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:
[email protected] 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
Tony M Consulting Pty. Ltd
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
Tony M Consulting Pty. Ltd
T MC GEOMETRIC CHARACTERISTICS Symbols (General Outline). Detailed Discussion, application techniques, Interpretations & practical exercises.
Tony M Consulting Pty. Ltd
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
Tony M Consulting Pty. Ltd
T MC FMEA & GD&T Function Matrix Co-ordination & interaction
WORKSHOP Critique of drawings Review of real examples from your organization
Tony M Consulting Pty. Ltd
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
Tony M Consulting Pty. Ltd
T MC Design – A Definition
The PHYSICALISATION of the IMAGINATION
Tony M Consulting Pty. Ltd
8
4
T MC Engineering Structures 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
Tony M Consulting Pty. Ltd
T MC Engineering Structures 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.
Tony M Consulting Pty. Ltd
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 Tony M Consulting Pty. Ltd
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
Tony M Consulting Pty. Ltd
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 O S T
S K I 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. Tony M Consulting Pty. Ltd
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.
Tony M Consulting Pty. Ltd
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
Tony M Consulting Pty. Ltd
T MC Things That can Go Wrong
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.
Tony M Consulting Pty. Ltd
16
8
T MC Things That can Go Wrong 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
Tony M Consulting Pty. Ltd
T MC Things That can Go Wrong
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.
Tony M Consulting Pty. Ltd
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
Tony M Consulting Pty. Ltd
Cost of correction
T MC
Design
Prototype
Tooling
Pilot Prodn. Serial Prodn.
In Market
Prod. Recall
Error Detection Stage Tony M Consulting Pty. Ltd
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
Tony M Consulting Pty. Ltd
T MC
COMMUNICATIONS Communications between Human Beings is by means of “LANGUAGE”
Tony M Consulting Pty. Ltd
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
Tony M Consulting Pty. Ltd
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.
Tony M Consulting Pty. Ltd
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
Tony M Consulting Pty. Ltd
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-
Tony M Consulting Pty. Ltd
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
Tony M Consulting Pty. Ltd
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.”
Tony M Consulting Pty. Ltd
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
Tony M Consulting Pty. Ltd
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.
Tony M Consulting Pty. Ltd
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 Subassembly) can reliably perform its design intent.
31
Tony M Consulting Pty. Ltd
T MC
Define the CONDITIONS & EXPECTATIONS for the Functions Corrosion Resistance
Environment
Temperature/Humidity Ageing (Accelerated)
Customer Life Expectation
Number of Cycles Fatigue
Interacting Features
Critical Features
Strength
& Legal Requirements
Specifications
Mass Manufacturability
Tony M Consulting Pty. Ltd
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
Tony M Consulting Pty. Ltd
T MC
Design Function/Relationship Matrix (Dimensioning)
Component/Sub-Assy. Pt. No. Datum Feature
Prim
Seco n
Criticality Rating Tert.
Siz e
Positio n
Shap e
Control Symbol Prim. Datum
Sec. Datum
‘A’ Surface ‘B’ Hole ‘C’ Hole ‘D’ Thicknes s ‘E’ Width Etc.
Tony M Consulting Pty. Ltd
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
Tony M Consulting Pty. Ltd
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.
Tony M Consulting Pty. Ltd
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
Tony M Consulting Pty. Ltd
T MC What is the Engineer’s “ 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
Tony M Consulting Pty. Ltd
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.
Tony M Consulting Pty. Ltd
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.
Tony M Consulting Pty. Ltd
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. 15011101Technical Drawings Geometrical tolerancing Technical Drawings Positional tolerancing 2. ISO/54583.
ISO/5459-
Technical Drawings Datums and Datum Systems
4. 5.
ISO/2692-
Technical Drawings Maximum material principle
ISO/3040-
Technical Drawings Cones
6.
ISO/1660-
Technical Drawings Profiles
7.
ISO/129ISO/406-
Technical Drawings General principles Technical Drawings Linear and angular dimensions
ISO/10578
Technical Drawings Projected tolerance zones
8. 9. 10. 11. 12. 13.
ISO/2692:1988/DAM 1 Technical Drawings Least material principle ISO/8015 Technical Drawings Fundamental tolerance principle ISO/7083 Technical Drawings Symbols proportions ISO/10579 Technical Drawings Non-rigid parts
Additional 1S0 standards involved: 1. ISO/1000 - SI Units 2. 3. 4. 5.
ISO/286 ISO/TR5460 ISO/2768-2 ISO/1302
6.
ISO/2768-1
7.
Other peripheral standards on screw threads, gears, drills, welding, etc., may also be required for coverage beyond Y 14.5 for product design.
Tony M Consulting Pty. Ltd
- Limits & Fits Technical Drawings-Verification principles General geometrical tolerances - Surface Texture Tolerances for linear and angular dimensions
41
T MC Complete Symbols List
Items Marked # are not described in detail in this course as they are self explanatory
Tony M Consulting Pty. Ltd
42
21
T MC GEOMETRIC DIMENSIONING & TOLERANCING (GD&T) Session 1 43
Tony M Consulting Pty. Ltd
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 his -DESIGN INTENT-
Tony M Consulting Pty. Ltd
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 Subassembly) can perform its DESIGN INTENT. 45
Tony M Consulting Pty. Ltd
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 20°C. 8] All dimensions & tolerances apply in a free state condition (unless otherwise specified). This principle does not apply to “non–rigid” 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 46 drawing.
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
Tony M Consulting Pty. Ltd
T MC
RFS “ Rule #2:
Regardless of Feature Size [RFS] applies, with respect to individual tolerances, datum references or both where no modifying symbol is specified. [Y14.5]
Tony M Consulting Pty. Ltd
Examples:
0.12
A
C
0.12 M A M
RFS is the default condition in the absence of any “modifier”.
Maximum Material Condition
B
C
B L
Least Material Condition
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
Tony M Consulting Pty. Ltd
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
Tony M Consulting Pty. Ltd
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
Tony M Consulting Pty. Ltd
T MC
Degrees of freedom
To stabilize a part in Space All 6 Degrees of Freedom MUST be controlled
Tony M Consulting Pty. Ltd
52
26
T MC
Attributes of a “ cylinder” as a Datum feature
Cylindrical form may be a hole, spigot or shaft.
53
Tony M Consulting Pty. Ltd
T MC
Tony M Consulting Pty. Ltd
Problem of IMPLIED Datums
54
27
T MC CONTROL SYMBOLS
XXX
BASIC
MAX. MATERIAL CONDITION TANGENT PLANE
LEAST MATERIAL CONDITION
DATUM
FREE FORM
DIAMETER
PROJECTED TO:-
A
DATUM TARGET
CR
CONTOLLED RADIUS
ST
Statistical Tolerance
55
Tony M Consulting Pty. Ltd
T MC
Control Symbols BASIC
XXX.XX
“ BASIC” dimensions are only used to LOCATE Tolerance Zones
A A1
Tony M Consulting Pty. Ltd
DATUM TARGET
DATUM This edge to be located at the feature or surface nominated as the datum
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
Tony M Consulting Pty. Ltd
T MC
EXAMPLES WITH DATUMS
NO CONFUSION!!!!!
58 Tony M Consulting Pty. Ltd
29
T MC
Datum prioritisation – why?
59
Tony M Consulting Pty. Ltd
T MC
ESTABLISHING DATUM PLANES FROM DATUM SURFACES/FEATURES – 3 PLANE CONCEPT- DATUM REFERENCE FRAME
ESTABLISHING THE DATUM PLANES
Tony M Consulting Pty. Ltd
60
30
T MC Datum Plane (Surface)
61
Tony M Consulting Pty. Ltd
T MC
Datum Plane (Surface)
Surface nominated as Datum
Note! Datum symbol is NOT at the feature size Tony M Consulting Pty. Ltd
62
31
T MC
DATUM TARGET SYMBOLS
Datum Target Symbols are used to establish datum planes & part orientation 63
Tony M Consulting Pty. Ltd
T MC
Tony M Consulting Pty. Ltd
DATUM TARGETS
64
32
T MC
DATUM TARGETS
2
1
3
65
Tony M Consulting Pty. Ltd
T MC
Surface to surface [Formed part] Secondary Datum
Tertiary Datum
Primary Datum Tony M Consulting Pty. Ltd
66
33
T MC Partial Surface datum target Pressure Applied to simulate function Less than Height tolerance
Functional location 67
Tony M Consulting Pty. Ltd
T MC
Requires ‘Flatness’ or similar callout
Tony M Consulting Pty. Ltd
?
68
34
T MC
Locations on Casting surface for Machining
69
Tony M Consulting Pty. Ltd
T MC
Feature nominated as Datum
Feature nominated as Datum
Establishing Datum Centre Planes from Datum Features
Surface nominated as Datum
Note! RFS
CAUTION! The FUNCTIONAL requirements should be carefully considered before use
Tony M Consulting Pty. Ltd
70
35
T MC
Axial Location [position] established by Datum Target Secondary Datum
Primary Datum
71
Tony M Consulting Pty. Ltd
T MC
Tony M Consulting Pty. Ltd
Features as Datums
72
36
T MC
Attributes of a hole[cylinder] as a Datum feature
73
Tony M Consulting Pty. Ltd
T MC
Tony M Consulting Pty. Ltd
Attributes of a hole[cylinder] as a Datum feature
74
37
T MC
Features as Datums
75
Tony M Consulting Pty. Ltd
T MC
Tony M Consulting Pty. Ltd
Features as Datums
76
38
Features as Datums
T MC Datum features
Datum Surface
77
Tony M Consulting Pty. Ltd
T MC
Tony M Consulting Pty. Ltd
Feature Pattern as Datum
78
39
T MC
Tony M Consulting Pty. Ltd
Features as Datums
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 Tony M Consulting Pty. Ltd
80
40
T MC
SURFACE(3) (wedge)
SURFACE(2)
PIVOT(2)
PIVOT(1)
SURFACE(1) + Feature(hole)
PIVOT(3) 81
Tony M Consulting Pty. Ltd
T MC
BELLCRANK Ø0.75 in
3.002 in
Ø1.125 in
Ø0.813 in 5 in
4.251 in 1.501 in
0.49 in
Tony M Consulting Pty. Ltd
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
Tony M Consulting Pty. Ltd
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 CONDITION
DATUM
FREE FORM
DIAMETER
PROJECTED TO:-
A
DATUM TARGET
CR
CONTOLLED RADIUS
Statistical Tolerance
85
Tony M Consulting Pty. Ltd
T MC
Tony M Consulting Pty. Ltd
ST
Control Symbols
M
Maximum Material Condition
L
Least Material Condition
MMC
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
Tony M Consulting Pty. Ltd
T MC
L
Least Material Condition 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 desirable alternative to MMC under certain design function requirements.
Tony M Consulting Pty. Ltd
NOTE! Rule #1 allows feature distortion within the “ MMC 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]
Ø0.08 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
Tony M Consulting Pty. Ltd
T MC
CONTROLLED RADIUS
Note! The magnification limit MUST be stated to appropriate to the function!!
Tony M Consulting Pty. Ltd
90
45
T MC CONTROL SYMBOLS
XXX
BASIC
MAX. MATERIAL CONDITION TANGENT PLANE
LEAST MATERIAL CONDITION
DATUM
FREE FORM
DIAMETER
PROJECTED TO:-
A
DATUM TARGET
CR
ST
CONTOLLED RADIUS
Statistical Tolerance
91
Tony M Consulting Pty. Ltd
T MC
TANGENT PLANE
0.1 T
A
Applicable to the 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. Tony M Consulting Pty. Ltd
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 3540Nm before checking
F
93
Tony M Consulting Pty. Ltd
T MC
ST
Statistical 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 Ø6.15 +/- 0.08
Tony M Consulting Pty. Ltd
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
Tony M Consulting Pty. Ltd
T MC GEOMETRIC CHARACTERISTICS Symbols (General Outline). Detailed Discussion, application techniques, Interpretations & practical exercises.
Tony M Consulting Pty. Ltd
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
96
48
T MC
TOLERANCES OF FORM For Single Feature For Related Features FLATNESS SQUARENESS PERPENDICULAR TO:-
STRAIGHTNESS
ANGULARITY
ROUNDNESS CIRCULARITY
PARALLEL TO:-
CYLINDRICITY
RUNOUT PROFILE
TOTAL RUNOUT SURFACE
97
Tony M Consulting Pty. Ltd
T MC TOLERANCES OF POSITION
TRUE POSITION
CONCENTRICITY
SYMETRY
Tony M Consulting Pty. Ltd
98
49
T MC FLATNESS Note! Surface finish control can be used in conjunction with Flatness control BUT NOT instead of Flatness control
99
Tony M Consulting Pty. Ltd
T MC
FLATNESS
Inspection & Gauging methods
Tony M Consulting Pty. Ltd
100
50
T MC
STRAIGHTNESS [Applied to a FLAT surface]
101
Tony M Consulting Pty. Ltd
T MC
STRAIGHTNESS [Applied to a cylinder]
Tony M Consulting Pty. Ltd
102
51
T MC
STRAIGHTNESS (Use of Modifier)
MAX. MATERIAL CONDITION DIAMETER
103
Tony M Consulting Pty. Ltd
T MC
STRAIGHTNESS
Compare with “ Cylindricity” call out later
Tony M Consulting Pty. Ltd
104
52
T MC
STRAIGHTNESS– Unit Length Basis
Compare with “ Cylindricity” call out later
105
Tony M Consulting Pty. Ltd
T MC
Tony M Consulting Pty. Ltd
ROUNDNESS (CIRCULARITY)
106
53
T MC
Roundness of a Cone
107
Tony M Consulting Pty. Ltd
T MC
Tony M Consulting Pty. Ltd
Inspecting Roundness
108
54
T MC
Roundness of a Sphere
109
Tony M Consulting Pty. Ltd
T MC
Tony M Consulting Pty. Ltd
CYLINDRICITY
110
55
T MC Cylindricity & Roundness
0.05 M
0.10/25 M
Part or Element length 25mm
111
Tony M Consulting Pty. Ltd
T MC
Tony M Consulting Pty. Ltd
ROUNDNESS & CYLINDRICITY EVALUATION
112
56
T MC
PROFILE
42 33
113
Tony M Consulting Pty. Ltd
T MC
Tony M Consulting Pty. Ltd
SURFACE
114
57
T MC
115
Tony M Consulting Pty. Ltd
T MC
Application of Tolerance Zone Profile or Surface
Equi-spaced either side of the NOMINAL form
Tony M Consulting Pty. Ltd
NOMINAL is Least Material Condition (LMC)
NOMINAL is Maximum Material Condition (MMC)
116
58
T MC
Complex Surface or Profile
117
Tony M Consulting Pty. Ltd
T MC
Tony M Consulting Pty. Ltd
Complex Surface or Profile
118
59
T MC
119
Tony M Consulting Pty. Ltd
GEOMETRIC DIMENSIONING & TOLERANCING (GD&T) Session 2 120
60
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
121
Tony M Consulting Pty. Ltd
TOLERANCES OF FORM For Single Feature For Related Features FLATNESS SQUARENESS STRAIGHTNESS
ROUNDNESS
PERPENDICULAR TO:ANGULARITY
CIRCULARITY
CYLINDRICITY
PARALLEL TO:-
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
PARALLEL TO:-
PERPENDICULAR TO:-
FLATNESS
140
70
T MC
TOLERANCES OF FORM For Single Feature For Related Features FLATNESS SQUARENESS PERPENDICULAR TO:-
STRAIGHTNESS
ANGULARITY
ROUNDNESS CIRCULARITY
PARALLEL TO:-
CYLINDRICITY
RUNOUT PROFILE
TOTAL RUNOUT SURFACE
141
Tony M Consulting Pty. Ltd
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
3.
CONCENTRICITY TOLERANCE
4.
PROFILE OF A SURFACE
(MMC or RFS) (RFS) (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.)
Tony M Consulting Pty. Ltd
142
71
T MC
CO-AXIAL FEATURES Selection of Proper Control 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
Tony M Consulting Pty. Ltd
T MC
CO-AXIAL FEATURES Selection of Proper Control
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 inter- changeability or assemblability, use: POSITION
(IF MMC) EXAMPLE (IF RFS) EXAMPLE OR RFS DATUM
This will be dealt with in detail in the session on 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-ofcircularity, 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 Tony M Consulting Pty. Ltd
EXAMPLE
144
72
T MC
RUNOUT
TOTAL RUNOUT
145
Tony M Consulting Pty. Ltd
T MC
Tony M Consulting Pty. Ltd
RUNOUT
146
73
T MC
RUNOUT
147
Tony M Consulting Pty. Ltd
Dimensioning a conical form Dwg. callout 18.5+/- 0.1
?
10.00
15.00
6.5 +/- 0.1
0.03
A
A
0.03 0.03
A
148
74
Dimensioning a conical form Meaning 0.042
18.6
10.00
15.00
6.4
6.6 18.4
0.03 0.03
T MC
A
149
TOTAL RUNOUT
Feature may be “bent” Tony M Consulting Pty. Ltd
A
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
Tony M Consulting Pty. Ltd
T MC
TOTAL RUNOUT
151
RUNOUT
? ? ?
?
Tony M Consulting Pty. Ltd
152
76
T MC
TOTAL RUNOUT
?
RUNOUT
?
?
?
Establish common AXIS between DATUM DIAMETERS 153
Tony M Consulting Pty. Ltd
T MC
TOTAL RUNOUT
FUNCTION MUST Determine the primary datum
Tony M Consulting Pty. Ltd
RUNOUT
?
154
77
T MC
TOTAL RUNOUT
RUNOUT
155
Tony M Consulting Pty. Ltd
T MC
TOTAL RUNOUT NON – FUNCTIONAL Datums used to enable efficient manufacturing PROCESS
Tony M Consulting Pty. Ltd
IMPORTANT! Consider Functional relationships when establishing Dimensions &Tolerances
156
78
T MC
TOTAL RUNOUT
157
Tony M Consulting Pty. Ltd
T MC
TOTAL RUNOUT
?
Tony M Consulting Pty. Ltd
158
79
T MC
TOTAL RUNOUT
? ?
159
Tony M Consulting Pty. Ltd
T MC
TOTAL RUNOUT
Axial float occurs during rotation
Tony M Consulting Pty. Ltd
160
80
T MC
TOTAL RUNOUT
Function must be considered in respect to these interpretations to determine correct dimensions & tolerances (& Datum reference) 161
Tony M Consulting Pty. Ltd
T MC
TOTAL RUNOUT
Target Datum would Minimize effect of surface irregularities
Tony M Consulting Pty. Ltd
162
81
T MC
TOTAL RUNOUT
163
Tony M Consulting Pty. Ltd
T MC
TOTAL RUNOUT IMPORTANT!
“ TOTAL RUNOUT” CAN ONLY BE APPLIED TO SURFACES OR FEATURES THAT ARE CO-AXIAL, PARALLEL OR PERPENDICULAR TO A DATUM AXIS OR SURFACE
Tony M Consulting Pty. Ltd
30º
164
82
T MC
Rotating Function Complete the DATUM references to ensure all features are “ Co-axial”
165
Tony M Consulting Pty. Ltd
T MC GEOMETRIC DIMENSIONING & TOLERANCING (GD&T) Session 3
Tony M Consulting Pty. Ltd
166
83
T MC
TOLERANCES OF LOCATION (Part 1)
SYMETRY
CONCENTRICITY
TRUE POSITION
167
Tony M Consulting Pty. Ltd
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. SymmetrySymmetry 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. Tony M Consulting Pty. Ltd
168
84
T MC
SYMETRY
169
Tony M Consulting Pty. Ltd
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.
Tony M Consulting Pty. Ltd
170
85
T MC
CONCENTRICITY
171
Tony M Consulting Pty. Ltd
T MC
Tony M Consulting Pty. Ltd
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
Tony M Consulting Pty. Ltd
T MC
TRUE POSITION
Tony M Consulting Pty. Ltd
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. Tony M Consulting Pty. Ltd
175
T MC Position Theory
Possible hole centre positions Tolerance zone applies to part thickness
Tony M Consulting Pty. Ltd
Note! Tolerance zone should be derived from the design/functional requirement NOT conversion of Co-ordinates
176
88
T MC Possible hole centre positions
177
Tony M Consulting Pty. Ltd
T MC
PROOF ! Tony M Consulting Pty. Ltd
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. Tony M Consulting Pty. Ltd
179
T MC
Simulated part or Gauge Pins
Tony M Consulting Pty. Ltd
180
90
T MC
Simulated part or Gauge Pins
Only available when
BONUS POSITION TOLERANCE
M applies [Rule #2]
181
Tony M Consulting Pty. Ltd
T MC IF RFS ie, without M
4
Tolerance NOT available Tony M Consulting Pty. Ltd
182
91
T MC
Primary
Secondary Tertiary
Tony M Consulting Pty. Ltd
Note! Surfaces are Datums NOT Features
183
T MC
Tony M Consulting Pty. Ltd
184
92
T MC
Tertiary
Secondary
Tony M Consulting Pty. Ltd
Primary
185
T MC
Tony M Consulting Pty. Ltd
186
93
T MC
Tony M Consulting Pty. Ltd
Floating Fastener Application
187
T MC MATING PARTS Floating Fastener Application
Note! Gauge Pin Height equals Part Thickness
Tony M Consulting Pty. Ltd
188
94
T MC
Fixed Fastener Application
Tony M Consulting Pty. Ltd
189
T MC MATING PARTS Fixed Fastener Application Note! Pin height equals part thickness
Note! Gauge Thickness equals Stud Height Consider FUNCTION
Tony M Consulting Pty. Ltd
190
95
T MC MATING PARTS Fixed Fastener Application Note! Gauge Pin Height equals part Thickness
Note! Gauge thickness equals Stud height
191
Tony M Consulting Pty. Ltd
T MC
Location
Patterns & Location Pattern
Tony M Consulting Pty. Ltd
192
96
T MC Pattern features tolerance zone
Pattern Location tolerance zone
Tony M Consulting Pty. Ltd
193
T MC Pattern Features Tolerance zone
WRONG!
Pattern location tolerance zone
Tony M Consulting Pty. Ltd
CORRECT 194
97
T MC Pattern Gauge
Tony M Consulting Pty. Ltd
195
T MC Pattern Gauge
Tony M Consulting Pty. Ltd
196
98
T MC
PATTERN LOCATING GAUGE All Slip Pins
Tony M Consulting Pty. Ltd
197
T MC Composite Pattern
Tony M Consulting Pty. Ltd
198
99
T MC HOLE PATTERN AS DATUM
199
Tony M Consulting Pty. Ltd
T MC
Datum Feature at MMC Tony M Consulting Pty. Ltd
200
100
T MC
Functional Gauges
Slip Pin
Slip Pins
Tony M Consulting Pty. Ltd
T MC
Tony M Consulting Pty. Ltd
201
Fixed Pin
DATUM Feature
RFS
202
101
T MC
Functional Gauges
Slip Pin
Slip Pins
203
Tony M Consulting Pty. Ltd
T MC
MMC feature related to MMC Datum feature
Note! 3rd Datum NOT Specified
Tony M Consulting Pty. Ltd
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
Tony M Consulting Pty. Ltd
205
T MC
Where is this surface relative to Datum “ B” ?
Tony M Consulting Pty. Ltd
206
103
T MC
Unequal distribution of position
Tony M Consulting Pty. Ltd
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 Ø8
Tony M Consulting Pty. Ltd
208
104
T MC
A] Sketch the Gauge(s) to functionally check this part B] Dimension the important features 209
Tony M Consulting Pty. Ltd
T MC
Consider the callout items indicated, “ circle” if you agree, modify to what you consider to be correct callout. Tony M Consulting Pty. Ltd
Are there any other changes or options necessary
210
105
T MC GEOMETRIC DIMENSIONING & TOLERANCING (GD&T) Session 4 TRUE POSITION [Continued] Tony M Consulting Pty. Ltd
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. Tony M Consulting Pty. Ltd
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.
Tony M Consulting Pty. Ltd
213
T MC
Tony M Consulting Pty. Ltd
214
107
T MC
True Position LMC
Minimum Condition
215
Tony M Consulting Pty. Ltd
T MC
Non-cylindrical mating parts
SHAFT
Tony M Consulting Pty. Ltd
216
108
T MC
Non-cylindrical mating parts
COLLAR
217
Tony M Consulting Pty. Ltd
T MC
Non-cylindrical mating parts BASE
Tony M Consulting Pty. Ltd
218
109
T MC
Non-cylindrical mating parts COVER
219
Tony M Consulting Pty. Ltd
T MC
Tony M Consulting Pty. Ltd
Non-cylindrical mating parts
220
110
T MC
Non-cylindrical mating parts
PLUS TOTAL 12.6 PROJECTION SIZE TOL
12.60 MMC
25.60 MMC PLUS TOTAL 25.60 DATUM SLOT SIZE TOL
221
Tony M Consulting Pty. Ltd
T MC
Tony M Consulting Pty. Ltd
Non-cylindrical mating parts
222
111
T MC
Non-cylindrical mating parts
223
Tony M Consulting Pty. Ltd
T MC
Tony M Consulting Pty. Ltd
Non-cylindrical mating parts
224
112
T MC
This requirement is extremely difficult to check other than by a Tracing of each requirement (say 10X)
Profile – Position related
If the tolerance zone is not shown as uni-lateral then the tolerance is Bi-lateral
225
Tony M Consulting Pty. Ltd
T MC
Profile – Position related
This requirement is extremely difficult to check other than by a Tracing of each requirement (say 10X)
Tony M Consulting Pty. Ltd
226
113
T MC
Profile – Position related
Note! Bi-lateral tolerance applies How do we determine the variation from MMC to apply ‘Bonus tolerance??
Tony M Consulting Pty. Ltd
T MC
Highly complex to check!! Check that FUNCTION REALLY requires this ‘call-out’
227
Co-axial features NOTE! STATIC FUNCTION ONLY
Tony M Consulting Pty. Ltd
228
114
T MC
Co-axial features
229
Tony M Consulting Pty. Ltd
T MC
Co-axial features NOTE! Rotating Function only
Tony M Consulting Pty. Ltd
230
115
T MC
Co-axial Mating Parts Static Function
231
Tony M Consulting Pty. Ltd
T MC
Co-axial Mating Parts Static Function
Tony M Consulting Pty. Ltd
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
Tony M Consulting Pty. Ltd
T MC
Dwg. Callout
Radial holes- Axial part
Tony M Consulting Pty. Ltd
234
117
T MC
Radial holes- Axial part
235
Tony M Consulting Pty. Ltd
T MC
Projected tolerance zones
Projected length equal to Part Thickness for Bolt or Total Stud Height
Tony M Consulting Pty. Ltd
236
118
T MC
Elongated Holes – Bi-directional Position Tolerances
237
Tony M Consulting Pty. Ltd
T MC
Elongated Holes – Bi-directional Position Tolerances
GAUGE
“ Diamond” shaped Gauge Pins Slip pins Tony M Consulting Pty. Ltd
238
119
T MC
Tolerance “ stacks”
239
Tony M Consulting Pty. Ltd
T MC
Tony M Consulting Pty. Ltd
Tolerance “ stacks”
240
120
T MC ADVANCED POSITION THEORY
No. 1 Advantage: Functional Parts will NOT be rejected
241
Tony M Consulting Pty. Ltd
T MC
Co-axial features Static Application
ADVANCED POSITION THEORY
Tony M Consulting Pty. Ltd
242
121
T MC
Fixed Fasteners (Threaded) ADVANCED POSITION THEORY
Note! Datum Features
243
Tony M Consulting Pty. Ltd
T MC
Fixed Fasteners (Threaded)
Note! Datum Feature
Tony M Consulting Pty. Ltd
ADVANCED POSITION THEORY
244
122
T MC
State this requirement into drawing format
Squareness 0.04
245
Tony M Consulting Pty. Ltd
T MC
Tony M Consulting Pty. Ltd
Drawing callout
246
123
T MC
Tony M Consulting Pty. Ltd
Design a Functional Gauge to check the location of the holes
247
T MC
Tony M Consulting Pty. Ltd
248
124
T MC
Determination of POSITION using Co-ordinate Measuring Machine
249
Tony M Consulting Pty. Ltd
T MC
Tony M Consulting Pty. Ltd
Determination of POSITION using Co-ordinate Measuring Machine
250
125
T MC
Determination of POSITION using Co-ordinate Measuring Machine
Size – MMC = Bonus 7.663 – 7.6 = 0.063 Tol. + bonus = allowed tol. 0.25 + 0.063 = 0.313
251
Tony M Consulting Pty. Ltd
T MC
DIMENSION REVIEW
1.4/1.7 Typ.
Tony M Consulting Pty. Ltd
252
126
T MC
DIMENSION REVIEW g on A Wr
37.2/36.2
7.7min
21.5/20.5 7.3 min.typ.
W
RO NG
1.5 A
10.5 min
A
30 deg.
8.9 min.typ
253
Tony M Consulting Pty. Ltd
T MC
Tony M Consulting Pty. Ltd
Assembly [part only]
254
127
T MC
HOUSING Length C
Surface A
Diameter D
PCD E
Surface B Tapped holes F
Diameter G
255
Tony M Consulting Pty. Ltd
T MC
Design Function/Relationship Matrix (Dimensioning)
Component/Sub-Assy. Pt. No. 123-456A Housing Datum Feature ‘A’ Surface
Prim
Seco n
Criticality Rating Tert.
Size
Positi on
Y
Shap e
L
‘C’ Length
L
‘D’ Dia.
M
‘E’ PCD
H
H
‘F’ Tap’d holes
H
SC
Tony M Consulting Pty. Ltd
Sec. Datum
H
‘B’ Surface
‘G’ Dia.
Control Symbol Prim. Datum
‘G’
P 6.7
Y
SC
256
128
T MC
HOUSING 6x M8 X 20/22 full thd.
10/11
47/47.5 DIA
120/119.8 DIA [SC]
[SC]
A
C 257
Tony M Consulting Pty. Ltd
T MC
FLANGE MOUNT Surface A
Dia H
Holes F Dia J
Dia B
Dia D
Dia C
Ref. Surf.
Length M Length L
Length K
Thread E
Length G
Tony M Consulting Pty. Ltd
258
129
T MC
Design Function/Relationship Matrix (Dimensioning)
Component/Sub-Assy. Pt. No. 123-457 Flange Mount Datum Feature
Prim
Sec on
Criticality Rating Tert.
Control Symbol
Size
Positi on
Shap e
Prim. Datum
‘A’ Surface
Y
-
-
M
Ref surf
‘B’ Dia.
Y
SC
M
H
‘A’
H
H
H
‘B’
‘D’ Dia.
M
M
M
‘B’
‘E’ Thread
M
M
‘B’
‘F’ Holes
H
SC
‘B’
‘G’ Length
M
-
-
Ref surf
L
L
L
Manuf Loctn.
‘C’ Dia.
‘H’ Dia
Y
Manuf
Loctn
Sec. Datum
259
Tony M Consulting Pty. Ltd
T MC
FLANGE MOUNT
? B [SC]
[SC]
Tony M Consulting Pty. Ltd
260
130
T MC
SHAFT Surface A Dia C
Dia B
U’cut
261
Tony M Consulting Pty. Ltd
T MC
Design Function/Relationship Matrix (Dimensioning)
Component/Sub-Assy. Pt. No. 123-458 Shaft Datum Feature
Prim
Seco n
Criticality Rating Tert.
Siz e
Positio n
‘A’ Surface ‘B’ Dia
Y
M
Control Symbol
Shap e
Prim. Datum
L
‘B’
M
‘C’ Dia
M
M
M
‘B’
U’cut
L
L
L
‘B’
Tony M Consulting Pty. Ltd
Sec. Datum
262
131
T MC
SHAFT
44.4/44.25 dia
U’cut 1/1.5wide X 0.7/1 deep
19/18.95 dia.
A
263
Tony M Consulting Pty. Ltd
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 engineer’s 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.
Tony M Consulting Pty. Ltd
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
Tony M Consulting Pty. Ltd
T MC Geometric Dimensioning & Tolerancing
Practical exercises
Tony M Consulting Pty. Ltd
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
Tony M Consulting Pty. Ltd
T MC
Part 1 Component Drawing review [Basics]
Tony M Consulting Pty. Ltd
268
134
T MC
Primary
Secondary
Tertiary
269
Tony M Consulting Pty. Ltd
TMC
Basic Fitment
?
270 Tony M Consulting Pty. Ltd
135
TMC
Tony M Consulting Pty. Ltd
Yes, only when balance of feature is at MMC[Rule271 #1]
T MC
95
Tony M Consulting Pty. Ltd
272
136
T MC
4 SURFACES
MI N.
BOTH SIDES
291
Tony M Consulting Pty. Ltd
TMC
Bolt MMC Fixed Fastener
? 292 Tony M Consulting Pty. Ltd
146
TMC
Female Part
Male Part
Unilateral tolerance from MMC
?
Unilateral tolerance from MMC
Note! True Position callout is not required 293
Tony M Consulting Pty. Ltd
T MC
Part 3 Component Drawing review [Sub-assembly reference]
Tony M Consulting Pty. Ltd
294
147
TMC
Floating Fastener
? ?
295 Tony M Consulting Pty. Ltd
TMC
Equivalent to “ Fixed Fastener”
296 Tony M Consulting Pty. Ltd
148
TMC Fixed Fastener ?
297 Tony M Consulting Pty. Ltd
TMC
?
298 Tony M Consulting Pty. Ltd
149
T MC
?
Fixed Fastener ?
?
Housing interchangeability NOT required
Fixed Fastener ?
299
Tony M Consulting Pty. Ltd
T MC
Bolt Dia MMC Ø 8.00
Functional Parts will NOT be rejected. Option 2 Tony M Consulting Pty. Ltd
Functional Parts [u/s dia] will be rejected. Option 1
300
150
T MC
Improved drawing based on FUNCTION Functional Datum?
Functional Datum?
301
Tony M Consulting Pty. Ltd
T MC Functional Requirements defined
Tony M Consulting Pty. Ltd
302
151
T MC
R 100 90º incl.
3X R 20
Functional Requirements defined
Functional Datums?
303
Tony M Consulting Pty. Ltd
TMC
Part 4 Critique of existing Drawings
304 Tony M Consulting Pty. Ltd
152
TMC
307 Tony M Consulting Pty. Ltd
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
Tony M Consulting Pty. Ltd
154
TMC
STATIC APPLICATION
Use “ True Position” Is this the correct FUNTIONAL DATUM? 309 Tony M Consulting Pty. Ltd
TMC 60º
310 Tony M Consulting Pty. Ltd
155
TMC
311 Tony M Consulting Pty. Ltd
TMC
Part 5 Assembly [Drawing callout development]
312 Tony M Consulting Pty. Ltd
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 Tony M Consulting Pty. Ltd
TMC
Design Function/Relationship Matrix (Dimensioning)
Component/Sub-Assy. Pt. No. Datum Feature
Prim
Seco n
Criticality Rating Tert.
Siz e
Positio n
Shap e
Control Symbol Prim. Datum
Sec. Datum
‘A’ Surface ‘B’ Hole ‘C’ Hole ‘D’ Thicknes s ‘E’ Width Etc.
314 Tony M Consulting Pty. Ltd
157
TMC
St ub Be A ar xle in & gs
Hub
Studs
Wheel Rim
Brake Disc
Wheel Nuts
315
Tony M Consulting Pty. Ltd
Wheel Studs
Bearing Dias
TMC
A-B
110 PCDia
Wheel Hub
316 Tony M Consulting Pty. Ltd
158
TMC
Wheel Hub
5x H7 Ø 14
110 PCDia
C
317 Tony M Consulting Pty. Ltd
TMC Ø 14 g8 (press fit)
M12 x 1.0
A
Ø 18.00 +/- 0.5 Free form
318 Tony M Consulting Pty. Ltd
159
TMC
Brake Disc
[Rotating Function]
5x H9 Ø 14
110 PCDia
Control for other rotating surfaces
C
319
Tony M Consulting Pty. Ltd
TMC
WHEEL [Rotating Function]
75º incl. 5x Ø 17
320 Tony M Consulting Pty. Ltd
160
TMC
14.8+/-0.2
5.5/ 5.0
75º incl.
5x Ø 17
Enlarged View Wheel Nut Location
15.5/17.0
321
Tony M Consulting Pty. Ltd
TMC 18 A/F Hex. Stock
25/24 2.4/2.2
75º incl.
M12 X 1.0
Ø 17
WHEEL NUT 322 Tony M Consulting Pty. Ltd
161
TMC
Part 6 Sheet metal [Structural fabrication components]
323 Tony M Consulting Pty. Ltd
TMC ?
?
? ? ? ?
?
?
324 Tony M Consulting Pty. Ltd
162
TMC ?
?
?
?
?
Note! All Geometric Controls to be inspected while Workpiece is constrained on Datum Target Areas A1-A3 & B1-B2
Tony M Consulting Pty. Ltd
TMC
325
?
?
?
?
? ? ?
? ?
?
326 Tony M Consulting Pty. Ltd
163
TMC
Note! Only the Geometric callouts are displayed. Coordinates are taken from CAD File.
? ?
?
?
?
? ?
?
?
?
327
Tony M Consulting Pty. Ltd
TMC ?
?
?
? ? ?
? 328 Tony M Consulting Pty. Ltd
164
TMC ?
?
?
?
? ?
329 Tony M Consulting Pty. Ltd
TMC
?
?
? ?
?
330
Tony M Consulting Pty. Ltd
165