A general geometric framework is developed to quantify the structure of pos
itional tolerance evaluation. The data graph, overlay graph, and configurat
ion framework of a feature set is defined and used in the evaluation of pos
itional tolerance. Two functionals based on the configuration framework are
introduced and lead to the development of optimal matings. The configurati
on functional quantifies the amount of "turning" the framework will allow w
hile satisfying the mating condition, while the mating functional is used t
o assess optimal mating conditions. A constructive geometric procedure is u
sed to develop the configuration and mating functionals for a given feature
Vector and tolerance specifications. Numerical examples are used to illust
rate the form of the functionals and the procedures involved in the analysi
s. (C) 2000 Elsevier Science S.A. All rights reserved.