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IE550 - Manufacturing Systems
PART DESIGN SPECIFICATION

Fall 2008

Dr. R. A. Wysk
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Agenda
Go over engineering specifications
Functional requirements
Form, fit and function
Dimensioning
Tolerancing
Engineering drawings
datum
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Materials
Read Chapter 2 and 3 from Computer Aided
manufacturing (3
rd
Edition)
Overview of engineering design
Mechanical design representations
Engineering drawing
Geometric dimensioning and tolerancing
AMSE Y14.5
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THE DESIGN PROCESS
Product Engineering
Design Process
Off-road bicycle that ...
1. Conceptualization
2. Synthesis
3. Analysis
4. Evaluation
5. Representation
Design Process
How can this be
accomplished?

1. Clarification of the task
2. Conceptual design
3. Embodiment design
4. Detailed design
Functional requirement -> Design


Steps 1 & 2 Select material and properties, begin geometric
modeling (needs creativity, sketch is sufficient)
3 mathematical, engineering analysis
4 simulation, cost, physical model
5 formal drawing or modeling
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DESIGN REPRESENTATION
Design Engineering
Representation
Manufac-
turing
Verbal
Sketch
Multi-view orthographic drawing (drafting)
CAD drafting
CAD 3D & surface model
Solid model
Feature based design
Requirement of the representation method
precisely convey the design concept
easy to use
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A FREE-HAND SKETCH
Orthographic Projection
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A FORMAL 3-VIEW DRAWING
0.9444"
4 holes 1/4" dia
around 2" dia , first
hole at 45
A
2.000

0.001
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DESIGN DRAFTING
Third angle projection
P r o f i l e p l a n e
Y
Z
X
I I I
H o r i z o n t a l
F r o n t a l p l a n e
I
I V
I I
top
front
side
a
b
c d
e
f
g
h i
j
Drafting in the third angle
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INTERPRETING A DRAWING



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DESIGN DRAFTING
Partial view
Cut off view and auxiliary view

Provide more local details
A
2 . 0 0 0 0 . 0 0 1
A
A
A - A
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DIMENSIONING
Requirements
1. Unambiguous
2. Completeness
3. No redundancy
0.83 ' 0.98 ' 1.22 '
3.03 '
Redundant dimensioning
0.83 ' 1.22 '
3.03 '
1.72 '
0.86 '
Adequate dimensioning
Incomplete
dimensioning
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TOLERANCE
Dimensional tolerance - conventional
Geometric tolerance - modern
unilateral

bilateral
1.00 0.05
+
-
nominal dimension
tolerance
0.95
+ 0.10
- 0.00
1.05
+ 0.00
- 0.10
1.00 0.05
+
-
0.95 - 1.05 means a range
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TOLERANCE STACKING
"TOLERANCE IS ALWAYS ADDITIVE" why?

What is the expected dimension and tolerances?

d = 0.80 +1.00 + 1.20 = 3.00

t = (0.01 + 0.01 + 0.01) = 0.03
0.80 ' 0.01 1.20 ' 0.01
1.00 ' 0.01
?
1. Check that the tolerance & dimension specifications are
reasonable - for assembly.
2. Check there is no over or under specification.
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TOLERANCE STACKING (ii)
What is the expected dimension and tolerances?

d = 3.00 - 0.80 - 1.20 = 1.00

t = (0.01 + 0.01 + 0.01) = 0.03
0.80 ' 0.01 1.20 ' 0.01
3.00 ' 0.01
?
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TOLERANCE STACKING (iii)
Maximum x length = 3.01 - 0.79 - 1.19 = 1.03
Minimum x length = 2.99 - 0.81 - 1.21 = 0.97

Therefore x = 1.00 0.03
0.80 ' 0.01 1.20 ' 0.01
3.00 ' 0.01
?
x
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TOLERANCE GRAPH
G(N,d,t)
N: a set of reference lines, sequenced nodes
d: a set of dimensions, arcs
t: a set of tolerances, arcs
A B C D E
d,t
d,t d,t
d,t
d : dimension between references i & j

t : tolerance between references i & j
ij
ij
Reference i is in front of reference j in the sequence.
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EXAMPLE TOLERANCE GRAPH
A B C D E
A B C D E
d,t
d,t d,t
d,t
different properties
between d & t

d
DE
= d
DA
+ d
AE
= d
AD
+ d
AE
= (d
AB
+ d
BC
+ d
CD
) + d
AE
t
DE
= t
AB
+ t
BC
+ t
CD
+ t
AE
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OVER SPECIFICATION
If one or more cycles can be detected in the graph, we say that the
dimension and tolerance are over specified.
A B C
A B C
A B C
d1 d2
d3 d1,t1 d2,t2
d3,t3
t1 t2
t3
Redundant dimension
Over constraining tolerance
(impossible to satisfy) why?
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UNDER SPECIFICATION
A B C D E
A B C D E
d1
d2
d3
C D is disconnected from the
rest of the graph.

No way to find

d
BC
and d
DE
When one or more nodes are disconnected from the graph, the
dimension or tolerance is under specified.
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PROPERLY TOLERANCED
A B C D E
A B C D E
d,t
d,t d,t
d,t

d
DE
= d
DA
+ d
AE
= d
AD
+ d
AE
= (d
AB
+ d
BC
+ d
CD
) + d
AE
t
DE
= t
AB
+ t
BC
+ t
CD
+ t
AE
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TOLERANCE ANALYSIS
For two or three dimensional tolerance analysis:

i. Only dimensional tolerance

Do one dimension at a time.
Decompose into X,Y,Z, three one dimensional problems.

ii. with geometric tolerance
? Don't have a good solution yet. Use simulation?
t r u e p o s i t i o n
d i a m e t e r & t o l e r a n c e
A circular tolerance zone, the size is influenced
by the diameter of the hole. The shape of the
hole is also defined by a geometric tolerance.
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3-D GEOMETRIC TOLERANCE
PROBLEMS
t
datum surface
datum
surface
Reference
frame
perpendicularity
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TOLERANCE ASSIGNMENT
Tolerance is money

Specify as large a tolerance as possible as long as functional and
assembly requirements can be satisfied.
(ref. Tuguchi, ElSayed, Hsiang, Quality Engineering in Production
Systems, McGraw Hill, 1989.)
function
cost
Tolerance value
d ( n o m i n a l d i m e n s i o n )
Q u a l i t y
C o s t
- t
+ t
Quality cost
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REASON OF HAVING TOLERANCE
No manufacturing process is perfect.

Nominal dimension (the "d" value) can not be
achieved exactly.

Without tolerance we lose the control and as a
consequence cause functional or assembly
failure.
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EFFECTS OF TOLERANCE (I)
1. Functional constraints

e.g.
d t
flow rate
Diameter of the tube affects the flow. What is the allowed
flow rate variation (tolerance)?
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EFFECTS OF TOLERANCE (II)
2. Assembly constraints
e.g. peg-in-a-hole
dp
dh
How to maintain the
clearance?

Compound fitting
The dimension of
each segment
affects others.
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RELATION BETWEEN
PRODUCT & PROCESS
TOLERANCES
S e t u p
l o c a t o r s
0 . 0 0 5
0 . 0 0 5
0 . 0 0 5
Design specifications
Process tolerance
Machine uses the locators as
the reference. The distances
from the machine coordinate
system to the locators are
known.
The machining tolerance is
measured from the locators.
In order to achieve the 0.01
tolerances, the process
tolerance must be 0.005 or
better.
When multiple setups are used,
the setup error need to be taken
into consideration.
A
0 . 0 1 t o l e r a n c e s
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TOLERANCE CHARTING
A method to allocate process tolerance and verify that the process
sequence and machine selection can satisfy the design tolerance.


0.01 0.01
0.01
st ock
boundary
Dim t ol
1.0 0.01
1.0 0.01
3.0 0.01
Op code
10 lat he
10 lat he
20 lat he
20 lat he
10
12
20
22
blue print
Operation
sequence
Not shown are
process tolerance
assignment and
balance
produced tolerances:
process tol of 10 + process tol of 12

process tol of 20 + process tol 22

process tol of 22 + setup tol
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SURFACE FINISH
w a v i n e s s w i d t h
r o u g h n e s s w i d t h
w a v i n e s s
r o u g h n e s s
63 0.010

0.005
0.002 - 2
roughness
height
waviness height
waviness width
roughness width cutoff
default is 0.03" (ANSI Y14.36-1978)
roughness width
Lay
(m inch)
(inch)
63
Usually
simplified:
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PROBLEMS WITH DIMENSIONAL
TOLERANCE ALONE
1 . 0 0 1
1 . 0 0 1
1 . 0 0 1
6 . 0 0
1 . 0 0 0 . 0 0 1
6 . 0 0 0 . 0 0 1
As designed:
As manufactured:
Will you accept the part
at right?

Problem is the control of
straightness.

How to eliminate the
ambiguity?
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GEOMETRIC TOLERANCES
FORM
straightness
flatness
Circularity
cylindricity
ORIENTATION
perpendicularity
angularity
parallelism

LOCATION
concentricity
true position
symmetry
RUNOUT
circular runout
total runout


PROFILE
profile
profile of a line
ANSI Y14.5M-1977 GD&T (ISO 1101, geometric tolerancing;
ISO 5458 positional tolerancing; ISO 5459 datums;
and others), ASME Y14.5 - 1994
Squareness
roundness
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DATUM &
FEATURE CONTROL FRAME
Datum: a reference plane, point, line, axis where usually a plane
where you can base your measurement.

Symbol:

Even a hole pattern can be used as datum.

Feature: specific component portions of a part and may include one
or more surfaces such as holes, faces, screw threads, profiles, or
slots.

Feature Control Frame:

A
// 0.005 M A
symbol tolerance value
modifier
datum
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MODIFIERS
M Maximum material condition MMC assembly
Regardless of feature size RFS (implied unless specified)
L Least material condition LMC less frequently used
P Projected tolerance zone
O Diametrical tolerance zone
T Tangent plane
F Free state
maintain critical
wall thickness or
critical location of
features.
MMC, RFS, LMC

MMC, RFS

RFS
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SOME TERMS
MMC : Maximum Material Condition
Smallest hole or largest peg (more material left on the part)
LMC : Least Material Condition
Largest hole or smallest peg (less material left on the part)

Virtual condition:
Collective effect of all tolerances specified on a feature.

Datum target points:
Specify on the drawing exactly where the datum contact points
should be located. Three for primary datum, two for secondary
datum and one or tertiary datum.


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DATUM REFERENCE FRAME
Three perfect planes used to
locate the imperfect part.
a. Three point contact on the
primary plane
b. two point contact on the
secondary plane
c. one point contact on the tertiary
plane
Secondary
.
P r i m a r y
S e c o n d a r y
T

e

r

t

i

a

r

y

A
B
C
O 0.001 M A B C
primary
Tertiary
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STRAIGHTNESS
Value must be smaller
than the size tolerance.
1.000 ' 0.002
0 . 0 0 1
M e a s u r e d e r r o r 0 . 0 0 1
1.000 ' 0.002
0 . 0 0 1
0 . 0 0 1
Design Meaning
Tolerance zone between two straightness lines.
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FLATNESS
1.000 ' 0.002
0 . 0 0 1
0 . 0 0 1
p a r a l l e l
p l a n e s
Tolerance zone defined by two parallel planes.
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CIRCULARITY (ROUNDNESS)
1.00 ' 0.05
0 . 0 1
0 . 0 1 T o l e r a n c e z o n e
At any section along the cylinder
a. Circle as a result of the intersection by any plane perpendicular to
a common axis.
b. On a sphere, any plane passes through a common center.

Tolerance zone bounded by two concentric circles.


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CYLINDRICITY
1.00 ' 0.05
0 . 0 1
0 . 0 1
Rotate in a V
Rotate between points
Tolerance zone bounded by two concentric cylinders
within which the cylinder must lie.
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PERPENDICULARITY
A surface, median plane, or axis at a right angle to the datum plane
or axis.
0 . 0 0 2
t o l e r a n c e
z o n e p e r p e n d i c u l a r
t o t h e d a t u m p l a n e
. 0 0 2 A
O 1 . 0 0 0 . 0 1
A
0 . 0 0 2 d i a m e t e r t o l
z o n e i s p e r p e n d i c u l a r
t o t h e d a t u m p l a n e
1.000 ' 0.005
. 0 0 2 A
0.500 ' 0.005
2.000 ' 0.005
A
. 0 0 2 T A
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ANGULARITY
A surface or axis at a specified angle (orther than 90) from a datum
plane or axis. Can have more than one datum.
3.500 ' 0.005
1 . 5 0 0 0 . 0 0 5
4 0
0 . 0 0 5 A
A
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PARALLELISM
1.000 " 0.005
2.000 " 0.005
. 0 0 1 A
A
The condition of a surface equidistant at all points from a datum plane,
or an axis equidistant along its length to a datum axis.
0 . 0 0 1
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PROFILE
A uniform boundary along the true profile within whcih
the elements of the surface must lie.
A
B
0 . 0 0 5 A B
0 . 0 0 1
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RUNOUT
0.361 " 0.002
1.500 " 0.005
A
0 . 0 0 5 A
A composite tolerance used to control the functional relationship
of one or more features of a part to a datum axis. Circular runout
controls the circular elements of a surface. As the part rotates
360 about the datum axis, the error must be within the tolerance
limit.
D a t u m
a x i s
D e v i a t i o n o n e a c h
c i r c u l a r c h e c k r i n g
i s l e s s t h a n t h e
t o l e r a n c e .
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TOTAL RUNOUT
D a t u m
a x i s
D e v i a t i o n o n t h e
t o t a l s w e p t w h e n
t h e p a r t i s r o t a t i n g
i s l e s s t h a n t h e
t o l e r a n c e .
0.361 " 0.002
1.500 " 0.005
A
0 . 0 0 5 A
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TRUE POSITION
1 . 2 0
0 . 0 1
1 . 0 0 0 . 0 1
1 . 2 0
1 . 0 0
T o l e r a n c e z o n e
0 . 0 1 d i a
O 0 . 0 1 M A B
O . 8 0 0 . 0 2
Dimensional
tolerance
True position
tolerance
Hole center tolerance zone
A
B
T o l e r a n c e z o n e
0 . 0 2
2
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HOLE TOLERANCE ZONE
Tolerance zone for dimensional toleranced
hole is not a circle. This causes some assembly
problems.
For a hole using true position tolerance
the tolerance zone is a circular zone.
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TOLERANCE VALUE MODIFICATION
Produced True Pos tol
hole size
0.97 out of diametric tolerance
0.98 0.01 0.05 0.01
0.99 0.02 0.04 0.01
1.00 0.03 0.03 0.01
1.01 0.04 0.02 0.01
1.02 0.05 0.01 0.01
1.03 out of diametric tolerance

1 . 2 0
1 . 0 0
O 0 . 0 1 M A B
O 1 . 0 0 0 . 0 2
M L S
The default modifier for
true position is MMC.
MMC





LMC
For M the allowable tolerance = specified tolerance + (produced hole
size - MMC hole size)
A
B
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MMC HOLE
Given the same peg (MMC peg), when the produced hole size
is greater than the MMC hole, the hole axis true position
tolerance zone can be enlarged by the amount of difference
between the produced hole size and the MMC hole size.
hole axis t olerance zone
MMC hole
LMC hole
MMC peg will f it in t he hole
axis must be in t he t olerance zone
,
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PROJECTED TOLERANCE ZONE
Applied for threaded holes or press fit holes to ensure interchangeability
between parts. The height of the projected tolerance zone is the thickness
of the mating part.
O . 0 1 0 M A B C
. 2 5 0 p
. 3 7 5 - 1 6 U N C - 2 B
Proj ect ed t olerance
zone
0.25
0.01
Produced part
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SOME NUMBERS
Krulikowski, A., GD&T Challenges the Fast Draw, MFG ENG, Feb 1994.
GD&T drawings are more expansive to make, however, saves revision
cost.

Drawing revision costs $500 - $2000 on the paper work

How much does it cost to put a part number onto a part? Estimates
range from $1,000 -$10,000.