True Position (Boundry)

[[Cl...]]

Beneath the true position callout it states; "Boundry" I've never seen that before?

[[Ro...]]

It means the result can't violate the virtual/resultant condition of the feature at it's worst case.

Basically, they want to make sure that the feature at it's worst case (smallest & largest) doesn't violate the boundary. I almost always use curve to check this, as checking it as a diameter, for example, is using a fitting method to determine the size and center, and doesn't check the surface boundary itself.

Essentially, you're checking the position of the feature AND it's profile. For a hole, I'd check the position as normal and also check the profile of the hole to it's virtual/resultant condition.

[[Cl...]]

This is an ID, six sided hex.(a screw head).

[[Ro...]]

What's the callout, including any datums and what they constrain?

[[Cl...]]

It's a screw, the top of the head is Datum -A- and the thread major is Datum -B-, (no tertiary for clocking). The position is for the hex ID. It doesn't state 3x, but I'm assuming that's what they want. So .004 diametric T/P of the hex width(s) to -A- &-B- @ MMC.

[[Ro...]]

What's the nominal size and size tolerance for the hex widths?

[[Cl...]]

.1382 + .0019 /- .000

[[Ro...]]

.1342 is your virtual condition (.1382 MMC -.004)
.1441 is your resultant condition (.1401 LMC +.004)

Here's how I would check it...
1) Create your Base Alignment. Spatial -A- and Z origin, -B- X&Y origin, and clock to one of the flats of the hex for rotation and to fully constrain the alignment.
2) Section the hex and create 6 curves, one for each side of the hex. (If this was an OD you could scan the whole outside but since it's an ID you can't get a probe into the corner, most likely, so you'll need to do each side as a separate feature).
3) Create an alignment from several curves based on your Base Alignment, select all 6 curves, and Best Fit for rotation only around the Z axis (-B-).
4) Copy all 6 of the original curves and recall the feature points into each one of the copied curves from the original curve. You'll now have 6 exact copies of the original curves. Change the alignment for each curve to the Best Fit alignment you made from all 6.
5) Report the profile and/or curve form for each curve in the Best Fit alignment. Since the tolerance is diametrical and you will be checking the radial distance, you need to divide you tolerances in half. So each curve would be toleranced -.002/+.00295.
6) If they want a position reported diametrically then you can create a Max Inscribed circle from the curves and report that to satisfy that request. It's not a perfect number because you can't into the corners to get the peaks, but if it passes the virtual/resultant condition then it will pass the position. You could also report the position of each line, but that would be a linear tolerance.

Hope that helps, Clarke.