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1、NADCA StandardLinear Dimensions: Standard TolerancesLinear Dimensions: Precision Tolerances Parting Line: Standard TolerancesParting Line Tolerance is the maximum amount of die separation allowed for the end product to meet specified requirements of form, fit and function. This is not to be confused
2、 with Parting Line Shift Tolerance which is the maximum amount die halves shift from side to side in relation to one another.Parting Line Tolerance is a function of the surface area of the die from which material can flow from one die half to the other. This is also known as Projected Area.Projected
3、 Area is always a plus tolerance since a completely closed die has 0 separation. Excess material and pressure will force the die to open along the parting line plane creating an oversize condition. The excess material will cause the part to be thicker than the ideal specification and that is why Pro
4、jected Area only has plus tolerance. It is important to understand that Table S-4A-2 (Projected Area Tolerance) does not provide Parting Line Tolerance by itself. Part thickness or depth must be factored in to give a true idea of Parting Line Tolerance. Parting Line Tolerance is a function of part t
5、hickness perpendicular to the Projected Area plus the Projected Area Tolerance.Example: An aluminum die casting has 75 in2 (483.9 cm2) of Projected Area on the parting die plane. From table S-4A-2, Projected Area Tolerance is +0.012. This is combined with the total part thickness tolerance from tabl
6、e S-4A-1 to obtain the Parting Line Tolerance.The total part thickness including both die halves is 5.00 in. (127 mm) which is measured perpendicular to the parting die plane (dimension “E2 E1”). From table S-4A-1, the Linear Tolerance is 0.010 for the first inch and 0.001 for each of the four addit
7、ional inches. The Linear Tolerance of 0.014 inches is combined with the Projected Area Tolerance of +0.012 to yield a Standard Parting Line Tolerance of +0.026/-0.014 in. or in metric terms 0.35 mm from Linear Tolerance table S-4A-1 plus +0.30 mm from Projected Area Tolerance table S-4A-2 = +0.65/-0
8、.35 mm.Parting Line Shift: Standard ToleranceExample: Parting Line Shift ToleranceThe cavity area at the parting line is 75 inches squared. From Table S-4A-6, the Projected Area Parting Line Shift Tolerance is 0.006 (0,152 mm). This is added to the Linear Tolerance from table S/P-4A-1.Draft Requirem
9、ents: Standard TolerancesIn the case of an inside surface for an aluminum cast part, for which the constant “C” is 30 (6 mm), the recommended Standard Draft at three depths is:Cored Holes for Cut Threads: Standard TolerancesCored holes for cut threads are cast holes that require threads to be cut (t
10、apped) into the metal. The table below provides the dimensional tolerances for diameter, depth and draft for each specified thread type (Unified and Metric Series). When required, cored holes in Al, Mg, Zn and ZA may be tapped without removing draft. This Standard Tolerance recommendation is based o
11、n allowing 85% of full thread depth at the bottom D2 (small end) of the cored hole and 55% at the top D1 (large end) of the cored hole. A countersink or radius is also recommended at the top of the cored hole. This provides relief for any displaced material and can also serve to strengthen the core.
12、Threads extend through the cored hole as by Y. X shows the actual hole depth. As with the countersink at the top of the hole, the extra hole length provides relief for displaced material and allows for full thread engagement. Tolerances below apply to all alloys.Table S-4A-9: Cored Holes for Cut Thr
13、eads (Standard Tolerances) Unified Series and Metric SeriesAdditional Considerations for Large Castings1 Fillet Radii:1.1: Definition: Wall thickness is the distance between two parallel or nearly parallel surfaces. Wall thickness may vary depending on the application of draft. Wall thickness should
14、 be maintained as uniform as possible. A general guideline would be to keep the range of thickness within 2X of the thinnest wall. A second guideline is to keep the wall as thin as possible to meet the castings functional requirements.1.2: General: 0.14” (3.5mm (+/- 0.5mm)1.2.1 Deviations: from the
15、nominal condition are based upon product function and manufacturing process requirements.2 Radii:2.1 Fillet Radii: 2.1.1 General: 0.14” (+0.08/-0.04”) 3.5mm (+2.0mm/-1.0mm)2.1.1.1 Deviations: from the nominal condition are based upon product function and manufacturing process requirements.2.1.2 Mini
16、mum: 0.060” (1.5mm)2.2 Corner Radii:2.2.1 General: 0.060” (+0.08/-0.04”) 1.5mm (+2mm/-1mm)2.2.1.1 Deviations: from the nominal condition are based upon product function and manufacturing process requirements.2.2.2 Minimum: 0.020” (0.5mm)3 Cores:3.1 Guidelines: Cores should be used to minimize machin
17、ing stock, and should be pulled perpendicular to each other. Use stepped cores where possible to minimize finish stock, reduce heavy sections, and minimize porosity.3.2 Minimum: Cored hole diameter to be 0.25” (6.0mm) in and parallel to the direction of die draw.3.3 For holes Less Than: 0.50” (12.5m
18、m) diameter the core hole length to diameter (L/D) ratio should not exceed 4:1.3.4 For Holes Greater Than: 0.50” (12.5mm) diameter the core pin length to diameter (L/D) ratio should not exceed 10:1Ejector Pin Bosses:Surface Geometry:6.2.1: 0.06” (1.5mm) raised to 0.03” (0.8mm) depressed.7 Trimming &
19、 Cleaning:7.1 Parting Lines:7.1.1 Trim Ribs-Gate and Parting Line: 0.12” maximum (1.5mm)7.1.2 Gates & Overflows: 0-0.059” (0-1.5mm)7.1.3 Flash: As specified in normal standard.7.2 Cored Holes: 0-0.02” (0-0.5mm)7.3 Openings:7.3.1: 0-0.06” (0-1.5mm) at the finish machined face7.3.2: 0-0.03” (0-0.8mm)
20、on as-cast surfaces7.3.3: 0-0.01” (0-2.5mm) of corner radii7.4 Corners - Sharp: Not removed.7.5 Ejector Pin Flash (Max. Projection):7.5.1: 0-0.12” (0-3.0mm) on machined surfaces.7.5.2: 0-0.04” (0-1.0mm) on as-cast surfaces.7.6 Machined Surfaces: 0.12” (0-0.3mm) max.7.7 Seam Lines: 0-0.02” (0-0.5mm)7
21、.8 Negative trim (shearing): condition is allowed when the nominal wall thickness is maintained. Engineering & Design: Additional Specification GuidelinesAcceptable Ejector Pin MarksEjector pin marks on most die castings may be raised or depressed .015” (.381 mm). Raised ejector pin marks are prefer
22、red for optimum production. Larger castings may require additional ejector pin tolerances for proper casting ejection.Ejector Pin FlashEjector pin marks are surrounded by a flash of metal. Normally, ejector pin flash will not be removed, unless it is objectionable to the end use of the part.Alternat
23、ively, ejector pin flash may be specified as crushed or flattened.In the case of either nonremoval or crushing/flattening, flash may flake off in use.Complete removal of ejector pin marks and flash by machining or hand scraping operations should be specified only when requirements justify the added
24、expense.With each die casting cycle, the die opens and the ejector plate in the ejector half of the die (Fig. A) automatically moves all ejector pins forward (Fig. B), releasing the casting from the die. Then, the die casting is removed from the die manually or mechanically.5 Metal Extension (Flash)
25、 RemovalGuidelines to Extent of RemovalThe table below provides a guide to the types of die casting metal extension (flash) which occurs in typical die castings and the amount of metal extension material which remains after (1) degating (removal of any gates and runners from the casting), and (2) co
26、mmercial trimming of die casting metal extension.Note that in some instances, where special surface finish characteristics are not involved, the most economic method of degating and metal extension (flash) removal may include a tumbling or vibratory deburring operation.Surface Finish, As-CastGeneral
27、 Guidelines for As Cast Surface Finish on Die Cast PartsThe specification of external surface finish requirements is desirable for selected die casting applications and, in the case of some decorative parts, essential.The purpose of the guidelines presented here is to classify as-cast surface finish
28、 for die castings into a series of grades so that the type of as-cast finish required may be addressed and defined in advance of die design.These guidelines should be used for general type classification only, with final surface finish quality requirements specifically agreed upon between the die ca
29、ster and the customer.The first four classes listed relate to cosmetic surfaces. Class five relates to selected surface areas where specified surface finish limitations are required.7 Die Cast Lettering and OrnamentationLettering, medallions, logotypes, trademarks and a range of identification symbo
30、ls may be reproduced on the surfaces of die cast parts.Such as-cast ornamentation may be raised or depressed, but note that raised lettering will result in lower die construction costs and reduced die maintenance over the life of the die.Raised lettering on a depressed panel can be an economical sub
31、stitute for depressed letters, as shown in the illustration below.Cast-in Lettering/Ornamentation GuidelinesIn addition to the avoidance of depressed lettering or symbols in the casting surface, the following guidelines will achieve the most satisfactory results. The terms used refer to the illustra
32、tions below.1. The Line Thickness (or “face”) of any letter to be clearly cast should be 0.010 in. (0.254 mm) or greater.2. The Height (or raised dimension) of a cast letter or symbol should be equal to or less than the line thickness.3. The Draft Angle should be greater than 10.4. Letters or symbols containing fine serifs or delicate lines cannot be expected to die cast cleanly.