Geometrical Dimensioning and Tolerancing for Design, Manufacturing and Inspection, Second Edition: A Handbook for Geometrical Product Specification using ISO and ASME standards

411 Pages·2006·3.51 MB·English

by  Georg Henzold

Geometrical Dimensioning and
Tolerancing for Design,
Manufacturing and Inspection
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Geometrical Dimensioning
and Tolerancing for Design,
Manufacturing and Inspection
A Handbook for Geometrical Product
Specification using ISO and ASME
Standards
Second edition
Georg Henzold
AMSTERDAM• BOSTON• HEIDELBERG• LONDON• NEWYORK• OXFORD
• PARIS• SANDIEGO• SANFRANCISCO• SINGAPORE• SYDNEY• TOKYO
Butterworth-Heinemann is an imprint of Elsevier
iii
Butterworth-Heinemann is an imprint of Elsevier
Linacre House, Jordan Hill, Oxford OX2 8DP
30 Corporate Drive, Suite 400, Burlington, MA 01803
First edition published by John Wiley and Sons Ltd 1995
Second edition published by Elsevier Ltd 2006
Copyright © 2006, Georg Henzold. Published by Elsevier Ltd.
All rights reserved
The right of Georg Henzold to be identified as the author of this work has been asserted in
accordance with the Copyright, Designs and Patents Act 1988
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British Library Cataloguing in Publication Data
A catalogue record for this book is available from the British Library
Library of Congress Cataloging-in-Publication Data
A catalog record for this book is available from the Library of Congress
ISBN-13: 978-0-7506-6738-8
ISBN-10: 0-7506-6738-9
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Contents
Preface xi
Acknowledgements xiii
Notation xiv
Abbreviations xvi
ISO Text Equivalents xvii
New ISO Terminology xviii
1 Properties of the surface 1
2 Principles for tolerancing 6
3 Principles for geometrical tolerancing 7
3.1 Symbols 7
3.2 Definitions of geometrical tolerances 9
3.3 Tolerance zone 20
3.3.1 Form of the tolerance zone 20
3.3.2 Location and orientation of the tolerance zone 23
3.3.3 Width of the tolerance zone 26
3.3.4 Length of the tolerance zone 27
3.3.5 Common tolerance zone 27
3.4 Datums 28
3.5 Axes and median faces 33
3.6 Screw threads, gears and splines 36
3.7 Angularity tolerances and angular dimension tolerances 37
3.8 Twist tolerance 38
4 Profile tolerancing 40
5 Tolerancing of cones 43
5.1 General 43
5.2 Form tolerance and dimensioning of the cone 44
5.3 Tolerancing of the axial location of the cone 45
5.4 Tolerancing of the orientation and radial location of the cone 47
5.5 Related profile tolerance for tolerancing form, orientation, radial
and axial location of the cone 48
5.6 Relationship between the cone tolerances 48
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vi Contents
6 Positional tolerancing 51
6.1 Definition 51
6.2 Theoretical exact dimensions 51
6.3 Form of the positional tolerance zone 52
6.4 Positional tolerances on a circle 54
6.5 Positional tolerances related to a datum 54
6.6 Tolerance combinations 54
6.6.1 Combination of dimensional coordinate tolerancing
and positional tolerancing 54
6.6.2 Combination of positional tolerances (composite
positional tolerancing) 56
6.7 Calculation of positional tolerances 57
6.8 Advantages of positional tolerancing 60
7 Projected tolerance zone 61
8 Substitute elements 64
8.1 General 64
8.2 Vectorial dimensioning and tolerancing 67
8.3 Comparison of the systems 78
8.3.1 Sizes 78
8.3.2 Form deviations 81
8.3.3 Deviations of orientation and location 82
8.3.4 Datum systems 84
8.4 Conversion between systems and combination of systems 86
9 Maximum material requirement 87
9.1 Definitions 87
9.2 Description of the maximum material requirement 88
9.3 Application of the maximum material requirement 90
9.3.1 General 90
9.3.2 Maximum material requirement for the toleranced feature 91
9.3.3 Maximum material requirement for the datum 95
9.3.4 Maximum material requirement 0 M 98
9.3.5 Comparison of 0.1 M and 0 M 99
9.3.6 Reciprocity requirement associated with the maximum
material requirement 100
9.4 Education 101
10 Envelope requirement 103
10.1 Definition 103
10.2 Application of the envelope requirement 103
10.3 Cross-sections within size tolerance fields 106
11 Least material requirement 108
11.1 Definitions 108
11.2 Description of least material requirement 108
11.3 Application of least material requirement 109
11.3.1 General 109
11.3.2 Least material requirement for the toleranced feature 109
Contents vii
11.3.3 Least material requirement for the datum 110
11.4 Reciprocity requirement associated with least
material requirement 113
12 Tolerancing of flexible parts 114
13 Tolerance chains (accumulation of tolerances) 116
14 Statistical tolerancing 123
15 Respecting geometrical tolerances during manufacturing 132
15.1 Manufacturing influences 132
15.2 Recommendations for manufacturing 133
16 General geometrical tolerances 137
16.1 Demand for general geometrical tolerances 137
16.2 Concept of general tolerances 137
16.3 Derivation and application of general geometrical tolerances 139
16.3.1 Straightness and flatness 139
16.3.2 Roundness (circularity) 140
16.3.3 Cylindricity 142
16.3.4 Line profile, surface profile and position 142
16.3.5 Parallelism 142
16.3.6 Perpendicularity 143
16.3.7 Angularity 144
16.3.8 Coaxiality 144
16.3.9 Symmetry 144
16.3.10 Circular run-out 145
16.3.11 Total run-out 146
16.4 Datums 147
16.5 Indication on drawings 147
16.6 Envelope requirement in addition to general form tolerances 147
16.7 Application of the general geometrical tolerances according
to ISO 2768-2 148
16.8 General tolerances for castings 149
16.9 General tolerances for welded parts 150
16.10 General tolerances for parts out of plastics 151
17 Tolerancing principles 152
17.1 Limitation by function 152
17.2 Need for completely toleranced shape 152
17.3 Situation in the past 153
17.4 Principle of independency 154
17.5 Identification of drawings 157
17.6 Principle of dependency 158
17.7 Choice of tolerancing principle 158
18 Inspection of geometrical deviations 160
18.1 General 160
18.2 Terms 161
18.3 Alignment of the workpiece 162
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18.3.1 General 162
18.3.2 Minimum requirement 163
18.3.3 Additional alignment requirements for the measurement
of roundness or cylindricity deviations 164
18.3.4 Minimum rock requirement 166
18.4 Interchanging the datum feature and the toleranced feature 167
18.5 Simplified inspection method 168
18.6 Evaluation of measurement 170
18.7 Methods of inspection 171
18.7.1 Assessment of straightness deviations of lines
of surfaces 172
18.7.2 Assessment of straightness deviations of axes 177
18.7.3 Assessment of flatness deviations 183
18.7.4 Assessment of roundness deviations 186
18.7.5 Assessment of cylindricity deviations 194
18.7.6 Assessment of profile deviations of lines 199
18.7.7 Assessment of profile deviations of surfaces 200
18.7.8 Assessment of orientation deviations 200
18.7.9 Assessment of location deviations 203
18.7.10 Assessment of run-out deviations 209
18.7.11 Inspection of the envelope requirement 215
18.7.12 Inspection of the maximum material requirement 218
18.7.13 Inspection of the least material requirement 228
18.7.14 Assessment of the positional deviation for projected
tolerance zones 230
18.8 Assessment of geometrical deviations of threaded features 231
18.9 Tracing and probing strategies 235
18.9.1 General 235
18.9.2 Tracing strategies 237
18.9.3 Probing strategies 238
18.9.4 Number of points 241
18.10 Separation from roughness and waviness 242
18.11 Measurement uncertainty 249
18.11.1 Definition 249
18.11.2 Application 249
18.11.3 Assessment 250
18.11.4 Calibration of measuring instruments 254
19 Function-, manufacturing-, and inspection-related geometrical
tolerancing 255
19.1 Definitions 255
19.1.1 Function-related geometrical dimensioning and
tolerancing 255
19.1.2 Manufacturing-related geometrical dimensioning and
tolerancing 255
19.1.3 Inspection-related geometrical dimensioning and
tolerancing 258
19.2 Method of geometrical dimensioning and tolerancing 261
Contents ix
19.3 Assessment of function-related geometrical dimensioning
and tolerancing 261
19.3.1 Tolerancing of orientation, location and run-out 262
19.3.2 Tolerancing of form 262
19.3.3 Type of tolerance 262
19.4 Assessment of the optimum geometrical dimensioning
and tolerancing 262
20 Examples of geometrical tolerancing 264
20.1 Restrictions of geometrical tolerances 264
20.1.1 Restricted range of application 264
20.1.2 Geometrical tolerances and additional smaller
tolerances of their components 265
20.1.3 Superposition of positional tolerances 266
20.2 Tolerances for section lines 266
20.3 Tolerances of profiles 267
20.4 Position of a plane 269
20.5 Perpendicularity tolerances in different combinations 272
20.6 Location of axes and median faces 272
20.6.1 Angular location of features 272
20.6.2 Cosymmetry of holes in line 274
20.6.3 Crossed axes 274
20.6.4 Different locational tolerances for different
features drawn on the same centre line 275
20.6.5 Positional tolerances for features located symmetrically
to a symmetry line and multiple patterns of features 276
20.7 Datums 280
20.7.1 Plane surface as datum for a symmetry tolerance 280
20.7.2 Plane surface as datum for a run-out tolerance 280
20.7.3 Envelope requirement and maximum material
requirement with datums 280
20.7.4 Positional tolerances with and without datums 281
20.7.5 Sequence and maximum material requirement
for datums 281
20.7.6 Interchanging toleranced feature and datum feature 284
20.8 Clearance fit 285
20.8.1 Coaxiality of holes 285
20.8.2 Coaxiality of bearing surfaces 290
20.8.3 Tolerancing of rings, bushes and hubs for fits 293
20.8.4 Rectangular fit 294
20.8.5 Hexagon fit 295
20.8.6 Cross fit, only side faces 297
20.8.7 Cross fit, all around 298
20.8.8 Splines 299
20.8.9 Plug and socket fit 300
20.8.10 Synopsis tolerancing of clearance fits 305
20.9 Interference fits and kinematics 306
20.9.1 Coaxial holes 306