CAEDSHighPressureDieCastingDesign

Castingdimensionalstabilityandtolerances
TampereUniversityofTechnologyTuulaHk
Highpressurediecastingdimensionalandgeometricalaccuracydependsonthe
followingdetails:

diethermalbalance
diemechanicalstrengthandstiffness
draggingduringejection
partinglineposition
movingcoresposition

Diethermalbalance
Diethermalbalanceinfluencescastingdimensionalandgeometricalaccuracyin
manydifferentmechanisms.Basicallytherearetwosubjectsofthemechanisms:die
andthecastingitself.
Diesteelshavecertaincoefficientsofthermalexpansion,whichhavebeennoticed
asapartofthecastingshrinkagefactor.Basicallythecastingshrinkagefactor
consistsofthermalexpansionofthecastingalloyatthecastingejectiontemperature
andthermalexpansionofthediesteel.Thecastingejectiontemperaturemayvary
fromcycletocycledependingonthedietemperature;temperatureofthealloy;and
heatlossesduringdosingandthecastingshot.Ifthethermalconditionsarestable,
theejectiontemperaturevariationisminimal.Itmaytake12hoursafterproduc
tionstartupbeforeallequipmentshavereachedathermalbalance.Ifthereiseven
a510minutesbreakbetweenmachinecycles,thethermalbalanceislost.
Thermalexpansionofthediesteelatthetimeoftheejectionisverydifficultto
predict,becausethedietemperaturevariesbetweendifferentpartsinsidethecavity
andasafunctionoftime.Heatflowsratherslowlyandasaresultthisphenomenon
thediesteelundercavitywarmsupafewsecondsafterthecastingisalready
ejected.Highandnarrowprojectionstendtoheatupafterafewtensofcasting
shots.Narrowprojectionsheatupmorethancavityshapesandflatsurfaces,be
causethereislessheatconductingmaterial.(Seeimagebelow.)

Image1. Acavityorflatsurfaces
havemoresurroundingmaterialto
conductheatthancoresurface.For
thisreasoncorestendtoheatup
morethanflatcavityareas.

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CAEDSHighPressureDieCastingDesign
Coresresistcastingshrinkage.Flatareainacastingmayshrinknearlytwiceas
muchasanareaaroundacore.(Seeimagebelow)

Image2. Differentcastingshapesshrink
differently.Ifthecastingontheleftwere
madeofsteel,theshrinkageswouldbeas
presented.ThefigurebasesonJ.Campbell,
Castings,2ndedit.
2,4%

1,64%

0,92%

Basicallythediecavityismachinedalittlelargerthanthewanteddimensionsina
casting.Thecastingdimensionsaremultipliedwithacoefficientcalledashrinkage
factor.Itshouldbepossibletodeterminethefactorfromlinearthermalcoefficients
ofthediematerialandthecastingalloy,butasaresultofallthedescribedvague
ness,theshrinkagefactorisgivenasanempiricallyderivedinhousestandard.The
standardmaybedifferentfordifferentcastingtypes.Typicalshrinkageinalumi
numhighpressurediecastingisforexamplebetween0,5%0,7%eventhoughthe
coefficientofthermalexpansionwouldforetellmore.
Ifthecastinghassomeimportanttolerateddimensions,thecastingcompany
shouldbeabletomaintainthethermalconditionsinsidethedieassteadyaspossi
ble.Thecastingejectiontemperaturevariationhastobekeptassmallaspossible.If
requirementsareespeciallytight,thereshouldbesomeadvancedtemperature
controlsystemsinuse.Traditionaltemperingdeviceswithcirculatinghotoildonot
controldietemperaturedirectly.Theycontrolonlytheoiltemperatureandwiththe
oiltemperaturethedietemperature.Thecontrolsystemdoesnothavealinkto
temperaturesinsidethedie.Thesamegoeswithsprayingdevices.Ifthereisaneed
foraccuratedietemperaturecontrol,thesystemmusthavesensorformeasuring
temperatureofcriticalplacesinsidethedie.
Whenthediematerialheatsupitexpandsaccordingtothelinearthermalcoeffi
cientsandtemperaturesofthedifferentdieparts.Ifthediematerialshavesimilar
coefficientsoflinearthermalexpansionandthetemperatureisthesameinalldie
parts,thediemaintainstotallyflatandthetwodiehalvesfittogetheraswellas
possible.Usuallythisisnotthecase.Usuallythematerialnearthediecavitysur
faceishotterthantheotherareas.Andasaresultthediewillbend(Image3a)next
page).
Inidealsituationthediehalveswouldbeinthesametemperature.Usuallythecore
sidetendstoheatupmoreandcavitysideless.Thetemperaturedifferencebetween
thediehalvesposeasituationpresentedinthesameimageb).

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CAEDSHighPressureDieCastingDesign

a)

Core

Cavity

Core

Cavity

b)

Image3. a)Bendingduetotemperaturedifferencesinsidediematerialsb)Bendingdueto
temperaturedifferencesinsidethediematerialsandbetweendiehalves.Coresidetypically
tendstoheatupmorethanthecavityside.
Minimumdieguidingsystemconsistsofguidepillarsandsleeves.Withthismini
mumsystemthedimensionaldifferencesbetweenthediehalvescanbebalancedto
acertaindegree,butformoreaccuratedimensionalcontrol,thediedesignershould
adoptsideguides(Seethefollowingimage).

Guidesleevesand
pillars

Straightinterlock

Image4. Sideinterlocksforhighpressurediecastingdieandforexampleforinjection
moldingmould.Sideinterlockswillguidethediehalvesmoreaccuratelytogetherthanthe
standardguidepillarandsleevesystem.Guidepillarsandsleevesaremanufacturedto
toleratesomethermalimbalancebetweenthetwodiehalves,butatthesametimetheyallow
someinaccuracyinpositioningthedieormouldhalves.
Iftherearehotandcoolerpartsinsidethediecavity,thediebends,butsodoesalso
thecasting.Thevariationsindietemperaturescausealsootherkindsofproblems:
Temperaturevariationscausevariationsinshrinkageandsolidificationconditions
andthecastingmaybuildupinternalstresses.Afterthecastingisejected,the
internalstressesrelieveandthecastingbends.Ifthecastingisdesignedwithboth
thinandthicksectionsorsections,whichwillforsomeotherreason,concentrate
heatinthedie,itmaybeverydifficulttocopewiththeseinthecastingshopand
difficultwarpageproblemsarise.
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CAEDSHighPressureDieCastingDesign
Iftheinternalstressesconcentrateinanunfavorableway,thethickersectionsmay
evenbreakunderservice.Thecastingmayhavestructures,whicharesimilarto
stresslattices.Specialconsiderationshouldbetakenwhendesigningfeatures
similartothese(Seeimagebelow).

Image5. Castingstructures,which
aresimilartostresslattices.Differ
entcoolingratescausewarpageand
internalstresses.Thecastingmay
evenbreakfromthethickestpart
underserviceconditionsasaresult
ofthestressconcentrations.Fasten
ingribsmayhavesimilareffectsif
notcarefullydesigned.

Dieandmachinemechanicalstrengthandstiffness
Eachcastingshotposesapowerfulstresstothecavityblockofthediemovinghalf
andtothemachineclosingsystem.Themovinghalfcavityplaterestsonrisersand
thereisnosupportfromthemachineplatenlikeinthefixedside.Forthatreason
thedieistypicallyequippedwithsupportpillars.Withoutthesupportpillarsthe
incavitypressurewouldbendthecavityplate.
Thehighpressurediecastingmachineisequippedwithacombinedhydraulicand
mechanicalclosingunittokeepthediehalvestogetherduringthecastingshot.In
allelectricmachinestheclosingunitiscombinedelectricalandmechanical.Ifthe
machineisstrongenough,thediehalvesstaytightlyclosed.Ifthemachineclosing
forceisnotstrongenough,thedieopensslightlyandletssomealloytopasstothe
partingsurface.Thecastingwillhavesomeflasharoundthepartinglineandalso
thedimensionsperpendiculartothepartingsurfacewillbeslightlylargerthan
intended.

Image6. Asupportpillarbehindthediecavityplateinthemovingside.
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CAEDSHighPressureDieCastingDesign

Draggingduringejectionormouldopening
Draggingisaphenomenonthatoccursif

thecastingisdesignedwithtoosmalldraftangles
thereisabackdraftcondition
thealloy(typicallyaluminiumorzinc)solderstothediesurface
thetabletstickstotheplunger

Draggingbreaksthecastingsurfaceandsurfacedefectsmaysolelycauserejection
ofthepart.Draggingcausesalsodimensionalinstability.Iftabletsticksbetweena
plungerandacastingchamber,thecastingusuallybreaksatagate.Beforethe
breakingoccurs,thecastingisaffectedwithtensilestresses,whichcausedistortions
anddimensionalinaccuracy.Image7presentsenlargedeffectofastucktablet.The
similareffecthappenswhenthecastingdragsinthefixeddiehalfasaconsequence
ofsoldering,abackdraftconditionorazerodraftcondition.Nextimage(Image9)
showsaneffectofasolderingorazero/backdraftconditioninthemovingdiehalf.
Thedieejectionsystemsetsanunevenejectionforcetothecasting,becausesome
partsofthecastingreleasewitheaseandsomedonot.Asaresultthecastingbends.

Image7. Left:Undistorted
runnersystemanddimension
allyaccuratecasting.Right:
Distortedrunnerandbent
castingwithdimensional
inaccuracy.Bendingduetoa
stuckcoldchamberdiecasting
tablet.

Image8. Warpageoftherunner.Therunnermaybreakfrom
thethick,butstillwarmandsoftpartsoratthegate.Before
thebreakoccurs,castingisexposedtotensilestresses.

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CAEDSHighPressureDieCastingDesign

Image9. Left:Normal,dimensionallyaccuratecasting.Right:Distortioncausedbyuneven
ejectionforces.Enlargedeffect.Thewholeejectionsystemmaytiltifthecastingstickstothe
dieduringejection.

Partinglineandmovingcorespositionandtheireffectto
thecastingtolerances
Selectionofpartinglinepositionandpositionsofmovingcoreshaveaneffecttothe
castingtolerances.AccordingtotherulesoftheNorthAmericanDieCastingAsso
ciation(NADCA)thetoleranceiscalculatedseparatelytodimensionsorfeatures
insideonediehalfanddimensionsbetweentheoppositediehalves.Theparting
lineandmovingcoresaddtotolerancesinthe+direction.TheinternationalISO
standardmentions,thatManydimensionsofacastingareaffectedbythepresenceofa
mouldjointoracore,requiringincreaseddimensionaltolerance.However,thestandard
doesnotgiveruleshowtodefinetheincreaseintolerance.
Dimensionswithcriticaltolerancesshouldbeinonediehalfifpossible.Sometimes
itisdifficulttoseewhetherthedimensionsareonlyinonediehalforcrossingthe
partingline(Seethefollowingimage).

Image10.
Dimensionsinonedie
halfandacrossthepartingline.Dimen
sions174mmand70mmarebetween
featuresinonediehalf.Dimension61
mmcrossesthepartingline,becauseitis
adimensionbetweenthepartouterand
innersurfaces.

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CAEDSHighPressureDieCastingDesign

Settingoftolerances

TheNorthAmericanDieCastingAssociation(NADCA)hasstandardspecifications
forsettinghighpressurediecastingtolerances.ThereisalsoaninternationalISO
standardseries,whichfocusesoncastingtolerances.Thisseriesreplacestheformer
ISO8062:1994.ISO8062:1994didnothavespecificationstohighpressurediecast
ings.Thenewstandardseriescoversthemalso.
ThenewISO806213seriesdefinescastingtolerancesasDCT(Dimensional
CastingTolerance)gradesandGCT(GeometricalCastingTolerance)grades.The
formerISO8062definedtolerancesonlyasCT(CastingTolerance)grades.

ISO806213consistsofthefollowingtitles.

ISO80621:2007Geometricalproductspecifications(GPS)Dimensional
andgeometricaltolerancesformouldedpartsPart1:Vocabulary
ISO/TS80622Geometricalproductspecifications(GPS)Dimensionaland
geometricaltolerancesformouldedpartsPart2:Rules(Notpublished
yet)
ISO80623:2007Geometricalproductspecifications(GPS)Dimensional
andgeometricaltolerancesformouldedpartsPart3:Generaldimen
sionalandgeometricaltolerancesandmachiningallowancesforcastings

AccordingtoNADCAspecifications,highpressurediecastingtolerancesaredi
videdintotwogroups:normalandprecisiontolerances.InternationalISOstandard
doesnotusetheseterms,butspecifiesthetightestgeometricaltolerancegradeas
onetobeusedonlybyspecialagreement.Theprecisiontolerancesmaybemore
costlytoachieve,becausethediecasterhastopaymoreattentiontothethermal
stabilityduringcastingcyclesandalsothediehastobemorerigidandwelltested.
Usuallyrigidityrequiresthickerplatesandtheseaddtothediecosts.
NADCAspecificationscoverthefollowinghighpressurediecastingtolerances 1 :

dimensionaltolerance
angulartolerance,whichincludesflatness,parallelismandperpendicular
itytolerances
concentricitytolerance
partinglineshifttolerance
flatnesstolerance

ISO8062coversthefollowingtolerances:

dimensionaltolerances
combinedroundness,parallelism,perpendicularityandsymmetrytoler
ance
concentricitytolerance
straightnesstolerance
flatnesstolerance

NADCA:ProductSpecificationStandardsforDieCastings,USA,2006

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CAEDSHighPressureDieCastingDesign

Dimensionaltolerances
Dimensionaltolerancescovertolerancesfordimensionsinonediehalfanddimensionsoverpartingline.
ISO80623standardaskstonoticethedimensionsoverpartingline,butdoesnotgivepreciseruleshow.
Table1. NADCAdimensionaltolerances,dimensionsinonediehalf
Standard

Aluminum

Magnesium

Zinc

Copper

Normal

+/0,25mmper25mm+additional+/0,025mm
pereachfull25mm

+/0,36mmper25mm+addi
tional+/0,076mmpereachfull
25mm

Precision

+/0,05mmper25mm+additional+/0,025mm
pereachfull25mm

+/0,18mmper25mm+addi
tional+/0,05mmpereachfull
25mm

Table2. ISO80623:2007dimensionaltolerances
Largestoveralldimensio

Aluminum

50mm

DCTG6:

>50mm180mm

DCTG7

>180mm500mm

DCTG8

>500mm

DCTG9

Magnesium

Zinc

Copper

DCTG36

DCTG68

Table3. NADCAdimensionaltolerances,dimensionoverpartingline;normal(andprecision)tolerances
Projectedareaof
thecasting

Zinc

Aluminum

Magnesium

Copper

65cm2

+0,114mm
(+0,076)mm

+0,14mm
(0,089)mm

+0,14mm
(+0,089)mm

+0,20mm
(+0,20)mm

65130cm2

+0,13mm
(+0,089)mm

+0,165mm
(+0,102)mm

+0,165mm
(+0,102)mm

+0,23mm
(+0,23)mm

130325cm2

+0,15mm
(+0,102)mm

+0,19mm
(+0,153)mm

+0,19mm
(+0,153)mm

+0,25mm
(+0,25)mm

325650cm2

+0,23mm
(+0,153)mm

+0,30mm
(+0,203)mm

+0,30mm
(+0,203)mm

6501300cm2

+0,30mm
(+0,203)mm

+0,46mm
(+0,305)mm

+0,46mm
(+0,305)mm

13001950cm2

+0,46mm
(+0,305)mm

+0,61mm
(+0,406)mm

+0,61mm
(+0,406)mm

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CAEDSHighPressureDieCastingDesign
Table4. NADCAdimensionaltolerances,dimensiontowardsamovingcore;normal(andprecision)tolerances
Projectedareaof
thecasting

Zinc

Aluminum

Magnesium

Copper

65cm2

+0,15mm
(+0,127)mm

+0,20mm
(0,152)mm

+0,20mm
(+0,127)mm

+0,12mm
(+0,254)mm

65130cm2

+0,23mm
(+0,178)mm

+0,33mm
(+0,254)mm

+0,33mm
(+0,178)mm

130325cm2

+0,33mm
(+0,254)mm

+0,48mm
(+0,356)mm

+0,48mm
(+0,254)mm

325650cm2

+0,48mm
(+0,356)mm

+0,61mm
(+0,457)mm

+0,61mm
(+0,356)mm

6501300cm2

+0,66mm
(+0,483)mm

+0,81mm
(+0,61)mm

+0,81mm
(+0,483)mm

13001950cm2

+0,81mm
(+0,61)mm

+0,1mm
(+0,762)mm

+0,1mm
(+0,61)mm

Geometricaltolerances
Geometricaltolerancesincludestraightness,flatness,combinedroundness,parallelism,perpendicularity
andsymmetrytolerance,concentricity,partinglineshiftandflatnesstolerance.
Table5. ISO80623straightnesstolerance
Rawcastingbasic
dimension(mm)

GeometricalcastingtolerancegradeGCTGforstraightness

From

To

2:Onlybyspecial
agreement

3:Commoncastings
withoutbackdraft
featureswithmoving
diecomponents

4:Complexcastings
andcastingswith
movingdiecompo
nents

10

0,08

0,12

0,18

>10

30

0,12

0,18

0,27

>30

100

0,18

0,27

0,4

>100

300

0,27

0,4

0,6

>300

1000

0,4

0,6

0,9

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CAEDSHighPressureDieCastingDesign

Table6. ISO80623andNADCAflatnesstolerances
GeometricalcastingtolerancegradeGCTGforflatness

From

To

2:Onlyby
specialagree
ment

3:Commoncast
ingswithoutback
draftfeatures
withmovingdie
components

4:Complexcastings
andcastingswith
movingdiecompo
nents

10

0,12

0,18

0,27

>10

30

0,18

0,27

0,4

>30

100

0,27

0,4

0,6

>100

300

0,4

0,6

0,9

>300

1000

0,6

0,9

1,4

NADCA
casting
tolerance
forflat
ness

Atthefirst75mm0,20
mm+0,08mmafter
eachadditional25
mm 2

Rawcastingbasic
dimension(mm)

Tolerancemm

Table7. NADCApartinglineshifttolerance
Projectedarea

Tolerance

<325cm2

0,102mm

325650cm2

0,152mm

6501290cm2

0,203mm

12901940cm2

0,279mm

19403225cm2

0,406mm

32255160cm2

0,508mm

51607740cm2

0,635mm

Calculatedforthelargestdimension,forexamplediameter,measurefromcornertocornerinthecaseof
rectangularobjects,etc.

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CAEDSHighPressureDieCastingDesign

Table8. ISO80623:2007combinedtoleranceforroundness,parallelism,perpendicularityandsymmetry
Rawcastingbasic
dimension(mm)

2: Only by special
agreement

3: Common castings
without back draft
features with moving
diecomponents

4: Complex castings
and castings with
moving die compo
nents

From

To

10

0,18

0,27

0,4

>10

30

0,27

0,4

0,6

>30

100

0,4

0,6

0,9

>100

300

0,6

0,9

1,4

>300

1000

0,9

1,4

Tolerancemm

Table9. NADCAangulartolerance(combinedflatness,parallelismandperpendicularitytolerance)
Standard

Bothsurfacesin
thesamedie
half

Surfacesacross
thepartinglineor
theothersurface
partingsurface

Bothsurfacesinthe
samediehalf,the
othersurfaceisa
movingcoresurface

Surfacesacrossthe
partinglineorthe
othersurfacepart
ingsurface,
tolerancetowardsa
movingcoresur
face

Normal

0,13mmper75
mm+0,025mm
pereachaddi
tional25mm

0,20mmper75
mm+0,038mm
pereachaddi
tional25mm

0,20mmper75mm
+0,038mmpereach
additional25mm

0,28mmper75mm
+0,076mmpereach
additional25mm

0,08mmper75
mm+0,025mm
pereachaddi
tional25mm

0,13mmper75
mm+0,025mm
pereachaddi
tional25mm

0,13mmper75mm
+0,025mmpereach
additional25mm

0,20mmper75mm
+0,05mmpereach
additional25mm

Precision

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CAEDSHighPressureDieCastingDesign

Table10.

ISO80623:2007cocentricitytolerances

Rawcastingbasic
dimension(mm)

2:Onlybyspecial
agreement

3:Commoncastings
withoutbackdraft
featureswithmov
ingdiecomponents

4:Complexcastings
andcastingswith
movingdiecompo
nents

From

To

10

0,27

0,4

0,6

>10

30

0,4

0,6

0,9

>30

100

0,6

0,9

1,4

>100

300

0,9

1,4

>300

1000

1,4

Tolerancemm

Table11.

NADCAconcentricitytolerances

Projectedarea

Bothsurfacesinthesame
diehalf

Surfacesacrossthe
partingline,addi
tionaltolerance

<325cm2

0,20mmper75mm+0,05
mm to each additional 25
mm

0,20mm

6501290cm2

0,41mm

12901940cm2

0,56mm

325650cm2

0,30mm

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CAEDSHighPressureDieCastingDesign

Annex1:ISO8062:2007Dimensionalcastingtolerancegrades(DCTG)
Thetablepresentsthegradesanddimensionintervals,whichareworkableforhighpressurediecastings.
Rawcastingbasic
dimension(mm)

DimensionalcastingtolerancegradeDCTG

From

To

10

10

0,09

0,13

0,18

0,26

0,36

0,52

0,74

1,5

10

16

0,1

0,14

0,2

0,28

0,38

0,54

0,78

1,1

1,6

2,2

16

25

0,11

0,15

0,22

0,3

0,42

0,58

0,82

1,2

1,7

2,4

25

40

0,12

0,17

0,24

0,32

0,46

0,64

0,9

1,3

1,8

2,6

40

63

0,13

0,18

0,26

0,36

0,5

0,7

1,4

2,8

63

100

0,14

0,2

0,28

0,4

0,56

0,78

1,1

1,6

2,2

3,2

100

160

0,15

0,22

0,3

0,44

0,62

0,88

1,2

1,8

2,5

3,6

160

250

0,24

0,34

0,5

0,7

1,4

2,8

250

400

0,4

0,56

0,78

1,1

1,6

2,2

3,2

4,4

400

630

0,64

0,9

1,2

1,8

2,6

3,6

630

1000

1,4

2,8

1000

1600

1,6

2,2

3,2

4,6

Tolerancemm

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CAEDSHighPressureDieCastingDesign

Annex2:ISO8062:1994Castingtolerancegrades(CTG)
ThetolerancegradeisdescribedwithCT.Itvariesdependingonthecastingmethodandalsoonusedmaterialandalloy.Normalhighpressurediecasting
tolerancegradeisCT57foraluminiumandmagnesium,CT68forcopperandCT46forzinc.
Rawcastingbasic
dimension(mm)

CastingtolerancegradeCTG

From

To

10

11

12

13

14

10

0,26

0,36

0,52

0,75

1,00

1,5

2,0

2,8

4,2

10

16

0,28

0,38

0,54

0,78

1,10

1,6

2,2

3,0

4,4

16

25

0,30

0,42

0,58

0,82

1,20

1,7

2,4

3,2

4,6

6,0

8,0

25

40

0,32

0,46

0,64

0,90

1,30

1,8

2,6

3,6

5,0

7,0

9,0

40

63

0,36

0,50

0,70

1,00

1,40

2,0

2,8

4,0

5,6

8,0

10,0

63

100

0,40

0,56

0,78

1,10

1,60

2,2

3,2

4,4

6,0

9,0

11,0

100

160

0,44

0,62

0,88

1,20

1,80

2,5

3,6

5,0

7,0

10,0

12,0

160

250

0,50

0,70

1,00

1,40

2,00

2,8

4,0

5,6

8,0

11,0

14,0

250

400

0,56

0,78

1,10

1,60

2,20

3,2

4,4

6,2

9,0

12,0

16,0

400

630

0,64

0,90

1,20

1,80

2,60

3,6

5,0

7,0

10,0

14,0

18,0

630

1000

1,00

1,40

2,00

2,80

4,0

6,0

8,0

11,0

16,0

20,0

1000

1600

1,6

2,2

3,0

4,6

7,0

9,0

13,0

18,0

23,0

Tolerancemm

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CAEDSHighPressureDieCastingDesign

References
J.Campbell,Castings,2ndedition,Elsevier,UK,2005
ISO8062:1994CastingsSystemofdimensionaltolerancesandmachiningallowances
EN ISO 80623:2007 Geometrical Product Specifications (GPS). Dimensional and geometrical tolerances
formouldedparts.Part3:Generaldimensionalandgeometricaltolerancesandmachiningallowancesfor
castings
ProductDesignforDieCasting,NADCA,USA1998
ProductSpecificationStandardsforDieCastings,NADCA,USA,2006

Castingdimensionalstabilityandtolerances15