Dimensional Analysis and

Achievable Tolerances in Die Casting

Anup G
PGTE - 04104
III Semester
 • Die casting is a precision casting process. However,
there are very specific dimensional constraints that
must be recognized. These limitations effect the
tolerances on the casting dimensions and the
functioning of the moving parts of the die.

• The die designer should analyze all casting dimensions

and features for Linear dimensional variation, Shift
between the die halves or other die components,
Parting Line separation (i.e." Blow") of the die halves,
casting and die Warpage which also influences flatness,
Moving Core Registration, and Draft.

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 • Tolerancing of diecastings is highly dependant on the
shape, length and location of each feature as well as
the alloy being used for the application.

• The most important factors when tolerancing a

component are not how tight any tolerance can be, or
the process capability that can be achieved, but what is
needed to meet functional requirements and which
dimensions and features are critical.

• Tolerances should be as tight as necessary, not as tight

as possible.

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 Casting Precision

Precision is dependent on

1. Accuracy in making the die cavity.

 Depends on process used.

2. Shrinkage conditions of the casting.

 Depends on wall thickness and shape
 Influenced by the time that elapsed until the ejection
temperature is reached.

3. Thermal expansion of the die during operation.

 Depends on alloy, shape of casting, speed of operation and
cooling of die.

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 4. Position of the movable die parts with respect to
each other in casting position.
 Includes core rams, slides, closing of two die half.

5. Wear of the die.

 Erosion
 Repolishing of die surface will increase external dimensions
and reduce internal dimensions.

6. Dimensional stability of the alloy.

 Important only for Zn based alloy of high Cu content. Part
made of above alloy will first shrink and then expand (up to
0.2%) slowly.

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 Kind of Size Limiting Surface
• Three types of size limiting surfaces

1.Both external surfaces:

The material contracts away from the die wall.
Easier to make to close tolerances

2.One external and one shrink surface:

e.g.: wall thickness

3.Both shrink surfaces:

e.g.: Internal surfaces, Centre distances. Requires
larger tolerances, since shrinkage force may
cause damage.

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 Obtainable Precision (ISA system)
(Within One Die Half)

Location at
Pb and Mg
Die Cast Zn Alloys Al Alloys Cu Alloys Remarks
Sn Alloys Alloys
part

Small draft -
External desirable for Al.
DT4 DT6 DT8 DT10 DT16
surfaces alloys, required for
Cu Alloys

External and
Shrink surface with
shrink DT4 DT7 DT9 DT11 DT18
draft, if possible
surfaces

Draft required for

Shrink
DT5 DT8 DT10 DT12 DT20 light metal and Cu
surfaces
alloys.

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 Type of Dimensions
• All possible types of die components can be divided
into two main groups

 Size limitation within one die half

 Size limitation by both die halves

• Dimensions within on die half

1. Dimension size limited by solid, fixed die sections
2. Dimension size limited by movable die sections

• Dimensions determined by both die half

1. Size limitation parallel to die parting
2. Size limitation vertical to die parting

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 Obtainable Precision (ISA system)
(Within One Die Half in inch)

Nominal Pb and Zn
Mg Alloys Al Alloys Cu Alloys
Dimension Sn Alloys Alloys

To 4” .00118 .00158 .00236 .00236 .00315

One fixed Over 4” .00158 .00236 .00394 .00394 .0047
and one
movable To 4” .00079 .00118 .00158 .00158 .00236
Over 4” .00118 .00197 .00236 .00236 .00315

To 4” .00197 .00276 .00394 .00394 .0055

Over 4” .00276 .00394 .0063 .0063 .0079

Both To 4” .00236 .00315 .0047 .0047 .0063

movable Over 4” .00315 .0047 .0079 .0079 .0095
To 4” .00158 .00236 .00315 .00315 .0047
Over 4” .00236 .00394 .0047 .0047 .0063

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 Obtainable Precision (ISA system) (Both Die Half in inch)
Pb and Sn
Zn Alloys Mg Alloys Al Alloys Cu Alloys
Alloys
Parallel to Die Parting

Area of casting in die

parting plane, sq. in.
Nominal Dimensions
To 3.875 .00079 .00118 .00158 .00158 .00315
Over 3.875 - 38.75 .00158 .00197 .00236 .00236 .00236
Over 38.75 - 155 -- .00315 .00394 .00394 .00394
Over 155 -- .0047 .00591 .00591 .00591
Vertical to Die Parting

Area of casting in die

parting plane, sq. in.
Nominal Dimensions
To 3.875 .00118 .00158 .00236 .00236 .00394
Over 3.875 - 38.75 .00197 00315 .0047 .0047 .00591
Over 38.75 - 155 -- 0047 .0071 .0071 .0079
Over 155 -- .0079 .0099 .0099 --
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 Permissible Deviations for Dimensions without specified Tolerance
Concerning Die Cast Parts Made of Zinc and Light Metal Alloys

Permissible Deviation in mm
Over Over Over Over
Over 10 Over 30 Over 80
Dimension group Up to 10 180 315 500 700
-30 -80 -180
-315 -500 -700 -1000

1. Pilot dimensions,
±0.1 ±0.2 ±0.3 ±0.4 ±0.6 ±0.8 ±1 ±.1.5
Centre distances

2. External
+0.2 +0.4 +0.6 +0.8 +1 1.5 +2 +2.5
dimensions

3. Internal
-0.2 -0.4 -0.6 -0.8 -1 -1.5 -2 -2.5
dimensions

4. Internal
-0.3 -.6 -1 -1.2 -1.5 +2 -2.5 -3
roundness

5. External
+0.3 +.6 +1 +1.2 +1.5 +2 +2.5 +3
roundness

Up to 6 = ±0.2
6. Wall thickness
Over 6 = ±0.4
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 Tolerances On Linear Dimensions

• This is the tolerance on dimensions formed between

features on the same die half.

• The term Linear includes diameters also.

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 • Linear variation depends on
1. Normal fluctuations in die temperature
2. Casting ejection temperature
3. Quenching rate
4. Stress relieving heat treatment of the casting
5. The accuracy of die construction.

• All of these variables except die accuracy, are

independent of the die design and construction

• Therefore the process must be accurately controlled

to achieve the required dimensional accuracy.

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 Linear Dimension Vs Time

The relative influence of each of the factors for a casting shrink

feature formed completely in one die half.
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 Linear Variation and Shrinkage Variation
for Critical Dimensions
Expected linear dimensional variation
in inch (mm)
Zinc Aluminum Magnesium Copper
In terms of ±0.002 ± 0.0025 ± 0.0025 ± 0.005
die preciseness (± 0.05) (± 0063) (± 0.063) (± 0.10)
Shrinkage Variation in inch/inch (mm/mm)

up to
Additional ± 0.001 ± 0.0015 ± 0.0015 ± 0.002
300 mm
Tolerance (± 0.025) (± 0.038) (± 0.038) (±0.05)
(12”)
for each
inch (25
over
mm) of ± 0.001 ± 0.001 ± 0.001
300 mm XX
length (± 0.025) (± 0.025) (± 0.025)
(12”)

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 Linear Variation and Shrinkage Variation
for Non Critical Dimensions
Expected linear dimensional variation
in inch (mm)
Zinc Aluminum Magnesium Copper
In terms of +0.0085 +0.008 +0.008 +0.014
die preciseness (+0.25) (+0.20) (+0.20) (+0.35)
Shrinkage Variation in inch/inch (mm/mm)
Additional up to
+0.0015 0.002 +0.002 +0.003
Tolerance 12”
(+0.038) (+0.05) (+0.05) (+0.075)
for each (300mm)
inch (25 over
mm) of +0.001 +0.001 +0.001
12” XX
of length (0.025) (+0025) (+0.025)
(300mm)

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 Analysis
• The first step in the die designer's dimensional
analysis is to subtract the linear shrinkage allowance
from every tolerance on the product design drawing.

• The shrinkage factor is identified in the table as

"Additional Tolerance for each unit of Length."

• The nominal size of each dimension is multiplied by

the shrinkage factor, and the product is subtracted
from the dimension's original part print tolerance.

• Remaining Tolerance is available for die construction

and other dimensional variations related to process.

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 • If any of the tolerances would have gone to zero, or
to a minus value, the die designer would have to
specify some type of process control to reduce the
shrinkage variation of the casting.

• Identification of "Linear Only" Dimensions

The final step in the dimensional analysis of
the Linear Dimensional Variation is to identify all
those part print dimensions that are not subject to
any other type of dimensional variation. Usually it is
safe to assume that any casting feature which is
formed completely in one die component will be
subject to linear type of dimensional variation only.

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 • Die Construction Tolerance
The tolerances on the circled dimensions show
the tolerance available for the die construction. Those
dimensions not circled have tolerances that include
allowances for operating as well as construction
variables. Those dimensions must be analyzed in
more detail.

• Some of the dimensions circled may have less

tolerance than recommended for the die tolerance.
The die designer must analyze each of these
situations in terms of the die manufacturing technique
most likely to be used.

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 • When the die designer finds critical tolerances that
seem illogical he should question the customer
(through proper channels of course) as to its
necessity. If such tolerances can be relaxed, it can
eliminate the need for inspection gages, periodic
checks of production parts, and some cost in the die
construction and maintenance.

• If one of the die construction tolerances, becomes

impossibly or prohibitively tight, one of several
courses of action may be taken. First, the need for the
close tolerance should be investigated. Second,
controls may be added to the die and machine to
stabilize the relevant variables. And, third, an
inspection operation can be specified to sort the good
parts from the out-of-tolerance parts.
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 Dimensional Variation from Die Shift
• The temperatures of the two die halves vary in respect to
each other. Like most materials, the die steel changes
size with temperature, the two die halves are actually
changing size in respect to each other constantly
throughout a regular production.

• Therefore, even if it were possible to achieve perfect

alignment repeatedly for one point in the die, all other
points would still shift position with time.

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 • Die shift affects dimensions formed by both die
halves at right angles to the direction of die opening,
the match of sidewalls at the parting line, and
concentricity of diameters in opposite die halves.

• Analyzing Shift Allowance

1. Sort the dimensions which limits the die shift.
2. Negate the shrinkage variation allowance from all
tolerances.
3. Negate die construction tolerances.
4. Least of these remaining tolerances are allocated
to die shift allowances.

• The die construction tolerance for other dimensions

can be increased accordingly.
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 This dimension is the
limitation on die shift,
even though it might
appear to be a non-critical
dimension.

Finally the die construction

tolerance for Φ0.500 and
end mismatch will be ±.0052
and ±.006 respectively.

10/24/22 Dim Analysis & Tol in Die Casting 26

 • Determining Maximum Die
Size

Normal variations in die

temperature cause
corresponding changes in the
size of the die.

The amount B that the

die halves move in respect to
each other depends on the
size A of the die and the
temperature difference
between the two halves.

The dimension A could

be between any two points on
the die parting surface

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 Shift allowance Vs Die size

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 Tolerance on Parting Line Dimensions
(Blow)
• The parting line tolerances are measured as
dimensions perpendicular to the parting line.

• These dimensions are not effected by the registration

of the die, but rather by the tightness with which the
die halves are pressed together.

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 • The most obvious effect of die "blow" is the
occurrence of flash around the casting. Variation of
the parting line dimensions will always affect the
casting's thickness.

• Like all other dimensions, these parting line

dimensions are subject to linear variation which must
be subtracted from each dimension's tolerance. The
remaining tolerance must be divided between the
parting line variation allowance and the die building
tolerances.

• The die separation allowance is unilateral because it

allows for the opening of the die only.(+ only)

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 • Two things happen that cause the dies to separate at
the parting line
1. Natural thermal gradients shown through the die
material that tend to warp the material like a bi-
metal strip.
2. Excessive internal cavity force called die "blow“.

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 Total amount of unrestrained crowning, h in

10/24/22
Total amount of unrestrained
crowning, h in

Total amount of unrestrained crowning, h in

Dim Analysis & Tol in Die Casting

32
 Moving Core Registration
• Since the core and the die are separate pieces, and
subject to different heat transfer loads, they will
usually operate at different temperatures and hence
will expand differently during both warm-up and
operation.

• There must be space between the end of the core

and the cavity surface. (Miniature dies can be
exceptions and not require the space at the end of
the core.)

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 Flat Parting Line Cores
• Flat parting line cores are moving cores that fit between
the two halves of the die. They align to one half of the
die only. Usually, these cores are carried on the ejector
die. Clearances in the ejector die gibs allow the core to
float into alignment as it registers with the cover die.

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 • Since the core is aligned by the cover die, those
casting features formed by the core can have close
tolerance relationships to features formed in the
cover cavity. However, the relationship between
those features formed by the core and features in the
ejector cavity are subject to shift misalignment .

• Frequently, die castings are not designed properly for

fitting of the core. In those situations it is necessary to
design flash around the core for whatever distance is
required to blend to the general shape shown

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 Flatness Tolerance
• The flatness tolerance is the total deviation permitted
from the datum and consists of the distance between
two parallel planes within which the entire surface so
tolerated must lie.

• The flatness of a casting can be measured by

supporting the surface in question on three widely
separated points to establish a datum and measuring
the deviation from that plane by the use of feeler
gauges.

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 Causes
• Casting warpage : unequal shrinkage that results
from non-uniform casting temperature at ejection.

• Bending of Casting : when one part of the casting

sticks during removal of the casting from the die

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 Pressure Diecasting
Maximum Dimension
Up to 75mm Within 0.2mm
For each additional 25 mm Add 0.075mm
The values shown represent production practice at the
most economical level. Greater accuracy involving extra
work or care in production should be specified only when
and where necessary.

The maximum dimension is

The diameter of a circular surface
or diagonal of a rectangular surface
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 Draft Requirements
• Draft is necessary on surfaces parallel to the direction
of die draw because it facilitates ejection of the
casting from the die.

• Twice as much draft is generally recommended for

inside walls or surfaces as for outside walls or
surfaces. The reason for this is that as the alloy
solidifies and shrinks onto the die features that form
the inside surfaces and away from the features that
form the outside surfaces.

• Casting surfaces that are 10O or more from line of

opening are not considered to have draft. These
surfaces are merely conforming to design
requirements.
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• The Standard Tolerance draft can be approximated by the formula:

• D = (sqrt L) /C
Where: D = draft in mm
L = depth or height of feature from the parting line
C = a constant, based on the type of feature and the alloy
A = (D/L)/0.01746 or (tan -1(D/L))
A = draft in angle

C value for the features shown in figure

Inside Outside
Hole Total
Alloy Group Surface Surface
(mm)
(mm) (mm)
Zinc and ZA 9.90 19.80 6.75

Magnesium 6.00 12.00 4.68

Aluminium 7.00 14.00 4.67

Copper 4.90 9.90 3.33

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 Position Dimensions

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 PRESSURE DIECASTINGS (HOT AND COLD CHAMBER) (mm)
ALLOY
LOCATION IN DIE AL. &
ZINC BRASS
MG
A. Between fixed points across parting plane +0.10 +0.15 +0.20
B. Fixed points in opposite blocks parallel to
±0.08 ±0.10 ±0.15
parting
C. Between core centres and fixed location ±0.03 ±0.05 ±0.08
D. Between moving core and location in
±0.15 ±0.20 ±0.30
opposite block
E. Shoulder height on moving core ±0.03 ±0.05 ±0.08
+0.13 +0.20 +0.20
F. Core shoulder to opposite block
-0.03 -0.05 -0.08
+0.10 +0.15 +0.20
G. Moving core centres in opposite blocks
-0.05 -0.08 -0.10
H. Opposed moving cores across parting ±0.15 ±0.20 ±0.30

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 ALLOY
LOCATION IN DIE AL. &
ZINC BRASS
MG
+0.15 +0.20 +0.30
K. Moving cores at 90 within one block
O
-0.05 -0.10 -0.15
L. Moving cores at 90O taken parallel to
±0.15 ±0.20 ±0.30
parting
M. Moving cores at 90O taken across +0.20 +0.25 +0.35
parting -0.05 -0.08 -0.10
N. Opposed cores parallel to parting ±0.20 ±0.30 ±0.40
P. Between moving core and point in same +0.10 +0.15 +0.20
block -0.03 -0.05 -0.10
Q. Between moving core and point in
±0.15 ±0.20 ±0.30
opposite block
R. Warpage factor. Possible variation
between nominally identical dimensions ‘R’
±0.03 ±0.05 ±0.08
and ‘S’. For each 100mm separating the
core centres.
Add for each 10mm of dimension ±0.05 ±0.08 ±0.10
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 LOW PRESSURE AND GRAVITY DIECASTINGS (mm)
MAX. DIAGONAL OF
COMPONENT
LOCATION IN DIE
LESS 150 TO ABOVE
THAN 150 400 400
+0.25 +0.35 +0.45
A. Between fixed points across parting plane
-0.10 -0.15 -0.20
B. Fixed points in opposite blocks parallel to
±0.15 ±0.20 ±0.25
parting
C. Between core centres and fixed location ±0.20 ±0.25 ±0.30
D. Between moving core and location in
±0.30 ±0.40 ±0.50
opposite block
E. Shoulder height on moving core ±0.20 ±0.25 ±0.30
F. Core shoulder to opposite block ±0.30 ±0.40 ±0.50
G. Moving core centres in opposite blocks ±0.60 ±0.75 ±0.90
H. Opposed moving cores across parting ±0.15 ±0.20 ±0.30
J. Opposed moving cores within one block ±0.50 ±0.65 ±0.80
K. Moving cores at 90O within one block ±0.35 ±0.45 ±0.55

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 MAX. DIAGONAL OF
COMPONENT
LOCATION IN DIE LESS
150 TO ABOV
THAN
400 E 400
150
L. Moving cores at 90O taken parallel to
±0.50 ±0.65 ±0.80
parting
M. Moving cores at 90O taken across +0.65 +0.85 +1.00
parting -0.30 -0.35 -0.40
N. Opposed cores parallel to parting ±0.80 ±0.90 ±1.00
P. Between moving core and point in same +0.35 +0.45 +0.55
block -0.20 -0.25 -0.30
Q. Between moving core and point in +0.6 +0.70 +0.80
opposite block -0.40 -0.45 -0.50
R. Warpage factor. Possible variation
between nominally identical dimensions ‘R’
±0.10 ±0.12 ±0.15
and ‘S’. For each 100mm separating the
core centres
Add for each 10mm of dimension ±0.06 ±0.08 ±0.10

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 Raw Casting Size
A certain material allowance is required to permit post
casting material removal by machining. Hence, in the case of
machining on both sides, the size of raw casting can be calculated
as 
R=(F+2x(RMA+CT/2))±CT/2
where: R – raw casting size
F – size after final machining
CT – casting tolerance
RMA – required machining allowance

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 • As a rule, for the entire casting, only one allowance
value is specified. This depends on the type of the
casting (metal or alloy applied, type of pattern or die
equipment etc.) and on the largest overall dimension
of the casting after it’s machining. According to ISO
8062, there are 10 RMA grades, designated A to K;
in most cases the grades C to K are applied.

• There are 16 casting tolerance grades, designated

CT1 to CT16 The designer specifies a tolerance
grade taking into account the type of alloy and
casting process that is to be applied. 

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 References
1. Die Casting Dies: Designing by E.A. Herman (SDCE)

2. Design of Die Castings by Gustav Lieby (AFS)

3. NADCA

4. MRT castings (UK) (www.mrt-castings.co.uk)

5. Dynacast International Limited (www.dynacast.com)

6. Specifying Dimensional Tolerance for Die Casting

by Leo J Baran (DDC)

7. NTTF Design Standards

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 Thank You

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