SAA HB471993

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Handbook
Dimensioning and Tolerancing to AS 1100.1011992 and AS 1100.2011992

SAA HB471993

This is a free 8 page sample. Access the full version at http://infostore.saiglobal.com.

Handbook
Dimensioning and Tolerancing to AS 1100.1011992 and AS 1100.2011992

by

Leonard E. FARMER
BE, MEngSc, PhD (NSW) School of Mechanical and Manufacturing Engineering The University of New South Wales

First published as SAA HB471993.

PUBLISHED BY STANDARDS AUSTRALIA (STANDARDS ASSOCIATION OF AUSTRALIA) 1 THE CRESCENT, HOMEBUSH, NSW 2140
ISBN 0 7262 8325 8

SAA HB471993

PREFACE
There have been considerable developments in the dimensioning and tolerancing of product designs since the mid 1940s. These have accelerated in recent years in response to the demands of internationalised markets, increasing product sophistication and the need for more accurate and unambiguous design specifications for operating the deskilled automated manufacturing processes and quality inspection methods that are now extensively used in manufacturing. The system of dimensioning and tolerancing that is evolving integrates market needs with product design and manufacturing technology requirements. It comprises an overall strategy that is supported by theoretical principles and widely accepted industrial practices. An ever-improving system of recommended practices continues to be formalised by international committees working under the auspices of the International Organization for Standardization (ISO). These recommendations of ISO are being widely adopted throughout industrialised countries and are either adopted in their entirety or are the principal components of most of todays national Standards. Thus, the degree of consistency in dimensioning and tolerancing practices throughout the industrialised world is rapidly increasing. Australia has adopted, with some minor exceptions, the current ISO recommendations related to dimensioning and tolerancing and these are embodies in Australian Standards AS 1100.101 1992, Technical drawing General principles and AS 1100.201 1992, Technical drawing Mechanical engineering drawing. It has been recognised that the volume of information surrounding the subject of dimensioning and tolerancing is so vast that Standards now tend to concentrate on how to apply dimensions and tolerances. This is to achieve a reasonably compact Standard containing appropriate information in a form that can be used efficiently and effectively. The questions of why certain principles and practices have evolved generally have to be left aside. The purpose of this book is to address these why issues and provide a cohesive, overall view of the dimensioning and tolerancing system with further explanations of the principles, practices and recent developments in this subject. The Handbook relates principally to AS 1100.101 1992 and AS 1100.201 1992 and can be extended to most of the current ISO recommendations. It should in no way be considered to override, replace or be a substitute for any Australian Standard but rather, to support and enhance the understanding and use of AS 1100.101 1992 and AS 1100.201 1992. The dimensioning and tolerancing material contained in this Handbook has been accumulated by the author over a period of 30 or more years of working in industry, teaching, researching, and as a member of the Standards Australia ME/72 Committee Working Group on Dimensioning and Tolerancing. I gratefully acknowledge the numerous people that have assisted me in my understanding of this subject. Much of this Handbook is a reflection of their efforts. Two dear friends and colleagues who gave me wise counsel and invaluable insights into dimensioning and tolerancing are the late Cyril Gladman and Ken Edensor. Not only did they have a profound influence on my knowledge, but more importantly, they made most significant contributions to the advancement of the overall subject and were leading contributors to the development of Australian and ISO Standards in this area. Finally, I acknowledge, with gratitude, the brief extracts contained in this Handbook from the Institute of Manufacturing Management and Technology, UNSW, course notes "How to ... Interpret, Manufacture & Inspect to Geometry Tolerance Specifications" and Australian Standards AS 1100.101 1992 and AS 1100.201 1992. Copies of the complete Standards can be obtained in Australia from Standards Australia, PO Box 1055, Strathfield NSW 2135.

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SAA HB471993

CONTENTS

Page
SECTION 1 SECTION 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SOME GENERAL ASPECTS OF TECHNICAL DRAWING . . . . . . . . . . Compliance with AS 1100.1011992 and AS 1100.2011992 Projection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coordinate Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fundamental Rules for Dimensioning and Tolerancing . . . . . . . Functional and NonFunctional Dimensions . . . . . . . . . . . . . Basic Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tolerance Frame and Tabular Method for Specifying Geometry Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 9 9 9 9 9 13 15 19 19

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.........

SECTION 3 3.1 SECTION 4 SECTION 5 5.1 5.2 5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.3.6 5.4 5.5 5.6 SECTION 6

CURRENT SYSTEM OF DIMENSIONING AND TOLERANCING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . An Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THE PRINCIPLE OF INDEPENDENCY . . . . . . . . . . . . . . . . . . . . . . SIZE DIMENSIONS AND TOLERANCES . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Methods for Specifying Size Dimensions and Tolerances Linear Size Dimensions . . . . . . . . . . . . . . . . . . . . . . . . Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Datum Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centre Distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . Locating the Axes of Features . . . . . . . . . . . . . . . . . . . Angular Size Dimensions . . . . . . . . . . . . . . . . . . . . . . . Implied Size Dimensions . . . . . . . . . . . . . . . . . . . . . . . Functional and Non-Functional Size Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 22 26 29 29 29 30 30 33 33 33 35 35 38 38 40 42

THE ENVELOPE PRINCIPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAA HB471993

Page
SECTION 7 7.1 7.2 7.3 SECTION 8 8.1 8.2 8.3 8.3.1 8.3.2 8.3.3 8.3.4 8.4 8.5 SECTION 9 9.1 9.2 9.2.1 9.2.2 9.3 9.3.1 9.3.2 9.4 THE GEOMETRIC REFERENCE FRAME . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Geometric Reference Frame (GRF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tolerance Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FORM TOLERANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . Specification of Form . . . . . . . . . . . . . . . . . . . . Interpretation of Form Tolerance Specifications . . CIRCULARITY of Cylinder A . . . . . . . . . . . . . . . CYLINDRICITY of Cylinder A . . . . . . . . . . . . . . . FLATNESS of Face B . . . . . . . . . . . . . . . . . . . . STRAIGHTNESS of Cylinder A . . . . . . . . . . . . . Assessment of Form Tolerance Specifications . . Functional and Non-Functional Form Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 44 44 46 48 48 48 50 50 50 53 53 53 54 55 55 55 57 57 59 59 59 59 61 61 61 64 64 66 68 70 70 70 72 74

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MAXIMUM MATERIAL PRINCIPLE . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . Maximum Material Principle (MMC) . . . . . Virtual Condition . . . . . . . . . . . . . . . . . . . Bonus Tolerances . . . . . . . . . . . . . . . . . . General Rules for Calculating Virtual Sizes External Features (SHAFTS) . . . . . . . . . . Internal Features (HOLES) . . . . . . . . . . . Application of MMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 10.1 10.2 10.3 10.3.1 10.3.2 10.4 10.5 10.5.1 10.5.2 10.6 10.6.1

DATUMS AND DATUM SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction . . . . . . . . . . . . . . . . . . . . . Specification of a Single Datum Feature . Interpretation of a Single Datum Feature Interpretation of a Datum Plane . . . . . . . Interpretation of a Datum Cylinder . . . . . Specification of Multiple Datum Features Interpretation of Multiple Datum Features Primary, Secondary and Tertiary Datums Six Point Location Principle . . . . . . . . . . Datum Targets . . . . . . . . . . . . . . . . . . . Datum Target Areas . . . . . . . . . . . . . . .

SAA HB471993

Page
SECTION 11 11.1 11.2 11.3 11.4 11.5 ORIENTATION TOLERANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 78 78 78 80 80 83 83 85 85 88 88 91 97 97 97 103 103 103 103 104 104 105 113 113 114 114 114 116 116

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specification of Orientation . . . . . . . . . . . . . . . . . . . . . Interpretation of Orientation Tolerance Specifications . . . Assessment of Orientation Tolerance Specifications . . . Functional and NonFunctional Orientation Dimensions

SECTION 12 12.1 12.2 12.3 12.4 12.5

LOCATION TOLERANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specification of Location . . . . . . . . . . . . . . . . . . . . Interpretation of Location Tolerance Specifications . Assessment of Location Tolerance Specifications . . Functional and Non-Functional Location Dimensions

SECTION 13 SECTION 14 14.1 14.2

GROUPING GEOMETRY TOLERANCES . . . . . . . . . . . . . . . . . . . . . PROJECTED TOLERANCE ZONES . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interpretation of Projected Tolerance Zone Specifications . . . . . . . . . . . . . APPLICATION OF THE MAXIMUM MATERIAL PRINCIPLE . . . . . . . ....... ....... ....... ....... ....... Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 15 15.1 15.2 15.2.1 15.2.2 15.2.3 15.3

Introduction . . . . . . . . . . . . . . . . . . . . . . . Fitting Components . . . . . . . . . . . . . . . . . . Clearance Fits . . . . . . . . . . . . . . . . . . . . . Interference or Press Fits . . . . . . . . . . . . . Threaded Fits . . . . . . . . . . . . . . . . . . . . . "Flow On" Benefits of the Maximum Material

SECTION 16 16.1 16.2 16.3 16.3.1 16.3.2 16.3.3

SURFACE TEXTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction . . . . . . . . . . . . . . . . . . . . . Basic Symbols . . . . . . . . . . . . . . . . . . . The Extended Symbol . . . . . . . . . . . . . Ra Roughness value . . . . . . . . . . . . . . . Production Method, Treatment or Coating Cut-off (Sampling Length) . . . . . . . . . . .

SAA HB471993

Page
16.3.4 16.3.5 16.3.6 16.3.7 16.4 Indication of Lay . . . . . . . . . Machining Allowance . . . . . . Waviness Requirements . . . . Other Roughness Values . . . . Functional and Non-Functional ....................... ....................... ....................... ....................... Surface Texture Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 116 116 117 117 119 119 119 122 125 126

SECTION 17 17.1 17.2 17.3

GENERAL TOLERANCE ACCURACY GRADES

..............

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Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machined Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Castings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INDEX .........................................................

Copyright

Leonard E FARMER 1993 STANDARDS AUSTRALIA INSTITUTE FOR MANUFACTURING MANAGEMENT AND TECHNOLOGY

Except where the Copyright Act otherwise allows, no part of this publication may be reproduced, stored in a retrieval system in any form or transmitted by any means without prior permission in writing from ALL of the following Leonard E FARMER, STANDARDS AUSTRALIA and the INSTITUTE FOR MANUFACTURING MANAGEMENT AND TECHNOLOGY.

SAA HB471993

SECTION 1 INTRODUCTION
The dimensions and tolerances that are placed on product design drawings are a necessary part of the language of technical drawing. They are the means by which a designer specifies and communicates details of the size and shape requirements of a product, to those who will manufacture the design, and to those who will inspect the product to determine its conformance to the design specification. The three principal objectives of a system for dimensioning and tolerancing are:
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1. to enable designers to clearly, concisely and unambiguously specify the functional requirements of their designs, 2. be consistent and compatible with the technology and practices in current use for design, manufacture and inspection and quality control, and 3. enable products to be designed and produced efficiently and at minimum cost. Probably the most significant change to dimensioning and tolerancing occurred during the late 1940s. Up to this time the dimensioning and tolerancing information specified by designers on their drawings was essentially what is termed " process oriented " and this generally needed to be supported with the skill and knowledge of the shop floor personnel. During the Second World War difficulties were experienced with the performance of certain armaments that were being produced in the UK. The matter was investigated and it was found that a principal cause of these difficulties was due to inadequate and often ambiguous specifications of design information. It was concluded that the problems could be remedied if the designers approach to dimensioning and tolerancing was " function oriented " rather than " process oriented ". That is, designs, should be dimensioned and toleranced to meet the functions they are expected to perform. Functional Requirement Analysis methods, such as those described in [1], were developed to assist designers with this new approach to dimensioning and tolerancing. These methods of analysis uncovered the necessity to specify the permissible variations in the geometry of some features of certain designs in order to achieve required function or performance levels. Hence, geometry tolerances for specifying flatness, squareness, straightness, etc. were introduced into the practice of dimensioning and tolerancing.

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HB 47-1993, Dimensioning and tolerancing to AS 1100.101-1992 and AS 1100.201-1992

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