features
Specifications
Critical Features Strength
Mass
Manufacturability
32
16
T MC Function Loss Matrix
Refer ISO/QS 9000 PPAP Manual
1) List all the Features of the Component/system/assembly.
2) Indicate which features have a DATUM function
3) Determine the Criticality/Severity Rating if those features are

OUTSIDE the Specification [L-Low, M-Medium or H-High]
4) Indicate each feature s dependence [datum reference]
5) Indicate the control symbol(s) appropriate to each feature
6) Review the Matrix
33
T MC Design Function/Relationship Matrix
Component/Sub-Assy. Pt. No.

(Dimensioning)
Datum Criticality Rating Control Symbol

Feature Seco Siz Positio Shap Prim. Sec.
Prim Tert. Datum Datum
n e n e
A
Surface
B
Hole
C
Hole
D
Thicknes
s
E
Width
Etc.
34
17
T MC MYTHS
1) Using GD&T increases Cost !!
Proper use of GD&T reduces cost by

MAXIMISING the tolerances of features.
It is provable that the cost of production of a feature

increases according to the inverse of the size of the
tolerance
35
T MC MYTHS
2) Computer generated Data/Drawings are precise

& do not require additional information !!
Complex surfaces such as styled features must still be

located in a mechanical environment within an
acceptable tolerance.
Eg. A instrument panel surface profile must be

located so that it fits properly in its environment so
that the overall style of the interior of the vehicle
meets the designers intent.
36
18
T MC MYTHS
3) GD&T can not be applied to all situations !!
GD&T is not just the use of a library of symbols, but a

LANGUAGE to communicate design intent.
If a situation occurs during the establishment of functional
requirement of a feature that is not covered by the standard
library then the requirement can be noted using the
GD&T principles to convey that requirement.
Use the GD&T language/vocabulary in a combination

that truly conveys the DESIGN INTENT
37
T MC
What is the Engineers CRUTCH ?
That note on the drawing that classifies the tolerance

according to the number of decimal points on the
feature dimension.
0 ---------- +/- 1 mm
0.0---------+/- 0.2 mm
0.00--------+/- 0.1 mm
38
19
T MC
What should we do instead?
1) Refer to the Function Matrix for guidance to

evaluate the REAL tolerance requirement.
2) Are there any formal standards that cover the function

that is required? Eg, Hole/shaft fits, Injection moulding
tolerances, codes of practice etc.
3) Consider how the feature will be Manufactured,

& what is the relative cost in Tooling & Piece cost.
39
T MC
International Standards & Conventions
Agreement between US ANSI/ASME & ISO Standards

covering GD&T is about 90 95% .
Other national standards such as Australian Stds. Are generally
aligned with ISO.
Overall it can be considered that the GD&T language is
UNIVERSAL in its application & understanding. Ie, no matter
which ethnic group needs to know what the designers intent is,
can understand, provided the GD&T language is understood.
40
20
T MC Standards necessary for GD&T coverage
ANSI/ASME Y14.5M
The following documents must be considered when adopting ISO/GD&T standards

1. 15011101- Technical Drawings Geometrical tolerancing
2. ISO/5458- Technical Drawings Positional tolerancing
3. ISO/5459- Technical Drawings Datums and Datum Systems
4. ISO/2692- Technical Drawings Maximum material principle
5. ISO/3040- Technical Drawings Cones
6. ISO/1660- Technical Drawings Profiles
7. ISO/129- Technical Drawings General principles
8. ISO/406- Technical Drawings Linear and angular dimensions
9. ISO/10578 Technical Drawings Projected tolerance zones
10. ISO/2692:1988/DAM 1 Technical Drawings Least material principle
11. ISO/8015 Technical Drawings Fundamental tolerance principle
12. ISO/7083 Technical Drawings Symbols proportions
13. ISO/10579 Technical Drawings Non-rigid parts
Additional 1S0 standards involved:

1. ISO/1000 - SI Units
2. ISO/286 - Limits & Fits
3. ISO/TR5460 Technical Drawings-Verification principles
4. ISO/2768-2 General geometrical tolerances
5. ISO/1302 - Surface Texture
6. ISO/2768-1 Tolerances for linear and angular dimensions
7. Other peripheral standards on screw threads, gears, drills, welding, etc., may also
be required for coverage beyond Y 14.5 for product design.
41
T MC
Complete Symbols
List
Items Marked #
are not
described in
detail in this
course as they
are self
explanatory
42
21
T MC
GEOMETRIC
DIMENSIONING &
TOLERANCING
(GD&T)
Session 1
43
T MC
Geometric Dimensioning &
Tolerancing System-
-Isthe Language that Engineers use

to communicate their requirements
of a component or an assembly so
that the end product meets his
-DESIGN INTENT-
44
22
T MC
FUNCTION
An ASSEMBLY (or Sub-assembly) is a group of

components that are joined together or interact such that
for a given physical INPUT manipulates that input to
create an OUTPUT which achieves a desired objective
A COMPONENT is a single piece within an

Assembly (or Sub-assembly) that has essential
characteristics/features which interact with other
components in order that the Assembly (or Sub-
assembly) can perform its DESIGN INTENT.
45
T MC Fundamental Dimensioning Rules[Y14.5]

1] Each dimension shall have a tolerance, except those dimensions specifically identified as
reference, maximum, minimum or commercial stock size.
2] Dimensioning & tolerancing will be complete so there is full definition of each part feature
3] Dimensions shall be selected & arranged to suit the function & mating relationship of a part
& shall not be subject to more than one interpretation.
4] The drawing should define a part without specifying manufacturing methods
5] A 90 angle applies where centrelines & lines depicting features are shown on a drawing at
right angles, & no dimension is shown.
6] A 90 angle applies where centrelines of features in a pattern or surfaces shown at right
angles on a drawing are located & defined by BASIC dimensions, & no angle is specified.
7] Unless otherwise specified, all dimensions are applicable at 20C.
8] All dimensions & tolerances apply in a free state condition (unless otherwise specified). This
principle does not apply to nonrigid parts.
9] Unless otherwise specified, all geometric tolerances apply to the full depth, length &
width of the (subject) feature.
10] Dimensions & tolerances apply only at the drawing level where they are specified. A
dimension specified on a detail drawing is NOT mandatory for that feature on the assembly
drawing. 46
23
T MC
Rule #1:
Where only a
tolerance of size
is specified, the
limits of size of
an individual
feature
prescribe the
extent to which
variations in its
form as well as
its size are
allowed.
[Y14.5]
ie Perfect
form at MMC
or the
Envelope rule
47
T MC RFS
Examples:
Rule #2:
Regardless of
0.12 A C B
Feature Size
[RFS] applies,
with respect to
individual
tolerances, 0.12 M A M C B L
datum
references or
both where no
modifying
symbol is
specified. Maximum Least
[Y14.5] RFS is the Material Material
default Condition Condition
condition in
the absence of
any
modifier. 48
24
T MC
What is a Tolerance ??
A TOLERANCE is the TOTAL amount by

which a feature may vary from the perfect
conditions of Structure, Size, Shape and/or
Position while the Design Intent is
maintained.
49
T MC
DATUM THEORY
What is a DATUM ?
3-Plane Concept.
Datum Features - Planes
- Cylinders
- Targets
Effect of Size & Form
Gauge/Inspection Datum Set-up
Practical exercises
50
25
T MC
What is a DATUM ??
A DATUM is:-
1) A theoretically exact point, axis or plane derived from the

true geometric counterpart of a specified datum feature .
2) The origin from which the location of geometric

characteristics of features of a part are established.
51
T MC Degrees of freedom
To stabilize a
part in Space
All 6 Degrees
of Freedom
MUST be
controlled
52
26
T MC Attributes of a cylinder as a Datum feature
Cylindrical form
may be a hole,
spigot or shaft.
53
T MC Problem of IMPLIED Datums
54
27
T MC
CONTROL SYMBOLS
XXX BASIC
MAX. MATERIAL
CONDITION
TANGENT PLANE
LEAST MATERIAL
FREE FORM
CONDITION
DATUM
DIAMETER
PROJECTED TO:-
DATUM TARGET
A
CR CONTOLLED ST Statistical Tolerance
RADIUS
55
T MC Control Symbols
XXX.XX BASIC
BASIC dimensions are only used to LOCATE

Tolerance Zones
A DATUM
This edge to be located

at the feature or surface
DATUM TARGET nominated as the datum
A1
Used to indicate points
or areas on a surface
which together form the
DATUM reference.
56
28
T MC Problem of IMPLIED Datums
CONFUSION!!!!
57
T MC
EXAMPLES WITH DATUMS
NO CONFUSION!!!!!
58
29
T MC Datum prioritisation why?
59
T MC
ESTABLISHING DATUM PLANES FROM DATUM SURFACES/FEATURES
3 PLANE CONCEPT- DATUM REFERENCE FRAME
ESTABLISHING THE DATUM PLANES
60
30
T MC
Datum Plane
(Surface)
61
T MC Datum Plane
(Surface)
Surface
nominated as
Datum
Note! Datum symbol is

NOT at the feature size
62
31
T MC DATUM TARGET SYMBOLS
Datum Target Symbols are used to

establish datum planes & part orientation
63
T MC DATUM TARGETS
64
32
T MC DATUM TARGETS
1
3
65
T MC Surface to surface [Formed part]
Secondary Datum
Tertiary Datum
Primary Datum 66
33
T MC
Partial Surface datum target
Pressure Applied to
simulate function
Less than
Height
tolerance
Functional location
67
T MC
?
Requires
Flatness or
similar callout
68
34
T MC Locations on Casting surface for Machining
69
T MC Feature nominated
as Datum
Feature nominated
as Datum
Establishing Datum Centre

Planes from Datum Features
Surface nominated Note! RFS
as Datum
CAUTION!
The FUNCTIONAL
requirements should be
carefully considered
before use
70
35
T MC Axial Location [position]
established by Datum Target
Secondary Datum
Primary Datum
71
T MC Features as Datums
72
36
T MC Attributes of a hole[cylinder] as a Datum feature
73
T MC Attributes of a hole[cylinder] as a Datum feature
74
37
75
76
38
Features as Datums
T MC
Datum features
Datum Surface
77
T MC Feature Pattern as Datum
78
39
79
T MC
1] The Datum Feature
Simulator is the surface of
Manufacturing or
Verification equipment
2] The Datum Axis is

derived from the Datum
Feature Simulator
Note! Simulated Datum

Features are used as the
practical embodiment of
the Datums during
manufacture &
Inspection
80
40
T MC SURFACE(3)
(wedge)
SURFACE(2) PIVOT(2)
PIVOT(1)
SURFACE(1)
+ PIVOT(3)
Feature(hole)
81
T MC
BELLCRANK
0.75 in
3.002 in
1.125 in 0.813 in
5 in
4.251 in
1.501 in
0.49 in
82
41
T MC
Nominate the
DATUM features that
are used to control the
fasteners locations
B
B
A
A
83
Tony M
Tony
Consulting
M Consulting
Pty. LtdPty. Ltd
T MC Nominate the DATUM features that are used

to control the locations of the COVER &
KEY to the BODY
84
42
T MC
CONTROL SYMBOLS
XXX BASIC
MAX. MATERIAL
CONDITION
TANGENT PLANE
LEAST MATERIAL
FREE FORM
CONDITION
DATUM
DIAMETER
PROJECTED TO:-
DATUM TARGET
A
RADIUS
85
T MC Control Symbols
Maximum Material Condition

M MMC
Least Material Condition

L LMC
P Projected Tolerance Zone
CR Controlled Radius
86
43
T MC M
Maximum Material Condition
MMC
The MMC principle is normally only valid when BOTH of the

following conditions are fulfilled:
-Two or more features are interrelated with respect to
orientation or location [eg, a hole & an edge or surface, two
holes, etc.]. At least ONE of these related features is to be a
feature of size.
-- The feature(s) to which the MMC principle is to apply MUST
be a feature of size [eg, a hole, slot, shaft, etc] with an axis or
centre plane.
Application of this Modifier in the

context of applicable Geometric
Controls allows BONUS
tolerance as the actual feature of
size departs from the MMC
condition.
87
T MC Least Material Condition

L LMC
The condition of a feature of size which contains the

least amount of material within the stated limits of size
[eg, smallest pin, largest hole.
NOTE! The least material condition may be a NOTE! Rule #1 allows feature
desirable alternative to MMC under certain distortion within the MMC
design function requirements. Envelope
88
44
T MC
P Projected Tolerance Zone
Usually used in context of Position control

of Tapped Holes or Locating Pin holes
[ Fixed Fastener applications]
0.08 M P 6.4 A B M C
Projected Tol Zone 6.4mm,

usually equal to max.
thickness of mating part or
total protrusion of fixed
fastener.
89
T MC CONTROLLED RADIUS
Note! The
magnification limit
MUST be stated to
appropriate to the
function!!
90
45
T MC
CONTROL SYMBOLS
XXX BASIC
MAX. MATERIAL
CONDITION
TANGENT PLANE
LEAST MATERIAL
FREE FORM
CONDITION
DATUM
DIAMETER
PROJECTED TO:-
DATUM TARGET
A
RADIUS
91
T MC TANGENT PLANE
Applicable to the
0.1 T A following Geometric
controls:
Function Note!
-Only the tangent plane of the
toleranced surface must be within the
tolerance zone.
-The flatness of the surface is NOT
controlled by the modifier. 92
46
T MC FREE FORM
Principle: Applicable to parts that are non rigid or liable to distortion under certain
conditions.
Conditions of support must be specified before determination of

conformance to specification.
Free State feature of size may be specified if the correct constraint

conditions of assembly can be met.
Example
F
M12 Bolt Torque 35-
40Nm before checking
93
T MC Statistical
ST
Tolerance
This modifier may be used to indicate that the

associated dimension is derived from a statistically
dependent assembly condition & that interacting
component features are similarly derived.
The resultant assembly condition MAY NOT
function correctly if the combination of assembled
parts are at extremes of the permitted tolerances.
May be used in the context of selective assembly of
very close tolerance features.
ST
6.15 +/- 0.08
94
47
T MC BONUS TOLERANCES
Bonus Tolerances are :-

Additional tolerances
for Geometric control.
Only permissible when
an MMC or LMC
modifier is shown in the
feature control frame.
Only come from the
actual feature
tolerance.
The amount of bonus
is only the amount the
actual mating size
departs from MMC or
LMC.
95
T MC

96
48
T MC
TOLERANCES OF FORM
For Single Feature

For Related Features
FLATNESS
SQUARENESS
PERPENDICULAR
STRAIGHTNESS TO:-
ANGULARITY
ROUNDNESS
CIRCULARITY
PARALLEL TO:-
CYLINDRICITY
RUNOUT
PROFILE
TOTAL RUNOUT
SURFACE
97
T MC
TOLERANCES OF POSITION
TRUE POSITION
CONCENTRICITY
SYMETRY
98
49
T MC
FLATNESS
Note! Surface finish
control can be used in
conjunction with
Flatness control BUT
NOT instead of Flatness
control
99
T MC FLATNESS
Inspection & Gauging methods
100
50
T MC STRAIGHTNESS
[Applied to a FLAT surface]
101
T MC STRAIGHTNESS
[Applied to a cylinder]
102
51
T MC STRAIGHTNESS
MAX. MATERIAL
(Use of Modifier) CONDITION
DIAMETER
103
T MC STRAIGHTNESS
Compare with
Cylindricity
call out later
104
52
T MC STRAIGHTNESS Unit Length Basis
Compare with
Cylindricity
call out later
105
T MC ROUNDNESS (CIRCULARITY)
106
53
T MC Roundness of a Cone
107
T MC Inspecting Roundness
108
54
T MC Roundness of a Sphere
109
T MC CYLINDRICITY
110
55
T MC
Cylindricity & Roundness
0.05 M 0.10/25 M
Part or Element length
25mm
111
T MC ROUNDNESS & CYLINDRICITY

EVALUATION
112
56
T MC PROFILE
42
33
113
T MC SURFACE
114
57
T MC
115
T MC Application of
Tolerance Zone
Profile or Surface
Equi-spaced either side NOMINAL is Least NOMINAL is

of the NOMINAL form Material Condition Maximum Material
(LMC) Condition (MMC)
116
58
T MC Complex Surface or Profile
117
T MC Complex Surface or Profile
118
59
T MC
119
GEOMETRIC
DIMENSIONING &
TOLERANCING
(GD&T)
Session 2
120
60
T MC

121
TOLERANCES OF FORM
For Single Feature

FLATNESS
SQUARENESS
PERPENDICULAR
STRAIGHTNESS TO:-
ANGULARITY
ROUNDNESS
CIRCULARITY
PARALLEL TO:-
CYLINDRICITY
RUNOUT
PROFILE
TOTAL RUNOUT
SURFACE
122
61
SQUARENESS
PERPENDICULAR
TO:-
123
SQUARENESS
PERPENDICULAR
TO:-
124
62
SQUARENESS
PERPENDICULAR
TO:-
125
SQUARENESS
PERPENDICULAR
TO:-
126
63
SQUARENESS
PERPENDICULAR
TO:-
127
SQUARENESS
PERPENDICULAR
TO:-
128
64
SQUARENESS
PERPENDICULAR
TO:-
129
SQUARENESS
PERPENDICULAR
TO:-
130
65
ANGULARITY
131
ANGULARITY
132
66
ANGULARITY
133
PARALLEL TO:-
Form tolerance
MUST be Less than
size tolerance
134
67
PARALLEL TO:-
135
PARALLEL TO:-
136
68
PARALLEL TO:-
137
PARALLEL TO:-
138
69
PARALLEL TO:-
139
PERPENDICULAR
PARALLEL TO:- TO:- FLATNESS
140
70
T MC
TOLERANCES OF FORM
For Single Feature

FLATNESS
SQUARENESS
PERPENDICULAR
STRAIGHTNESS TO:-
ANGULARITY
ROUNDNESS
CIRCULARITY
PARALLEL TO:-
CYLINDRICITY
RUNOUT
PROFILE
TOTAL RUNOUT
SURFACE
141
T MC
CO-AXIAL FEATURES
Selection of Proper Control
There are four characteristics for controlling interrelated coaxial features:
1. RUNOUT TOLERANCE (circular or total) (RFS)
2. POSITION TOLERANCE (MMC or RFS)
3. CONCENTRICITY TOLERANCE (RFS)
4. PROFILE OF A SURFACE (RFS DATUM)
Any of the above methods provides effective control. However, it is important to select the
most appropriate one to both meet the design requirements and provide the most economical manufacturing
conditions. (See also details of preceding and following sections.)
142
71
T MC CO-AXIAL FEATURES
If the need is to control only CIRCULAR cross-sectional elements in a composite

relationship to the datum axis, RFS, e.g., multi-diameters on a shaft, use:
CIRCULAR RUNOUT EXAMPLE
(This method controls any composite error effect of circularity, concentricity, and
circular cross-sectional profile variations.)
If the need is to control the TOTAL cylindrical or profile surface in composite

relative to the datum axis RFS, e.g., multi-diameters on a shaft, bearing mounting
diameters, etc., use:
TOTAL RUNOUT EXAMPLE
(This method controls any composite error effect of circularity, cylindricity,

straightness, co-axiality, angularity, and parallelism.)
NOTE Runout is always implied as an RFS application. It cannot be applied on an
MMC basis, since an MMC situation involves functional interchangeability or
assemblability (probably of mating parts), in which case POSITION tolerance
would be used. See later. 143
T MC CO-AXIAL FEATURES
If the-need is to control the total cylindrical or profile surface and its actual mating envelope axis relative to the
datum axis on an MMC or RFS basis, e.g., on mating parts to assure interchangeability or assemblability, use:
POSITION (IF MMC) EXAMPLE

This will be dealt with in
(IF RFS) EXAMPLE
detail in the session on
OR RFS DATUM POSITION
If the need is to control the axis of one or more features in composite relative to a datum axis, RFS, e.g., to control
such as balance of a rotating part, use:
CONCENTRICITY EXAMPLE See Concentricity
NOTE Concentricity is always implied as an RFS application. Variations in size (departure from MMC size, out-of-
circularity, out-of-cylindricity, etc.) do not in themselves conclude axis error.
If the need is to control the total cylindrical or profile surface simultaneously with the size
dimension(s) (using basic dimensions for both), relative to a datum axis, e.g., precise fit, multi- diameters, etc., use:
PROFILE OF A SURFACE EXAMPLE
144
72
T MC RUNOUT TOTAL RUNOUT
145
T MC RUNOUT
146
73
T MC RUNOUT
147
Dimensioning a conical form

Dwg. callout
18.5+/- 0.1 ?
6.5 +/- 0.1

15.00
10.00
0.03 A 0.03 A
0.03 A 148
74
Dimensioning a conical form
Meaning
18.6 0.042
6.4
15.00
10.00
6.6
A
18.4 0.03
0.03 A
149
T MC TOTAL RUNOUT
Feature may be bent 150

75
T MC TOTAL RUNOUT
RUNOUT
Feature can only be bent or

tapered within Runout tolerance
Feature may be bent or

tapered within feature tolerance 151
T MC TOTAL RUNOUT RUNOUT
?
?
152
76
?
?
?
?
Establish common
AXIS between
DATUM
DIAMETERS
153
?
FUNCTION
MUST
Determine
the primary
datum
154
77
155
T MC TOTAL RUNOUT
NON FUNCTIONAL
Datums used to enable
efficient manufacturing
PROCESS
IMPORTANT!
Consider Functional
relationships when
establishing
Dimensions
&Tolerances 156
78
T MC TOTAL RUNOUT
157
T MC TOTAL RUNOUT
158
79
T MC TOTAL RUNOUT
? ?
159
T MC TOTAL RUNOUT
Axial float occurs

during rotation
160
80
T MC TOTAL RUNOUT
Function must be considered

in respect to these
interpretations to determine
correct dimensions &
tolerances (& Datum
reference)
161
T MC TOTAL RUNOUT
Target Datum would

Minimize effect of
surface irregularities
162
81
T MC TOTAL RUNOUT
163
T MC TOTAL RUNOUT
IMPORTANT!
30
TOTAL RUNOUT CAN ONLY BE
APPLIED TO SURFACES OR
FEATURES THAT ARE CO-AXIAL,
PARALLEL OR PERPENDICULAR
TO A DATUM AXIS OR SURFACE
164
82
T MC Rotating Function
Complete the DATUM references to

ensure all features are Co-axial
165
T MC
GEOMETRIC
DIMENSIONING &
TOLERANCING
(GD&T)
Session 3
166
83
T MC TOLERANCES OF LOCATION
(Part 1)
SYMETRY
CONCENTRICITY
TRUE POSITION
167
T MC SYMETRY
Where a feature, such as a slot, is required to be symmetrical to the datum center plane of
another feature, the symmetry characteristic may be used.
To specify symmetry the following conditions must exist:
1. Non-cylindrical features (slots, tabs, projections, etc.) only are to be controlled.
2. The material condition RFS only is to apply.
3. The feature and its datum must be symmetrically configured to each other.
4. The datum feature is usually non-cylindrical but may be cylindrical if appropriate to the
part.
Symmetry-
Symmetry is that condition where the median points of all opposed or correspondingly located
elements of two or more feature surfaces are congruent with the axis or centre plane of a datum
feature.
168
84
T MC SYMETRY
169
T MC CONCENTRICITY
Definition. Concentricity is that condition where the median points of all diametrically
opposed elements of a figure of revolution (or corresponding-located elements of two or
more radially disposed features) are congruent with the axis (or centre point) of a datum
feature.
Concentricity tolerance. A concentricity tolerance is a cylindrical (or spherical)
tolerance zone whose axis (or centre point) coincides with the axis (or centre point) of
the datum feature(s). The median points of all correspondingly-located elements of the
feature(s) being controlled, regardless of feature size, must be within the cylindrical (or
spherical) tolerance zone. The specified tolerance and the datum reference can only
apply on an RFS basis.
170
85
T MC CONCENTRICITY
171
T MC CONCENTRICITY
172
86
T MC
IMPORTANT!!!
Symmetry & Concentricity usually require a

detailed & time consuming analysis to derive data
for the verification process.
A Computer Measuring Machine process is usually
employed to determine compliance with such
requirements.
ONLY use these requirements for functions that can
NOT be controlled by DIRECT Dimensions or
True Position
173
T MC
TRUE POSITION
174
87
T MC
Definition. True Position is a term used to describe the
perfect (exact) location of a point, line, or plane of a
feature in relationship with a datum reference or datum
feature.
POSITION TOLERANCE
A position tolerance is the total permissible variation in
the location of a feature about its exact (true) position.
For cylindrical features (holes and bosses) the position
tolerance is the diameter (cylinder) of the tolerance zone
within which the axis of the feature must lie, the centre
of the tolerance zone being at the exact (true) position.
For other features (slots, tabs, etc.) the position
tolerance is the total width of the tolerance zone within
which the centre plane of the feature must lie, the centre
plane of the zone being at the exact (true) position.
175
T MC
Position Theory
Possible hole centre

positions
Tolerance zone
applies to part Note! Tolerance
thickness zone should be
derived from the
design/functional
requirement
NOT conversion
of Co-ordinates
176
88
T MC
Possible hole
centre positions
177
T MC
PROOF !
178
89
T MC IMPORTANT!
Rule #2: RFS applies, with respect to the individual

tolerance, datum reference or both, where no
modifying symbol is specified. MMC or LMC must be
specified on the drawing where required.
179
T MC
Simulated part
or Gauge Pins
180
90
T MC Simulated part
or Gauge Pins
Only available when BONUS

M POSITION
TOLERANCE
applies [Rule #2]
181
T MC
IF RFS ie, without M
Tolerance NOT
available
182
91
T MC
Primary
Secondary
Tertiary
Note! Surfaces are Datums NOT

Features 183
T MC
184
92
T MC
Tertiary
Primary
Secondary
185
T MC
186
93
T MC Floating Fastener
Application
187
T MC
MATING
PARTS
Floating Fastener
Application
Note! Gauge Pin

Height equals Part
Thickness
188
94
T MC
Fixed Fastener
Application
189
T MC
MATING
PARTS
Fixed Fastener
Application
Note! Pin
height equals
part thickness
Note! Gauge Thickness

equals Stud Height
Consider FUNCTION
190
95
T MC
MATING
PARTS
Fixed Fastener
Application
Note! Gauge Pin

Height equals part
Thickness
Note! Gauge
thickness equals
Stud height
191
T MC
Location
Patterns
&
Location
Pattern
192
96
T MC
Pattern features
tolerance zone
Pattern Location
tolerance zone
193
T MC
Pattern Features
Tolerance zone
WRONG!
CORRECT
Pattern location
tolerance zone
194
97
T MC
Pattern
Gauge
195
T MC
Pattern
Gauge
196
98
T MC PATTERN LOCATING
GAUGE
All Slip Pins
197
T MC
Composite
Pattern
198
99
T MC
HOLE
PATTERN AS
DATUM
199
T MC
Datum Feature at
MMC
200
100
T MC Functional Gauges
Slip Pin
Slip Pins
Fixed Pin 201

T MC DATUM Feature
RFS
202
101
T MC Functional Gauges
Slip Pin
Slip Pins
203
T MC MMC feature related to

MMC Datum feature
Note! 3rd Datum NOT

Specified
204
102
T MC
Note! Datum
reference
57.6-28.2 =29.4(Max)
56.4-28.8= 27.6(Min)
IE, 1.8 variation
205
T MC
Where is this
surface relative to
Datum B ?
206
103
T MC Unequal distribution of position
207
T MC
Task
A] Identify the type of
fastener system
B]Calculate the Position
tolerance for each part
C] Assume the M8 Bolts
to be perfect, ie 8
208
104
T MC
A] Sketch the Gauge(s) to functionally check this part

B] Dimension the important features
209
T MC
Consider the callout items indicated, circle if you

agree, modify to what you consider to be correct callout.
Are there any other changes or options necessary 210
105
T MC
GEOMETRIC
DIMENSIONING &
TOLERANCING
(GD&T)
Session 4
TRUE POSITION
[Continued]
211
T MC
Definition. True Position is a term used to describe the
perfect (exact) location of a point, line, or plane of a
feature in relationship with a datum reference or datum
feature.
POSITION TOLERANCE
A position tolerance is the total permissible variation in
the location of a feature about its exact (true) position.
For cylindrical features (holes and bosses) the position
tolerance is the diameter (cylinder) of the tolerance zone
within which the axis of the feature must lie, the centre
of the tolerance zone being at the exact (true) position.
For other features (slots, tabs, etc.) the position
tolerance is the total width of the tolerance zone within
which the centre plane of the feature must lie, the centre
plane of the zone being at the exact (true) position.
212
106
T MC
PO SITIO N TO LERA NC E-LEAST M A TERIAL CO ND IT IO N (LM C)
O ccasionally a method is required to control a situation w hich is essentially the reverse of the usual position relationship; that is, the
stated position tolerance applies at the least m aterial condition, LM C, of the feature or datum, instead of at M M C, and increases as the
feature or datum departs from the least material condition.
Definition. Least M aterial condition (LM C) is the condition in which a feature of size contains the least amount of material within the
stated limits of size: for examp le, maximu m hole diameter, minimu m shaft diameter. Least material condition is the condition
opposite to M M C. For examp le, a shaft is at least material condition w hen it is at its low limit of size and a hole is at least material
condition when it is at its high limit of size.
This method is applicable to special design requirements that w ill not permit M M C or that do not w arrant the exacting requirements
of RFS. It can be used to maintain critical wall thickness or critical centre locations of featu res for which accuracy of location can be
relaxed (position tolerance increased) w hen the feature leaves least material condition and approaches M M C. The amount of increase
of positional tolerance permissib le is equal to the feature actual size departu re from least material condition.
The term "least material condition" and the abbreviation LM C have been used instead of "minimum material condition" (which is
synonymous) to avoid confusion, since the abbreviation would be the same as that for maximum material condition. The symbol
modifier L is used to indicate the LM C requirement applicable to feature or datum.
Although the use of LM C does impose exacting requirements on both manufacturing and inspection, it permits additional tolerances.
W henever least material condition (LM C) or L is specified on a drawing, the position tolerance applies only w hen the feature is
produced at its LM C size. See Fig. 1.
Additional positional tolerance is permissib le but is dependent on, and equal to, the difference betw een the actually p roduced featu re
size (w ithin its size tolerance) and LM C. See Fig. 2.
213
T MC
214
107
T MC True Position LMC
Minimum
Condition
215
T MC Non-cylindrical mating parts
SHAFT
216
108
COLLAR
217
BASE
218
109
COVER
219
Non-cylindrical mating parts

T MC
220
110
12.60 MMC
PLUS TOTAL 12.6 PROJECTION SIZE TOL
25.60 MMC
PLUS TOTAL 25.60 DATUM SLOT SIZE TOL
221
222
111
223
224
112
T MC Profile Position related
This requirement
is extremely
difficult to check
other than by a
Tracing of each
If the tolerance
requirement zone is not shown
(say 10X)
as uni-lateral then
the tolerance is
Bi-lateral
225
This requirement
is extremely
difficult to check
other than by a
Tracing of each
requirement
(say 10X)
226
113
Note! Bi-lateral
tolerance applies
How do we determine the
variation from MMC to
apply Bonus tolerance??
Highly complex to check!! Check that
FUNCTION REALLY requires this call-out 227
Co-axial features
T MC
NOTE! STATIC FUNCTION ONLY
228
114
Co-axial features
T MC
229
T MC Co-axial features
NOTE! Rotating Function only
230
115
T MC Co-axial Mating Parts
Static Function
231
T MC Co-axial Mating Parts

Static Function
232
116
T MC Co-axial Features - Static Function
[Wall Thickness Control]
Minimum Wall Thickness

= (24.2 20.8 0.2)/2
= 1.6
233
T MC Dwg. Callout
Radial holes- Axial part
234
117
T MC Radial holes- Axial part
235
Projected tolerance zones

T MC
Projected length
equal to Part
Thickness for Bolt
or Total Stud
Height
236
118
T MC Elongated Holes Bi-directional Position Tolerances
237
T MC Elongated Holes Bi-directional Position Tolerances
GAUGE
Diamond shaped
Gauge Pins
Slip pins
238
119
Tolerance stacks
T MC
239
Tolerance stacks
T MC
240
120
T MC
ADVANCED
POSITION
THEORY
No. 1 Advantage:
Functional Parts will NOT
be rejected
241
T MC Co-axial features
Static
Application
ADVANCED
POSITION
THEORY
242
121
T MC Fixed Fasteners (Threaded)
ADVANCED
POSITION
THEORY
Note! Datum
Features
243
T MC Fixed Fasteners (Threaded)
ADVANCED
POSITION
Note! Datum
Feature THEORY
244
122
T MC State this requirement
into drawing format
Squareness 0.04
245
T MC
Drawing callout
246
123
T MC Design a Functional Gauge to
check the location of the holes
247
T MC
248
124
T MC Determination of POSITION using
Co-ordinate Measuring Machine
249
Determination of POSITION using

T MC Co-ordinate Measuring Machine
250
125
Determination of POSITION using
T MC Co-ordinate Measuring Machine
Size MMC = Bonus

7.663 7.6 = 0.063
Tol. + bonus = allowed tol.
0.25 + 0.063 = 0.313
251
T MC DIMENSION REVIEW
1.4/1.7 Typ.
252
126
T MC DIMENSION REVIEW
g
on A
37.2/36.2 Wr
21.5/20.5
7.7min
7.3 min.typ.
W
RO
NG
1.5 A
A 30 deg.
10.5 min
8.9 min.typ
253
T MC Assembly [part only]
254
127
T MC HOUSING
Length C
Surface A
Diameter D
PCD E
Surface B
Tapped holes F
Diameter G
255

(Dimensioning)
Component/Sub-Assy. Pt. No. 123-456A Housing

Feature Seco Positi Shap Prim. Sec.
Prim Tert. Size Datum Datum
n on e
A
Surface
Y H
B
Surface
L
C
Length
L
D
Dia.
M G
E
PCD
H H
F
Tapd
H SC P
holes 6.7
G
Dia.
Y SC
256
128
T MC HOUSING
6x M8 X 20/22 full thd.
10/11
[SC]
120/119.8 DIA [SC]

47/47.5 DIA
A C
257
T MC FLANGE MOUNT
Surface A Dia H
Holes F
Dia J
Dia B Dia D
Dia C
Ref. Surf.
Length M
Length L
Thread E
Length K
Length G
258
129
(Dimensioning)
Component/Sub-Assy. Pt. No. 123-457 Flange Mount

Feature Sec Positi Shap Prim. Sec.
Prim Tert. Size Datum Datum
on on e
A
Surface
Y - - M Ref
surf
B
Dia.
Y SC M H A
C
Dia.
Y H H H B
D
Dia.
M M M B
E
Thread
M M B
F
Holes
H SC B
G Ref
Length
M - -
surf
H Manuf Manuf
Dia
Loctn L L L Loctn.
259
T MC FLANGE MOUNT
?
B
[SC]
[SC]
260
130
T MC SHAFT
Surface A
Dia C
Ucut Dia B
261

(Dimensioning)
Component/Sub-Assy. Pt. No. 123-458 Shaft

n e n e
A
Surface
L B
B
Dia
Y M M
C
Dia
M M M B
Ucut
L L L B
262
131
T MC SHAFT
44.4/44.25 dia
19/18.95 dia.
Ucut 1/1.5wide
X 0.7/1 deep
263
T MC Failure Mode & Effects Analysis
A Design potential FMEA is an analytical technique utilised primarily by a

Design Responsible Engineer/Team as a means to assure that, to the extent
possible, potential failure modes and their associated causes/mechanisms have
been considered and addressed. End items, along with every related system,
subassembly and component, should be evaluated.
In its most rigorous form, an FMEA is a summary of an engineers and the
team's thoughts (including an analysis of items that could go wrong based on
experience and past concerns) as a component, subsystem or system is designed.
This systematic approach parallels, formalises and documents the mental
disciplines that an engineer normally goes through in any design process.
264
132
T MC Failure Mode & Effects Analysis
The Design potential FMEA supports the design process in reducing

the risk of failures by:
A] Aiding in the objective evaluation of design requirements and

design alternatives.
B] Aiding in the initial design for manufacturing and assembly

requirements.
C] Increasing the probability that potential failure modes and their

effects on system and vehicle operation have been considered in the
design/development process.
265
T MC
Geometric
Dimensioning &
Tolerancing
Practical exercises
266
133
T MC
CONTENT
Component Drawing Review Basics

Callout Evaluation
Sub-Assembly Reference
Critique of existing drawings
Assembly Drawing callout development
Sheet Metal [Structural fabrication components]
267
T MC
Part 1
Component
Drawing review
[Basics]
268
134
T MC Primary
Secondary
Tertiary
269
TMC Basic Fitment
270
135
TMC
Yes, only when balance of

feature is at MMC[Rule271
Tony M Consulting Pty. Ltd #1]
T MC
95
272
136
T MC 4 SURFACES
MI
N.
BOTH SIDES
291
TMC
Bolt MMC
Fixed Fastener
292
146
TMC Female Part
Male Part
Unilateral tolerance
from MMC
Note! True
Position callout
? Unilateral tolerance
from MMC is not required
293
T MC
Part 3
Component Drawing review
[Sub-assembly reference]
294
147
TMC Floating
Fastener
295
TMC
Equivalent to
Fixed Fastener
296
148
TMC
Fixed Fastener
297
TMC
298
149
T MC
? Housing
Fixed interchangeability
Fastener
NOT required
?
?
Fixed
Fastener
?
299
T MC
Bolt Dia
MMC 8.00
Functional Parts
will NOT be Functional Parts
rejected. [u/s dia] will be
rejected.
Option
2 Option
1
300
150
T MC Improved drawing
based on
FUNCTION
Functional
Datum?
Functional
Datum?
301
T MC
Functional
Requirements
defined
302
151
T MC
R 100
90
incl.
3X
R 20
Functional
Functional Requirements
Datums? defined
303
TMC
Part 4
Critique of existing
Drawings
304
152
TMC
307
TMC
BEWARE!
Do NOT use same I/D
letters for different
situations.
[Static Application]
Use True Position
Note! M required on
Datums A & B
308
154
TMC
STATIC
APPLICATION
Use True
Position
Is this the
correct
FUNTIONAL
DATUM?
309
TMC
60
310
155
TMC
311
TMC
Part 5
Assembly
[Drawing callout development]
312
156
TMC Function Loss Matrix
Refer ISO/QS 9000 PPAP Manual
1) List all the Features of the Component/system/assembly.
2) Indicate which features have a DATUM function
3) Determine the Criticality/Severity Rating if those features are

OUTSIDE the Specification [L-Low, M-Medium or H-High]
4) Indicate each feature s dependence [datum reference]
5) Indicate the control symbol(s) appropriate to each feature
6) Review the Matrix
313
TMC Design Function/Relationship Matrix
Component/Sub-Assy. Pt. No.

(Dimensioning)

n e n e
A
Surface
B
Hole
C
Hole
D
Thicknes
s
E
Width
Etc.
314
157
TMC St
ub Hub
Be A
ar xle
in &
gs
Studs
Wheel Rim
Brake Disc
Wheel Nuts
315
TMC
Wheel Studs
Bearing Dias
A-B
110 PCDia Wheel Hub
316
158
TMC Wheel Hub
5x H7 14
110 PCDia C
317
TMC
14 g8 (press fit)
M12 x 1.0
A
18.00 +/- 0.5

Free form
318
159
TMC Brake Disc [Rotating Function]
5x H9 14
Control for other 110 PCDia

rotating surfaces
C
319
TMC
WHEEL
[Rotating Function]
75 incl.
5x 17
320
160
TMC
5.5/ 5.0
14.8+/-0.2
75 incl.
5x 17
Enlarged
View Wheel
Nut Location
15.5/17.0
321
TMC
25/24
18 A/F Hex.
Stock 2.4/2.2
75 incl.
M12 X 1.0 17
WHEEL
NUT
322
161
TMC
Part 6
Sheet metal
[Structural fabrication components]
323
TMC
?
?
?
?
?
?
324
162
TMC
?
?
Note! All Geometric Controls to be

inspected while Workpiece is constrained
on Datum Target Areas A1-A3 & B1-B2 325
TMC ? ?
?
?
?
?
? ?
326
163
TMC Note! Only the
Geometric callouts ?
are displayed. Co-
ordinates are taken ?
from CAD File. ?
?
?
?
? ?
? 327
TMC
?
?
?
328
164
TMC
? ?
?
?
329
TMC ?
?
330
165

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Roll of design Engineers in Industry

Datum Features - Planes

Effect of Size & Form

Gauge/Inspection Datum Set-up

Detailed Discussion, application techniques,

A] Capturing DESIGN INTENT

T h e R ole o f D esign E n g ineers in Ind u stry

The major function of a Design Engineer in Industry today is to Develop information

The Design Engineer plays a pivotal role in manufacturing

Under this type of structure accountability is through the Team Leader

1) Laws of Physics as they apply to the concept

3) Mechanical systems, their functions & their environmental

4) Various materials available, their characteristics & applicability

5) Any Legal or other demands relevant to the application of the

8) Performance evaluation techniques (statistics)

10)Using TOOLS Effectively (eg. CAD)

11) Effective Engineering Communications

An Engineer s capability is measured according to how well

In order to demonstrate the above capability the Engineer must

Every COMPONENT drawing in whatever form has a cost

No. Made No. Made

The above curves apply to all enterprises, whether producing components,

Well executed Drawings/Specifications also minimize

a) The supplier made a mistake

b) The Supplier Mis-interpreted the Drawing

2) The component was made to the Drawing BUT:-

a) The Engineer/Draughtsman made a mistake

b) The Engineer/Draughtsman put INCORRECT information on

A component is submitted for Off Tool Sample approval which(after an

2) The Engineer/Draughtsman did not investigate the TRUE tolerance

a) He/she played safe in allocating the tolerance(s)

b) he/she did not understand/investigate the true FUNCTIONAL

These examples are intended to illustrate some of the

Highlighted are the effects of not understanding or using

1] In respect to contract between Supplier &

2] In respect to Product Liability issues that

All languages have common attributes:-

SOUNDS are used to communicate feelings,

SYMBOLS are used to communicate

WRITTEN communication is also

Reliance on VERBAL communication used in

Geometric Dimensioning & Tolerancing

-Is the Language that Engineers use to

FIRST AND FOREMOST ITS USE SAVES MONEY!

How do we define FUNCTION

There are TWO entities that require consideration

1) An ASSEMBLY (or Sub-assembly)

1) An ASSEMBLY (or Sub-assembly)

An Assembly (or Sub-assembly) is a group of components

A COMPONENT is a single piece within an Assembly

T MC Define the CONDITIONS & EXPECTATIONS for the

1) List all the Features of the Component/system/assembly.

2) Indicate which features have a DATUM function

3) Determine the Criticality/Severity Rating if those features are

4) Indicate each feature s dependence [datum reference]

5) Indicate the control symbol(s) appropriate to each feature

6) Review the Matrix

T MC Design Function/Relationship Matrix

Component/Sub-Assy. Pt. No.

Datum Criticality Rating Control Symbol

1) Using GD&T increases Cost !!

GD&T Book Complete

GD&T Book Complete