06-04-2022

19P603 DESIGN FOR MANUFACTURE AND ASSEMBLY

Positional Tolerance with MMC, LMC and RFS

Dr. RAJAMANI R
Department of Production Engineering
PSG College of Technology

Tolerance of Position (TOP)

RFS

 MMC

 LMC

27 February 2024 DR. RAJAMANI R, PSG CT 2

Dr. Rajamani R, PSG CT 1

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CHOICE OF MODIFIERS

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CHOICE OF MODIFIERS

Maximum Material Condition (MMC) is used to

a) guarantee assembly for non critical feature
b) allow fixed gage usage when dealing with mass production
Minimum Material Modifier (least material requirement, LMR) is generally used to
a) control the minimum wall thickness;
b) ensure a minimum distance between one feature and another;
c) control a well-defined angular position
Regardless of Feature Size ( RFS) is used for
a) critical features like where press fit needed
b) threaded holes.
27 February 2024 DR. RAJAMANI R, PSG CT 4

Dr. Rajamani R, PSG CT 2

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CHOICE OF MODIFIERS

 Maximum Material Condition (MMC)

Design Intent: Easier Assembly (Implied: Less Location Accuracy)
 Minimum Material Modifier
Design Intent: More Location Accuracy (Implied: Less Easy Assembly)
 Regardless of Feature Size ( RFS)
Design Intent: High and Robust Location Accuracy

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Applicability of MMC or LMC

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Dr. Rajamani R, PSG CT 3

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Applicability of MMC or LMC

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GD&T Rule 1

Rule #1 states that where only a tolerance of size is specified, the limits of size of an
individual feature of size prescribe the extent to which variations in its geometric form, as
well as its size, are allowed.

 When a size dimension and tolerance is applied to a feature of size. The Feature of size
should have perfect form at Maximum material condition.

27 February 2024 DR. RAJAMANI R, PSG CT 8

Dr. Rajamani R, PSG CT 4

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GD&T Rule 1
 When a size dimension and tolerance is applied to a feature of size. The Feature of size
should have perfect form at Maximum material condition.

27 February 2024 DR. RAJAMANI R, PSG CT 9

GD&T Rule 1

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Dr. Rajamani R, PSG CT 5

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GD&T Rule 2

Rule #2 states that RFS automatically applies, in a feature control frame, to

individual tolerances of size features and to datum features of size. MMC and
LMC must be specified when these conditions are required.

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GD&T Rule 2

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Dr. Rajamani R, PSG CT 6

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Tolerance of Position (TOP)

TOP is commonly used to control four types of part relationships:

 The distance between features of size, such as holes, bosses, slots, tabs, etc.
 The location of features of size (or patterns of features of size) such as holes, bosses,
slots, tabs, etc.
 The coaxiality between features of size
 The symmetrical relationship between features of size

27 February 2024 DR. RAJAMANI R, PSG CT 13

TOP Theories

Two theories can be used to visualize the effects of a TOP control:

1. The virtual condition boundary theory—A theoretical boundary limits the location of
the surfaces of a FOS.
2. The axis theory—The axis (or centerplane) of a FOS must be within the tolerance
zone.

 The axis theory is most common in RFS TOP applications, and

 The boundary theory is most common in MMC tolerance of position applications.

27 February 2024 DR. RAJAMANI R, PSG CT 14

Dr. Rajamani R, PSG CT 7

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TOP Virtual Condition Boundary Theory

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TOP Axis Theory

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Dr. Rajamani R, PSG CT 8

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Actual Local Size and Actual Mating Envelope

 Actual local size is the value of any individual distance at any cross section of a FOS. The
actual local size is a two-point measurement, taken with an instrument like a caliper or micrometer,
that is checked at a point along the cross section of the part. A FOS may have several different
values of actual local size.

 Actual Mating Envelope (AME): The actual mating envelope of an external feature of size is a
similar perfect feature counterpart of the smallest size that can be circumscribed about the
feature so it just contacts the surfaces at the highest points.

 For example, a similar perfect counterpart could be:

 a smallest cylinder of perfect form
 two parallel planes of perfect form at a minimum separation

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Actual Mating Envelope of an External Feature of Size

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Dr. Rajamani R, PSG CT 9

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Actual Mating Envelope of an Internal Feature of Size

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ACTUAL MATING ENVELOPE (AME)

AME is a similar perfect feature(s) counterpart of smallest size that can be contracted about
an external feature(s) or of largest size that can be expanded within an internal feature(s) so that
it coincides with the surface(s) at the highest points.

There are two types of envelopes:

 Unrelated actual mating envelope: It is closest fit counterpart perfect feature without
considering any datum feature or constraint.
 Related actual mating envelopes, It is also the closest fit counterpart perfect feature while
constrained either orientation or location, or both by applicable datum(s)

27 February 2024 DR. RAJAMANI R, PSG CT 20

Dr. Rajamani R, PSG CT 10

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ACTUAL MATING ENVELOPE (AME)

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Coordinate Tolerance

(a) Square tolerance Zone (b) Rectangular Tolerance Zone00

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Dr. Rajamani R, PSG CT 11

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Position Tolerances

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Coordinate Tolerance Vs Position Tolerance

Square Tolerance Zone Using Round Tolerance Zone Using Position Tolerance
Coordinate Dimensioning

27 February 2024 DEPARTMENT OF PRODUCTION ENGINEERING, PSGCT, CBE 24

Dr. Rajamani R, PSG CT 12

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Coordinate Tolerance Vs Position Tolerance

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Advantage of the application of the Maximum Material requirement

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Dr. Rajamani R, PSG CT 13

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Positional Tolerancing with Modifiers

Bonus Tolerance with Modifiers

Internal Feature External Feature
MMC – AME
Modifiers AME – MMC

Modifiers LMC – AME AME – LMC

Modifiers 0 0

27 February 2024 DR. RAJAMANI R, PSG CT 27

Positional Tolerancing with MMC

For internal feature : Bonus Tolerance at MMC = AME – MMC

Total Position Tolerance = BT + PT
Hole AME Position Bonus Total Position
Tol. (PT) Tol. (BT) Tolerance
14.0 MMC 0 0.2
14.1 0.1 0.3
14.2 0.2 0.2 0.4
14.3 0.3 0.5
14.4 0.4 0.6
14.5 LMC 0.5 0.7

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Dr. Rajamani R, PSG CT 14

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Positional Tolerancing with LMC

For internal feature : Bonus Tolerance at LMC = LMC – AME

Total Position Tolerance = BT + PT
Hole AME Position Bonus Total Position
Tol. (PT) Tol. (BT) Tolerance
14.0 MMC 0.5 0.75
14.1 0.4 0.65
14.2 0.25 0.3 0.55
14.3 0.2 0.45
14.4 0.1 0.35
14.5 LMC 0 0.25

27 February 2024 DR. RAJAMANI R, PSG CT 29

Positional Tolerancing with RFS

For internal feature :

Bonus Tolerance at RFS = 0
Hole AME Position
Tol. (PT)
14.0 MMC
14.1
14.2 0.25
14.3
14.4
14.5 LMC

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Dr. Rajamani R, PSG CT 15

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Zero Positional Tolerancing with MMC

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Ref: https://iigdt.com/Products/ProdDetails/GDT_Intermediate_Principles_Details.htm

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Dr. Rajamani R, PSG CT 16

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Positional Tolerancing

Calculate Positional tolerance with MMC, LMC and RFS Modifiers

Positional tolerance with

Hole AME MMC LMC RFS
6.0
.
.
.
.
6.4

27 February 2024 DR. RAJAMANI R, PSG CT 33

Positional Tolerancing

Calculate Positional tolerance with MMC, LMC and RFS Modifiers

For External feature :

Bonus Tolerance at MMC = MMC – AME

Bonus Tolerance at LMC = AME – LMC

Bonus Tolerance at RFS = 0

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Dr. Rajamani R, PSG CT 17

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Positional Tolerancing

Calculate Positional tolerance with MMC, LMC and RFS Modifiers

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VIRTUAL CONDITION

 Virtual Condition (VC): a constant boundary generated by the collective effects of a

considered feature of size’s specified MMC or LMC and the geometric tolerance for that
material condition.

 VC is the extreme boundary that represents the worst-case for such functional
requirements, such as clearance, assembly with a mating part, thin wall conservation or
hole alignment.

 The functional gauge can be created based off of the Virtual Condition of the feature.

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Dr. Rajamani R, PSG CT 18

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VIRTUAL CONDITION (VC)

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VIRTUAL CONDITION (VC)

VIRTUAL CONDITION: The worst case boundary generated by the collective effects of a size
feature’s specified MMC or LMC material condition and the specified geometric tolerance.

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Dr. Rajamani R, PSG CT 19

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VIRTUAL CONDITION (VC)

Internal feature:
Virtual Condition = MMC (smallest size) – Geometric Tolerance

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VIRTUAL CONDITION (VC)

External feature :
Virtual Condition = MMC (largest size) + Geometric Tolerance

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Dr. Rajamani R, PSG CT 20

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VIRTUAL DIMENTION (VC)

Virtual dimension of center hole (VC) =

MMC (smallest size) – Geometric Tolerance

VC = 40.1 - 0.2 = 39.9 mm

Virtual dimension of 16 mm Holes =

VC = 16.0-0.4 = 15.6 mm

27 February 2024 DR. RAJAMANI R, PSG CT 41

VIRTUAL DIMENTION (VC) APPLICATION

Functional gauge,

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Dr. Rajamani R, PSG CT 21

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VIRTUAL CONDITION (VC)

Virtual Condition Boundary Using the LMC Concept — External Feature

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VIRTUAL CONDITION (VC)

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Dr. Rajamani R, PSG CT 22

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Projected Tolerance Zone

The application of this concept is recommended whenever a variation in perpendicularity of

threaded or press-fit holes could cause fasteners, such as screws, studs or pins, to interfere with
mating parts

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Projected Tolerance Zone

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Dr. Rajamani R, PSG CT 23

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Projected Tolerance Zone

Projected zone should be indicated with a symbol placed inside the tolerance indicator, and
the length of the projected external zone should then be indicated, as shown in the Fig

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Projected Tolerance Zone

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Dr. Rajamani R, PSG CT 24

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Functional Gauge Design

When a part is checked for true position under a feature of

Part
size specification, usually a functional gauge is used to ensure
that the entire feature envelope is within specification.

Gauge

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Functional Gauge Design

Gauging of an Internal Feature:
For the true position under MMC of a hole:
Pin Gauge Diameter = Min diameter of hole (MMC) - True Position Tolerance

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Dr. Rajamani R, PSG CT 25

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Functional Gauge Design

Gauging of an External Feature :

For true position under MMC of a Shaft :

Hole Gauge diameter = Max. diameter of shaft (MMC) + True Position Tolerance

 The tolerance on a gauge is generally about 10% of the tolerance that has to be controlled, under a
temperature condition of 20° and humidity no higher than 45%.
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Functional Gauge Design

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Dr. Rajamani R, PSG CT 26

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Functional Gauge Design

Functional gauge to measure the true position of all holes:

 Individual Pin Diameters = Min hole diameter ( MMC) – True position tolerance (bonus)

• Pin Diameter = 9.9 – 0.2 = Ø 9.7 mm.

• Tolerance for Pin = Tolerance at MMC / 10 = 0.2/10 = 0.02 mm
• Angularity of PIN Tan  = Thickness of plate / GT = 25 / 0.2 (Thickness of plate = 25 mm)
 = 89.54o

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Functional Gauge Design

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Dr. Rajamani R, PSG CT 27

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Functional Gauge Design

4 x ø10.0  0.1

Hole Dia (mm) Functional Gauge Design Specification

10.1 Ok Ok
10 Ok Ok
9.9 Ok Ok
9.8 Ok Not Ok

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Functional Gauge Design

4x ø 9.9  0.2

Hole Dia (mm) Functional Gauge Design Specification

10.1 Ok Ok
10 Ok Ok
9.9 Ok Ok
9.8 Ok Ok

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Dr. Rajamani R, PSG CT 28

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Functional Gauge Design

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Functional Gauge Design

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Dr. Rajamani R, PSG CT 29

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Zero True Positional Tolerancing

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Zero True Positional Tolerancing

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Dr. Rajamani R, PSG CT 30

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Functional Gauge Design

Functional gauges - Advantages:
1. a workpiece can be controlled immediately and quickly;
2. particular technical knowledge is necessary to use them;
3. a workpiece that does not comply with the tolerance is never accepted;
4. they represent the physical materialisation of the workpiece that has to be mated;
5. they allow the effect of the bonus and of the virtual conditions to be understood.
Functional gauges - Disadvantages:
1. they are expensive to build;
2. even a minimum variation of the design of a workpiece renders them obsolete;
3. they do not quantify the results of the control;
4. they require a great design effort

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FLOATING FASTENER ASSEMBLY

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Dr. Rajamani R, PSG CT 31

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FLOATING FASTENER ASSEMBLY

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FLOATING FASTENER ASSEMBLY

Position tolerance of plate A = T1 and

Position tolerance of plate B = T2

T1 + T2 = 2 x Diameter play at MMC

If Working tolerance W c is considered,

Governing equations for floating fastener assembly =

T1 + T2 + Wc = 2 x Diameter play at MMC

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Dr. Rajamani R, PSG CT 32

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FLOATING FASTENER ASSEMBLY

Let us assume that a hole diameter of 7 mm (clearance hole for fasteners) and that deviations of
± 0.2 mm have been assumed for the holes. Two plates are joined by M6 bolt.

Calculation of Positional Tolerance:

Hole diameter = 7 mm, and Nominal diameter of the screw = 6 mm
Diameter play at MMC = 0.4 mm (  Positional Tolerance of hole = ± 0.2 mm)
At MMC Positional Tolerance of hole = T1 + T2 = 2 x Diameter play at MMC
= 2 x .04 = 0.8 mm

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FLOATING FASTENER ASSEMBLY

Practical examples for the calculation of position tolerances for the joining with floating fasteners

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Dr. Rajamani R, PSG CT 33

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FIXED FASTENER ASSEMBLY

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FIXED FASTENER ASSEMBLY

Position tolerance of plate A = T1 and

Position tolerance of plate B = T2

T1 + T2 Diameter play at MMC

If Working tolerance W c is considered,

Position tolerances for connections with fixed fasteners

Governing equations for fixed fastener assembly =

T1 + T2 + Wc = Diameter play at MMC

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Dr. Rajamani R, PSG CT 34

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Governing Equations for Floating Fastener Assembly

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Governing Equations for Fixed Fastener Assembly

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Dr. Rajamani R, PSG CT 35

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Governing Equations for Compound Assembly

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Compound Assembly
Components 1 and 2 are to be assembled as shown in Fig. Check whether the dimensioning has been done
properly to ensure assembly (Only diameter dimensions and tolerances are to be considered for analysis).

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Dr. Rajamani R, PSG CT 36

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References

 ASME Y14.5-2018 - Dimensioning and Tolerancing, The American Society of

Mechanical Engineers, 2019.

 Stefano Tornincasa, Technical Drawing for Product Design, Springer, 2021.

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Dr. Rajamani R, PSG CT 37