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

Core Cavity Core Cavity

a) 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

1 NADCA:ProductSpecificationStandardsforDieCastings,USA,2006

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Dimensionaltolerances
Dimensionaltolerancescovertolerancesfordimensionsinonediehalfanddimensionsoverpartingline.
ISO80623standardaskstonoticethedimensionsoverpartingline,butdoesnotgivepreciseruleshow.

Table1. NADCAdimensionaltolerances,dimensionsinonediehalf
Standard Aluminum Magnesium Zinc Copper

Normal +/0,25mmper25mm+additional+/0,025mm +/0,36mmper25mm+addi

pereachfull25mm tional+/0,076mmpereachfull
25mm

Precision +/0,05mmper25mm+additional+/0,025mm +/0,18mmper25mm+addi

pereachfull25mm tional+/0,05mmpereachfull
25mm

Table2. ISO80623:2007dimensionaltolerances
Largestoveralldimensio Aluminum Magnesium Zinc Copper

50mm DCTG6: DCTG36 DCTG68

>50mm180mm DCTG7

>180mm500mm DCTG8

>500mm DCTG9

Table3. NADCAdimensionaltolerances,dimensionoverpartingline;normal(andprecision)tolerances
Projectedareaof Zinc Aluminum Magnesium Copper
thecasting

65cm2 +0,114mm +0,14mm +0,14mm +0,20mm

(+0,076)mm (0,089)mm (+0,089)mm (+0,20)mm

65130cm2 +0,13mm +0,165mm +0,165mm +0,23mm

(+0,089)mm (+0,102)mm (+0,102)mm (+0,23)mm

130325cm2 +0,15mm +0,19mm +0,19mm +0,25mm

(+0,102)mm (+0,153)mm (+0,153)mm (+0,25)mm

325650cm2 +0,23mm +0,30mm +0,30mm

(+0,153)mm (+0,203)mm (+0,203)mm

6501300cm2 +0,30mm +0,46mm +0,46mm

(+0,203)mm (+0,305)mm (+0,305)mm

13001950cm2 +0,46mm +0,61mm +0,61mm

(+0,305)mm (+0,406)mm (+0,406)mm

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 CAEDSHighPressureDieCastingDesign

Table4. NADCAdimensionaltolerances,dimensiontowardsamovingcore;normal(andprecision)tolerances
Projectedareaof Zinc Aluminum Magnesium Copper
thecasting

65cm2 +0,15mm +0,20mm +0,20mm +0,12mm

(+0,127)mm (0,152)mm (+0,127)mm (+0,254)mm

65130cm2 +0,23mm +0,33mm +0,33mm

(+0,178)mm (+0,254)mm (+0,178)mm

130325cm2 +0,33mm +0,48mm +0,48mm

(+0,254)mm (+0,356)mm (+0,254)mm

325650cm2 +0,48mm +0,61mm +0,61mm

(+0,356)mm (+0,457)mm (+0,356)mm

6501300cm2 +0,66mm +0,81mm +0,81mm

(+0,483)mm (+0,61)mm (+0,483)mm

13001950cm2 +0,81mm +0,1mm +0,1mm

(+0,61)mm (+0,762)mm (+0,61)mm

Geometricaltolerances
Geometricaltolerancesincludestraightness,flatness,combinedroundness,parallelism,perpendicularity
andsymmetrytolerance,concentricity,partinglineshiftandflatnesstolerance.

Table5. ISO80623straightnesstolerance
Rawcastingbasic GeometricalcastingtolerancegradeGCTGforstraightness
dimension(mm)

From To 2:Onlybyspecial 3:Commoncastings 4:Complexcastings

agreement withoutbackdraft andcastingswith
featureswithmoving movingdiecompo
diecomponents 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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Table6. ISO80623andNADCAflatnesstolerances
Rawcastingbasic GeometricalcastingtolerancegradeGCTGforflatness NADCA
dimension(mm) casting
tolerance
From To 2:Onlyby 3:Commoncast 4:Complexcastings forflat
specialagree ingswithoutback andcastingswith ness
ment draftfeatures movingdiecompo
withmovingdie nents
components

10 0,12 0,18 0,27

Atthefirst75mm0,20
mm+0,08mmafter
eachadditional25
>10 30 0,18 0,27 0,4

>30 100 0,27 0,4 0,6

>100 300 0,4 0,6 0,9

mm 2
>300 1000 0,6 0,9 1,4

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

2Calculatedforthelargestdimension,forexamplediameter,measurefromcornertocornerinthecaseof
rectangularobjects,etc.

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Table8. ISO80623:2007combinedtoleranceforroundness,parallelism,perpendicularityandsymmetry
Rawcastingbasic 2: Only by special 3: Common castings 4: Complex castings
dimension(mm) agreement without back draft and castings with
features with moving moving die compo
From To diecomponents nents

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 2

Tolerancemm

Table9. NADCAangulartolerance(combinedflatness,parallelismandperpendicularitytolerance)
Standard Bothsurfacesin Surfacesacross Bothsurfacesinthe Surfacesacrossthe
thesamedie thepartinglineor samediehalf,the partinglineorthe
half theothersurface othersurfaceisa othersurfacepart
partingsurface movingcoresurface ingsurface,
tolerancetowardsa
movingcoresur
face

Normal 0,13mmper75 0,20mmper75 0,20mmper75mm 0,28mmper75mm

mm+0,025mm mm+0,038mm +0,038mmpereach +0,076mmpereach

pereachaddi pereachaddi additional25mm additional25mm

tional25mm tional25mm

Precision 0,08mmper75 0,13mmper75 0,13mmper75mm 0,20mmper75mm

mm+0,025mm mm+0,025mm +0,025mmpereach +0,05mmpereach

pereachaddi pereachaddi additional25mm additional25mm

tional25mm tional25mm

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Table10. ISO80623:2007cocentricitytolerances
Rawcastingbasic 2:Onlybyspecial 3:Commoncastings 4:Complexcastings
dimension(mm) agreement withoutbackdraft andcastingswith
featureswithmov movingdiecompo
From To ingdiecomponents nents

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 2

>300 1000 1,4 2 3

Tolerancemm

Table11. NADCAconcentricitytolerances
Projectedarea Bothsurfacesinthesame Surfacesacrossthe
diehalf partingline,addi
tionaltolerance

<325cm2 0,20mmper75mm+0,05 0,20mm

mm to each additional 25
325650cm2 0,30mm
mm
6501290cm2 0,41mm

12901940cm2 0,56mm

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 CAEDSHighPressureDieCastingDesign

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

Rawcastingbasic DimensionalcastingtolerancegradeDCTG
dimension(mm)

From To 1 2 3 4 5 6 7 8 9 10

10 0,09 0,13 0,18 0,26 0,36 0,52 0,74 1 1,5 2

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 1,4 2 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 1,4 2 2,8 4

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 5

630 1000 1 1,4 2 2,8 4 6

1000 1600 1,6 2,2 3,2 4,6 7

Tolerancemm

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

Rawcastingbasic CastingtolerancegradeCTG
dimension(mm)

From To 4 5 6 7 8 9 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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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

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