W e’ve been led to believe that more is better—more speed, more filled seats per flight, more miles per gallon, ance is zero at MMC. Figure 2: Non-Zero and Zero Tolerance Part Acceptance Virtual condition remains unchanged. Hole Ø Total Tol. Ø V Cond. Hole Ø Total Tol. Ø V Cond. LMC .270 .020 .250 LMC .270 .020 .250 more inspection tolerance and so on. (See the example in .269 .019 .250 .269 .019 .250 With tolerances, one might think that figure 1.) .268 .018 .250 .268 .018 .250 .267 .017 .250 .267 .017 .250 a large value in a feature-control frame As you can see, the .266 .016 .250 .266 .016 .250 is better than a small value. When using change to zero toler- Accept .265 .015 .250 .265 .015 .250 .264 .014 .250 .264 .014 .250 geometric dimensioning and tolerancing ance isn’t difficult. .263 .013 .250 .263 .013 .250 (GD&T) and talking about position tol- This little change .262 .012 .250 .262 .012 .250 .261 .011 .250 Accept .261 .011 .250 erances, the greatest allowable variation allows acceptance of MMC .260 .010 .250 .260 .010 .250 actually comes from the application of the full range of parts Reject .259 .259 .009 .250 Reject .258 .258 .008 .250 zero tolerance on a maximum material that will assemble Reject .257 .257 .007 .250 condition (MMC) basis. and meet the hole Reject .256 .256 .006 .250 Reject .255 .255 .005 .250 Put in simple terms, tolerance is air. size and location tol- Reject .254 .254 .004 .250 We can see this demonstrated by the for- erance. Reject .253 .253 .003 .250 Reject .252 .252 .002 .250 mula shown in the ASME Y14.5 (GD&T) Virtual condition Reject .251 .251 .001 .250 standards, where tolerance = hole – fas- remains unchanged Reject .250 MMC .250 .000 .250 tener, or T = H – F. for both methods. As an example, let’s assume a hole Caution: Do not apply regardless of fea- virtual condition (absolute policy), the use diameter of 0.260 – 0.270 and a fastener ture size with zero tolerance. Remember, of zero tolerance on the work piece is the diameter of 0.250. Both H and F will be all the tolerance comes from the bonus preferred combination. the MMC value of the respective features. and with no bonus you get no tolerance If a virtual condition functional gage So, H (0.260) – F (0.250) = T (0.010). Theat all. is used with the toleranced method, the problem with this method is that holes less Manufacturing may not warm up to this gage will accept parts with holes smaller than 0.260 (down to 0.250) aren’t allowed idea right away, but when they achieve than the specified MMC, provided that regardless of their location. greater tolerance with this method, they they’re located within the acceptable Now this is where zero is more. We’re should come around, and may even location. These are parts that would have going to modify the formula slightly to request it. been rejected, based on size check, per the read T(0) = H – F. Now we have a value of In the example seen in figure 2, for drawing. zero that the MMC hole minus the MMC the non-zero toleranced part (left side of There are circumstances where this fastener must satisfy: H(0.250) – F(0.250)graphic), the range of acceptance falls off method is not necessarily the best choice. =T(0). at the MMC hole size, which is far short However, for most conventional assem- In other words, we have modified the of the virtual condition. Any hole size blies zero tolerancing will work well. MMC hole size to equal the MMC fastener less than 0.260, regardless of its location, If you want to do more with less, try diameter. The new hole size is a 0.250 should be rejected. doing the most with nothing (zero, that is). – 0.270 diameter and the location toler- The range for the zero tolerance part (right side of the About the author Figure 1: Modified MMC Hole Size = MMC Fastener Diameter graphic) is equal to the James Keith is a member of the ASME virtual condition and Y14.5 Standards Committee, and a consul- will allow acceptance tant and instructor with Crucial Knowl- of all parts that meet edge (www.crucial-knowledge.info), the hole size and loca- based in Wichita, Kansas. QD tion requirements. When using func- tional gaging (ASME Comments Y14.43) designed for Send feedback to comments@qualitydigest.com. verification based on Quality Digest/March 2006 55