HPDC design Tolerances

CAE DS  Hig Hi gh PressureDi ure DieC eCa asting Desig sign n

Casti Cas ting ng di dim mens nsii ona onall sta stabi bill i ty and to toll era ranc nce es Tam TampereUnive reUniversity rsityo of Technolog logy  Tuu TuulaHö laH öök H igh press pressure ure die casting sting dimens dimensiona ionall and geom geome etrica trical accura curac cy depe depends nds on the following followi ng deta details: ils: die di e thermal thermal balance balance die di e mec mechanica hanicall stren strength gth and stiff stiffne ness ss dragging dragging during eject jection ion partin parting g line pos position moving moving cores ores position position

D i e therm therma al b ba al ance nce Die Di e therma thermall balanc balance e influe infl uence nces casting sting dim di mensional nsional and and geom geome etrical trical accuracy curacy in many many different mechanism hanisms. s. Basic Basica ally ll y there are two subje subjec cts of the the mechanism hanisms: s:die die and thec the casting sting itse itself. Die Di e stee teels have have certain rtain coe coefficient fficients s of thermal rmal expans xpansion, ion, which have have been notice noticed d as a part part of the the casting sting shrinkag shrinkage e fac factor. tor. Basic Basica ally ll y thecast thecasting ing shrinkag shrinkage e fac factor tor cons consists istsof of thermal rmal expans xpansion ion of thecast thecasting ing alloy ll oy at the the casting sting ejec jection tem tempera perature ture and thermal rmal expans xpansion ion of thedie the die steel. Theca The casting sting eject jection ion tem temperat perature ure may may vary vary from cyc cycle to cyc cycle depe depending nding on thedie thedi e tem temperat perature ure;; tem temperat perature ure of thealloy; and hea heat loss losses during dosing dosing and thecast thecasting ing shot shot.. If thetherma thethermall conditions conditions are sta stable, ble, thee the ejec jection tempe mperature ratureva variatio riation n is minima minimal. It may may take take 1  2 hours hours afte fter produc produc tion sta start up beforea fore all equipme quipmentsha nts have ve rea reache ched a thermal rmal balan balanc ce. If there is even ven a 5 10 minute minutes break betwe betwee en mac machinecy hine cyc cles, les, thetherma thethermall balan balancei ceis s lost. lost. Therm Therma al expans pansion ion of the the die steel at the the timeof the the ejection tion is very very difficult difficult to predict, predict, because use thedie thed ie temperature ratureva varies riesbe betwee tween different different parts parts insidetheca inside thecavity vity and as a functio function n of time. ime. H eat flows rath rathe er slowly and as a res result this this phenom nomenon non the the die steel under cavity warm warms s up a few few seconds onds afte fter the the castingis ting is alrea lready ejec jected. ted. H igh and narrow narrow proje projec ctions tions tend to hea heat up afte fter a few few tens of casting shot shots. s. N arrow projec projectionshe tions hea at up more more than than cavity sha shapes pes and flat surfa surfac ces, be causethe use there re is less less hea heat conduct conducting ing mate materi rial. al. (Se (See image imagebe below.) low.)

Image1.A ge1.A ca cavity or flat surfac urfaces havem vemoresurround re surrounding ing materia ri al to conduct nduct heat than coresurfa re surfac ce. For this rea reason cores res tend tohe to heat up moretha re than fla flat cavity vity area reas.

Casting Casting dimensi nsional nal stab tabili il ity andto nd tollerances 1

CAE DS  High PressureDieCasting Design Cores resist casting shrinkage. Flat area in a castingmay shrink nearly twiceas much as an area around a core. (Seeimagebelow)

Image2.Different casting shapes shrink differently. If thecasting on theleft were madeof steel, theshrinkages would beas presented. Thefigurebases on J. Campbell, Castings, 2nd edit. 2,4%

1,64%

0,92%

Basically the die cavity is machined a littlelarger than the wanted dimensions in a casting. The casting dimensions are multiplied with a coefficient called a shrinkage factor. It should bepossible to determinethefactor from linear thermal coefficients of thedie material and the castingalloy, but as a result of all the described vague ness, the shrinkage factor is given as an empirically derived in house standard. The standard may bedi fferent for different casting types.Typical shrinkagein alumi num high pressuredie casting is for example between 0,5% 0,7% even though the coefficient of thermal expansion would foretell more. If thecasting has someimportant tolerated dimensions, thecasting company should beable to maintain the thermal conditions inside thedie as steady as possi ble. Thecasting ejection temperature variation has to bekept as small aspossible. If requirements are especially tight, there should besomeadvanced temperature control systemsin use. Traditional tempering devices with circulating hot oil do not control die temperaturedirectly. They control only theoil temperatureand with the oil temperaturethedie temperature. The control system does not havea link to temperatures inside thedie. The same goes with spraying devices. If there is a need for accurate die temperature control, thesystem must have sensor for measuring temperature of critical places insidethedie. When thedie material heats up it expands according to thelinear thermal coeffi cients and temperatures of thedifferent die parts. If thedie materials have similar coefficientsof linear thermal expansion and thetemperatureis thesame in all die parts, thedie maintains totally flat and thetwo die halves fit together as well as possible. Usually this is not the case. Usually the material near the die cavity sur faceis hotter than the other areas. And as a result the die will bend (Image3 a) next page). In ideal situation the die halves would bein thesametemperature. Usually the core sidetends to heat up more and cavity sideless. Thetemperaturedifference between thedie halves pose a situation presented in thesameimageb).

Casting dimensional stability andtolerances 2

CAE DS  High PressureDieCasting Design

Core

a)

Cavity

Core

Cavity

b)

Image3.a) Bendingduetotemperaturedifferencesinsidediematerials b) Bending dueto temperaturedifferences insidethediematerialsand between diehalves. Coresidetypically tends toheat upmorethan thecavity side. Minimum die guiding system consists of guide pillars and sleeves. With this mini mumsystem thedimensional differences between thedie halvescan bebalanced to a certain degree, but for more accuratedimensional control, thedie designer should adopt sideguides (See thefollowing image).

Guide sleeves and pillars

Straight interlock

Image4. Sideinterlocksfor high pressurediecasting dieand for examplefor injection molding mould. Sideinterlocks will guidethediehalves moreaccurately together than the standard guidepillar and sleevesystem. Guidepillars and sleeves aremanufactured to toleratesomethermal imbalancebetween thetwo diehalves, but at thesametimethey allow someinaccuracy in positioning thedieor mould halves. If therearehot and cooler parts inside thedie cavity, the diebends, but so does also thecasting. Thevariationsin die temperatures cause also other kinds of problems: Temperaturevariations cause variations in shrinkageand solidification conditions and thecasting may build up internal stresses. After thecasting is ejected, the internal stresses relieve and thecasting bends. If thecasting is designed with both thin and thick sectionsor sections, which will for some other reason, concentrate heat in thedie, it may bevery difficult to copewith these in the casting shop and difficult warpageproblemsarise. Casting dimensional stability andtolerances 3

CAE DS  High PressureDieCasting Design If theinternal stresses concentratein an unfavorableway, thethicker sectionsmay even break under service. Thecasting may have structures, which are similar to stress lattices. Special consideration should betaken when designing features similar to these (See imagebelow).

Image5.Casting structures, which aresimilar tostresslattices. Differ ent cooling rates causewarpageand internal stresses. Thecasting may even break fromthethickest part under serviceconditions asaresult of thestressconcentrations. Fasten ing ribsmay havesimilar effects if not carefully designed.

Die and machine mechanical strength and stiffness Each castingshot poses a powerful stress to the cavity block of the die moving half and to the machineclosing system. Themoving half cavity plate rests on risers and there is no support fromthe machineplaten like in the fixed side. For that reason the die is typically equipped with support pillars. Without the support pillars the in cavity pressurewould bend the cavity plate. Thehigh pressuredie casting machineis equipped with a combined hydraulic and mechanical closing unit to keep thedie halvestogether during thecasting shot. In all electric machines theclosing unit is combined electrical and mechanical. If the machineis strong enough, thedie halves stay tightly closed. If the machineclosing force is not strong enough, the die opens slightly and letssome alloy to pass to the parting surface. Thecasting will havesomeflash around the parting line and also thedimensions perpendicular to theparting surface will beslightly larger than intended.

Image6.A support pillar behind thediecavity platein themoving side. Casting dimensional stability andtolerances 4


Dragging during ejection or mould opening Dragging is a phenomenon that occurs if thecasting is designed with too small draft angles there is a back draft condition the alloy (typically aluminiumor zinc) solders to thedie surface thetablet sticks to theplunger Dragging breaks thecasting surface and surfacedefects may solely causerejection of thepart. Dragging causes also dimensional instability. If tablet sticks between a plunger and a casting chamber, thecasting usually breaks at a gate. Beforethe breaking occurs, thecasting is affected with tensile stresses, which cause distortions and dimensional inaccuracy. Image7 presentsenlarged effect of a stuck tablet. The similar effect happens when thecasting dragsin thefixed die half as a consequence of soldering, a back draft condition or a zero draft condition. Next image(Image9) shows an effect of a soldering or a zero/back draft condition in themoving diehalf. Thedie ejection system sets an uneven ejection force to thecasting, because some partsof the castingreleasewith easeand somedo not. A s a result the casting bends.

Image7.Left: Undistorted runner systemand dimension ally accuratecasting. Right: Distorted runner and bent casting with dimensional inaccuracy. Bending duetoa stuck cold chamber diecasting tablet.

Image8.Warpageof therunner. Therunner may break from thethick, but still warmandsoft parts or at thegate. Before thebreak occurs, casting isexposed totensilestresses.



Image9.Left: Normal, dimensionally accuratecasting. Right: Distortion caused by uneven ejection forces. Enlarged effect. Thewholeejection systemmay tilt if thecasting stickstothe dieduring ejection.

Parting li ne and moving cores position and their effect to the casting tolerances Selection of parting line position and positions of moving cores havean effect to the casting tolerances. According to the rules of the North A merican Die Casting A sso ciation (NA DCA ) thetoleranceis calculated separately to dimensions or features inside onedie half and dimensions between the opposite die halves. Theparting line and moving cores add to tolerances in the + direction. Theinternational ISO standard mentions, that Many dimensionsof acasting areaffected by thepresenceof a mould joint or acore, requiring increased dimensional tolerance. However, thestandard does not giverules how to definetheincrease in tolerance. Dimensions with critical tolerances should bein onedie half if possible. Sometimes it is difficult to see whether thedimensions are only in one diehalf or crossing the parting line(See thefollowing image).

Image10. Dimensionsin onedie half andacrosstheparting line. Dimen sions 174 mmand 70mmarebetween featuresin onediehalf. Dimension 61 mmcrosses theparting line, becauseit is adimensionbetween thepart outer and inner surfaces.



Setting of tolerances TheN orth American Die Casting A ssociation (NA DCA) has standard specifications for setting high pressure die casting tolerances. There is also an international ISO standard series, which focuses on casting tolerances. This series replaces theformer ISO 8062:1994. ISO 8062:1994 did not have specifications to high pressure die cast ings. The new standard seriescovers them also. Thenew ISO 8062 13 series defines casting tolerances asDCT (Dimensional Casting Tolerance) gradesand GCT (Geometrical Casting Tolerance) grades. The former ISO 8062 defined tolerances only as CT (Casting Tolerance) grades. ISO 8062 13 consists of thefollowing titles. ISO 8062 1:2007 Geometrical product specifications (GPS) Dimensional and geometrical tolerances for moulded parts Part 1: Vocabulary ISO/TS 8062 2 Geometrical product specifications (GPS) Dimensional and geometrical tolerances for moulded parts Part 2: Rules (Not published yet) ISO 8062 3:2007 Geometrical product specifications (GPS) Dimensional and geometrical tolerances for moulded parts Part 3: General dimen sional and geometrical tolerances and machining allowances for castings According to NADCA specifications, high pressure die casting tolerances are di vided into two groups: normal and precision tolerances. International ISO standard does not usetheseterms, but specifies thetightest geometrical tolerancegrade as oneto beused only by special agreement. Theprecision tolerances may bemore costly to achieve, becausethedie caster has to pay moreattention to thethermal stability during casting cycles and also thedie has to bemorerigid and well tested. Usually rigidity requires thicker plates and these add to thedie costs. NADCA specifications cover thefollowing high pressure die casting tolerances1: dimensional tolerance angular tolerance, which includesflatness, parallelism and perpendicular ity tolerances concentricity tolerance parting line shift tolerance flatness tolerance ISO 8062 covers thefollowing tolerances: dimensional tolerances combined roundness, parallelism, perpendicularity and symmetry toler ance concentricity tolerance straightness tolerance flatness tolerance

1

NADCA : Product Specification Standards for Die Castings, USA, 2006 Casting dimensional stability andtolerances 7


Dimensional tolerances Dimensional tolerances cover tolerances for dimensions in onedie half and dimensions over parting line. ISO 8062 3 standard asks to notice thedimensions over partingline, but does not givepreciserules how. Table1. NADCA dimensional tolerances, dimensions in onediehalf Standard

Aluminum

Magnesium

Zinc

Copper

Normal

+/ 0,25 mmper 25mm+additional +/ 0,025 mm per each full 25 mm

+/ 0,36mmper 25 mm+addi tional +/ 0,076 mmper each full 25 mm

Precision

+/ 0,05 mmper 25mm+additional +/ 0,025 mm per each full 25 mm

+/ 0,18mmper 25 mm+addi tional +/ 0,05 mmper each full 25 mm

Table2. ISO 8062 3:2007 dimensional tolerances L argest overal l di mensi o 50mm

A l umi num

M agnesi um

DCTG 6:

>50mm 180 mm

DCTG 7

>180mm 500mm

DCTG 8

>500mm

DCTG 9

Zi nc

Copper

DCTG 3  6

DCTG 6  8

Table3. NADCA dimensional tolerances, dimension over partingline; normal (and precision) tolerances Projected area of the casting

Zinc

Aluminum

M agnesium

Copper

65cm2

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

+0,14mm (0,089) mm

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

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

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

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

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

+0,23mm (+0,23) mm +0,25mm (+0,25) mm

65  130 cm2

130  325cm2

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

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

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

325  650cm2

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

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

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

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

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

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

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

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

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

650  1300 cm2

1300  1950 cm2


CAE DS  High PressureDieCasting Design Table4. NADCA dimensional tolerances, dimension towards amoving core; normal (and precision) tolerances Projected area of the casting

Zinc

Aluminum

M agnesium

Copper

65cm2

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

+0,20mm (0,152) mm

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

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

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

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

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

65  130 cm2

130  325cm2

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

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

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

325  650cm2

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

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

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

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

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

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

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

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

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

650  1300 cm2

1300  1950 cm2

Geometrical tolerances Geometrical tolerances include straightness, flatness, combined roundness, parallelism, perpendicularity and symmetry tolerance, concentricity, parting line shift and flatnesstolerance. Table5. ISO 8062 3 straightness tolerance Raw casting basic dimension (mm)

Geometrical casting tolerance grade GCTG for straightness

From

To

2: Only by special agreement

3: Common castings without back draft features with moving die components

4: Complexcastings and castings with moving die compo 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



Table6. ISO 8062 3 and NADCA flatnesstolerances Raw casting basic dimension (mm)

Geometrical casting tolerance grade GCTG for fl atness

From

To

2: Only by special agree ment

3: Common cast ings without back draft features with moving die components

4: Complex castings and castings with moving die compo 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 for flat ness

0 2 , 0 r e t 5 f m a 2 m l a 5 m n 7 m o i t t s 8 i r 0 d i , f 0 d e + a 2 h h t t m c a m A m e m

Tolerance mm

Table7. NADCA partinglineshift tolerance Projected area <325cm2 325 650 cm2 650 1290 cm2

Tolerance

±0,102mm

±0,152mm

±0,203mm

1290 1940 cm2

±0,279mm

1940 3225 cm2

±0,406mm

3225 5160 cm2

±0,508mm

5160 7740 cm2

±0,635mm

Calculated for thelargest dimension, for examplediameter, measure from corner to corner in thecase of rectangular objects, etc. 2



Table8. ISO 8062 3:2007 combined tolerancefor roundness, parallelism, perpendicularity and symmetry Raw casting basic dimension (mm)


3: Common castings without back draft features with moving die components


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

2

Tolerance mm

Table9. NADCA angular tolerance(combined flatness, parallelismand perpendicularitytolerance) Standard

Both surfaces in thesame die half

Surfaces across the parting li ne or the other surface parting surface

Both surfaces in the same die half, the other surface is a moving core surface

Surf aces across the parting li ne or the other surface part ing surface, tolerance towards a moving coresur face

0,13 mmper 75 mm +0,025mm per each addi tional 25mm

0,20 mmper 75 mm +0,038mm per each addi tional 25 mm

0,20mmper 75 mm +0,038 mm per each additional 25mm

0,28mmper 75 mm +0,076 mm per each additional 25 mm

Precision 0,08 mmper 75 mm +0,025mm per each addi tional 25mm

0,13 mmper 75 mm +0,025mm per each addi tional 25 mm

0,13mmper 75 mm +0,025 mm per each additional 25mm

0,20mmper 75 mm +0,05 mm per each additional 25 mm

Normal



Table10.

ISO 8062 3:2007cocentricity tolerances

Raw casting basic dimension (mm)


3: Common castings without back draft features with mov ing die components


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

2

>300

1000

1,4

2

3

Tolerance mm

Table11.

NADCA concentricitytolerances

Projected area

Both surfaces in thesame die half

Surfaces across the parting li ne, addi tional tolerance

<325cm2

0,20 mm per 75 mm +0,05 mm to each additional 25 mm

0,20 mm

325  650cm2 650  1290 cm2 1290 1940 cm2

0,30 mm 0,41 mm 0,56 mm


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0 , 0 , 0 , 0 , 0 , 0 , 0 , 0 , 0 , 0 , 0 1 2 4 6 8 6 7 8 9 1 1 1 1 1 1

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0 , 0 , 0 , 2 , 4 , 6 , 0 , 6 , 0 , 0 , 0 , 0 , 0 1 3 4 4 4 5 5 6 7 8 9 1 1 1

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8 , 0 , 2 , 6 , 0 , 4 , 0 , 6 , 2 , 0 , 0 , 0 , 2 3 3 3 4 4 5 5 6 7 8 9

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0 , 2 , 4 , 6 , 8 , 2 , 6 , 0 , 4 , 0 , 0 , 0 , 2 2 2 2 2 3 3 4 4 5 6 7

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5 , 6 , 7 , 8 , 0 , 2 , 5 , 8 , 2 , 6 , 0 , 6 , 1 1 1 1 2 2 2 2 3 3 4 4

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7

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References J. Campbell, Castings, 2nd edition, Elsevier, UK , 2005 ISO 8062: 1994 Castings  System of dimensional tolerances and machining allowances EN ISO 8062 3:2007 Geometrical Product Specifications (GPS). Dimensional and geometrical tolerances for moulded parts. Part 3: General dimensional and geometrical tolerances and machining allowances for castings Product Design for Die Casting, NADCA, USA 1998 Product Specification Standards for Die Castings, NADCA , USA, 2006


HPDC design Tolerances

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