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DIMENSIONAL
ENGINEERING
Based on the ASME Y14.5M-1994
Dimensioning and Tolerancing
Standard
Compiled & Edited

Velmurugan Sivaraman
Velmurugan Sivaraman 1 2/25/2018

What is dimension?
Dimension (Latin, "measured out") is a
parameter or measurement required to
define the characteristics of an object—i.e.
length, width, and height or size and
shape.
Types
2nd dimensional
For example, locating a point on a plane
requires two parameters — latitude and
longitude.
3rd dimensional
Locating the exact position of an aircraft in
flight (relative to the Earth) requires another
dimension (altitude) with latitude and
longitude.
4th dimension
aircraft's estimated "speed" may be
calculated from a comparison between the
times associated with any two positions.
Angle of projections

What is tolerance?
What is tolerance?
It is almost impossible to maintain the strict
degree of accuracy as listed on a plan. To
accommodate this, it is normal to display
measurements with a plus or minus (+/-)
tolerance which allows for some margin of
error.

Geometric standard deviation
Describes how spread out are a set of numbers

whose preferred average is the geometric mean

Tolerances of
Form
Straightness Flatness
Circularity Cylindricity

Straightness (Flat
Surfaces)
0.5 0.1
25 +/-0.25
0.1 Tolerance
0.5 Tolerance
Straightness is the condition where an element of a

surface or an axis is a straight line
Straightness
(Flat Surfaces)
0.5 Tolerance Zone
25.25 max
24.75 min
0.1 Tolerance Zone
In this example each line element of the surface must lie within a
tolerance zone defined by two parallel lines separated by the specified
tolerance value applied to each view. All points on the surface must lie
within the limits of size and the applicable straightness limit.
The straightness tolerance is applied in the view where the elements to be

controlled are represented by a straight line.
Straightness
(Surface Elements)
0.1
0.1 Tolerance Zone
MMC
0.1 Tolerance Zone
MMC
0.1 Tolerance Zone
MMC
In this example each longitudinal element of the surface must lie within a
tolerance zone defined by two parallel lines separated by the specified tolerance
value. The feature must be within the limits of size and the boundary of perfect
form at MMC. Any barreling or waisting of the feature must not exceed the size
limits of the feature.
Outer Boundary = Actual Feature Size + Straightness Tolerance
Straightness (MMC)
15
14.85
0.1 M
0.1 Diameter
15
Tolerance Zone
(MMC)
15.1 Virtual Condition
14.85 0.25 Diameter

(LMC) Tolerance Zone
15.1 Virtual Condition

In this example the derived median line of the feature’s actual local size must lie
within a tolerance zone defined by a cylinder whose diameter is equal to the
specified tolerance value at MMC. As each circular element of the feature departs
from MMC, the diameter of the tolerance cylinder is allowed to increase by an
amount equal to the departure from the local MMC size. Each circular element of
the feature must be within the specified limits of size. However, the boundary of
perfect form at MMC can be violated up to the virtual condition diameter.
Virtual Condition = MMC Feature Size + Straightness Tolerance

Flatness
0.1
25 +/-0.25
0.1 Tolerance Zone
0.1 Tolerance Zone
25.25 max
24.75 min
In this example the entire surface must lie within a tolerance zone
defined by two parallel planes separated by the specified tolerance
value. All points on the surface must lie within the limits of size and
the flatness limit.
Flatness is the condition of a surface having all elements in one plane.

Flatness must fall within the limits of size. The flatness tolerance must
be less than the size tolerance.

Circularity
(Roundness)
0.1
90
0.1
90
0.1 Wide Tolerance Zone
In this example each circular element of the surface must lie within a
tolerance zone defined by two concentric circles separated by the
specified tolerance value. All points on the surface must lie within the
limits of size and the circularity limit.
Circularity is the condition of a surface where all points of the surface

intersected by any plane perpendicular to a common axis are equidistant
from that axis. The circularity tolerance must be less than the size tolerance

Cylindricity
0.1
0.1 Tolerance Zone
MMC
In this example the entire surface must lie within a tolerance zone
defined by two concentric cylinders separated by the specified tolerance
value. All points on the surface must lie within the limits of size and the
cylindricity limit.
Cylindricity is the condition of a surface of revolution in which all points are

equidistant from a common axis. Cylindricity is a composite control of form
which includes circularity (roundness), straightness, and taper of a cylindrical
feature.

Tolerances of
Orientation
Angularity
Perpendicularity
Parallelism

Angularity
(Feature Surface to Datum Surface)
20 +/-0.5
0.3 A
o
30
A
19.5 min 20.5 max
o o
30 30
0.3 Wide 0.3 Wide

A Tolerance
A Tolerance
Zone Zone
The tolerance zone in this example is defined by two parallel planes
oriented at the specified angle to the datum reference plane.
Angularity is the condition of the planar feature surface at a specified angle
(other than 90 degrees) to the datum reference plane, within the specified
tolerance zone.
Angularity
(Feature Axis to Datum Surface)
NOTE: Tolerance applies
to feature at RFS
0.3 A
0.3 Circular
0.3 Circular Tolerance Zone
Tolerance Zone
o
60
A A
The tolerance zone in this example is defined by a cylinder equal to the
length of the feature, oriented at the specified angle to the datum
reference plane.
Angularity is the condition of the feature axis at a specified angle (other than
90 degrees) to the datum reference plane, within the specified tolerance
zone
Angularity
(Feature Axis to Datum Axis)
NOTE: Feature axis must lie within tolerance zone cylinder
0.3 A
NOTE: Tolerance
applies to feature
at RFS
A 0.3 Circular
0.3 Circular Tolerance Zone
Tolerance Zone
45 o
Datum Axis A

length of the feature, oriented at the specified angle to the datum
reference axis.
Angularity is the condition of the feature axis at a specified angle (other than
90 degrees) to the datum reference axis, within the specified tolerance zone.

Perpendicularity
0.3 A
A
0.3 Wide 0.3 Wide Tolerance
Tolerance Zone Zone
A A

oriented perpendicular to the datum reference plane.
Perpendicularity is the condition of the planar feature surface at a right
angle to the datum reference plane, within the specified tolerance
zone. 2/25/2018
Velmurugan Sivaraman 21
Perpendicularity
0.3 Diameter
Tolerance Zone

to feature at RFS
C
0.3 Circular
Tolerance Zone 0.3 Circular
Tolerance Zone
0.3 C
The tolerance zone in this example is defined by a cylinder equal to

the length of the feature, oriented perpendicular to the datum
reference plane.
Perpendicularity is the condition of the feature axis at a right angle to
the datum reference plane, within the specified tolerance zone.

Parallelism
0.3 A
25 +/-0.5
0.3 Wide Tolerance Zone 0.3 Wide Tolerance Zone
25.5 max 24.5 min
A A
oriented parallel to the datum reference plane.
Parallelism is the condition of the planar feature surface equidistant at all
points from the datum reference plane, within the specified tolerance zone.
Parallelism
NOTE: The specified tolerance

does not apply to the orientation
of the feature axis in this
direction

to feature at RFS 0.3 Wide Tolerance
Zone
0.3 A
A A
oriented parallel to the datum reference plane.
Parallelism is the condition of the feature axis equidistant along its length
from the datum reference plane, within the specified tolerance zone.
Parallelism
(Feature Axis to Datum Surfaces)
0.3 Circular
Tolerance Zone

to feature at RFS
0.3 Circular
Tolerance Zone 0.3 Circular
Tolerance Zone
0.3 A B
A A
length of the feature, oriented parallel to the datum reference planes.
from the two datum reference planes, within the specified tolerance zone.
Parallelism
(Feature Axis to Datum Axis)
The tolerance zone in this example
is defined by a cylinder equal to the
length of the feature, oriented
parallel to the datum reference axis.

to feature at RFS
0.1 Circular
Tolerance Zone 0.1 A
0.1 Circular Datum Axis A

Tolerance Zone
from the datum reference axis, within the specified tolerance zone.
Tolerances
of Profile
Profile of a Line
(ASME Y14.5M-1994, 6.5.2b)
Profile of a Surface
(ASME Y14.5M-1994, 6.5.2a)

Profile of a Line
The profile tolerance zone in this example is defined by two parallel
lines oriented with respect to the datum reference frame. The profile
tolerance zone is free to float within the larger size tolerance and
applies only to the form and orientation of any individual line
element along the entire surface.

Location &
0.5 A Orientation
0.1 Form Only
25
25.25
24.75
Composite Profile of Two Coplanar

Surfaces w/o Orientation Refinement
0.5 A Location
0.1 A Form & Orientation
25

25.25
A 0.1 Wide Tolerance Zone
24.75
Composite Profile of Two Coplanar

Surfaces With Orientation Refinement
Tolerances
of Location
True Position
Concentricity

Symmetry
Coordinate vs Geometric
Tolerancing Methods
8.5 +/- 0.1
1.4 A B C
8.5 +/- 0.1
Rectangular Circular Tolerance
Tolerance Zone Zone
10.25 +/- 0.5 10.25

B
10.25 +/- 0.5 10.25 C
Coordinate Dimensioning Geometric Dimensioning

Increased Effective Tolerance
+/- 0.5
1.4
+/- 0.5
Rectangular Tolerance Zone Circular Tolerance Zone
Circular Tolerance Zone

57% Larger
Tolerance Zone
Rectangular Tolerance Zone

Positional Tolerance Verification
(Applies when a circular tolerance is indicated)
X
Z
Feature axis actual
location (measured)
Positional
tolerance zone
Y
cylinder
Actual feature Feature axis true
boundary position (designed)
Formula to determine the actual radial

position of a feature using measured
coordinate values (RFS)
Z= X2 + Y2
Z positional tolerance /2
Z = total radial deviation

Positional Tolerance Verification
(Applies when a circular tolerance is indicated)
X
Z
Feature axis actual
location (measured)
Positional
tolerance zone
Y
cylinder
Actual feature Feature axis true
boundary position (designed)
Formula to determine the actual radial position of a

feature using measured coordinate values (MMC)
Z = X2 + Y2
Z +( actual - MMC)
2
= positional tolerance
Z = total radial deviation
X 2 = “X” measured deviation
Y 2 = “Y” measured deviation
Bi-directional True Position
Rectangular Coordinate Method
2X 1.5 A B C
2X 0.5 A B C
C A
10
B As Shown
10 35 on Drawing
2X 6 +/-0.25
Means This:
True Position Related
1.5 Wide to Datum Reference Frame
Tolerance
Zone Each axis must
lie within the
C 1.5 X 0.5
rectangular
tolerance
zone basically
located to the
10 datum
B reference
frame
10 35 0.5 Wide
Tolerance Zone

Bi-directional True Position
Noncylndrical Features (Boundary Concept)
2X 13 +/-0.25 2X 6 +/-0.25
1.5 M A B C 0.5 M A B C
BOUNDARY BOUNDARY
C A
10
B As Shown
10 35 on Drawing
5.75 MMC length of slot

Means This: -0.50 Position tolerance
Both holes must be within the size limits and no 5.25 maximum boundary
portion of their surfaces may lie within the area
described by the 11.25 x 5.25 maximum
boundaries when the part is positioned with 12.75 MMC width of slot
respect to the datum reference frame. The -1.50 Position tolerance
boundary concept can only be applied on an 11.25 Maximum boundary
MMC basis.
True position boundary related
to datum reference frame
90 o
10 A
10 35 B
Location (Concentricity)
Datum Features at RFS
6.35 +/- 0.05

0.5 A
A
15.95
15.90
As Shown on Drawing
Means This: Axis of Datum 0.5 Coaxial
Feature A Tolerance Zone
Derived Median Points of

Diametrically Opposed Elements
Within the limits of size and regardless of feature size, all median points
of diametrically opposed elements must lie within a Ø 0.5 cylindrical
tolerance zone. The axis of the tolerance zone coincides with the axis of
datum feature A. Concentricity can only be applied on an RFS basis.
Location (Symmetry)
Datum Features at RFS
6.35 +/- 0.05

0.5 A
A
15.95
15.90
As Shown on Drawing
Means This: Center Plane of 0.5 Wide
Datum Feature A Tolerance Zone
Derived Median
Points
Within the limits of size and regardless of feature size, all median points
of opposed elements must lie between two parallel planes equally
disposed about datum plane A, 0.5 apart. Symmetry can only be applied
on an RFS basis.
Tolerances
of Runout
Circular Runout
(ASME Y14.5M-1994, 6.7.1.2.1)
Total Runout
(ASME Y14.5M-1994 ,6.7.1.2.2)

Features Applicable
to Runout Tolerancing
Internal surfaces
constructed around a
datum axis
External surfaces
constructed around a
datum axis Angled surfaces
constructed around
a datum axis
Datum axis (established
from datum feature
Surfaces constructed
perpendicular to a
datum axis
Datum feature
Circular Runout
Total Circular runout can only be applied on an
Tolerance RFS basis and cannot be modified to MMC
or LMC.
Maximum Minimum
Full Indicator
Movement
Maximum Minimum
Reading Reading Measuring position #1
(circular element #1)
-
0
+
Full Part
Rotation
Measuring position #2
(circular element #2)
When measuring circular runout, the indicator must be reset to zero at each measuring
position along the feature surface. Each individual circular element of the surface is
independently allowed the full specified tolerance. In this example, circular runout can be
used to detect 2-dimensional wobble (orientation) and waviness (form), but not 3-
dimensional characteristics such as surface profile (overall form) or surface wobble (overall
orientation).
Circular Runout
(Angled Surface to Datum Axis)
0.75 A
50 +/-0.25
o o
50 +/- 2
As Shown
on Drawing
Means This: The tolerance zone for any individual circular

element is equal to the total allowable movement
of a dial indicator fixed in a position normal to
Allowable indicator the true geometric shape of the feature surface
reading = 0.75 max. when the part is rotated 360 degrees about the
( Full Indicator
Movement ) datum axis. The tolerance limit is applied
independently to each individual measuring
-
0
+ position along the feature surface.
Collet or Chuck
When measuring circular
runout, the indicator must
be reset when repositioned
Datum axis A
along the feature surface.
360 o Part
Rotation
NOTE: Circular runout in this example only

Velmurugan Sivaraman 42the 2-dimensional circular elements
controls 2/25/2018
Single circular (circularity and coaxiality) of the angled feature
element surface not the entire angled feature surface
Total Runout
Total Total runout can only be applied on an
Tolerance RFS basis and cannot be modified to MMC
or LMC.
Maximum Minimum
Full Indicator
Movement
Maximum Minimum
Reading Reading
+
0
-
Indicator Full Part

Path Rotation
+
0
-
When measuring total runout, the indicator is moved in a straight line along the feature
surface while the part is rotated about the datum axis. It is also acceptable to measure total
runout by evaluating an appropriate number of individual circular elements along the
surface while the part is rotated about the datum axis. Because the tolerance value is
applied to the entire surface, the indicator must not be reset to zero when moved to each
measuring position. In this example, total runout can be used to measure surface profile
(overall form) and surface wobble (overall orientation).
Total Runout (Angled
Surface to Datum Axis)
0.75 A
A
50 +/-0.25
o o
50 +/- 2
As Shown
on Drawing
Means This: The tolerance zone for the entire angled surface
is equal to the total allowable movement of a dial
indicator positioned normal to the true geometric
When measuring total runout, the
indicator must not be reset when shape of the feature surface when the part is
repositioned along the feature rotated about the datum axis and the indicator is
surface. moved along the entire length of the feature
-
0
+ surface.
Allowable indicator reading = 0.75 max.

-
0
+
(applies to the entire feature surface)
Collet or Chuck
Full Part Datum axis A

Rotation
NOTE: Unlike circular runout, the use of total runout

Velmurugan Sivaraman 44 3-dimensional composite control
will provide 2/25/2018
of the
cumulative variations of circularity, coaxiality,
angularity, taper and profile of the angled surface
Total Runout
(Surface Perpendicular to Datum Axis)
0.75 A
10
35
50 +/-0.25
A As Shown
on Drawing
Means This: The tolerance zone for the portion of the feature surface
indicated is equal to the total allowable movement of a dial
indicator positioned normal to the true geometric shape of the
feature surface when the part is rotated about the datum axis
and the indicator is moved along the portion of the feature
surface within the area described by the basic dimensions.
-
0
+
When measuring total runout, the indicator
10 -
0
+ must not be reset when repositioned along
the feature surface.
35 Allowable indicator reading = 0.75 max.

(applies to portion of feature surface indicated)
Full Part
Rotation Datum axis A
NOTE: The use of total runout in this example

will provide composite control of the cumulative
Velmurugan Sivaraman 45 of perpendicularity (wobble)
variations 2/25/2018
and
flatness (concavity or convexity) of the feature
surface.
Fixed and
Floating
Fastener
Exercises

Floating Fasteners
In applications where two or more mating details are assembled, and all parts
have clearance holes for the fasteners, the floating fastener formula shown
below can be used to calculate the appropriate hole sizes or positional
tolerance requirements to ensure assembly. The formula will provide a “zero-
interference” fit when the features are at MMC and at their extreme of
positional tolerance
2x M10 X 1.5
(Reference)
General Equation Applies to
Each Part Individually
A H=F+T or T=H-F
B H= Min. diameter of clearance hole
F= Maximum diameter of fastener
T= Positional tolerance diameter
2x 10.50 +/- 0.25

?.? M Calculate Required
Positional Tolerance
T=H-F
H = Minimum Hole Size = 10.25
F = Max. Fastener Size = 10
T = 10.25 -10
A
T = ______
remember: the size tolerance must be
??.?? added to the calculated MMC hole size to
Calculate 2x +/- 0.25
obtain the correct nominal value.
Nominal Size
0.5 M
H = F +T
T = Positional Tolerance = 0.50
B H = 10 + 0.50
Velmurugan Sivaraman 47 H = ______ 2/25/2018
Floating Fasteners
In applications where two or more mating details are assembled, and all parts
have clearance holes for the fasteners, the floating fastener formula shown
below can be used to calculate the appropriate hole sizes or positional
tolerance requirements to ensure assembly. The formula will provide a “zero-
interference” fit when the features are at MMC and at their extreme of
positional tolerance
2x M10 X 1.5
(Reference)
General Equation Applies to
Each Part Individually
A H=F+T or T=H-F
B H= Min. diameter of clearance hole
F= Maximum diameter of fastener
2x 10.50 +/- 0.25

0.25 M Calculate Required
Positional Tolerance
T=H-F
H = Minimum Hole Size = 10.25
T = 10.25 -10
A
T = 0.25
remember: the size tolerance must be
Calculate 2x 10.75 +/- 0.25 added to the calculated MMC hole size to
Nominal Size obtain the correct nominal value.
0.5 M
H = F +T
T = Positional Tolerance = 0.5
B H= 10 + .5
Velmurugan Sivaraman 48 H= 10.5 Minimum
2/25/2018
REMEMBER!!! All Calculations Apply at MMC

Fixed Fasteners
In fixed fastener applications where two mating details have equal positional
tolerances, the fixed fastener formula shown below can be used to calculate
the appropriate minimum clearance hole size and/or positional tolerance
required to ensure assembly. The formula provides a “zero-interference” fit
when the features are at MMC and at their extreme of positional tolerance.
(Note that in this example the positional tolerances indicated are the same for
both parts.)
APPLIES WHEN A PROJECTED TOLERANCE ZONE IS USED

2x M10 X 1.5
(Reference)
General Equation Used When

Positional Tolerances Are Equal
10 A H=F+2T or T=(H-F)/2
H= Min. diameter of clearance hole
B F= Maximum diameter of fastener
remember: the size tolerance

Calculate Required must be added to the calculated
Clearance Hole Size. 2x ??.?? +/- 0.25
MMC size to obtain the correct
0.8 M nominal value.
A
H = F + 2T
Nominal Size
F = Max. Fastener Size = 10.00
2X M10 X 1.5 (MMC For Calculations) T = Positional Tolerance = 0.80
0.8 M P 10
H = 10.00 + 2(0.8)
H = _____

Surface finish
Surface finish is a characteristic of any machined surface. It is
sometimes called surface texture or roughness. The design
engineer is usually the person that decides what the surface
finish of a work piece should be. They base their reasoning on
what the work piece is supposed to do.

Types of Surface finish?

*
Surface Texture Analysis of
cylinder bore


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DIMENSIONAL

Compiled & Edited

Velmurugan Sivaraman 1 2/25/2018

Velmurugan Sivaraman 3 2/25/2018

Velmurugan Sivaraman 7 2/25/2018

Describes how spread out are a set of numbers

Velmurugan Sivaraman 8 2/25/2018

Velmurugan Sivaraman 9 2/25/2018

Straightness is the condition where an element of a

0.1 Tolerance Zone

The straightness tolerance is applied in the view where the elements to be

0.1 Tolerance Zone

0.1 Tolerance Zone

0.1 Tolerance Zone

15.1 Virtual Condition

14.85 0.25 Diameter

15.1 Virtual Condition

Virtual Condition = MMC Feature Size + Straightness Tolerance

0.1 Tolerance Zone

0.1 Tolerance Zone

Flatness is the condition of a surface having all elements in one plane.

Velmurugan Sivaraman 14 2/25/2018

0.1 Wide Tolerance Zone

Circularity is the condition of a surface where all points of the surface

Velmurugan Sivaraman 15 2/25/2018

0.1 Tolerance Zone

Cylindricity is the condition of a surface of revolution in which all points are

Velmurugan Sivaraman 16 2/25/2018

Velmurugan Sivaraman 17 2/25/2018

0.3 Wide 0.3 Wide

NOTE: Feature axis must lie within tolerance zone cylinder

The tolerance zone in this example is defined by a cylinder equal to the

Velmurugan Sivaraman 20 2/25/2018

The tolerance zone in this example is defined by two parallel planes

NOTE: Tolerance applies

The tolerance zone in this example is defined by a cylinder equal to

Velmurugan Sivaraman 22 2/25/2018

0.3 Wide Tolerance Zone 0.3 Wide Tolerance Zone

25.5 max 24.5 min

NOTE: The specified tolerance

NOTE: Tolerance applies

NOTE: Tolerance applies

NOTE: Tolerance applies

0.1 Circular Datum Axis A

Velmurugan Sivaraman 27 2/25/2018

Velmurugan Sivaraman 28 2/25/2018

0.1 Wide Tolerance Zone

Composite Profile of Two Coplanar

0.1 Wide Tolerance Zone

A 0.1 Wide Tolerance Zone

Composite Profile of Two Coplanar

Velmurugan Sivaraman 31 2/25/2018

10.25 +/- 0.5 10.25

10.25 +/- 0.5 10.25 C

Coordinate Dimensioning Geometric Dimensioning

Rectangular Tolerance Zone Circular Tolerance Zone

Circular Tolerance Zone

Velmurugan Sivaraman 32 2/25/2018

Formula to determine the actual radial

Velmurugan Sivaraman 33 2/25/2018

Formula to determine the actual radial position of a

Velmurugan Sivaraman 35 2/25/2018

5.75 MMC length of slot