Lesson 1 of 12: The Major Principles
This 70 minute CD-ROM or DVD covers the major principles of geometric tolerancing. While tolerancing a simple 2-part assembly, Jim Meadows discusses the following topics:
Plus and Minus Tolerancing as it Relates to Profile and Position Tolerancing
Converting from Plus and Minus to Position Tolerancing to Avoid Ambiguities
Selecting Datum Features
Tolerancing Datum Features
General Rules of Tolerancing
Calculating Geometric Tolerances
Worst Case Boundaries for Tolerancing Analysis
Minimum Wall Thickness Calculations
Maximum and Least Material Conditions
Virtual and Resultant Conditions
Basic Dimensions and Where Their Tolerances Come From
How to Tolerance without Too Much Symbology

Lesson 2 of 12: Tolerancing Mating Parts in a Rotating Assembly
This 63 minute CD-ROM or DVD is a powerful learn-while-doing training session.
While tolerancing a crankshaft and coupling assembly, Mr. Meadows discusses the following topics:
Criteria for Optimum Datum Feature Selection
Form Controls for Assembly and Inspection Repeatability
Orientation Controls for Datum Feature Interrelationships
The Definition and Use of Positional Controls
How to Calculate and Distribute Tolerances throughout an Assembly
Tolerancing for Assemblability and Balance
The Difference between Bonus Tolerance and Pattern Shift
The Effect of Maximum Material Condition Symbols after Datum Features of Size and Uniformity of Assembly Airspace and Balance in a Rotating Assembly
Tolerancing Threaded Holes and the Use and Inspection of Projected Tolerance Zones
What the Geometric Characteristics Really Control


Lesson 3 of 12: Direct vs. Indirect Datum Structures
This 50 minute CD-ROM or DVD explores various datum structures and their effect on the availability of tolerances while tolerancing a three-part assembly. Topics discussed include
Direct vs. Indirect Functional Relationships
Tolerancing for Producibility and Functionality
The Goal of Datums in Inspection and Assembly
How to Choose between Datum Structures
How to Mathematically Calculate the Feasibility of Various Datum Schemes
Consistency in Geometric Controls from Part to Part in an Assembly
Weighing One Geometric Control Against Another for Suitability
How to Spot Similarities in Dissimilar Part Configurations
How to Lower Cost without Adversely Affecting Functionality and Ability to Assemble Mating Features
Comparison of Coaxiality Controls and How to Choose Between Them

Lesson 4 of 12: The Basics of Symbology
This 46 minute CD-ROM or DVD covers the meaning of, and various inspection procedures for, controls of form, orientation, profile, runout and location. It addresses the basic questions of: "What does it mean?" and "How do I inspect it?" Topics discussed include:
Straightness
Flatness
Perpendicularity
Parallelism
Angularity
Dimension Origin vs. Profile of a Surface
Circularity, Cylindricity, Circular Runout
Total Runout
Compound Datums and Concentricity

Lesson 5 of 12: Allowed vs. Actual Deviation from True Position: Bonus Tolerancing and Virtual Condition Boundaries
This 38 minute CD-ROM or DVD uses imagery and storytelling to convey the functional reasons behind the growth of geometric tolerance zones as features are produced at varying sizes. It covers the logic of the concept of Maximum Material Condition and the functional worst mating boundaries created and protected. This session is a combination of calculations to determine how far from perfect a feature has been produced versus how far from geometric perfection it may stray before it fails to function. Topics discussed include:
Calculating Bonus Tolerances
How to Read a Feature Control Frame to Determine Part Function
Calculating Actual Deviation from True Position
Determining if Features have Violated their Geometric Tolerances
Assessing Spherical Features for Compliance with Spherical Tolerance Zones
Protecting Virtual Condition Boundaries, and
How Additional Geometric Tolerances Derived from Feature Size Limits Relate to Worst Mating Condition Boundaries

Lesson 6 of 12: Profile, Flexible Parts and Datum Targets
This 74 minute CD-ROM or DVD uses a wide variety of complex geometric configurations to show the viewer how to choose datums and tolerancing schemes for sheet metal and plastic parts as well as other parts with multiple curvatures and angles. It discusses free state variation and restrained versus free state inspection requirements. Topics discussed include:
Profile of a Line
Profile of a Surface
Unilateral, Equal Bilateral and Unequal Bilateral Profile Tolerances
Varying Tolerances from Segment to Segment on Surfaces
Inspection Procedures for Profile Controls
Basic Dimensions for Size, Shape, Angle, and Location Toleranced by Profile
All Around and All Over Controls
Eliminating Tolerance Accumulation
Tolerancing Curved Mating Features for Fit
Measuring Parts as They Function
Implying a Manufacturing Sequence
Simultaneous vs. Separate Gaging Requirements
Pattern Shift with Simultaneous Requirements
Orienting all Part Features to Each Other
Amoebae Shaped Parts
Fixturing and Stabilizing Parts in Presses
Patterns of Features as Datums
Compound Pattern Datums
Poka-yoke (Foolproofing)
Fixtures as Gages
Functional Gage Tolerancing
Datum Targets
Points, Lines and Areas
Dimension Origin Controls
Step Datums
Castings and Draft Angle
Sheet Metal/Complex Flexible Parts
Plastic Parts
Restrained vs. Free State Requirements
Boundary Concept
Automobile Panels
P.C. Boards

Lesson 7 of 12: Tolerancing Fixed Fastener Assemblies and Calculating Boundaries
This 52 minute CD-ROM or DVD helps the viewer to become comfortable with calculating geometric tolerances for mating features in fixed fastener assemblies. It shows all pertinent formulas and relates the process of part tolerancing and geometric control sequencing to manufacturing and gaging procedures. As with almost every session in this series, this session is completely applications-based. The participant learns by doing. Topics discussed include:
Calculating Geometric Tolerances for Mating Features in Assemblies
How to Relate the Job of Tolerancing to Manufacturing Procedures
How to Design Gages to Inspect Geometric Part Definitions
How Visualizing Gages Can Help to Understand Functionality
How to Read Feature Control Frames as though they were Sentences Describing How Parts Function
Shifting Patterns of Mating Features vs. Growing Tolerance Zone Sizes
Fixed Fastener Situations and How to Tolerance them
How to Rework Parts to bring Them into Tolerance

Lesson 8 of 12: Tolerancing Floating Fastener Assemblies With Two Single-Segment Positional Controls
This 48 minute CD-ROM or DVD focuses on the logic of datum feature selection and the cost-effective use of multi-level positional controls. Using a floating fastener assembly with radial hole patterns, Mr. Meadows introduces the methodical process of applying deductive reasoning to optimize geometric product definition. Topics discussed include:
What a Floating Fastener Situation Is
How to Calculate the Tolerances
Selecting the Best Datum Features
The Four Criteria for Datum Selection
Line Geometry/Relating Axes Radially to a Datum Axis for Angle and Distance
Considering All Spatial Degrees of Freedom
Rotation and Translation of Axes
Implied vs. Specified Datums
Datums for Ease of Part Setup during Inspection
The Logical Selection of Each Geometric Control and Datum Feature for Ease of Manufacture
Geometric Definition for a Sensible Manufacturing Sequence
Datum Feature Accessibility
Refining and Optimizing Geometric Controls for Greater Yields
The Two-Step Approach for Functionality and Cost Reduction
Datum Features at Maximum Material Condition
Equal vs. Unequal Airspace in Assemblies
Two Single-Segment Positional Controls
Moving Tolerance Zones within Stationary Tolerance Zones
Composite vs. Two Single-Segment Positional Controls
Separately Verifiable Controls
Zero Positional Tolerancing at Maximum Material Condition

Lesson 9 of 12: Tolerancing Complex Assemblies with Multi-Level Geometric Controls and Varying Datum Structures
This 59 minute CD-ROM or DVD focuses on the application of appropriate datum structures and geometric tolerances to a part that is both challenging and realistic. Participants are treated to a detailed analysis of the optimal use of datums and geometric controls that escalate in sophistication as the product definition progresses from beginning to end.
Form, orientation and location controls are added in what is determined to be the most functional and producible approach possible. Tolerances are calculated and distributed between three parts in this assembly. Geometric controls are converted to multi-level/two single-segment controls for cost reduction and compatible mating conditions. Tolerances are analyzed and minimum wall thicknesses protected.
New formulas are introduced for analysis and worst case boundaries for the first time in this session. Datum structures are changed for direct tolerancing relationships throughout the assembly for ease of manufacture, functional inspection and to produce the greatest yield of functional parts. This session is jam-packed with new information and reinforcement of previously discussed concepts. Exciting and fun!
[NOTE: This CD-ROM or DVD discusses some of the most critical and difficult concepts of geometric definition. We recommend viewing it in sequence to avoid confusion.]
Topics discussed are:
Varying Datum Structures
Multi-Level Geometric Controls
Projected Tolerance Zones for Threaded Holes
Manufacturing Sequencing through Geometric Symbology
Form, Orientation and Location Controls Properly Sequenced
Distributing Tolerances Throughout the Assembly
Pattern Shift with Datum Features at Maximum Material Condition
Tight Tolerances to Critical Datums and Looser Tolerances to Less Critical Datums
Multiple Virtual Condition Boundaries
Minimum Wall Thickness Calculations
The Key Questions to Ask That Lead One to the Optimum Controls
Two Single-Segment Positional Controls vs. Composite Positional Tolerancing
Zero Positional Tolerancing at MMC
Linear Logic of Geometric Product Definition

Lesson 10 of 12: Composite vs. Two Single-Segment Controls for Position and Profile
This 63 minute CD-ROM or DVD addresses a wide variety of new and complex geometric principles found in the latest revision of ASME Y14.5M-1994. The most sweeping change in this new standard is the redefinition of Composite Tolerancing and the added concept of Two Single-Segment Controls for Position and their extension to the concept of Profile Tolerancing. This session devotes its attention to thoroughly explaining each control, the rules, the differences and how they can accomplish geometric control never before available. It also employs the deductive reasoning skills of participants to logically deduce the meaning of these controls on complex part configurations. Topics discussed include:
Composite Positional Tolerancing
Feature Relating Tolerance Zone Frameworks
Pattern Locating Tolerance Zone Frameworks
The Dreaded Hypotenuse Effect
Rotating Patterns of Tolerance Zones
Composite Tolerancing and Orientation Only Datums
Two Single-Segment Positional Controls
Tighter Tolerances of Distance to One Datum Only
The Essence of Position
How to Keep One Set-up for Multiple Controls
Position without Datums
The Relative Strength of Various Geometric Characteristics
Tolerance Zone Paths of Movement vs. Tolerance Zone Configurations
ASME Y14.5M-1994 vs. ANSI Y14.5M-1982
Deductive Reasoning on Complex Geometries
Radial Hole Patterns
Slots as Angular Orientation Datums
The Logic of Geometric Tolerancing
The Strict Rules of Composite Tolerancing
Centerplane Datums and Their Set-up for Simulation
The Essence of Profile
Profile All-Around
Composite Profile Tolerancing
Multiple Tolerance Zones for Irregular Features
Two-Single-Segment Profile Controls

Lesson 11 of 12: Converting from Plus And Minus To Composite Position and Wall Thickness Calculations
This 73 minute CD-ROM or DVD is an applications-based training session that uses a variety of assemblies and part geometric configurations to show participants how to convert from plus and minus tolerancing to Composite Positional Tolerancing. It also shows how to calculate functional and cost-saving geometric tolerances, then analyze the tolerances for clearance, interference and minimum wall thickness.
Topics discussed include:
The Ambiguity of Plus and Minus tolerancing
Floating Fastener Situations
Establishing Functional Datum Features
Tighter Tolerances Between Features Within a Pattern than to the Datums
Converting from Plus and Minus to Composite Positional Tolerancing
Criteria for Datum Precedence and Usage
Tolerance Zone Descriptions
Material Condition Symbols
What Each Level of Control Tolerances
Calculating and Testing Tolerances
Bonus Tolerances
Determining Geometric Tolerances and Calculating Minimum Wall Thickness
Setting Minimum Wall Thickness, then Calculating Pattern Locating Geometric Tolerances from Them
Zeroing Out a Composite Positional Control for Greater Yields
Redistributing Tolerances Between Size Limits and Geometric Controls
The Effect of Size on Form and Wall Thickness
Angular Tolerances and How They Effect Wall Thickness
Optimizing Complex Controls Without Changing the Worst Case Boundaries
Differences Between Composite Position and Two-Single-Segment Positional Controls
Problem and Causal Statements
Sequential Controls of Form and Orientation for Geometric Definition and Problem Solving
Making Tolerance Analysis Easy
Positional Coaxiality
Centerplane Datums
Position With and Without Datums

Lesson 12 of 12: Complex Tolerancing Using Various Datum Structures
This 73 minute CD-ROM or DVD explores a wide variety of datum structures for ease of set-up in manufacturing and inspection and optimal interrelationships of functional features. It discusses patterns of holes used to create datum reference frames. It demonstrates the enormous power of creating simultaneous gaging requirements.
Participants are taught to use geometric controls and datum structures to dimension
and tolerance complex curved surfaces that mate with other complex curvatures, while additional features such as holes and shafts must simultaneously mate.
Centerplane and centering mating features on parts in an assembly are also shown. All concepts are reinforced through problem solving using a logical approach to geometric tolerancing. Topics discussed include:
Profile of a Surface on an Irregular Surface
Positioning of Hole Patterns
Datum Targets
Direct vs. Indirect Relationships
Patterns of Holes as Datum Features
Virtual Condition Boundaries
Unilateral Profile Tolerancing All-Around Controls
Centroids of Revolution of Groups of Features
Methods of Profile Inspection
Secondary and Tertiary Datum Features of Size
The Relative Power of Various Datum Structures
Angular Orientation
Compound Datum Features of Size vs. Secondary and Tertiary Datum Holes
Datum Structuring for Ease of Inspection
Fixturing and Gaging Visualization Techniques for Geometric Understanding
Immobilizing all Spatial Degrees of Part Freedom
The Power of Datum Precedence
Gage Pin Configurations/Cylindrical vs. Diamond
Compound Planar Datum Features
Coplanarity
Simultaneous Gaging Requirements to Gain Direct Geometric Relationships
Creative Tolerancing Schemes for Ease of Inspection and Optimal Power of Interrelationship
Indicating Specific Features for Clarity of Control
Pattern Shift Because of Datum Features Referenced at Maximum Material Condition
Separate Gaging Requirements
Sequential Creation of Geometric Definitions
Interrelating All Datum Features Before Using Them in Tandem