Dimensioning and Tolerancing Handbook

The need to make more precise products, the requirements of mass production, and the desire for
interchangeability have resulted in increased importance of clearly defining dimensions and tolerances.
Major products such as aircraft and automobiles are assembled from parts produced by many
companies. Only through clear definition of dimensional requirements is it possible for multiple companies to efficiently produce parts that will easily assemble and meet their functional requirements.
The United States national standard on dimensioning and tolerancing has been revised periodically to
include methods for defining dimensional requirements for increasingly complex applications. Recent
standards include: USASI Y14.5-1966, ANSI Y14.5-1973, ANSI Y14.5M-1982, and ASME Y14.5M1994. This book is based on ASME Y14.5M-1994, but also includes some description of past
practices for use by anyone who is required to maintain drawings created in compliance with a
previous standard. Past practices are clearly identified when shown within the Handbook.
Every attempt has been made to accurately describe the requirements of the current standard. The
material in this book is intended to make the standardized practices easier to understand. Use of this
publication will help ensure compliance with the related standard. However, should there be any
conflict between this book and a standard, the standard would take precedence.
This Dimensioning and Tolerancing Handbook contains information about the symbology used for
dimensions and tolerances, general dimensioning, general tolerancing, form tolerances, datums, location tolerances, orientation tolerances, runout tolerances, and profile tolerances. Calculation methods
and interpretation examples are included. A detailed table of contents makes location of any topic easy.
A separate list of figures follows the table of contents to assist in locating a graphic example of any
needed topic. There are over 250 figures to illustrate the concepts explained within the text. An index
at the back of the book is provided to simplify location of specific information.
About the Author
Bruce A. Wilson, author and illustrator of the Dimensioning and Tolerancing Handbook, has established exceptional credentials in the field of dimensioning and tolerancing. He has lead implementation
of Geometric Dimensioning and Tolerancing (GD&T) throughout the companies of a major
corporation and served as the technical leader for GD&T implementation on aircraft development
efforts that included multiple aircraft manufacturing corporations.
Mr. Wilsons industrial experience started with a position as a design drafter in an automated machine
tool manufacturing company. He has subsequently held positions as design engineer, design manager,
program manager, technology leader for dimensional management, and industrial consultant in the
field of dimensional management.
His dimensional management capabilities and technical leadership have had a strong influence on a
range of products from the wheels for childrens tricycles to laser target designators used by military
pilots. Tomahawk missiles, used at critical times like the Persian Gulf War, demonstrate the accuracy
of Mr. Wilsons designs, which all use GD&T to accurately define design requirements and the
allowable variations. His other product applications have ranged from miniature gear drives to structural designs for large aircraft.
A leader of multiple GD&T training programs for industry, Mr. Wilson has authored several other
publications on this subject. Through his publications, training programs, and development of GD&T
instructors, thousands of engineering, manufacturing, and inspection personnel have been trained.
Currently a member of the American Society of Mechanical Engineers subcommittee on
Dimensioning and Tolerancing (ASME Y14.5), Mr. Wilson is also a member of ASME Y14.1, ViceChairman of ASME Y14.2, Chairman of ASME Y14.3, and a member of the United States
TAG/ISO/TC10/SC5 on Dimensioning and Tolerancing and the TAG/ISO/TC10/SC10 on
Engineering Symbology.

Table of Contents

TABLE OF CONTENTS

CHAPTER 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
I. GENERAL ............................................................................ 3
II. COMPLETION LEVEL OF FIGURES....................................... 4
III. BASIS FOR GUIDELINES ...................................................... 4
IV. GAGING EXAMPLES ............................................................ 5
V. UNITS OF MEASURE............................................................ 6
CHAPTER 2
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
I. GENERAL ............................................................................. 9
II. GENERAL SYMBOLS............................................................10
Diameter............................................................................10
Counterbore Symbol............................................................11
Countersink .......................................................................11
Depth................................................................................12
Dimension Origin ...............................................................12
Square...............................................................................13
Reference ...........................................................................13
Arc Length.........................................................................14
Slope................................................................................14
Conical Taper .....................................................................15
LETTERS ............................................................................15
Letter X.............................................................................15
Radius...............................................................................15
Controlled Radius................................................................16
Spherical Radius .................................................................16
Spherical Diameter ..............................................................16
III. TOLERANCING SYMBOLS...................................................17
DATUM IDENTIFICATION SYMBOLS ...................................17
1994 Datum Feature Symbol.................................................17
1982 Datum Feature Symbol.................................................17
Datum Target Symbol..........................................................18
Target Point Symbol ...........................................................19
FORM.................................................................................20
Straightness .......................................................................20
Flatness.............................................................................20
Circularity .........................................................................21
Cylindricity........................................................................21
ORIENTATION.....................................................................22
Genium Publishing

ii

Dimensioning and Tolerancing Handbook

Parallelism.........................................................................22
Perpendicularity ..................................................................22
Angularity .........................................................................23
LOCATION ..........................................................................23
Position ............................................................................23
Concentricity......................................................................24
Symmetry..........................................................................24
PROFILE .............................................................................25
Line Profile........................................................................25
Surface Profile....................................................................26
RUNOUT.............................................................................26
Circular Runout ..................................................................26
Total Runout......................................................................27
MODIFIERS.........................................................................28
Maximum Material Condition ...............................................28
Least Material Condition ......................................................28
Regardless of Feature Size.....................................................29
Projected Tolerance..............................................................30
Statistical Value..................................................................30
Tangent Plane.....................................................................30
Free State ..........................................................................31
BETWEEN ...........................................................................31
IV. FEATURE CONTROL FRAMES ............................................32
Feature Control Frame Lines .................................................33

CHAPTER 3
GENERAL DIMENSION APPLICATION. . . . . . . . . . . . . . . . . . . . . . . . 3 7
I. GENERAL ...........................................................................37
DIMENSION VALUES ..........................................................37
Rounding Numbers..............................................................37
Fractions ...........................................................................38
LINE TYPES AND ARROWS.................................................38
Extension Lines ..................................................................38
Dimension Line ..................................................................39
Leader Lines.......................................................................39
Arrow and Number Placement................................................39
Arrow and Number Arrangements...........................................39
Line Uses for Clarity ...........................................................40
APPLICABLE LINEAR UNITS...............................................40
Linear Unit Notation............................................................40
Linear Unit Application........................................................40
Linear Unit Exceptions.........................................................41
Foot Dimensions ................................................................41
ANGULAR UNITS ................................................................41
Arc Minutes and Seconds......................................................41
II. FUNDAMENTAL RULES ......................................................41
SIZE AND LOCATION..........................................................41
Genium Publishing

Table of Contents

iii

DIMENSION TOLERANCES..................................................41
Dimension Tolerance Exceptions............................................41
Tolerance Accumulation .......................................................42
FUNCTIONALITY ................................................................42
PROCESS SPECIFICATION..................................................42
READABILITY.....................................................................42
Application to the Profile .....................................................42
Placement Between Views.....................................................43
Dimension Vsible Features ...................................................43
Placement..........................................................................43
90 ANGLES ........................................................................43
90 Angle Tolerances ...........................................................43
Basic 90 Angles.................................................................43
TEMPERATURE ..................................................................43
DOUBLE DIMENSIONING.....................................................43
REFERENCE DIMENSION....................................................44
STOCK SIZE........................................................................44
III. APPLICATION GUIDELINES.................................................44
SPACING ............................................................................44
Object to First Dimension ....................................................44
Between Dimension Lines.....................................................44
Extension Line Spaces .........................................................45
DIRECTION OF APPLICATION .............................................45
ANGLE DIMENSIONS ..........................................................46
DIMENSIONS APPLIED TO SMALL FEATURES....................46
Oblique Extension Lines.......................................................46
Offset Extension Lines.........................................................47
Extension Line Intersections..................................................47
DIMENSION VALUE LOCATION...........................................48
READING DIRECTION .........................................................49
OUTSIDE THE VIEW ............................................................49
NOT TO SCALE ...................................................................50
Scaling Drawings................................................................50
EXTENDED INTERSECTIONS...............................................50
LIMITED APPLICATION.......................................................51
IV. APPLICATION TO FEATURES..............................................51
DIAMETER..........................................................................51
RADII..................................................................................52
Located by Tangents ............................................................53
Located by arc centers...........................................................54
Foreshortened Radii .............................................................54
Spherical Radii ...................................................................54
True Radius........................................................................55
Radius Note .......................................................................55
CHORDS AND ARC LENGTHS .............................................55
ROUNDED ENDS.................................................................56
Genium Publishing

iv

Dimensioning and Tolerancing Handbook

Fully Rounded Ends.............................................................57

Partially Rounded Ends.........................................................57
IRREGULAR OUTLINE.........................................................57
SYMMETRICAL FEATURES ................................................57
HOLES................................................................................58
Hole Diameter and Depth......................................................59
Countersinks......................................................................60
Counterdrills ......................................................................60
Counterbores ......................................................................61
Spotfaces...........................................................................62
Slotted holes ......................................................................62
CHAMFERS ........................................................................63
Chamfered holes and shafts....................................................64
MACHINE CENTERS ...........................................................64
KEYSEATS..........................................................................64
KNURLS .............................................................................65
THREADS ...........................................................................66
SURFACE TEXTURE ...........................................................66
GEARS AND SPLINES .........................................................67
ROD AND TUBING DETAILS................................................67
V. LOCATION DIMENSIONS ......................................................68
RECTANGULAR COORDINATES..........................................68
Rectangular Coordinate Dimensions........................................69
Excluding Dimension Lines ..................................................69
Tabular Dimensions.............................................................70
POLAR COORDINATES .......................................................71
REPEATED DIMENSIONS ....................................................72
NUMBER OF TIMES ............................................................73
X TO INDICATE BY .............................................................73
CHAPTER 4
GENERAL TOLERANCES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 7
I. GENERAL ...........................................................................77
II. TOLERANCE APPLICATION METHODS ...............................77
NOTED TOLERANCES.........................................................77
DIRECT APPLICATION TO DIMENSIONS .............................78
Plus and Minus Tolerances....................................................78
Bilateral.............................................................................78
Unilateral...........................................................................79
Limit Dimensions...............................................................79
Single Limits .....................................................................79
LIMITS AND FITS................................................................80
Metric Limits and Fits .........................................................80
Inch Limits and Fits ............................................................81
DIRECT APPLICATION TO A FEATURE ...............................81
REFERENCED DOCUMENTS ...............................................81
PLATED PARTS ..................................................................81
Genium Publishing

Table of Contents

III. NUMERICAL FORMAT........................................................81

METRIC VALUES ................................................................82
Bilateral Tolerance...............................................................82
Unilateral Tolerance.............................................................82
Limit Dimensions...............................................................82
INCH VALUES.....................................................................83
ANGLE VALUES..................................................................83
Angles on Metric Drawings...................................................83
Angles on Inch Drawings......................................................83
Angle Units .......................................................................84
IV. TOLERANCE ACCUMULATION ...........................................84
DIRECT APPLICATION ........................................................84
BASE LINE DIMENSIONING.................................................85
CHAIN DIMENSIONING .......................................................86
REFERENCE DIMENSION....................................................86
Using Reference Dimensions .................................................87
V. SPECIFIED ORIGIN..............................................................88
DIMENSIONING FROM AN ORIGIN......................................88
Measurement From an Origin ................................................88
VI. MATERIAL CONDITIONS.....................................................89
PERFECT FORM AT MMC...................................................89
Perfect Form Example..........................................................89
Variations of Form Within the MMC Envelope ........................90
Specified Exceptions............................................................90
Relationships Between Features Not Controlled by MMC...........90
FREE STATE VARIATION....................................................91
MATERIAL CONDITION EFFECTS .......................................91
MMC Effect.......................................................................92
Zero Tolerance at MMC .......................................................92
LMC Effect........................................................................93
RFS Effect.........................................................................94
Assumed and Specified Material Conditions..............................94
United States (1994) ............................................................95
International.......................................................................95
VII. VIRTUAL CONDITION .........................................................96
VIRTUAL CONDITION OF A HOLE.......................................96
VIII. GEARS AND SPLINES .........................................................96
IX. THREADS ...........................................................................96
X. ANGULAR SURFACES ........................................................98
ANGULAR TOLERANCE......................................................98
BASIC ANGLES...................................................................99
XI. TAPERS..............................................................................99
CONICAL TAPERS ............................................................ 100
Conical Taper Calculation................................................... 100
Basic Taper, Basic Diameter, Toleranced Location.................... 100
Toleranced Taper, Toleranced Diameter .................................. 100
Genium Publishing

vi

Dimensioning and Tolerancing Handbook

Two Diameters and Length.................................................. 101

FLAT TAPERS................................................................... 102
Slope Calculation.............................................................. 103
XII. RADII................................................................................ 103
Controlled Radius.............................................................. 104
Radius............................................................................. 104
Previous Practice............................................................... 104
CHAPTER 5
DATUMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 7
I. GENERAL ......................................................................... 107
TERMINOLOGY................................................................. 107
Datum............................................................................. 107
Datum Feature .................................................................. 107
Datum Simulator .............................................................. 107
Datum Reference............................................................... 109
Datum Feature Symbol ...................................................... 109
Datum Reference Frame...................................................... 109
DATUM IDENTIFICATION LETTERS .................................. 109
TEMPORARY AND PERMANENT DATUM FEATURES........ 110
II. DATUM REFERENCE FRAME............................................ 110
III. ORDER OF PRECEDENCE ................................................. 112
SURFACES TO ESTABLISH DATUMS ................................ 113
Primary Surface ................................................................ 113
Tertiary Surface................................................................. 117
FEATURES OF SIZE TO ESTABLISH DATUMS ................... 117
Primary Axis.................................................................... 117
Primary Plane, Secondary Axis ............................................ 118
Primary Axis, Secondary Plane ............................................ 120
Primary Plane, Secondary Axis, Tertiary Plane ....................... 121
Primary Plane, Secondary Axis, Tertiary Axis ........................ 122
MULTIPLE DATUM REFERENCE FRAMES ........................ 123
IV. IDENTIFICATION OF DATUM FEATURES .......................... 123
IDENTIFICATION OF DATUM SURFACES.......................... 123
On Extension Lines ........................................................... 124
Application Using ASME Y14.5M-1994 Symbols.................. 124
Application Using ANSI Y14.5M-1982 Symbols ................... 125
Application on a Surface..................................................... 125
IDENTIFICATION OF DATUM FEATURES OF SIZE............. 125
Section View of a Hole ...................................................... 125
Applied to a Shaft ............................................................. 126
Applied to a Slot or Tab ..................................................... 127
Applied to One Hole in a Pattern.......................................... 128
Applied to a Feature Control Frame...................................... 128
V. DATUM REFERENCES AND DATUM SIMULATION ............ 129
SPECIFIED ORDER OF PRECEDENCE................................ 130
SIMULATION OF SURFACES............................................. 131
Genium Publishing

Table of Contents

vii

Surface as a Primary Datum ................................................ 131

Surface as a Secondary Datum.............................................. 132
Surface as a Tertiary Datum................................................. 134
SIMULATION OF FEATURES OF SIZE................................ 136
Hole as Primary Datum (MMC)........................................... 136
Hole as Secondary Datum (MMC) ........................................ 138
Hole as Primary Datum (RFS)............................................. 139
Hole as Secondary Datum (RFS).......................................... 140
TERTIARY DATUMS FOR CLOCKING................................ 141
VI. DATUM TARGETS............................................................. 143
Target Types .................................................................... 143
Identification .................................................................... 143
Near Side, Far Side............................................................ 143
POINTS............................................................................. 143
Number Needed ................................................................. 144
Simulation....................................................................... 144
LINES ............................................................................... 144
Simulation....................................................................... 145
AREAS.............................................................................. 145
Simulation....................................................................... 146
TARGET LOCATIONS........................................................ 146
TARGET TYPE COMBINATIONS ........................................ 147
VII. COMPLEX DATUMS.......................................................... 148
COMPOUND DATUMS....................................................... 149
Two on Axis.................................................................... 149
Modifiers......................................................................... 149
Two Surfaces.................................................................... 150
PATTERNS OF FEATURES AS DATUMS ............................ 151
Datum Identification and Reference ....................................... 151
PARTIAL SURFACE (Limited Zone) ..................................... 151
STEPPED DATUMS ........................................................... 151
Datum Plane Identification.................................................. 152
THREADS AS DATUM FEATURES..................................... 152
SPLINES AND GEARS AS DATUM FEATURES ................... 152
INCLINED DATUM FEATURES .......................................... 152
Simulating Inclined Datum Features ..................................... 153
EQUALIZING DATUMS...................................................... 153
Equalizing Target Location.................................................. 154
REPEATING DATUMS ....................................................... 154
Individually Notation ......................................................... 154
CHAPTER 6
FORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 7
I. GENERAL ......................................................................... 157
II. FORM ............................................................................... 157
Size Limits...................................................................... 157
Genium Publishing

viii

Dimensioning and Tolerancing Handbook

Maximum Material Condition ............................................. 157
Maximum Material Condition of a Shaft ............................... 157
Maximum Material Condition of a Hole................................ 158
Perfect Form Boundary at MMC .......................................... 158
Least Material Condition .................................................... 159
Least Material Condition of a Shaft ...................................... 159
Least Material Condition of a Hole ....................................... 159
No Perfect Form Boundary at LMC ...................................... 159
Form Controlled by Size .................................................... 159
Exceptions to Rule #1........................................................ 159
STRAIGHTNESS ................................................................ 160
Straightness Applied to Control Surface Errors ....................... 161
Straightness Applied to Control an Axis or Center Plane .......... 161
Straightness of a Flat Surface .............................................. 161
Straightness of Line Elements on a Cylinder .......................... 162
Straightness of Line Elements on a Shaft............................... 162
Straightness of Line Elements on a Hole ............................... 163
Axis Straightness.............................................................. 165
Axis Straightness of A Shaft ............................................... 165
Axis Straightness of A Hole................................................ 166
Applied RFS .................................................................... 166
Applied MMC .................................................................. 167
Straightness of A Center Plane ............................................ 169
Straightness Per Unit Length............................................... 169
FLATNESS........................................................................ 170
Flatness Control By Size Tolerance ...................................... 170
Flatness Specification ........................................................ 170
Flatness Interpretation........................................................ 171
Flatness Per Unit Area ....................................................... 171
CIRCULARITY .................................................................. 172
Circularity Control by Size Dimensions................................ 172
Specification of Circularity ................................................. 172
Circularity Interpretation..................................................... 173
CYLINDRICITY ................................................................. 174
Cylindricity Control By Size Dimensions.............................. 174
Specification Of Cylindricity............................................... 174
Cylindricity Interpretation ................................................... 174
EXCEPTION TO PERFECT FORM BOUNDARY ................... 176
Stock Shapes.................................................................... 176
Free State Variation ........................................................... 176
Noted Exception................................................................ 176

CHAPTER 7
ORIENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7 9
ANGULARITY ................................................................... 179
Angularity Applied to A Surface .......................................... 179
Angularity Interpretation..................................................... 180
Genium Publishing

Table of Contents

ix

PERPENDICULARITY........................................................ 180
Perpendicularity of A Surface............................................... 180
Perpendicularity of A Surface Interpretation............................ 181
Perpendicularity of A Feature of Size .................................... 181
Perpendicularity on A Pin ................................................... 182
Interpretation of Perpendicularity on A Pin............................. 184
Virtual Condition of A Pin ................................................. 184
Bonus Tolerance on Perpendicularity..................................... 184
Perpendicularity on A Hole ................................................. 184
Interpretation of Perpendicularity on A Hole ........................... 185
Virtual Condition of A Hole................................................ 185
Bonus Tolerance on Perpendicularity..................................... 186
Perpendicularity At Regardless of Feature Size ........................ 186
Perpendicularity on A Rectangular Feature of Size................... 188
PARALLELISM.................................................................. 189
Parallelism of Surfaces....................................................... 189
Parallelism of a Surface Interpretation ................................... 190
Parallelism of Holes .......................................................... 190
Parallelism Effect at MMC ................................................. 191
MMC Departure Effect on Parallelism................................... 191
Parallelism Applied to Multiple Features............................... 191
Referenced Datums Effect on Orientation Tolerances ................ 191
One Datum Reference......................................................... 191
Two Datum References....................................................... 193
DIMENSIONS RELATED TO A DATUM REFERENCE
FRAME............................................................................. 195
Noted Datum Reference Frame............................................. 195
Measurements from a Noted Datum Reference Frame ............... 195
CHAPTER 8
POSITION, CONCENTRICITY, AND SYMMETRY. . . . . . . . . . 1 9 9
I. GENERAL ......................................................................... 199
LOCATION TOLERANCES ................................................. 199
II. POSITION TOLERANCES ................................................... 200
Feature Control Frame ....................................................... 201
Position Tolerance Symbol................................................. 201
Tolerance Value ................................................................ 201
Material Condition Modifier (1994) ...................................... 201
Material Condition Modifier (1982) ...................................... 201
Datum References.............................................................. 202
Basic Location Dimensions................................................. 202
Locations From Referenced Datums...................................... 202
True Positions .................................................................. 202
Hole Locations ................................................................. 204
Comparison of Coordinate and Position Tolerances.................. 204
Coordinate (plus or minus) Tolerances................................... 204
Genium Publishing

Dimensioning and Tolerancing Handbook

Position Tolerances ........................................................... 206
Round vs. Square Tolerance Zones........................................ 208
Calculated Tolerance Zone Comparison ................................. 208
Square Tolerance Zones ...................................................... 208
Round Tolerance Zone........................................................ 209
CALCULATION OF POSITION TOLERANCES FOR
HOLES.............................................................................. 210
Floating Fastener .............................................................. 210
Calculations for a Floating Fastener Application..................... 211
One Clearance Hole Diameter .............................................. 211
Two Clearance Hole Diameters ............................................ 212
Unequal Distribution for Floating Fastener Applications........... 213
Fixed Fastener .................................................................. 213
Press Fit and Threaded Holes ............................................... 213
Fixed Fastener Assembly.................................................... 214
Single Fixed Condition ...................................................... 214
Permitted Location Tolerance............................................... 214
Calculations for a Fixed Fastener Application......................... 214
Clearance Hole Diameter Effect............................................ 215
Position Tolerance for a Dowel Pin ...................................... 215
Position Tolerance for a Screw............................................. 217
Unequal Distribution for Fixed Fastener Applications............... 217
Plus or Minus () Location Tolerances for Holes .................... 217
MATERIAL CONDITION MODIFIERS ON POSITION
TOLERANCES................................................................... 218
Material Condition Modifier Application, 1994....................... 218
Material Condition Modifier Application, ISO ........................ 218
Material Condition Modifier Application, 1982....................... 218
Material Condition Modifier Application, 1973....................... 218
Material Condition Basis of Positioned Feature....................... 219
Maximum Material Condition (MMC) .................................. 219
Departure from MMC ........................................................ 220
MMC Applications ........................................................... 221
Allowable Error at MMC.................................................... 221
Allowable Error Due to Departure from MMC ........................ 222
Regardless of Feature Size (RFS) ......................................... 222
RFS Applications ............................................................. 223
Least Material Condition (LMC).......................................... 224
Departure from LMC ......................................................... 225
LMC Applications ............................................................ 225
Material Condition Basis of Datum Features........................... 227
Material Condition Modifier Application on Datum
References, 1994 .......................................................... 227
Material Condition Modifier Application on Datum
References, ISO ........................................................... 227
Material Condition Modifier Application on Datum
References, 1982 .......................................................... 227
Genium Publishing

Table of Contents

xi

Material Condition Modifier Application on Datum

References, 1973 .......................................................... 227
Datum Reference at MMC .................................................. 227
Datum Reference at RFS .................................................... 228
Datum Reference at LMC ................................................... 229
ZERO POSITION TOLERANCE AT MMC............................. 229
Limited Position Tolerance Advantage................................... 229
Zero Position Tolerance at MMC Specification....................... 230
Calculating a Zero Position Tolerance at MMC ...................... 232
PROJECTED TOLERANCE ZONE........................................ 232
Projection Distance............................................................ 232
Application of the Projected Tolerance Zone Symbol ............... 232
Projected Tolerance Zone .................................................... 234
Interference Conditions When Projected Zones are Not Used ...... 234
Clearance Conditions When Projected Zones are Used............... 234
APPLICABLE FEATURES................................................... 235
Threads............................................................................ 236
Gears and Splines .............................................................. 236
SIMULTANEOUS REQUIREMENTS .................................... 236
Simultaneous Requirements Referenced to Datum Surfaces........ 236
Simultaneous Requirements Referenced to Datum Features
of Size ....................................................................... 237
Applicability of Simultaneous Requirements.......................... 237
Noted Separate Requirements............................................... 239
SINGLE SEGMENT FEATURE CONTROL FRAMES............. 240
COMPOSITE POSITION TOLERANCES............................... 240
Datum references ............................................................... 241
Levels of Control .............................................................. 241
Composite Position Tolerances on Flat Hole Patterns.............. 241
Pattern-Locating Tolerances................................................. 242
Pattern-Locating Tolerance Zone Framework .......................... 242
Feature-Relating Tolerance .................................................. 243
Feature-Relating Tolerance Zone Framework .......................... 243
Two Datum References on the Feature-Relating Tolerance......... 244
Composite Position Tolerances on Radial Hole Patterns ........... 246
Pattern-Locating Tolerance .................................................. 247
Feature-Relating Tolerance .................................................. 247
Hole Locations ................................................................. 248
Simultaneous Vs Separate Requirements on Composite
Position Tolerances ....................................................... 248
Simultaneous and Separate Requirement for Composite
Position Tolerances ....................................................... 249
Simultaneous Pattern and Simultaneous Feature-Relating
Tolerance Requirements.................................................. 251
MULTIPLE SINGLE SEGMENT FEATURE CONTROL
FRAMES........................................................................... 252
Genium Publishing

xii

Dimensioning and Tolerancing Handbook

Levels of Control .............................................................. 253

Two Single Segment Position Tolerances on a Flat Hole
Pattern ........................................................................ 253
Two Single-Segment Position Tolerances on a Radial Hole
Pattern ........................................................................ 255
BILATERAL POSITION TOLERANCES ................................ 257
Rectangular Bilateral Position Tolerance................................ 257
Material Condition Modifiers on Bilateral Position
Tolerances.................................................................... 258
Curved Bilateral Position Tolerance ...................................... 258
COUNTERBORED HOLES .................................................. 259
One Position Tolerance for Hole and Counterbore.................... 259
Separate Position Tolerances for the Hole and Counterbore........ 259
Counterbore Position Referenced to Hole Location .................. 259
TAPERED TOLERANCE ZONES ......................................... 261
POSITION OF NONCIRCULAR FEATURES ......................... 261
Rectangular Slots and Rails................................................. 261
Irregular Features (combined with profile) .............................. 263
Profile Tolerance Effect ...................................................... 264
Position Tolerance Effect .................................................... 265
COAXIAL FEATURES CONTROLLED WITH POSITION
TOLERANCES................................................................... 266
Single Line Position Tolerance on In-Line Holes .................... 266
Two Line Composite Tolerance on In-Line Holes.................... 268
Three Line Composite Tolerance on In-Line Holes .................. 270
Multiple Hole Sizes on Coaxial Holes .................................. 272
III. SYMMETRY...................................................................... 272
Symmetrical Applications................................................... 272
SYMMETRY AT MMC (Position)......................................... 272
Creating a Plane of Symmetry ............................................. 274
Locating Symmetrical Features ............................................ 274
Position Tolerance for Symmetry......................................... 274
SYMMETRY AT RFS WITH POSITION................................ 274
SYMMETRY TOLERANCE SPECIFICATION ....................... 275
IV. CONCENTRICITY .............................................................. 275
Caution Regarding Usage of Concentricity ............................. 275
CONCENTRICITY APPLICATION ....................................... 276
Concentricity Interpretation................................................. 276
CHAPTER 9
PROFILE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 8 1
I. PROFILE ........................................................................... 281
BILATERAL AND UNILATERAL......................................... 281
Bilateral Profile Tolerance................................................... 281
Unilateral Tolerance Zone, Outside ....................................... 281
Unilateral Tolerance Zone, Inside.......................................... 282
Offset Tolerance Zone ........................................................ 283
Genium Publishing

Table of Contents

xiii

LINE PROFILE................................................................... 284

SURFACE PROFILE........................................................... 285
LEVELS OF CONTROL ...................................................... 286
No Datum References......................................................... 286
Datum References.............................................................. 287
Datum References and Basic Dimensions For Location............. 288
LIMITS OF APPLICATION.................................................. 290
Default Limits of Application.............................................. 290
Restricted Limits of Application .......................................... 290
Extended Limits Of Application........................................... 291
All Around....................................................................... 291
CONE PROFILE ................................................................. 293
COPLANARITY ................................................................. 293
Coplanarity and Orientation................................................. 294
Coplanarity, Orientation, and Location .................................. 294
CHAPTER 1 0
RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 9 7
I. RUNOUT........................................................................... 297
CIRCULAR RUNOUT ......................................................... 297
Circular Runout Tolerance Application.................................. 297
Circular Runout Interpretation ............................................. 298
TOTAL RUNOUT ............................................................... 298
Total Runout Tolerance Application ..................................... 299
Total Runout Interpretation ................................................. 299
RUNOUT REFERENCED TO COMPOUND DATUMS ............ 300
RUNOUT REFERENCED TO TWO DATUMS........................ 301
CHAPTER 1 1
VERIFYING DIMENSIONAL REQUIREMENTS. . . . . . . . . . . . . . 3 0 5
I. GENERAL ......................................................................... 305
II. VERIFYING FORM TOLERANCES...................................... 306
STRAIGHTNESS OF A SURFACE ELEMENT....................... 306
Straightness Measured Using a Surface Plate .......................... 306
Straightness Measured with Hand Tools................................. 307
STRAIGHTNESS ON AN AXIS............................................ 308
Straightness of a Shaft Axis at MMC ................................... 308
Functional Gaging Shaft Axis Straightness at MMC ............... 308
Alternate Method for Verifying Shaft Axis Straightness
at MMC...................................................................... 308
Alternate Method #2 for Verifying Shaft Axis Straightness
at MMC...................................................................... 308
Straightness of a Shaft Axis at RFS ..................................... 309
Axis Error Determined from Surface Errors............................. 310
Round, Constant Diameter, Curved Axis ............................... 310
Irregular Surface, Irregular Axis............................................ 310
Genium Publishing

xiv

Dimensioning and Tolerancing Handbook

Straightness of a Hole Axis at MMC .................................... 310

Functional Gaging Hole Axis Straightness at MMC................ 311
Alternate Methods for Verifying Hole Axis Straightness at
MMC ......................................................................... 312
Straightness of a Hole Axis at RFS ...................................... 312
FLATNESS........................................................................ 312
Verifying Flatness with a Dial Indicator and Height Stand ......... 312
Adjustment of Part Orientation Permitted............................... 314
Alternate Flatness Check Method ......................................... 314
Quick Check Flatness Approximation................................... 315
CIRCULARITY .................................................................. 315
Dial Indicator Measurement of Circularity.............................. 316
CYLINDRICITY ................................................................. 317
III. VERIFYING ORIENTATION TOLERANCES ......................... 317
PERPENDICULARITY OF A SURFACE............................... 317
Two Datum References....................................................... 317
Simulation of the Datums................................................... 319
Measurement of the Perpendicularity Variations ...................... 319
One Datum Reference......................................................... 319
Simulation of the Datum.................................................... 319
Measurement of the Perpendicularity Variations ...................... 319
PERPENDICULARITY OF A FEATURE OF SIZE.................. 321
Perpendicularity of a Hole (MMC)........................................ 321
Datum Surface.................................................................. 321
Gage Pin Diameter ............................................................ 321
Datum Axis ..................................................................... 322
Datum Axis Simulation ..................................................... 322
Verifying Perpendicularity of the Hole................................... 323
Perpendicularity of a Hole (RFS).......................................... 324
Perpendicularity of a Pin (MMC) ......................................... 324
ANGULARITY OF A SURFACE .......................................... 325
Two Datum References....................................................... 326
Datum Simulation............................................................. 326
Angularity Error Measuring................................................. 327
One Datum Reference......................................................... 327
Datum Simulation and Angularity Measurement ..................... 328
PARALLELISM.................................................................. 328
Parallelism on a Surface ..................................................... 329
Measurement of Parallelism on a Flat Surface......................... 329
Parallelism of Holes at MMC.............................................. 329
Functional Gaging Parallel Holes......................................... 329
Parallelism of Pins at RFS ................................................. 330
IV. VERIFYING LOCATION TOLERANCES............................... 331
Evaluating Measured Locations ............................................ 332
Functional Gages .............................................................. 332
Coordinate Measuring Machines (CMM) ............................... 332
SINGLE LINE POSITION TOLERANCE ................................ 333
Genium Publishing

Table of Contents

xv

Position Tolerance On Holes (MMC) From Datum Surfaces ..... 333

Functional Gage................................................................ 333
Paper Gage....................................................................... 335
Location Measurements ...................................................... 335
Plotting X and Y Errors...................................................... 335
Checking Diameter Position Error ........................................ 335
Consideration of MMC ...................................................... 337
Calculated Position Errors................................................... 337
Position Tolerance RFS ..................................................... 337
Position Tolerance on Holes at MMC Relative to Datum
Feature of Size at MMC ................................................. 338
Functional Gaging Separate Requirements.............................. 340
Functional Gage Requirements............................................. 340
Simultaneous Requirement.................................................. 341
COMPOSITE POSITION TOLERANCE (MMC)...................... 341
Composite Position from Datum Surfaces ............................. 342
First Line Functional Gage ................................................. 342
Second Line Functional Gage .............................................. 342
Paper Gage....................................................................... 343
Paper Gaging the PLTZF.................................................... 343
Paper Gaging the FRTZF ................................................... 343
Plotting Location Errors..................................................... 345
TWO SINGLE SEGMENT POSITION TOLERANCES ............. 346
Gaging the First Line......................................................... 346
Gaging the Second Line...................................................... 347
CONCENTRICITY .............................................................. 348
Establish the Datum Axis................................................... 348
Axis Error Determined from Surface Errors............................. 348
V. VERIFYING RUNOUT TOLERANCES.................................. 350
CIRCULAR RUNOUT ......................................................... 350
TOTAL RUNOUT ............................................................... 351
APPENDICES
APPENDIX A
Tolerancing Symbols..............................................................353
General Dimension Symbols....................................................356
APPENDIX B
Feature Control Frames ...........................................................357
APPENDIX C
Datum Feature Symbol Application...........................................361
APPENDIX D
Formulas ..............................................................................365
INDEX
Index....................................................................................369
ABOUT THE AUTHOR................................................................381
Genium Publishing