Chapter 16

Tolerancing
 Objectives
Describe the purpose of conventional
tolerancing and its limitations
Use standard tables to specify an
appropriate fit between two mating parts
Explain the advantages of using geometric
dimensioning and tolerancing (GD&T) over
conventional tolerancing
 Objectives (contd.)
Recognize the datum reference frame on a
drawing with geometric dimensions and
tolerances
Describe the tolerance zone shape for
each geometric tolerance
Correctly read the feature control frames
on a drawing with geometric dimensions
and tolerances
 Introduction
Relationships between different parts
Necessary to specify intended fit between
parts
Problems with inexperience in new
engineers
Lack of knowledge in history, materials
Inappropriate tolerance values
 Formats for Tolerances
Displayed in several common formats

FIGURE 16.03. Formats for tolerance dimensioning in millimeters and inches.

 Tolerance Buildup Problems
Can be minimized depending on type of
dimensioning
Chain: yields largest tolerance buildup
Baseline: can eliminate some accumulation
Direct: best way to eliminate tolerance
accumulation
Single dimension placed between two key points
 Statistical Tolerance Control
Based on sound statistical practices
Can be applied only when appropriate
statistical process control methods used

FIGURE 16.07.
Tolerancing with
statistical process
control.
 Use of Tables for Fits
Types of fits

FIGURE 16.08. Specifying a FIGURE 16.09. Specifying an

CLEARANCE FIT with INTERFERENCE FIT with limit
limit dimensioning. dimensioning

FIGURE 16.10. Specifying a TRANSITION

FIT with limit dimensioning.
 Fit Terminology

FIGURE 16.11. FIGURE 16.12.

Clearance fit Interference fit
terminology. terminology.
 English Fits
Running or sliding clearance
Locational clearance
Locational transition
Locational interference (see next slide)
Force or shrink (see next slide)
 English Fits (contd.)

FIGURE 16.18. Locational interference and force fits.

 Metric Fits

FIGURE 16.19. Metric fit table.

 Fits Tables
To specify an inch fit between holes and
shafts from a standard table
Determine type of fit appropriate for the design
and locate corresponding table
Determine basic size of the parts
Find size range on the table
Determine tolerances for hole and shaft
Remember that values on the English tables
are in thousandths of an inch
Fits Tables (contd.)

FIGURE 16.23. A close sliding fit.

 Fits Tables (contd.)
To determine metric fits
Determine type of fit appropriate for the design
and locate corresponding table
Determine basic size of the parts
Find the size range on the table
Determine the tolerances for the hole and the
shaft
Conventional Tolerancing versus
Geometric Tolerancing
Feature with size
Cylindrical or spherical surface or set of two
opposed elements or opposed parallel
surfaces associated with size dimension
Feature without size
Planar surface or a feature where the normal
vectors point in the same direction
Conventional Tolerancing versus
Geometric Tolerancing (contd.)

FIGURE 16.29. Conventional

tolerance dimensioning of a block.
Conventional Tolerancing versus
Geometric Tolerancing (contd.)
FIGURE 16.30. How
conventional tolerancing
controls surfaces.
Location of Holes and Pins with
Conventional Tolerancing

FIGURE 16.35. Square

tolerance zones from
conventional tolerancing.
 Geometric Dimensioning and
Tolerancing (GD&T)
GD&T is a 3-D mathematical system for
describing the form, orientation, and
location of features on a part within precise
tolerance zones
Better communication throughout design
process
Almost nothing can be interpreted in more
than one way
The Datum Reference Frame

FIGURE 16.40. Components of the theoretical datum system.

The Datum Reference Frame
(contd.)

FIGURE 16.41.
Datum terminology.
Geometry Characteristic Symbols
and Feature Control Frames

FIGURE 16.42.
Geometric characteristic
symbols.
Geometry Characteristic Symbols
and Feature Control Frames
(contd.)
Feature control frame
Contains geometric characteristic symbol, the
geometric tolerance, and the relative datums

FIGURE 16.44. A feature FIGURE 16.45. A feature control

control frame with the frame with the position tolerance.
perpendicularity tolerance.
Order of Precedence for Datums

FIGURE 16.47. The

sequence of datum
features
 Position Tolerances versus
Conventional Tolerances

FIGURE 16.49. Geometric dimensioning and tolerancing of the PLATE.

 Position Tolerances versus
Conventional Tolerances (contd.)
Basic dimensions
Theoretically exact
Maximum material condition modifier
Size of zone changes if size of hole changes
Square vs. cylindrical tolerance zones

FIGURE 16.53. Cylindrical tolerance

zones for the position tolerance.
 Form Tolerances
For individual features and not related to
datums
Straightness
Flatness
Circularity
Cylindricity
Profile Tolerances

FIGURE 16.63.
Profile of a line.
 Profile Tolerances (contd.)
Profile of a surface
Inspection of profile tolerances
Optical comparitors
Overlay charts
Mechanical gaging
Used when datum reference frame applied
 Orientation Tolerances
Parallelism tolerance
Can be used to control a surface

FIGURE 16.69. Parallelism

tolerance used to control a
surface.
Orientation Tolerances (contd.)
Perpendicularity
Angularity

FIGURE 16.78. Inspecting the

angularity between two surfaces.
 Location Tolerances
Position
Can be used to locate axis of a hole

FIGURE 16.79. Using the position

tolerance to locate the axis of a hole.
 Location Tolerances (contd.)
Concentricity
Applied to cylinder

FIGURE 16.81.
Concentricity
applied to
a cylinder.

Symmetry
 Runout Tolerances
Circular runout
Total runout
Multiple datums
Tolerances applied based on function, so
careful specification of datums is necessary
Examples of Specifying Fits and
Geometric Tolerances
Specifying the fit between two parts

FIGURE 16.99. Coupling assembly.

Examples of Specifying Fits and
Geometric Tolerances (contd.)

FIGURE 16.101. Limit dimensions for the STUD and

BUSHING.
Adding Geometric Dimensions

FIGURE 16.102.
PLATE ASSEMBLY.

FIGURE 16.103. Establishing

the datums on the PLATE.
FIGURE 16.104.
Controlling the datums
on the PLATE.
FIGURE 16.105. Positioning the hole on the PLATE.
FIGURE 16.106. Controlling the other surfaces on the PLATE.
 Summary
Covered basic information related to
conventional tolerancing and GD&T
Discussed interchangeable manufacturing
and explained why it is important to the
way modern industry functions
 Summary (contd.)
Discussed conventional tolerancing,
including how to specify fits and how
tolerance dimensions control form and
location
Covered the basics of geometric
dimensioning and tolerancing
 Summary (contd.)
Discussed the advantages of geometric
tolerancing over conventional tolerancing
Explained the importance of the datum
reference frame to establish a coordinate
system for design manufacturing and
inspection
Explained how to read feature control
frames
Described each geometric tolerance