Process Focus

Specifying Dimensional Tolerances for Die Castings

Here are five standard coordinate dimensioning tolerance guides to aid in designing an economical die casting.
Leo J. Baran, Diecasting Development Council, Rosemont, Illinois George Tackes, Associate Editor

ne of the advantages of traditional coordinate didiecasting is that its dimensioning terms cover exmensional tolerances can be pected values consistent with A held closer than with other high diecasting cycle speeds, metalcasting processes. This uninterrupted production, high degree of precision and reasonable die life and die uniformity between castings maintenance costs, as well as A makes automatic assembly normal inspection, packing and machining of diecast and shipping costs. Conforcomponents easier. Knowmity to these standards by ing exactly which tolerances designers provides predictcan be specified and to what able service and lower cost for degree can aid an engineer die castings. to further reduce or elimiLinear dimensionThis nate machining or finishing is the measurement between Fig. 1. A indicates the linear dimensions of a theoretical diecast compooperations. Another advan- nent. The other tolerance guidelines for the parting line or moving die features formed on the same tage is the ability to consoli- parts directly relate to the linear dimensions. die part (Fig. 1). The values date numerous parts into for the standard tolerances one die casting. for linear dimensions are listed Table 1. Standard Tolerances for Linear Dimensions This article will present five in Table 1. As an example, if an Length of Diecasting critical tolerance guidelines of aluminum die casting has a 5Dimension A Alloys coordinate dimensioning to in. linear dimension, it can have Aluminum/Magnesium/Zinc Copper achieve net-shape and near-neta standard tolerance of 0.014 Basic Tolerance 0.010 in. 0.014 in. shape die castings. In addition, in. If that 5-in. dimension is po( 0.36 mm) Up to 1 in. (25.4 mm) ( 0.25 mm) in two sidebarsCoordinate sitioned between features Additional Tolerances 0.001 in. 0.003 in. Dimensioning Isnt the Only formed by the same die part, it ( 0.076 mm) for Each Additional in. ( 0.025 mm) Specification Method and Prehas an initial linear tolerance of More Than 1in. (25.4 mm) cise Coordinate Dimension 0.010 in. with four additional ingthe article looks beyond tolerance values of 0.001in. part by its location on a 3-D grid and uses standard coordinate dimensioning as a added. The linear tolerances must be inat least five sets of tolerance guidelines. The means for tolerance specification. During creased for dimensions of features formed five critical guidelines include: the casting design process, engineers must by the parting line (the line on a casting linear dimensions; balance the importance of tight tolerances corresponding to the separation of the dimensions across parting lines; against the economies of manufacturing two halves of a diecasting die) or by mov dimensions formed by moving die to ensure a component that is both funcing die parts. Also, casting configuration components (MDC); tional and cost-effective. and shrink factor may limit some dimen draft; sion control. Coordinate Dimensioning flatness. Parting line dimensionThe parting Most tolerancing and other specificaAlthough coordinate dimensioning line tolerances are measured as the dimention standards for diecasting are presented does have precision tolerances, the tolersions perpendicular to the die parting line in traditional coordinate dimensioning ance guidelines listed are presented at the (Fig. 2). These tolerances depend on a proterms. Coordinate dimensioning defines a standard level. The standard tolerances in jected area of the component in the plane
Parting Line
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Table 2. Standard Parting Line Tolerances (must be added to linear tolerances)

Parting Line

Projected Area of Die casting

Up to 10 sq in. (64.5 sq cm) 11 to 20 sq in. (71 to 129 sq cm)

Diecasting Alloys (tolerances can be positive values only)

Aluminum/Magnesium 0.0055 in. (0.14 mm) 0.0065 in. (0.165 mm) 0.0075 in. (0.19 mm) 0.012 in. (0.30 mm) 0.018 in. (0.46 mm) 0.024 in. (0.61 mm) Copper 0.008 in. (0.20 mm) 0.009 in. (0.23 mm) 0.010 in. (0.025 mm) Zinc 0.0045 in. (0.114 mm) 0.005 in. (0.13 mm) 0.006 in. (0.15 mm) 0.009 in. (0.23 mm) 0.012 in. (0.30 mm) 0.018 in. (0.46 mm)

Fig. 2. B marks from where the parting line dimension is measured on the theoretical diecast component. The measurement applies to the projected area in the plane of where the die parts.

21 to 50 sq in. (135.5 to 322.6 sq cm) 51 to 100 sq in. (329 to 645.2 sq cm) 101 to 200 sq in. (651.6 to 1290.3 sq cm)

Parting Line

Core Slide

201 to 300 sq in. (1296.8 to 1935.5 sq cm)

For projected area of a die casting that is more than 300 sq in. (1935.5 sq cm), consult a diecaster.
Table 3. Standard Tolerances for Moving Die Components (must be added to linear tolerances)

Fig. 3. The dimension for a moving die component (MDC) is labeled as C on this theoretical diecast design. This measurement depends on the projected area formed by the MDC perpendicular to the direction of the movement.

Projected Area of Die casting

Up to 10 sq in. (64.5 sq cm) 11 to 20 sq in. (71 to 129 sq cm) 21 to 50 sq in. (135.5 to 323.6 sq cm) 51 to 100 sq in. (329 to 645.2 sq cm) 101 to 200 sq in. (651.6 to 1290.3 sq cm) 201 to 300 sq in. (1296.8 to 1935.5 sq cm)

Diecasting Alloys (tolerances can be positive values only)

Aluminum/Magnesium 0.008 in. (0.20 mm) 0.013 in. (0.33 mm) 0.019 in. (0.48 mm) 0.024 in. (0.61 mm) 0.032 in. (0.81 mm) 0.040 in. (0.1 mm) Copper 0.012 in. (0.305 mm) Zinc 0.006 in. (0.15 mm) 0.009 in. (0.23 mm) 0.013 in. (0.33 mm) 0.019 in. (0.48 mm) 0.026 in. (0.66 mm) 0.032 in. (0.81 mm)

of the die parting. The tolerance values (Table 2) must be added to the linear dimension tolerance. Since the die at a closed position creates the bottom of the tolerance range, part dimensions that run across the die parting only can be of a positive tolerance value. Parting line die shift, however, has a left/right tolerance, which can have a positive or negative value. MDC dimensionTolerances for MDC are attributed mostly to core slides (Fig. 3), which are used to form inset holes or features in a die casting. These tolerances involve the dimensions of a projected area formed by the MDC perpendicular to the direction of movement. Like the parting line

For projected area of a die casting that is more than 300 sq in. (1935.5 sq cm), consult a diecaster.

tolerance, the values (Table 3) also must be added to the linear dimension tolerance. Due to the nature of the diecasting process, dies can separate imperceptibly at the part-

ing line, resulting in a larger tolerance but never a negative value. Draft dimensionDraft tolerances (Fig. 4) relate to cast surfaces perpendicu-

Coordinate Dimensioning Isnt the Only Specification Method

Although coordinate dimensioning of standard and precision tolerances is more commonly used, the more complex geometric dimensioning and tolerancing (GD&T) also can be used to specify tolerances. Unlike coordinate dimensioning, GD&T is a system of defining component features based on their relationships with other component features. GD&T states the necessary dimension and tolerance requirements on a drawing without relying on coordinate dimensions and notes. A GD&T print can provide designers and engineers with functional detail, close-ups and section drawings because part features are related to one another instead of a grid (Fig. 6). When used properly, GD&T can reduce costs by accommodating functional gauging.
Fig. 6. Coordinate dimensioning (l) lays out a design component on a grid and does not consider part function when defining dimensions and tolerances. With geometric dimensioning and tolerancing, dimension lines are provided for critical features such as the largest diameter.

Coordinate Dimension

Geometric Dimension (Datum Reference)

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Table 4. Standard Tolerance for Constant (C) Values of Draft by Features and Depth

Alloy
Zinc/ZA Aluminum Copper

Inside Wall for

Dimensions in in. (mm)

Outside Wall for

Dimensions in in. (mm)

Hole, Total Draft for

Dimensions in in. (mm)

50 30 25

(9.90 mm) (6.00 mm) (7.00 mm) (4.90 mm)

100 60 70 50

(19.80 mm) (12.00 mm) (14.00 mm) (9.90 mm)

34 20 24 17

(6.75 mm) (4.68 mm) (4.76 mm) (3.33 mm)

Magnesium 35

first dividing D by L and then dividing that amount by 0.01746.

A=(D/L)/0.01746.
L

Specifying draft separately for each feature is not common D practice. Draft is normally speciA fied by a general note with exceptions called out for indiFig. 4. This drawing exaggerates the draft dimension for interior and exterior surfaces as well as total draft for vidual features. Flatness dimensionFlatholes. L indicates the depth or height of the feature from the parting line; D indicates the draft in in.; and ness of a continuous plane surA indicates where the draft angle is measured. face on a die casting (Fig. 5) lar to the parting line that require tapershould be measured by locating the unreing (called draft) to allow the casting to strained part on three widely separated be ejected properly from the die. This points or datum targets. The locating dadraft requirement, expressed as an angle, tum targets and method of measurement is determined by the type of wall or surmust be determined before the start of the face specified, the depth of the surface and die design. The maximum dimension is the alloy used. The formula to calculate the diameter of a circular surface or didraft (D) is the square root of L (the depth agonal of a rectangular surface. In addior height of a feature from the parting line) tion to the dimension values (Table 5), the divided by C (constant, based on the type following design guidelines will aid in fulof feature and alloy listed in Table 4). filling flatness requirements: 1. All draft on walls, bosses and fins surD= (the square root of L)/C. rounding and underneath flat surfaces The draft angle (A) can be calculated by should be standard draft or greater.
L

Parting Line

2. Large bosses or cross sections can cause sinks and shrinkage distortions and should be avoided directly beneath flat surfaces. 3. Changes in cross sections should be gradual and well filleted to avoid stress and shrinkage distortions. 4. Symmetry is important to obtain flatness. Lobes, legs, bosses and variations in wall height can affect flatness. Other tolerance guidelines suggested by North American Die Casting Assn. (NADCA) include dimensions for cored holes for threads (holes for minimizing the use of diecasting alloys, clearing features and components, threading, inserting, or alignment), angularity (the angular departure from the designed relationship between the elements of the die casting), concentricity (cylindrical surfaces affected by the diecasting design) and parting line shift (a dimensional variation resulting from the mismatching between two die halves).
This article was adapted from information presented in the NADCA Product Specification Standards for Die Castings.
For a free copy of this article circle No. 341 on the Reader Action Card.

For More Information

NADCA Product Specification Standards for Die Casting, 4th Edition, Diecasting Development Council, Rosemont, IL (2000). Are Your Tolerances Too Tight?, D.W. Shepherd, pp. 51-53, Quality, Bensenville, Illinois (September 1992).

Table 5. Standard Tolerances for Flatness Dimensions (as-cast for all alloys)

Maximum Dimension of Diecast Surface

Up to 3 in. (76.2 mm) Additional Tolerance per in. (25.4 mm)
0.650 in. > 0.005 in.
0.002 in.

Tolerances
0.008 in. (0.20 mm) 0.003 in. (0.08 mm)

Precise Coordinate Dimensioning

When required, critical requirements for dimensional accuracy, draft, etc., beyond the standard tolerances can be specified for diecasting. The values for precision tolerances represent greater casting accuracy up to 65%. These tolerances involve extra precision in die construction and/or special process controls in production and should be used only when necessary. Tolerances can vary with the size and configuration of the part and castability of an alloy. Where a number of critical requirements are combined in a single die casting, early evaluation of a proposed design is essential. When specific designs are examined, tolerances even closer than the precision tolerances can be held by repeated production sampling and recutting of the die. Those steps will result in additional tooling and production costs, but savings can result by eliminating substantial, and costly, secondary machining and/or finishing operations.

Limits of Form (Parallel)

0.002 in.

0.002 in. Tolerance Zone

Within 0.002 in. Wide Tolerance Zone Total Over Entire Surface This Surface Must be Flat 0.655 in. High Size Limit 0.002 in. Tolerance Zone Entire Surface Must lie Between the Two Parallel Planes

0.002 in. Tolerance Zone

0.645 in. Low Size Limit

Possible Variation of Flatness Tolerance Zone Within Size Tolerance Range

Fig. 5. The top figure shows an example of the flatness dimension. The lower figures detail each tolerance zone.

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