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Exercise Complete the following table: Type of Tolerance
Characteristic
Symbol
Datum Required Yes / No
Applicable to Axis Yes / No
Form
Profile
Orientation
Location
Runout 2 Aditi Consultancy Services, Bangalore
Exercise Complete the following table: Type of Tolerance
Characteristic
Symbol
Datum Required Yes / No
Applicable to Axis Yes / No
Form
Profile
Orientation
Location
Runout 2 Aditi Consultancy Services, Bangalore
Exercise Complete the following table: Type of Tolerance
Form
Profile
Orientation
Location
Runout
Datum Required Yes / No
Applicable to Axis Yes / No
Straightness
No
Yes
Flatness
No
No
Circularity
No
No
Cylindricity
No
No
Profile of a Line
Yes / No
No
Profile of a surface
Yes / No
No
Angularity
Yes
Yes
Parallelism
Yes
Yes
Perpendicularity
Yes
Yes
Position
Yes
Yes
Concentricity
Yes
Yes
Symmetry
Yes
Yes
Circular Runout
Yes
No
Total Runout
Yes
No
Characteristic
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Symbol
3
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Mistakes in the drawing Aditi Consultancy Services, Bangalore
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Correct drawing Aditi Consultancy Services, Bangalore
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Geometric Tolerance Rule RULE – 1 (Limits of Size Rule): Where only a size dimension is given a) The size dimensions at any cross section must be within the size tolerance. b) The surface(s) shall not extend beyond the perfect form defined by the MMC Size. c) The form may vary within an envelope between the MMC and LMC.
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Straightness of Surface
Form variation
ø16.00
ø15.89
Form variation 8 Aditi Consultancy Services, Bangalore
Limits of Size Rule
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Limits of Size Rule
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Straightness of Surface
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Difference between axis and surface straightness
The axis is straight, surface elements bent (barrel shaped)
The axis is straight, surface elements bent (hourglass shaped)
Both axis and surface elements are bent(bowed) 12 Aditi Consultancy Services, Bangalore
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Geometric Tolerance Rule RULE – 2
Geometric tolerances for a feature of size are understood to be applied regardless of feature size (RFS). If MMC or LMC is required, it must be placed in the feature control frame.
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Straightness of Axis at RFS
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Precision Cylindrical Fit
Ø 20.008 (Minimum diameter of hole) Ø 20.003 (Maximum diameter of pin)
Should be less than 20.008
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RFS V/s MMC Modifier
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Straightness of Axis at RFS
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Straightness of Axis at MMC
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Straightness of Axis at MMC
S H
B Minimum Hole Size = Shaft Size + Bend in Axis of the Shaft i.e.
H=S+B Aditi Consultancy Services, Bangalore
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Straightness of Axis at MMC
S H
B Since minimum size of the hole remains the same, if the shaft size is smaller it can bend more and still assemble Aditi Consultancy Services, Bangalore
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Straightness of Axis at MMC
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Straightness of Axis at MMC
S
H
B
Maximum Shaft Size = Hole Size - Bend in Axis of the Hole i.e. S = H - B 22 Aditi Consultancy Services, Bangalore
Straightness of Axis at MMC
S
H
B
Since maximum size of the shaft remains the same, if the hole size is bigger it can bend more and still assemble 23 Aditi Consultancy Services, Bangalore
Straightness of Axis at MMC
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MMC Virtual Condition Virtual condition is the collective effect of size and geometric tolerances that must be considered in determining the fit or clearance between mating parts or features. To calculate virtual condition: External features:
MMC size + Geometrical Tolerance Internal features:
MMC size – Geometrical Tolerance A virtual condition will exist only for tolerances that control size features. 25 Aditi Consultancy Services, Bangalore
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Straightness per unit length with specified total straightness
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Straightness per unit length with specified total straightness
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LMC Principle
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Actual Minimum Material Envelope
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LMC Virtual Condition LMC Virtual condition is the collective effect of LMC size limit and geometric tolerances. It assures a protected core of part material within a pin, boss or tab or a protected case of part material around a hole or slot. To calculate virtual condition: External features:
LMC size limit – Geometrical Tolerance Internal features:
LMC size limit + Geometrical Tolerance
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FLATNESS
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FLATNESS ��������� ���� �� ������� �� ��� �������� ������ � �������� � �����
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FLATNESS OF SHEET METAL
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FLATNESS
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FLATNESS AT MMC
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FLATNESS AT MMC Functional Gauge
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UNIT FLATNESS AT MMC Functional Gauge
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Flatness Measurement
Indicator reading is the flatness error of the surface 40 Aditi Consultancy Services, Bangalore
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Flatness Measurement
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Flatness Measurement
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COORDINATE V/s ROUND TOLERANCE ZONE Ø
Ø
20.40 20.28
20.40 20.28
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Round Tolerance Zone
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Position Tolerance of a Hole at MMC
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Part must slide over Ø 13.88 gauge pin. Must lie flat on base of gage (Datum A). Touch Datum B along its length and simultaneously touch Datum C 46 Aditi Consultancy Services, Bangalore
Exercise Complete the drawings of the following 2 parts for interchangeable assembly.
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MMC Virtual Condition Virtual condition is the collective effect of size and geometric tolerances that must be considered in determining the fit or clearance between mating parts or features. To calculate virtual condition: External features:
MMC size + Geometrical Tolerance Internal features:
MMC size – Geometrical Tolerance A virtual condition will exist only for tolerances that control size features. 48 Aditi Consultancy Services, Bangalore
Exercise Using positional tolerance improve the design of the following part
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Datum Reference Frame
Free Movement
Restricted Movement 50 Aditi Consultancy Services, Bangalore
Datum Referencing
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Datum Referencing
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Datum Referencing
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Position Tolerance of a Hole Defines a zone in which the center axis or center plane is permitted to vary from true (theoretically exact) position.
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Hole axes in relation to Positional Tolerancing
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Design a rectangular part that sits on surface ‘A’ and three matching holes in it engage with the projecting cylindrical pins
A
X 56 Aditi Consultancy Services, Bangalore
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Dimensions (Without Datums)
15±0.1
30
30
a=15±0.1
b=15±0.1
c=15±0.1 57
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Dimensions (With Datums)
30 15 3X O 0.2 A
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Exercise Number of similar parts shown below are stacked one above the other and fastened using bolts passing through 4 holes. Central hole is used for locating and slot is used for aligning them. Complete the engineering drawing by adding the necessary datum and geometrical tolerances.
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Position Tolerance
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Two Datum Planes Through a Hole
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Two Datum Planes Through a Hole
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Restrained Features
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Inclined Datum Feature
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Inclined Datum Feature
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LMC Virtual Condition LMC Virtual condition is the collective effect of LMC size limit and geometric tolerances. It assures a protected core of part material within a pin, boss or tab or a protected case of part material around a hole or slot. To calculate virtual condition: External features:
LMC size limit – Geometrical Tolerance Internal features:
LMC size limit + Geometrical Tolerance
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Boss and Hole at LMC
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Measuring Accessories Surface Plate, Granite Square, Straight Edge, etc.
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Measuring Accessories
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Plunger Type Dial Gauges
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Lever Type Dial Gauges
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Dial Stands
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Slip Gauges
Slip blocks are used as standards for precision length measurement in the Engineering Industry. 73 Aditi Consultancy Services, Bangalore
Slip Blocks Four Grades of Accuracy Workshop Grade – Grade 2
Least Expensive
Inspection Grade – Grade 1 Calibration Grade – Grade 0 Reference Grade – Grade 00 or K
Most Expensive
Care of Block Gauges When not used, Slips should be kept in their Case. Avoid Excessive Handling - Don’t touch lapped faces. Wipe slips clean before and after they are used. Use soft linen or cambric cloth to clean slips. 74 Aditi Consultancy Services, Bangalore
Wringing of Slip Gauges
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Plug Gauges
A Plug Gauge is an precision-sized gauge which is used for size control of internal diameters/holes. Go No-Go gauges are double ended. If the Go end is sized to 20mm, the No-Go end is slightly bigger, i.e. 20.020mm. If the Go end fits in the machined hole and the No-Go end doesn’t then the hole is the an acceptable size. The tolerance on the gauges can vary and each gauge is usually specific to a particular job. 76 Aditi Consultancy Services, Bangalore
Ring Gauges
A Ring Gauge is a precision-sized gauge used for size control of external diameters/bars. It can be fitted over a bar end and moved along the length to test for roundness and accuracy of diameter. 77 Aditi Consultancy Services, Bangalore
Thread Plug and Ring Gauges
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Screw Pitch Gauges
A screw pitch gauge has a set of teeth which are of a known thread form. The gauge is used to determine the pitch of a thread on a bolt or screw of any diameter. 79 Aditi Consultancy Services, Bangalore
Feeler Gauges Feeler Gauges
Feeler Gauges are manufactured from accurately rolled shims and are used to measure gap sizes from 0.05mm up to about 1.25mm (0.002 to 0.050 inches). The numbers are marked on the gauge to give the thickness and thus the gap width. 80 Aditi Consultancy Services, Bangalore
Radius Gauges
Radius Gauges
Radius gauges are usually made of tool steel and cut with an inside and outside radius of a stated size. The gauges are grouped with other sizes to make a set. An accurately machined component can be easily compared with the profile of a radius gauge. Aditi Consultancy Services, Bangalore
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Sine Plate
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Sine Bar
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Sine Bar
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Angle Gauges
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Angle Gauges
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Angle Gauges
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Profile Projector
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Electronic Height Gauge
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Electronic Height Gauge
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Coordinate Measuring Machine (CMM)
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CMM PROBES
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CMM Scanning Probe Head
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COORDINATE MEASURING MACHINE
Bridge Type CMM
Cantilever Type CMM 96
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COORDINATE MEASURING MACHINE
Gantry Type CMM
High Precision and Multi Sensor CMM 97
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Portable CMM
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LASER scanner with an articulated arm
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Precision Form Tester
GAUGE
SPINDLE AND
COLUMN
Table Rotation
Spindle Rotation
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SURFACE FINISH & FORM MEASURING MACHINE
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3D Measurement
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Exercise Position all 5 the Holes relative to the two Centre Planes and the Bottom Surface of the part
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Positional Tolerancing relative to Datum Feature Centre Planes
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Multiple Pattern of Features
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Tolerance Zones for Patterns Aditi Consultancy Services, Bangalore
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PLTZF & FRTZF
PLTZF FRTZF 107 Aditi Consultancy Services, Bangalore
Composite Position Tolerancing
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Composite Position Tolerancing
One possible relationship between the PLTZF and FRTZF 109 ����� ����������� ��������� ���������
Composite Position Tolerancing
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Composite Position Tolerancing
One possible relationship between the PLTZF and FRTZF 111 ����� ����������� ��������� ���������
Composite Position Tolerancing
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Composite Position Tolerancing (Circular Pattern of Features)
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Functional Gage with Datum at RFS +0.25 0
AME of Ø 50
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Functional Gage with Datum at RFS
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Functional Gage with Datum at RFS
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Functional Gage with Datum at MMC Ø 50.25
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Functional Gage with Datum at MMC
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Functional Gage with Datum at MMC
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Bi Directional Position Tolerancing
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Bi Directional Position Tolerancing
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Projected Tolerance Zone
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Projected Tolerance Zone
Fastener and Hole 124 Aditi Consultancy Services, Bangalore
Projected Tolerance Zone
When the projected tolerance zone symbol is shown, it means that the stated tolerance zone is extended beyond the surface of the part, not within the part. 125 Aditi Aditi Consultancy Consultancy Services, Services, Bangalore Bangalore
Gauge for Projected Tolerance Zone
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Profile of a Surface Profile of surface is a tolerance zone, three-dimensionally extending along the length and width of the considered feature or features.
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Tolerance zone for the part
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Profile of a Surface (In Between) Profile of surface is a tolerance zone, three-dimensionally extending along the length and width of the considered feature or features.
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Tolerance zone for the part
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Profile of a Surface with Datums
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Profile of a Surface with Datums
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Profile of a Line A geometric tolerance that limits the amount of error for line elements relative to their true profile
Profile tolerances are often used to control irregular shapes. e.g. contours.
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Profile of a Line
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Profile of a Line (In Between) Profile of a line between two points of the considered feature.
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Profile of a Line (In Between)
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Profile of a Line with Datums
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Profile of a Line with Datums
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Profile of a Line
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Tolerance zone for the part
Unilateral: all inward from the basic profile.
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Unilateral: all outward from the basic profile.
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Checking Profile using Template
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Profile Tolerance Zone ASME For profile of a surface or line, the tolerance value represents the distance between two boundaries equally or unequally disposed about the true profile or entirely disposed on one side of the profile
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Profile Unilaterally Disposed
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Profile of a surface All around
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Profile All-Around Application
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Profile of a surface All Over
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Profile of a surface All Over
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Profile of a Surface
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Profile of a Surface
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Profile of a Surface
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Profile of a Surface (All Around)
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Composite Profile of a Surface
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Profile - Multiple or Co-Planar Surfaces
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Tangent Plane
A plane contacting the high points of the surface shall lie within two parallel planes 0.1 apart Aditi Consultancy Services, Bangalore
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Tangent Plane 0.01
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Tangent Plane
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Angularity
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Angularity
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Concentricity The condition where the median points of all diametrically opposed elements of a cylinder (or a surface of revolution) are congruent with the axis of a datum feature.
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Concentricity Circular tolerance zone of 0.1 mm diameter
Median points should fall with in the tolerance zone
Concentricity Circular tolerance zone of 0.1 mm diameter
Median points should fall with in the tolerance zone
Concentricity
162
Concentricity Between Features
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CIRCULAR RUNOUT A composite control that affects the form, orientation, and location of circular elements of a part feature relative to a datum axis.
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Run-out
A
Full Indicator Movement (FIM) should be less than .002
Rotating about datum axis A
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Circular Runout
Datum axis A
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Circular Runout - Axial The tolerance zone is limited to any radial position by two circles with a distance t apart lying in a cylindrical section, the axis of which coincides with the datum.
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TOTAL RADIAL RUNOUT
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Total Runout - Axial The tolerance zone is limited by two parallel planes a distance t apart and perpendicular to the datum.
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CIRCULAR RUNOUT
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Total Run-out Tolerance -- Radial Control affecting the form, orientation, and location of all surface elements of a diameter (or surface) relative to a datum A composite axis.
The tolerance zone is limited by two coaxial cylinders with a difference in radii of t, the axes of which coincide with the datum. Aditi Consultancy Services, Bangalore
CIRCULAR RUNOUT
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Coaxial Features
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Co-axiality Control
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Symmetrical Tolerancing
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Symmetry
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Position Tolerance for Symmetry
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