1

WELCOME

GEOMETRIC DIMENSIONING
&
TOLERANCING COURSE

By M.Hashim Khan
Manager QC 2
 Basics of Engg. Drawing

Dimensioning & Tolerancing

 Type No on Dwg
Classification of characteristics
(DoD-std-2101)
Critical (c1-c99) 1
Major (M101-M199) 3
Drawing Layout
Critical (C1 – C99) xxxxx
Minor (201 – 299) 2

Major (M101 – M199) xxxxx

Minor (201 -299) xxxx / All other
M3x0.5
(201)

DoD-STD-2101
CLASSIFICATION OF CHARACTERISTICS
(DOD-STD-2101) Ø15 Ø10±0.05
Critical (C1-C99) Nil (M102)
Major (M101-M199) 2
Minor (201 – 299) 1

10±0.1 10±0.1
(M101)
1 st vs. 3rd Angle Projection

First Angle Projection Third Angle Projection

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Different types of tolerances

Limit Tolerance Plus-Minus Tolerance

12.50
12.25 +/- 0.25
12.00
Dimensioning Styles Chain Method

Base line Method

Direct Method
 TABULAR DIMENSIONING

• Form of rectangular
coordinate
dimensioning without
dimension lines
• Features dimensioned
in a table

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 Tolerancing
Technique of dimensioning parts within a required
range of variation to ensure interchangeability

A tolerance should be as large as possible without

interfering with the function of the part to minimize
production costs.
Types of Tolerances

Normal Tolerances apply to all dimensions on a drawing.

Normal

Geometric Tolerances are concerned with a feature’s

Geometric shape or profile, orientation, location & runout.
 Linear Tolerance Linear

• It is an overriding tolerance used when a specific feature requires greater

accuracy than the one expressed by the general tolerance.

Limit Form Unilateral Form Bilateral Form

Tolerance Dimensions
• unilateral tolerance + 0
25 -0.2

• bilateral tolerance 25 ± 0.1

25.5
• limit tolerance 24.5

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 TOLERANCING PRACTICES
• METRIC SYSTEM  INCH SYSTEM
Cylindrical Fits – Metric Units
• fundamental deviation – a
letter grade that describes
the deviation closest to the
basic size
• International Tolerance (IT)
grade – a series of
tolerances that vary with the
basic size to provide a
uniform level of accuracy
within a given grade
• there are 18 IT grades:
IT01, IT0, IT1, …, IT16

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Fits (Selected)
18

Surface Finish Characteristics

• Roughness
• Waviness
• Lay
• Flaws
Numerical Values of Surface Texture
 MFG Process Vs Surface Texture
Drawing Indication VALUES Manufacturing
(micron) Process
N2 0.05 Lapping
N3 0.1 Lapping
N4 0.2 Polishing
N5 0.4 Grinding
N6 0.8 Grinding
N7 1.6 Horizontal Milling
N8 3.2 Vertical Milling
N9 6.3 Turning
N10 12.5 Turning
Basics of GD&T
Datum & DRF
 Primary datum feature (3 points of contact)
Datum Reference Frame - DRF Secondary datum feature (2 points of contact)
4X 12±0.3 Tertiary datum feature
0.6 M A B C (1 point of contact)

35

B
20

25 50 A

C 10±0.1

the DRF to the part.

Datum Reference Frame - DRF The DRF consists of points, axes and planes

Datum
Planes Datum
Axes

Datum Point

6.2
 The Datum Reference Frame constraints or arrests 6 degrees of freedom

Three Translation Controls Three Rotation Controls

X = Translation in “X” direction u = Rotation in “u” direction
Y = Translation in “Y” direction v = Rotation in “v” direction
Z = Translation in “Z” direction w = Rotation in “w” direction
 Planar Datum Example

Datum plane A is bottom plane of a perfect part

 Datum Simulators
High precision surfaces and gages are used to simulate theoretically
perfect datums, and therefore allow accurate measurement

Surface plate
Ground flat and highly polished – simulates datum plane
CAD/Fab GD&T 2 - Datums 31
Indicating Datum Features - Axis

A
datum feature

12.00-12.07

0.1 M A B C

In each case, the datum is the axis of the hole

or cylindrical datum feature
 Three-Jaw Chuck

datum feature

Jaws move radially

inward until they
contact part

Datum is axis of chuck

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Location & True Position
 Position Control

• Most powerful and versatile control in GD&T

• Capitalizes on MMC bonus tolerances 4X 12±0.3
0.6 M A B C

• Can be used to :
• Locate patterns of holes
• Locate center of feature (e.g. slot) 35

• Control perpendicularity of holes, etc. B

20

• Easy to check with functional gages 25 50 A

• Insures proper fit of assemblies C 10±0.1

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Coordinate
Dimensioning
EXAMPLE

PONITS REQUIRING CALRIFIACTION?

 REVIEW

ALL QUESTIONS ANSWERED?

Base line Method

Chain Method

Direct Method
TRUE POSITION
TRUE POSITION
TRUE POSITION
TRUE POSITION
TRUE POSITION
True Position
Position Tolerancing
Verification

1.500 B

.750
2.500 .758 ±.005
.750 A
C
.010 M A B C
Size of hole is produced X² + Y² = Z² - Pythagorean Theorem
at .750 (MMC). 2X .005 = Ø.010
X² + Y² = Z
Tol Zone
2 X² + Y² = Diameter Tol Zone
Actual Manufactured .005
Part .004

1.504 .003
Actual 1.500

Let us check this part to see if

2.500
the hole location is within
2.503 Actual tolerance.
Position Tolerancing
Verification MMC

1.500 B

.750
2.500 .758 ±.005
.750 A
C
.010 M A B C
Since the hole is produced at MMC (.750), it is allowed
2X .005 = Ø.010 Tol Zone .010 position tolerance. The actual calculated position
of the hole falls within the .010 zone.

Actual Manufactured .005

Part .004

1.504 .003
Actual 1.500

2.500
2.503 Actual
Position Tolerancing
Verification

1.500 B

.750
2.500 .758 ±.005
.750 A
C
.010 M A B C
Size of hole is produced Let us try another example, this time the hole is produced at .755.
at .755. Is the location good or bad?

Actual Manufactured
Part .005

1.505 .006
Actual 1.500

Let us check this part to see if

2.500
the hole location is within
2.506 Actual tolerance.
 HOW TO MEASURE HOLES
• Diameter
• Specified by diameter and tolerance (MMC/LMC)
• Measure accurately with micrometer/caliper
• Checked with GO – NO GO gages

• Position
– Specified by GD&T frame & basic dimensions
– Measure accurately with optical comparator
– Checked with functional gages

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 GO – NO GO Gages
Go No Go
Allowable
variation in hole
diameter

Hole Hole
LMC MMC

Go No Go

GO NO GO Handle
Gauge for TP
Bonus Tolerance
Bonus Tolerance
 MMC
Position tolerance applied at MMC
The larger the hole, the more
position tolerance.

3.10
 MMC
Position tolerance applied at MMC
The larger the hole, the more
position tolerance.

3.10
 MMC
Position tolerance applied at MMC
The larger the hole, the more
position tolerance.

3.10
 MMC
Position tolerance applied at MMC
The larger the hole, the more
position tolerance.

3.10
 MMC
Position tolerance applied at MMC
The larger the hole, the more
position tolerance.

3.10
 MMC
Position tolerance applied at MMC
The larger the hole, the more
position tolerance.

3.10
BONUS TOLERANCE
True Position
Form Tolerances
Flatness
Straightness
• It is a condition where all line elements of a feature lie in a straight
line

• The application of straightness for surface is same as discussed in

flatness
• The difference b/w both is that flatness applies to whole surface while
straightness applies to line elements only
STRAIGHTNESS - EXAMPLE
• Tolerance
value is
applied in
direction of
the view in
which it is
specified
Circularity
Checking for Cylindricity

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Parallelism
Perpendicularity
Perpendicularity
Checking for Perpendicularity

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Angularity
Five Ways to Control Coaxiality
Concentricity 0
25 -0.5

0.2 E
E

0
12 -0.2
Symmetry
8.8
8.2
A
0.4 A

20.5
20.0
RunOut
Checking for Runout

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Profile
 MODULE - II

INSPECTION
TECHNIQUES

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 INSPECTION TECHNIQUES

• WHAT IS INSPECTION

• INSPECTION TYPES

• INSPECTION SYSTEM

• BASICS OF SAMPLING

• INSPECTION TOOLS

• PRACTICAL SESSION
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 INSPECTION

• Comparing / Checking the part / product to

• Drawings / specifications
• Standards

• Use of
• Tools / Instruments / Equipments

• Results
• Pass / Fail
• Conform / Non-confroming

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 INSPECTION TYPES
• INCOMING INSPECTION
• Spec. Sheets, supplier Documents etc.
• Material testing / reports

• IN-PROCESS INSPECTION
• During Manufacturing / Assembly

• FINAL INSPECTION
• Inspection / testing before dispatch
• User requirements (contracts / work orders/ Stds.)
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 INSPECTION TYPES
• VISUAL INSPECTION
• With naked eye / magnifying glass
• Checking burrs / surface defects / paint etc.

• SEMI-AUTOMATED INSPECTION
• Inspector + Inspection Equipments

• AUTOMATED INSPECTION
• Equipment / sensor based e.g. CMM
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 INSPECTION TYPES

• FIRST ARTICLE INSPECTION

• Representative items before batch production
• Machine Setting
• Process verification

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 INSPECTION SYSTEM
• Inspection system is combination of:
• Inspection Plans & Work Instructions
• Specifications & Standards
• Inspection Personnel
• Inspection Tools
• Calibration
• Sampling Strategy
• Inspection Records & Reports

105
 INSPECTION PLANNING
• Characteristics to inspect
• Inspection Plan

• Quantity of Parts to inspect

• Sampling Plan

• Inspection Equipment or Method

• Skill, experience & Training of personnel

• Inspection Records
• Process Sheets, Inspection Reports, Check sheets etc

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 CHARASTERICTICS CLASSIFICATION

• Critical
• System / Mission / Human life critical
• 100% Inspection

• Major
• Function / Form fit of product / Assemblies

• Minor
• Visual appearances and all others

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 SAMPLING
• Random selection from a lot to check conformance

• MIL-STD 105 E

• LEVELS
• General (I, II & III)
• Special (S1-S4)
• AQL

• Advantages
• Less time
• Less cost
• Used in destructive testing
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109
110
 INSPECTION RECORDS

• CHECK SHEETS

• INSPECTION REPORTS (IRs)

• ROUTE SHEETS (RS) / PPS

• MATERIAL CERTIFICATES

• TREATMENT CERTIFICATES

• IN-PROCESS / FINAL IRs 111

 INSPECTION TOOLS
• Conventional Tools
• Vernier, Micrometer, Tri-o-bore, Dial Indicator,
Gauges etc
• Advanced Tools
• Height Master, Height gauge, Profile Projector
etc
• Precision Metrology
• CMM, Laser System, Mic-Trac, ULM etc
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 INSPECTION TOOLS – SELECTION
CRITERIA
• Parts Features
• Dimension Based
• Size Measurement
• Geometry Measurement
• Accuracy

• Discrimination Index
• 1-to-10 Rule

• Complexity / Cost / Speed 113

 VERNIER CALIPER

• Most versatile

• Measurements
• Length
• Depth
• Diameters etc.

• For Tolerance > 100μm (0.1 mm)

114
 MICROMETERS

• Very Accurate & Precise

• Measurements
• Length
• Depth
• Diameters etc.

• For Tolerance > 10 μm (0.01

mm)
• Less Skilled

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 MICROMETER - TYPES
Spline Mic.
For measuring splined
shafts, slots, and keyways.
Disc Mic.
Used to measure thin
sheets, gear blades, etc
Point Mic.
Measuring the web
thickness of drills, small
grooves, keyways, and
other hard-to-reach
dimensions.
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 MICROMETER - TYPES
• Pana Mic.
• wide range applications
• 7 interchangeable
optional anvils
• Flat
• Spline
• Spherical
• Point
• knife-edge
• Disk
• blade

117
 MICROMETER - TYPES
• Limit Mic.
• Can be used as a
GO/±NG gage by
setting the upper and
lower limits.

• Groove Mic.
• Width
• Depth
• Grooves
• Bores
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 BORE GAUGES (TRI-O-BORE)
• Used for:
• Accurate internal
diameter
measurement
• Deep hole dia.
with the help of
Extension rod
• Diameter of a
blind hole to the
bottom.
• Accuracy ± 1 micron

119
 THICKNESS GAUGE

• Thickness Measurement

• Handy, Accurate and

Reliable

• Parts
• Sheet Metals
• Plastic
• Delicate items e.g.
rubber parts

120
 GAUGE BLOCKS

• Highly accurate measuring

standards

• Accuracy ± 1 micron

• Serve as ready tools

to verify Calibration

• Sizes
• Range 0.5 – 500 mm
• Stacked
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 BEVEL PROTRACTOR

• Angle Measurement

• Accurate angle of
• Parts
• Machines
• Molds
• Jigs

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FEELER, RADIUS & PITCH GAUGES

RADIUS GAUGES

PITCH GAUGES FEELER GAUGES

123
 DIAL INDICATORS

• Precision Measuring
• Accuracy ± 1 micron

• Broad range applications

• Machine Setting

• GD&T
• Straightness
• Flatness
• Run-out etc.
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 HEIGHT GAUGE

• Height measurements
• Depth
• Line to Line Distance

• Advantages
• Handy
• Adjustable
• As Go / No Go Gauge
• Can be used with scrapers, DTI
etc.

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 HEIGHT MASTER
• Versatile
• Accuracy ± 5 micron

• Applications
• point to point / centre to surface
/ slot to slot
• GD&T
• Straightness / Flatness
• Parallelism
• Position
• Symmetry
• concentricity / co-axiality

126
 PROFILE PROJECTOR

• Digital Read Out

• Based on Shadowgraphy / Image of
parts
• Delicate
• Precise
• Complex

• Applications:
• centre to centre / centre to
surface / slot to slot distance
• GD&T 127
 SURFACE TEXTURE TESTING TOOLS

• Surface Finish Comparator

• Ready Made Specimens for
instant verification

• Surface tester measuring

device
• Peak to valley height
(Average Roughness)
• codes
• Ra, RMS, Rt, CLA etc

128
 SURFACE TEXTURE DETAILS
Drawing Indication VALUES Manufacturing
(micron) Process
N2 0.05 Lapping
N3 0.1 Lapping
N4 0.2 Polishing
N5 0.4 Grinding
N6 0.8 Grinding
N7 1.6 Horizontal Milling
N8 3.2 Vertical Milling
N9 6.3 Turning
N10 12.5 Turning 129
Typical
range of
Ra surface
roughness
values in
various
metal
forming
operations

130
THANK YOU!

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