Geometrical product specifications (GPS).

Geometrical tolerancing.
Tolerances of form, orientation, location and
run-out

Kalevi Aaltonen, Aalto University

Lecture content
Major turning point in international business behaviour
Standards support total quality management
Accuracy is expencive – too expencive?
Modern measuring methods - uncertainty
SFS – EN ISO 1101 –standard
Case studies: Papermachine roller and bearing house
Lessons to learn – if any?
End relief - Xunzi
 Geometrical tolerances
Turning point  new approach to tolerances:
• Subcontracting has major role in production
• From subcontracting to business partnership
• CCC – Competitive Cost Countries
• New methods – new tolerances
• Symbiousis: dimensional tolerances – geometrical
tolerances
• Too tight tolerances – empty cash register
• Modern measuring methods gives cost savings
Geometrical tolerances
• Companies consentrate on core business
• Subcontracting will increase
• Subcontracting gives major cost savings
• Manufacturing process know how is in danger
• Tolerances and accuracy requirements define sourcing
costs
• Products must have exact equivalence to drawings
and product models
• Sensible tolerances – reasonable product costs
Geometrical tolerances
• Partnership = win – win -principle
• Investments according to quality requirements
• Open book –principle rather than exploitation of
subcontractor
• Client know how important to interpret to technical
specification for subcontractor
• ”silent” product know how must be traslated to
geometrical tolerances
• Subcontractor must tutor the client in manufacturing
competence
Geometrical tolerances and LCC

• Low Cost Countries = Competitive Cost Countries

• China phenomenon – new attitude
• Not familiar with GPS
• Measuring skills are modest
• Geometrical tolerances – measuring methods - TQM
• Processes have significant hidden costs
• Training of subcontractor gives good results –
production culture is hard to change
New processes – new tolerances
• Manufacturing tolerances of the traditional production
methods are well known and tolerancing is cost
effective
• New methods – new tolerances
• Cutting and sheet metal working with conventional
tolerances – 3D printing unknown quantity?
• Lasercutting is very accurate – how to benefit
• Micromachining tolerances are unknown
• New procedures: casting, forging and welding with
high precision (no cutting needed)
Geometrical tolerances
• Geometrical tolerance and dimensional tolerance are
interchangeable according to maximum material
requirement principle
• Who understands – who dears to use?
• Difficulties and ignorance in geometrical toleranses
leads to super tight dimensional tolerances 
unreasonable production costs and difficulties in
manufacturing
• No stright rules how to veryfy geometrical tolerances
• COORDINATE MEASURING MACHINES CMM
Geometrical tolerances
• Inexperienced design engineer back up with
unreasonable tolerance requirements
• Accuracy cost curve is not linear
• It is valuable to know the limitations of preproduction
methods
• Every removed production step is valuable and
improves productivity and profitability
• Proactive maintenance create cost savings – accuracy
remains
• Odd tolerances create extra back up cost
 Geometrical tolerances
• Modern measuring – cost savings
• Statistical process control is essential part of quality system
• Measure faster – measure more accurate
• Complicated geometries are measureable
• Measuring systems cope with accurate tolerances
• CMM replaces hand held measuring devices
• Measurement instructions are part of component design
• Who ever makes the component he is responsible for
quality and measurements
Quality and quality management are not
separate items from business
Personnel

Management Quality

Economy Technology

Customers Society Environment

 GOOD PROFIT, PROFITABLE BUSINESS

QUALITY SYSTEM, QUALITY PRIZES

PRODUCTS, PROCESSES, PRODUCTION

MEASUREMENT DEVICES, CALIBRATION

LAWS, STANDARDS, MEASUREMENT ORGANIZATION

LOOK AT THE BIG PICTURE NOT THE SMALL DETAILS

MIKES

QUALITY TOOLS

PARETO-CHART
SYSTEMS DO NOT ACT; PEOPLE DO!
 Even the recipe is tested
… it is always worth taisting
 COMPETITORS

AUTHORITIES STANDARDS

OPERATION PROCESS

QUALITY QUALITY

AWARDS
LIABILITIES TQM
QUALITY PRODUCT
COSTS QUALITY

ENVIRONMENT METROLOGY
CUSTOMER
Tolerances equal to human hair

50 μm
Tolerances

Incompetent engineer requires

unrealistic tolerances to back up his
career

Tight tolerances = big production costs

Reasonable tolerances = small production

costs
Tolerances

Precision requirement defines

production method = defines
production costs
 Competent dimensions and tolerances

• tight tolerances means extra costs

• tolerances according to production method
• no calculation on shop floor level
• competent geometrical tolerances
 GENERAL TOLERANCES

Dimensional and geometrical tolerances shoud be

perfect => general tolerances make dimensioning
easier

SFS-EN 22768-1
General tolerances for length and angular dimensions

SFS-EN 22768-2
General geometrical tolerances
 General tolerances for length and angular dimensions

Permissible deviations for basic size range (mm)

Tolerance 0,5…3 3…6 6…30 30… 120… 400… 1000.. 2000..

class
120 400 1000 2000 4000

fine ±0,05 ±0,05 ±0,1 ±0,15 ±0,2 ±0,3 ±0,5 -

medium ±0,05 ±0,1 ±0,2 ±0,3 ±0,5 ±0,8 ±1,2 ±2

coarse ±0,2 ±0,3 ±0,5 ±0,8 ±1,2 ±2 ±3 ±4

very - ±0,5 ±1 ±1,5 ±2,5 ±4 ±6 ±8

coarse
 General tolerances on straightness and flatness for
ranges of nominal lengths (mm)

Tolerance …10 10…30 30… 100 100… 300… 1000…

class 300 1000 3000

H 0,02 0,05 0,1 0,2 0,3 0,4

K 0,05 0,1 0,2 0,4 0,6 0,8

L 0,1 0,2 0,4 0,8 1,2 1,6

General tolerances on perpendicularity for ranges of
nominal lengths of shorter side (mm)

Tolerance … 100 100… 300… 1000…

class 300 1000 3000

H 0,2 0,3 0,4 0,5

K 0,4 0,6 0,8 1

L 0,6 1 1,5 2
General tolerances on circular run-out (mm)

Tolerance Circular
class run-out

H 0,1

K 0,2

L 0,5
 Reference values for turned components (mm)

IT7…9 IT10…12 IT7…9 IT10…12

Diameter Ra < 6,3 μm Ra < 12,5 μm Ra < 6,3 μm Ra < 12,5 μm

30…120 0,02 0,08 0,05 0,2

120…315 0,025 0,12 0,08 0,3

315…630 0,03 0,16 0,10 0,4

630..1000 0,03 0,20 0,13 0,4

 Accuracy is expencive – more operations…
Hole Ø 25
- drilling with twist (spiral) drill
- cost: 1 €

Hole Ø 25 H8 0,010

- drilling with spiral drill

- drilling with boring drill
- reaming with reamer
- cost: 10 €
€
Unnecessary accurary –
useless production costs

IT 10 IT 9 IT 8 IT 7 IT 6 IT 5 IT 4 Accuracy
Mitutoyo Crysta Apex 9106
905 x 1005 x 605 mm, MPEE = (1.7+0.3L/100) μm
CMM PH10 and MCosmos2-software machine
installed and calibrated
Price: 85 000€

When measuring100 mm MPEE = 2,0 μm

Mitutoyo Legex 9106
905 x 1005 x 605 mm, MPEE = (0.48+0.1L/100) μm
CMM with scanning probe MPP-100 and
MCosmos3-software
installed and calibrated
Price: 320 000€

When measuring 100 mm MPEE = 0,58 μm

Measurement uncertainty:

Measuring uncertainty is the test

value which gives the border
lines for measured value with
certain probability

The borders define the performance of the measuring

system.
Big uncertainty leads to unnecessary
rejection of products, expencive
development projects or accepting
the defective products.
Measurement system resolution
requirement is 1/10 of the
tolerance zone

Measurement process variation

must be better than 10 % of the
process tolerance zone
 Because there is always a ”gray zone”
the only alternative is to minimize the
variation of the process so that the parts
are within the tolerance zone when taking
into account the measuring uncertainty.

 Statistical process control, probability,

the law of averages !
 accepted

?
Rejected !

Accepted !
Case study
Paper machine calender
Cardboard machine ValZone calender
(Metso Paper, M-real, Simpele)
Calender turned without online measurement and control system
(Aalto-yliopisto, Petri Kuosmanen)

Deviation 159 μm
Turning feedback measuring and machining system
(Aalto-yliopisto, Petri Kuosmanen)
Calender machined using the online measurement and control system
(Aalto-yliopisto, Petri Kuosmanen)

Deviation 30 μm
Grinded calender without feedback system
Aalto-yliopisto, Petri Kuosmanen)

Deviation 66 μm
Grinding feedback measuring and machining system
(Aalto-yliopisto, Petri Kuosmanen)
Grinded calender by using feedback system
Aalto-yliopisto, Petri Kuosmanen)

Deviation 20 μm
Bearing housing
Geometrical tolerancing
– Tolerances of form,
orientation, location and
run-out

Diamensional tolerances

Surface roughness
Symbols for geometrical characteristics

?
Symbols for geometrical characteristics
Symbols for geometrical characteristics

?
Symbols for geometrical characteristics
Symbols for geometrical characteristics

?
Symbols for geometrical characteristics
What is SFS-EN ISO 1101 ?
Straightness a piece of cake …

What is the difference ?

Flatness of three surfaces but what is CZ ?
Let’s Google: CZ ?
 CZ =
Common Zone
You bet! … Common Zone !
 Position tolerance for the hole,
but what is the letter P and the circle ?
 Google again
Letter P

• p (piko-) 10 -12
• Physics p eq. preasure
• P (peta-) 10 15
• Physics P eq. Power
• Chemistry P eq. phosphorus
• Currency p was pennies from heaven
• Country code P eq. Portugal
 P=
Projected tolerance zone
Of course - Projected tolerance zone!
 SFS-EN ISO 1101
good old story!
…but repetition is the
mother of learning
Bearing housing (© TU Chemnitz)
Bearing housing (© TU Chemnitz)
Bearing housing (© TU Chemnitz)
 Bearing housing (© TU Chemnitz)
Straightness

Roundness

Flatness
Bearing housing (© TU Chemnitz)

Perpendicularity
Concentricity

Parallelism
Bearing housing (© TU Chemnitz)

Roundness
Bearing housing (© TU Chemnitz)
Bearing housing (© TU Chemnitz)
 Bearing housing (© TU Chemnitz)
Geometrical tolerances with roundness measuring machine
Bearing housing (© TU Chemnitz)
Bearing housing (© TU Chemnitz)
Bearing housing (© TU Chemnitz)
Symbol Tolerances
Concentricity Location
CMM
Parallelism Orientation

Flatness Form Form

measurement
Roundness Form
Surface-
roughness
Roughness Surface measurement

Length, Angle Measure Manual

measuring
devices
Bearing housing (© TU Chemnitz)
Dimensions Form Location
Bearing housing (© TU Chemnitz)
Bearing housing (© TU Chemnitz)
Bearing housing (© TU Chemnitz)
Bearing housing (© TU Chemnitz)
LET’S GO FROM THE IRON AGE TO THE SPACE AGE
HANDICRAFTS WITH HAND HELD MEASURING
DEVICES
PRODUCTS FROM THE PAST
– ANTIQUE MEASURING DEVICES
PRODUCTS FROM THE PAST
– ANTIQUE MEASURING DEVICES
MODERN PRODUCTS REQUIRE MODERN
MEASURING DEVICES AND TECHIQUES
When the gentleman studies the aim is not
to climb fast on the career ladders but to
even as poor to live happy, as broken-
hearted to maintain his hope, and when
encountering happiness or hard luck to
understand their limited scope and to
maintain his mind bright.

Xunzi
Lessons to learn

 Geometrical tolerances are the short cut to the heaven

 Modern measurement technique supports the use of the
geometrical tolerances
 Networking, subcontracting and international sourcing
requires geometrical tolerances
 Patience and deep know how are good practices to define the
geometrical tolerances
 It is the euros that counts; no thingummies or gadget lovers
are accepted

Vita, si scias uti, longa est , Seneca

(Life, if well lived, is long enough)
 Acta est fabula.
Plaudite!
(Play is over. Applaud!)
(emperor Augustus)

© Professor Kalevi Aaltonen

3.11.2016 Aalto University 89