DIMENSIONS,

TOLERANCES,
AND SURFACES
 OVERVIEW
- Dimensions, Tolerances, and Related Attributes

- Conventional Measuring Instruments and Gages

Surfaces

-Measurement of Surfaces

-Effect of Manufacturing Processes

Manufacturing Process Flow
 Dimensions and Tolerances

Dimensions - linear or angular sizes of a component

specified on the part drawing

Tolerances - allowable variations from the specified

part dimensions that are permitted in manufacturing
 DEFINITION OF
DIMENSION!
a numerical value expressed in appropriate units of measure and
indicated on a drawing and in other documents along with lines,
symbols, and notes to define the size or geometric characteristic , or
both, of a part or part feature

DEFINITION OF
TOLERANCE!
the total amount by which a specific dimension is
permitted to vary . The tolerance is the difference between
the maximum and minimum limits.
Unit of Measure
Rectangular coordinate dimensioning , a base line (or datum line) is established
for each coordinate direction, and all dimensions specified with respect to these
baselines.

This is also known as datum dimensioning , or baseline dimensioning .

All dimensions are calculated as X and Y distances from an origin point, usually
placed at the lower left corner of the part.
Dimensions should be grouped for uniform appearance as shown.
Dimensioning Hints:
Where there are several parallel dimensions, the values should be staggered.
 Bilateral Tolerance
 Variation is permitted in
both positive and negative
directions from the nominal
dimension
 Possible for a bilateral
tolerance to be unbalanced
 Ex: 2.500 +0.010, -0.005
 Unilateral Tolerance
 Variation from the specified
dimension is permitted in
only one direction
 Either positive or negative,
but not both
 Limit Dimensions
 Permissible variation in a
part feature size consists of
the maximum and minimum
dimensions allowed
Geometric Dimensioning and Tolerancing
Feature Control Frame
Geometric Dimensioning and Tolerancing
Symbol
Straightness
 Accuracy & Precision
Accuracy - the degree to which a measured value agrees
with the true value of the quantity of interest
Avoid systematic error ( + / -
deviation)

Precision - the degree of repeatability in the measurement

process

Avoidance of random error

Conventional Measuring
Instruments and Gages

 Precision gauge blocks

 Measuring instruments for linear dimensions
 Comparative instruments
 Angular measurements
 Precision Gauge Blocks

 A standard
 Rectangular or blocks
 Mirror finished
 Surfaces are finished to be dimensionally accurate and
parallel to several millionths of an inch
 In variable shape, size and quantity
 Measurement of
Linear Dimensions
Graduated measuring device

Non graduated
measuring device
 Micrometers
 External micrometer, standard one-inch size
with digital readout (photo courtesy of L. S.
Starret Co.)
 Calipers
 Two sizes of outside calipers (photo courtesy
of L. S. Starret Co.)
 Comparative instrument:
Mechanical Gauges Dial Indicator

 Mechanically magnify the deviation to permit observation

Dial indicator – converts and amplifiers the linear movement

of a contact pointer into the rotation of a dial

Measuring straightness, flatness, etc

 Front view shows dial and

graduated face; back view shows
cover plate removed (photo
courtesy of Federal Products Co.)
 Dial Indicator Setup to
Measure Runout
 As part is rotated about its center, variations in
outside surface relative to center are indicated
on the dial
 Measurement of Angles
 Bevel protractor with Vernier scale (courtesy
L. S. Starrett Co.)
 Surfaces

Nominal surface …

Actual Surface …
 Surface Technology
 Concerned with:
 Defining the characteristics of a surface
 Surface texture
 Surface integrity
 Relationship between manufacturing processes
and characteristics of resulting surface
 Metallic Part Surface
 Magnified cross section of a typical metallic part
surface
 Surface Texture
 Repetitive and/or
random deviations
from the nominal
surface of an object

 Surface Texture
elements:
1. Roughness
2. Waviness
3. Flaws
4. Lay
Roughness

Small, finely-spaced deviations from nominal surface

Determined by material characteristics and processes that formed the surface

Waviness
deviations of much larger spacing;
Waviness deviations occur due to work deflection, vibration, tooling, and similar factors
Roughness is superimposed on waviness

Flaws
irregularities that occur occasionally on the surface Includes cracks,
scratches, inclusions, and similar defects in the surface;
Although some flaws relate to surface texture, they also affect surface
integrity
 Lay
Pattern of the surface texture. The direction of the predominant
surface pattern usually visible in naked eye.
Surface Roughness
 Surface Roughness Equation
 Arithmetic average (AA) based on absolute
values of deviations, and is referred to as
average roughness
Lm
y
Ra = ∫ dx
0 Lm

where R a = average roughness; y = vertical

deviation from nominal surface (absolute
value); and L m = specified distance over
which the surface deviations are measured
 Surface Roughness
Specification
 Surface texture symbols in engineering
drawings: (a) the symbol, and (b) symbol with
identification labels
 Surface Integrity

Why?
• These changes may have affected the material's mechanical properties

• Material may have a metallurgical change beneath the surface that has
undergone processing

study and control of this subsurface layer and the changes in it that
occur during processing which may influence the performance of the
finished part or product
 Surface changes caused by
energy processing
mechanical energy can also cause residual stresses,
work hardening, and cracks in the surface layers

 Mechanical energy
 Thermal energy
 Chemical energy
 Electrical energy
 Mechanical Energy

 Residual stresses in subsurface layer

 Example: bending of sheet metal
 Cracks - microscopic and macroscopic
 Example: tearing of ductile metals in machining
 Voids or inclusions introduced mechanically
 Example: centerbursting in extrusion
 Plastic deformation
 Example: strain hardening of new surface in
machining
 Thermal Energy
 Metallurgical changes (recrystallization, grain size changes, phase changes at surface)
 Re-deposited or re-solidified material (e.g., welding or casting)
 Heat-affected zone in welding (includes some of the metallurgical changes listed above)
 Hardness changes

Chemical Energy
 Intergranular attack
 Absorption of certain elements in metal surface
 Chemical contamination

Electrical Energy
 Changes in conductivity and/or magnetism
 Craters resulting from short circuits during certain electrical processing
techniques such as arc welding
Measurement of surfaces:

• Surface Roughness

• Stylus Instrument –Use stylus

• Optical Techniques – Use light reflectance
 Stylus
 Electronic devices, a cone-shaped diamond
stylus is traversed across test surface at slow
speed
 As the stylus head is traversed horizontally, it
also moves vertically to follow the surface
deviations
 The vertical movement is converted into an
electronic signal that can be displayed as
 Profile of the actual surface
 Average roughness value
Stylus traversing surface