Engineering Specification

Part Name: SPECIFICATION Part Number:

GLOBAL GENERIC TOLERANCES FOR SHEET METAL COMPONENTS ESBU5A-1294-AA
LET
FR
LET
FR
Date LET FR Revisions DR CK Reference:
A Released under notice # AB00-12310257-009 ES-YF12-1294-AA
3-May-12 A All Initial release corrections, released under notice Prepared/Approved By:
# AB00-12310257-011 Steve Gallagher
Checked By: Detailed By:
Andre Jurkiewicz
Jens Buechner
Manfred Hemb
Bernd Solbach
Concurrence/Approval
Signatures:
Design Engineering Manager

Shawn Morgans
Other Approvals/Concurrences
(as required):

Bruno Barthelemy Body Structure,

Closures, CAE Chief Engineer

Bernd Liesenfelder
Chief Body Ext EU

Steven Crosby
Chief Engineer Body APA

Ulrich Stuhec
Chief Engineer Body FSAO

Willi Wegener
Director of Manufacturing Eng VO

Paul Temple
Chief Engineer

Timothy Marasco
Chief Engineer SBU

Thomas Oberlaender
Manager Stamping

Guido Krings
Manager VOME DCD

Janice Gall
Manager DCD

Part Name:
GLOBAL GENERIC TOLERANCES FOR SHEET METAL COMPONENTS
Part Number:
Frame 1 of 7 REV 1.0 ESBU5A-1294-AA
G1S1 Item Number: 25.06
G1S2 Classification Proprietary
FAF03-150-1 (previously form: 3947-A1) Version Date: 3 MAY 2012
Author SGALLAG1
 Engineering Specification
Part Name:
GLOBAL GENERIC TOLERANCES FOR SHEET METAL COMPONENTS
Part Number:
Frame 2 of 7 REV 1.0 ESBU5A-1294-AA
I. Scope:
This specification is issued to provide generic tolerances for data files of sheet metal components.

II. Application:
Generic tolerances are to be applied if no other specified requirements exist for the specific
feature. Tolerances resulting from these specified requirements overwrite generic tolerances,
and have to be explicitly annotated to the CAD-part or shown on a drawing.
All features and geometric tolerances not covered within this specification have also to be
explicitly annotated to the CAD-part or shown on a drawing.
Every feature on the single CAD-part has to be designated in line with the feature names
determined within this specification

III. IN ACCORDANCE WITH THE A.S.M.E. Y14.5 - 2009 STANDARD, THE FOLLOWING
APPLIES:
Secondary
Tolerance Datum

Control Primary Tertiary

Datum Datum

All datum reference frames must contain primary, secondary and tertiary datums (herein represented
by the letters A, B and C) or a subset of them.
If, for functional reasons, a subdatum-system is used, this subdatum-system and the feature
tolerances referenced to it must be explicitly annotated to the CAD-part or shown on a drawing.

No MMC / LMC (Maximum / Least material condition) and MMB / LMB

(Maximum / Least material boundary) is to be applied.

IV. GENERAL TOLERANCES UNLESS OTHERWISE SPECIFIED.

If two or more general tolerances can be applied to one part condition, the most restrictive
will apply

G1S1 Item Number: 25.06

G1S2 Classification Proprietary
FAF03-150-1 (previously form: 3947-A1) Version Date: 3 MAY 2012
Author SGALLAG1
 Engineering Specification
Part Name:
GLOBAL GENERIC TOLERANCES FOR SHEET METAL COMPONENTS
Part Number:
Frame 3 of 7 REV 1.0 ESBU5A-1294-AA

HOLES / SLOTS
General agreement : "Holes" applies to round and square holes
"Slots" applies to round and rectangular slots
For all Slots the Boundary Concept / Control has to be applied
A) General Size Tolerance of Holes ((D) round/square) and Slots ((D1/D2) round/rectangular)
unless otherwise specified.
1.6 - 6.0 + / - 0.1
6.1 - 18.0 + / - 0.15
18.1 - 50.0 + / - 0.2
>50.0 + / - 0.4

D D

r D

D2
D2

r
D1 D1

B) Datums/Master Control Locators

Size tolerance for secondary and tertiary (master locator) feature to be
+/- 0.05 for hole and slot width and +/- 1.25 for slot length
If slot is used as a 4-way-locator, tolerance of slot length to be + / - 0.05
Secondary and tertiary MC-locator features have orientation tolerances of zero at MMC
referenced to datum A. This is verified by use of an attribute check utilizing simulators at
virtual condition.

Primary, Secondary and Tertiary Datums must be annotated to the CAD-part.

The term "Locator" is used to define features utilized as datums.

M [*] CM
A BM M [*]

* If secondary and / or tertiary datums are features of size, the datum feature simulator
has to be dimensioned based on the nominal feature size D / D1 with a tolerance range
of - 0.06 / -0.17.
For primary datum target feature execution see respective locator file (Checking fixture
group / datum group).

C) Laser Cut Datums/Master Control Locators

Size tolerance for secondary and tertiary (master locator) feature to be
+/- 0.1 for hole and slot width and +/- 1.25 for slot length
If slot is used as a 4-way-locator, tolerance of slot length to be + / - 0.1

G1S1 Item Number: 25.06

G1S2 Classification Proprietary
FAF03-150-1 (previously form: 3947-A1) Version Date: 3 MAY 2012
Author SGALLAG1
 Engineering Specification
Part Name:
GLOBAL GENERIC TOLERANCES FOR SHEET METAL COMPONENTS
Part Number:
Frame 4 of 7 REV 1.0 ESBU5A-1294-AA

D) Final Assy / Transferred Locators (Non-MC-Locators)

Size tolerance +/- 0.05 for hole and slot width, and +/- 1.25 for slot length
If slot is used as a 4-way-locator, tolerance of slot length to be + / - 0.05
Position
For holes: l O 0.5 A BMM [*] CM M [*]

For slots: l 0.5 M [*]

A BM M [*]
CM Width
l 0.5 M [*]
A BM M [*]
CM Length

E) Fabrication/Tooling Locators for Stamping

Size tolerance +/- 0.05 for hole and slot width and +/- 1.25 for slot length
If slot is used as a 4-way-locator, tolerance of slot length to be + / - 0.05
Position
For holes: l O5 A BMM [*] CM M [*]

For slots: l 5.0 M [*]

A BM M [*]
CM Width
l 5.0 M [*]
A BM M [*]
CM Length

F) Final Assembly Attachments (fixings)

Size tolerance is dependant on utilized fixing, needs to be functionally derived and must
explicitely be annotated to the CAD-part.
Position
For holes: l O 1.0 A BM M [*] CMM [*]

For slots: l 1.0 M [*]

A BM M [*]
CM Width
l 2.0 M [*]
A BM M [*]
CM Length

Refinement for feature group (tolerance to each other)

( A group / pattern of features defined as those which have the same function)

O 1.0 M [*]
A BM M [*]
CM
l OO 0.5
G) Extruded (Flanged) Tapped Holes
Extrusion length (Flange Height) +/- 0.5

Position
For holes: l O 1.0 M [*]
A BM M [*]
CM

G1S1 Item Number: 25.06

G1S2 Classification Proprietary
FAF03-150-1 (previously form: 3947-A1) Version Date: 3 MAY 2012
Author SGALLAG1
 Engineering Specification
Part Name:
GLOBAL GENERIC TOLERANCES FOR SHEET METAL COMPONENTS
Part Number:
Frame 5 of 7 REV 1.0 ESBU5A-1294-AA

H) Extruded (Flanged) Holes

Extrusion length (Flange Height) +/- 0.5
Size tolerance +/- 0.5 for hole and slot width and +/- 1.25 for slot length

Position
For holes: l O 3.0 M [*]
A BM M [*]
CM

For slots: l 3.0 M [*]

A BM M [*]
CM Width
l 3.0 M [*]
A BM M [*]
CM Length

I) Flared Out Holes

Size tolerance +/- 0.5 for hole and slot width and +/- 1.25 for slot length

Position
For holes: l O 2.0 M [*]
A BM M [*]
CM

For slots: l 2.0 M [*]

A BM M [*]
CM Width
l 2.0 M [*]
A BM M [*]
CM Length

J) Laser Cut Holes (Non-MC)

Size tolerance +/- 0.25 for hole and slot width and +/- 1.25 for slot length
Position
For holes: l O 1.0 A BM M [*] CM M [*]

For slots: l 1.0 M [*]

A BM M [*]
CM Width
l 1.0 M [*]
A BM M [*]
CM Length

K) Access (Clearance) Holes/Openings

" 2.5 U 0 M [*]
A BM M [*]
CM

L) Drainage Holes/Openings (non plugged)

Lightening Holes/Openings (non plugged)

" 5.0 M [*]

A BM M [*]
CM

M) Drainage Holes (plugged)

Lightening Holes (plugged)

Size tolerance is dependant on utilized plug size, needs to be functionally derived and will
explicitly be annotated to the CAD-part
Position
For holes: l O 5.0 A BM M [*] CM M [*]

For slots: l 5.0 M [*]

A BM M [*]
CM Width
l 5.0 M [*]
A BM M [*]
CM Length

G1S1 Item Number: 25.06

G1S2 Classification Proprietary
FAF03-150-1 (previously form: 3947-A1) Version Date: 3 MAY 2012
Author SGALLAG1
 Engineering Specification
Part Name:
GLOBAL GENERIC TOLERANCES FOR SHEET METAL COMPONENTS
Part Number:
Frame 6 of 7 REV 1.0 ESBU5A-1294-AA

N) Weld Nut Installation Holes

Size and size tolerance are determined within Fastener Engineering Specification
ESBM5A-1N265-AA or latest release
Position
l O 1.0 A BM M [*] CM M [*]

Refinement for feature group (tolerance to each other)

( A group / pattern of features defined as those which have the same function)

O 1.0 M [*]
A BM M [*]
CM
l OO 0.5
O) Weld Bolt Installation Holes
Size and size tolerance are determined within Fastener Engineering Specification
ESBM5A-1N265-AA or latest release
Position
l O 1.0 A BM M [*] CM M [*]

Refinement for feature group (tolerance to each other)

( A group / pattern of features defined as those which have the same function)

O 1.0 M [*]
A BM M [*]
CM
l OO 0.5
SURFACES:

A) Mating Surfaces

1.4 A BM M [*] M [*]

CM
h
0.5 / 250 x 250

B) Surfaces defining Gap / Margin

1.0 M [*]
A BM M [*]
CM
h
0.5 M [*]
A BM M [*]
CM

C) Surfaces defining Flushness

1.0 M [*]
A BM M [*]
CM
h
0.5 M [*]
A BM M [*]
CM

D) General surface tolerance

h 2 M [*]
A BM M [*]
CM

All over on design/dimensioned side.

G1S1 Item Number: 25.06

G1S2 Classification Proprietary
FAF03-150-1 (previously form: 3947-A1) Version Date: 3 MAY 2012
Author SGALLAG1
 Engineering Specification
Part Name:
GLOBAL GENERIC TOLERANCES FOR SHEET METAL COMPONENTS
Part Number:
Frame 7 of 7 REV 1.0 ESBU5A-1294-AA

LINES:

A) General trim line tolerance

" 2.5 M [*]

A BM M [*]
CM

B) Weld Lines of Tailored Welded Blanks (after forming)

" 10 M [*]
A BM M [*]
CM

C) Trim Lines for Weld Flanges

Trim Lines for Clinch Flanges
Trim Lines for Closure Panel Hem Flanges

" 2.0 M [*]

A BM M [*]
CM

G1S1 Item Number: 25.06

G1S2 Classification Proprietary
FAF03-150-1 (previously form: 3947-A1) Version Date: 3 MAY 2012
Author SGALLAG1