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1、STD.AA SUP-1-ENGL 1775 = Ob04500 002878L 474 I- - v I Understanding Aluminum Extrusion Tolerances The Aluminum Association I- I lid n I I : 1 1 n L I, I mil r n Copyright The Aluminum Association Inc. Provided by IHS under license with AA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for
2、Resale, 04/18/2007 05:28:01 MDTNo reproduction or networking permitted without license from IHS -,-,- S T D O A A SUP-II-ENGL 1995 Ob04500 OOII782320 About The Aluminum Association The Aluminum Association represents primary and secondary producers of aluminum, as well as semi- fabricated products,
3、Member companies operate approximately 400 plants in 30 states. The Associations mission is to increase understanding of aluminum and the aluminum industry and increase aluminums use through its technical, statistical, marketing and informational activities and services. The Associations programs ar
4、e designed to serve its customers, consumers, educators, students, government and the public generally. For the aluminum industry and its customers, the Association develops standards and designation systems, prepares codes and specifications involving aluminum products and addresses technical and m
5、arketing issues for the industry. The Association is the leading source of statistics for the aluminum industry. Copyright 1990. Unauthorized reproduction by photocopy o r any other method is illegal. The Aluminum Association, Inc. 900 19th Street, N.W. Washington, D.C. 20006 First Edition January 1
6、990 Second Edition February 1995 Copyright The Aluminum Association Inc. Provided by IHS under license with AA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 05:28:01 MDTNo reproduction or networking permitted without license from IHS -,-,- STD-AA SUP-1-ENGL 1995 O60
7、4500 00118783 267 Understanding Aluminum Extrusion Tolerances his publication explains and illustrates many aspects of the published standard tolerances for aluminum T alloy extrusions, such as those contained in The Aluminum Associations Aluminum Standards and Data and the American National Standar
8、d Dimensional Tolerances for Aluminum Mill Products, ANSI H35.2. These standards are maintained by The Aluminum Association, the latter on commission by the American National Standards Institute (ANSI). The tolerances published in Aluminum Standards and Data and in ANSI H 3 5 . 2 result f r o m the
9、voluntary consensus standards development process prescribed by ANSI. Hence, the existence of the standards do not preclude an individual or organization fiom manufacturing, marketing, purchasing, or using products not conforming to the tolerances covered by the standards and discussed in this publi
10、cation. The publication and the videotape upon which is was based were developed under the guidance of a technical task force of The Aluminum Associations Extruded Products Division, which sponsored their production. While the task force used its best efforts to ensure the accuracy of the content, t
11、he task force, the Extruded Products Division, and The Aluminum Association do not warrant, guarantee, or otherwise assume any responsibility for the use of the information provided in any specic application. This publication, Understanding Aluminum Extrusion Tolerances, was originally written as a
12、supple- ment for a 30-min video with the same title. The section and page numbers used in the publication were intended as references to sections of that videotape; in using the publication by itself, those designations have no special significance. The videotape Understanding Aluminum Extrusion Tol
13、erances is stili avail- able for purchase from The Aluminurn Association at the address printed inside the front cover. Acknowledgement is made to Aluminum Association consultants Stan Benjamin and Paul V. Mara for valuable technical assistance with the project leading to this publication and the as
14、sociated videotape. Copyright The Aluminum Association Inc. Provided by IHS under license with AA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 05:28:01 MDTNo reproduction or networking permitted without license from IHS -,-,- - STD-AA SUP-1-ENGL 1995 Ob04500 001878
15、4 lT3 m APPENDIX Gap Width Inches 0.040-0.062 0.063-0.124 0.1 25-4.249 0.250-0.499 O .500-0.999 1 .000-1.99 2.000 and over i m l Extrusion Forms c.1-1 CLASS 1 CLASS 2 Group A Group B Group A Group B Alloysa Alloys Alloys 0 Alloys Ratio ) 2.0 1.5 2.0 1 .o 3.0 2.0 2.5 i .5 3.5 2.5 3.0 2.0 4.0 3.0 3.5
16、2.5 4.0 3.5 3.5 2.5 3.5 3.0 3.0 2.0 3.0 2.5 3.0 2.0 Hollow Shapes C.4 Solid Shapes C.5, C.6 Semihollow Shapes C.6, C.7, C.8 Definitions of Products n dctermining the general configurations of desired shapes, notc the several basic classifications: solids, semiholiow, hollow, etc. These shapes are ai
17、l pro- ducible, but for economic consideration, solid shapes are most economical with costs increasing for the hoiow shapes for both metal and tooling. The produc- ers engineering and design personnel can be of assis- tance in re-designing, if needed, shapes which will ful- fill the desired function
18、, yet reduce overall costs. How- ever, even the most intricate extruded shapes may Of- ten still be the most economic solution to your specific need. l ExffuSbn: An extrusion is a product formed by pushing metal through a die. xtnrded ShUp: An extruded shape is a wrought product that is long in rela
19、tion to its cross sectional dimensions and has a cross section other than that of sheet, plate, rod, bar, tube or wire. solid Extnrded ShUpe: Any exuuded shape other than a hollow or semiholiow shape. Example, Figure 1. Figure 1 EXtnrded Rod: A solid extrusion whose cross section is round, and whose
20、 diameter is 0.375-inch or greater. Smaiier sizes are classified as wire. Table 1 : Classification-Semihollow Extruded Shapes Copyright The Aluminum Association Inc. Provided by IHS under license with AA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 05:28:01 MDTNo r
21、eproduction or networking permitted without license from IHS -,-,- STD-AA SUP-1-ENGL 1995 W Ob04500 0038785 03T m Semihollow Shapes C.6 Figure 2 Typical Semihollow Extruded Shapes. Use Void Area D and Gap Width B or Void Areas C and D and Gap Width A, Whichever Results In Larger Ratio. Cbss I Semiho
22、llow Extruded Shape: A semihollow extruded shape of two voids or less which i n the area of the voids and surrounding metal thickncss is symmetrical abut the centeriine of the gap. Example, Figures 3 a n d 4. Figure 3: Typical Class 1, Semihollow Extruded Shape Class 2 Semihollow Extnrded Shcrpe: An
23、y semihoilow exmded shape other than Qass 1. Example, Figures 5 and 6. n Figure 5: Typical Class 2, Semihollow Nonsymmetrical Void, Symmetrical Surrounding Metal Thickness Figure 4: Typical Class 1, Semihollow Extruded Shape Figure 6: Typical Class 2 Semihollow Symmetrical Void, Non-symmetrical Surr
24、ounding Metal Thickness Copyright The Aluminum Association Inc. Provided by IHS under license with AA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 05:28:01 MDTNo reproduction or networking permitted without license from IHS -,-,- STD-AA SUP-1-ENGL 1795 Ob04500 0016
25、786 T7b Hollow Shapes C.4 Hollow fxtruded Shape; An extruded shape, any part of whose cross section completely encloses a void. CksJ I Hollow ExtBldedShape: A hollow exuuded shape whose void is round and one inch or more in diameter and whose weight is equaiiy distnbuted on opposite sides of two or
26、more equaiiy spaced axes. Example, Figure 7. C k c r s s 2 lfo/bw Extnrdedshape: Any holiow extruded shape other than class 1 which does not exceed a 5-inch circumscribing circle and has a singie void of not less than 0.375-inch diameter or 0.1 10 square inch area. Example, Figure 8. Figure 7: Class
27、 1 Hollow Extruded Shape II Figure 8 Class 2 Hollow Extruded Shape ChSS 3 ffObw h d e t than class 1 or class 2. Example, Figure 6. Ope: An hollow extruded shape other Tube: A hollow section t h a t is long in relation to its cross-section, which is symmetrical and is round, square, rectangular, hex
28、agonal, octagonal, or ellipticai, with sharp or rounded comers, and having uniform wall thickness except as affected by comer radii. DrUWfI Tube: A tube having final dimensions produced by drawing through a die. Extruded Tube: A tube produced by hot extrusion. Pipe: A tube having certain standardize
29、d combinations of outside diameter and wall thickness, commonly designated by Nominal Pipe Sizes and ANSI (American National Standarh Institute) Schedule . Numbers. Figure 9 Class 3 Hollow Extruded Shape (“his information adapted from: Drafiing Standards for Aluminum Extruded and Tubular Products, T
30、he Aluminum Association, Washington, DC, 1981) Copyright The Aluminum Association Inc. Provided by IHS under license with AA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 05:28:01 MDTNo reproduction or networking permitted without license from IHS -,-,- STD-AA SUP-1
31、-ENGL 1995 W 0604500 0018787 902 W - APPENDIX JD.2/ Individual Tolerances D.2-1 Importance of Determining Tolerances Individually n examining extruded product specifications, it may sometimes ap I pear that if certain specifications are within standard tolerances, they should guarantee the accuracy
32、of others as well. It is never safe t o make that assumption. It is very important to determine and inspect each appiicabe standard tolerance individually, independent of all others. Consider, for example, a simple extruded channel of alloy 6063 with these dimensions and t h e standard tolerances in
33、dicated by Tables 1 1.2 ( C r o s s - S e c t i o n a i Dimension Tolerances) and 1 1.12 (Angularity) in ASD, 1988. See Figure 1. Even in this simple shape, several dimensions can be comfortably within tolerance, while another is not. Example 1, Tipre 2. In this example, the bottom and sides of the
34、channel are ail 0.012 less than their specified dimension of 1 .ooo“, while the top-outside measures 0.023“ more than its specified dimension of 1 .ooo“ and angle at the left measures exactly 90 degrees. Ail of those dimensions are within their standard tolerances. But the angle at the right, then,
35、must be 92 degrees, 2 minutes - 2 degrees, 2 min- utes larger than specified and 2 minutes larger than its allowable tolerance. in Example II, Figure 3, the sides and bottom each measure 1 .ooo“, ex- actly as specified. Each angle is 91 degrees, one degree larger than speci- fied, but well within th
36、e +/-2.Megree tolerance allowed by ASD Table 11.12. inch larger than the aiiowed tolerance of 1.ooo“ +/- 0.023. But the topoutside dimension is 1.035 inches, which is 0.012- Figure 1 91 Wo #. t-l.wO+ Figure 3 Copyright The Aluminum Association Inc. Provided by IHS under license with AA Licensee=IHS
37、Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 05:28:01 MDTNo reproduction or networking permitted without license from IHS -,-,- STD-AA SUP-L-ENGL 1995 Ob04500 0018768 849 - APPENDIX D.2 Individual Tolerances D.2-2 As the figures i n Example III, Fgure 4 make clear, ;niganty in
38、this shape can be far o u t of tolerance even i f aU of the perimeter linear dimen- sions are exactly as specified. i n fathe angies can take on any vahe at all, while he perimeter m a i n s within tolerance! Faure 4 Many other examples muid be pvided, but h e point m a i n s the same: each toleranc
39、e must be determined anci inspected independently of other tol- erances. Copyright The Aluminum Association Inc. Provided by IHS under license with AA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 05:28:01 MDTNo reproduction or networking permitted without license f
40、rom IHS -,-,- STD-AA SUP-II-.ENGL II995 W Ob04500 OOL8789 785 W APPENDIX Flatness Tolerancing G.1-1 What A Flatness Tolerance Means fa surface width of an extrusion is intended to ap- amount aiiowed for its width -the tolerance values. The baseline for fiames tolerancing is the ideal straight line c
41、onnecting the two end points of the profiled surface (in effect, an ideal flat plane, seen end-on). See Figure 1. pear in cross section, as a suaight line, a standar I tolerance for flatness applies to t h a t width. That means t h a t this surface, measured in cross- section at any location dong th
42、e exmion, may not deviate from a perfectly straight line by more than the +rT+ 4r-z-7- Fgure 1 The profiled piane must lie entirely within two planes which: side of the baseline (see Figui.c 2); 1. Just touch, but do not penetrate, (are tangent to) the surface on either ,=m= Right =m= I Wrong Figure
43、 2 2. Are parallel to Lhe baseline (see Figure 3); Right Wrong Figure 3 3. And are separated by a distance no greater than t h e allowed tolerance. If tolerance = .o04 inch: .4“ or L e s s Over ,004“ 1 - 4 In Tolerance Out o f Tolerance Figure 4 Copyright The Aluminum Association Inc. Provided by IH
44、S under license with AA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 05:28:01 MDTNo reproduction or networking permitted without license from IHS -,-,- APPENDIX G. 1 Flatness Toierancing G. 1-2 i n summary: deviations from flamess must be contained between two tang
45、en- tial planes parallel to a baseline representing the ideal flat surface. The flatness tolerance limits the maximum distance between these planes. the baseline itself becomes identical w i t h one of the two limiting planes: If deviations f r o m perfect flamess lie entirely to one side of the bas
46、cline, then Plane 1 .) Plane Base= Plane 1 Plane 2 Plane 2 Plane 2 Figure 5 The extruded flatness tolerance tables in Aluminum Standards and D a t a are il- lustrated, for simplicty and clarity, with shapes displaying concave deviations f r o m flamess. But it does not matter whether the fiat surfac
47、e has a concave deviation that dips “inside“ t h e ideai shape of the solid metal or a convex deviation that bulges “outside“ the ideai shape. The principle is the same: t h e deviation is measured fmm the baseline con- necting the ends of the tolerand width, see Figure 6. Flatness Toierans for Soli
48、d and Semihollow Shapes hollow shapes are given in ASD Table 11.6. The flamess tolerances for surfaces of extruded bar, solid shapes and semi- TABLE 11.6 Flatness (Flat Surfaces)o BAR, SOLID SHAPES AND SEMIHOLLOW SHAPES EXCEPT FOR SHAPES IN O. T3510.14510, T651O.l76510 and Ta510 TEMPERS3 SURFACE WIDTH In. u p m 1 1 m n i S . o O S In any 1 in. of mdM TOLERANCE-ln. Concave deviation *- Convex deviation f r o m flames Figure 6 N o t e th