AA-SPC18-2000.pdf

Standards f o r Aluminum Sand and Permanent 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 03:27:32 MDTNo reproduction or networking permitted without license from IHS -,-,- ABOUT THE ALUMINUM ASSOCIATION The Aluminum Association, based in Washington, DC with offices in Detroit, MI, represents primary producers of aluminum, recyclers, and producers of semi-fabricated products. Member companies operate almost 200 plants in 37 states. NOTICE Disclaimer The use of any information contained herein by any member or non-member of The Aluminum Association is entirely voluntav. The Aluminum Association has used its best efforts in compiling the information contained in this book. While the Association believes that its compilation procedures are reliable, it does not warrant, either expressly or impliedlx the accuracy or completeness of this information. The Aluminum Association assumes no responsibility or liability for the use of the infor- mation herein. The Aluminum Association published standards, data, specifications and other technical materials are reviewed at least every five years and revised, reaffirmed or withdrawn. Users are advised to contact the Aluminum Association to ascertain whether the information in this publication has been superseded in the interim between publication and proposed use. 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 03:27:32 MDTNo reproduction or networking permitted without license from IHS -,-,- PREFACE Standards For Aluminum Sand and Permanent Mold Castings THE ALUMINUM ASSOCIATION CASTING STANDARDS PROGRAM Aluminum permanent mold and sand castings are widely used in all types of applications due to aluminums exceptional characteristics and the great design flexibility inherent in these two casting processes. Historically, foundries each used their own individual standards covering the various aspects of permanent mold and sand castings. As new techniques and molding materials became available, they also contributed to further variations. The variations in that information, along with the lack of data in many areas, indicated the need for reliable and realistic criteria to which castings could be consistently produced. These criteria would provide all persons involved in the procurement of castings with an instrument by which they could expect foundries to base proposals and produce castings to a specific quality level. Therefore, The Aluminum Association, as a service to the customers of the industry, prepared this guide for designers, engineers, buyers and production personnel as to the most economical use of the permanent mold and sand casting processes. This guide has two series of product standards: E Series, Engineering Standards and M Series, Metallurgical Standards and Data. Dimensions, tolerances and other quantities expressed in both U.S. customary and Metric units in these standards are not necessarily identical due to rounding practices used by the committee. Where standards bear dates other than 2000 (e.g.: AA-CS-M9-74), they have nonetheless been reviewed and reaffirmed by the committee in 2000. These Product Standards are not intended to be limiting in any way but rather they are expected to provide a measure of optimum conditions for the most economical use of the processes included and to provide consistency in terminology and definition, thereby resulting in a better understanding between supplier and user. The use of these standards by any member or nonmember of The Aluminum Association is voluntary and issuance or existence of these standards does not in any respect prevent or restrict any member or nonmember from manufacturing or supplying products not in conformance with these standards. As all published material is subject to change as new experience is gained, it is suggested that the data contained herein be verified with The Aluminum Association if there is any doubt as to their current validity. FOURTEENTH EDITION MARCH 2000 This issue supersedes all prior issues. O Copyright 2000, The Aluminum Association, Inc. Unauthorized reproduction by photocopy or any other method is illegal. 1 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 03:27:32 MDTNo reproduction or networking permitted without license from IHS -,-,- INDEX Standards For Aluminum Sand and Permanent Mold Castings E- 1 E-2 E -3 E 4 l m - 1 E-5 E-6 E-7 E-8 E-1 O ,/ ?TJ E-13 - 1 E-14 E-15 E-16 E-17 ? q - E-18 E-19 - 1 E-20 E-21 M- 1 M -2 M-3 M-4 M-5 M-6 M-7 M -8 M-9 M-10 M-11 ENGINEERING SERIES (E) LINEAR TOLERANCES-One Side of Parting Line LINEAR TOLERANCES-Across Parting Line LINEAR TOLERANCES-Cored Areas; Sand and Moving Parts DRAFT REQUIREMENTS AND INTERPRETATION FLATNESS -STRAIGHTNESS HOLES AND POCKETS-Sand Cast HOLES AND POCKETS-Permanent Mold PROFILE TOLERANCE EJECTOR PIN MARKS FLASH R EMOVAL-Snagging, Grinding, Removal of P/L, Chill Marks, Gates and Risers ANGULARITY - PERPENDICULARITY - PARALLELISM CONCENTRICITY MACHINE FINISH ALLOWANCE POSITIONAL TOLERANCE WALLS, FILLETS Sand and Moving Parts Standards For Aluminum Sand and Permanent Mold Castings NOTE: The values shown herein represent normal production practice at the most economic level. Greater accuracy involving extra close work o r care in production should be specified only when and Mere necessary since additional costs may be inuohred. Conversely, more iiberal vaiues should be in- dicated, when acceptable, as these tend to keep costs to a minimum. Any variations in these values shall not be binding on the foundry unless accepted in miting. The use of sand and/or metal cores broaden the design flexibility of sand and permanent mold castings by allowing a hole or undercut to be produced in a surface of a casting perpendicular to the parting plane. Since these cores are separate from the sand or metal mold there must be a clearance allowance for pla- ment or movement. Such allowances create an added variation in dimensions of a surface produced by the core to a surface produced by the mold. The amount of this additional tolerance is governed by the projected area of the core. Projected Area x times y ADDITIONAL TOLERANCE, in., mm For over 1 O00 in2 (6500 cm2) of projected area, consult foundry. Metal Core +.O32 I . 8 1 NOTE: The above tolerances are to be added to those determined for a dimension as provided in Standards E l and E2. Dimensions wholly within the area of a single core need not have this tolerance added; linear tolerance, only, would apply. t 6 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 03:27:32 MDTNo reproduction or networking permitted without license from IHS -,-,- ENGINEERING SERIES (E) AA-CSE4-92 DRAFT REQUIREMENTS Pagelof2 Standards For Aluminum Sand and Permanent Mold Castings NOTE: The values shwn herein represent normal production practice at the most economic level. Greater ac- curacy involving extra close work o r cafe in production should be specified only when and where necessary since additional costs may be involved. Conversely, more liberal values should be indicated, when accept- able. as these tend to keep costs to a minimum. Any variations in these values shall not be binding on thefoun- dry unless accepted in writing. The molding procecs, the overall casting size and configuration need also be considered when specifiying draft requirements. All walls on castings that are perpendicular to the parting plane require drait or taper. This draft is not constant. It will vary with the length of draw (L). See sketches below and graph on Page 2 which applies to all surfaces except cored holes and pockets. II Normally the drawing does not show draft (Figure 1). Standard foundry practice is to add drait to the part. T o avoid misunderstanding, this is synonymous with saying it will add metal to the casting, thereby increasing its size and weight. Draft “d” will be added to “A“, increasing its size to “A,”. Note that added draft affects dimension “ B by decreasing its size to “BI”. This is shown in Figure 2. 4ACc Fig. 3 Lad Fig. 4 may be removed if desired but must be specified on drawing, as shown in Figure 3 . In holes, draft will be added to “a” decreasing its size to “a,”; see Figure 4. When the designer desires a hole dimension to become larger for reasons such as clearance, he should so indicate. PL 1 ALTER N ATE P/ F i g . 5 NG Fig. 6 The direction in which drait is applied is governed by the location of the parting line and will be at the foun- drys option unless otherwise specified; see Figure 5. When a parting line interrupts a surface to which draft is applied, the amount of draft to be added will be deter- mined by the longer portion of surface to be drawn. Drafts will be applied to the remainder of the surface to provide a match at the parting line; see Figure 6 , 7 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 03:27:32 MDTNo reproduction or networking permitted without license from IHS -,-,- ENGINEERING SERIES (E) AA-CSE4-92 DRAFT REQUIREMENTS Pag820f2 Standards For Aluminum Sand and Permanent Mold Castings 6 c m m s ! a E O 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 03:27:32 MDTNo reproduction or networking permitted without license from IHS -,-,- ENGINEERING SERIES (El i-; ,I GREATEST DIMENSION AA-CSE5-92 Greatest Dimension O thni 6 150 each addiional 1 thru 24 in. mm 25 thni 600 NOTE: The values shown herein represent normal production practice a t the most economic level. Greater ac- curacy involving extra close work o r care in production should be specified only when and where necessary since additional costs may be invoived. Conversely, more liberal values should be indicated, when accept- able,asthesetendtokeepcoststoaminimum.AnyMnationsinthesevaluesshall notbebindingonthefoun- dry unless accepted in writing. Pemanent Mold Tolerance in. mm within 0.020 within S O 0.003 per inch .O80 per 25 rnm FLATNESS: Flatness is that condition which exists when all points on a surface lie in the same plane. The sur- faces of castings can be measured for flatness by supporting the surface in question on three widely sepa- rated points to establish the basic plane. The flatness variation is the deviation from that plane as measured by mutually accepted methods. FLATNESS TOLERANCE: A flatness tolerance is that total deviation permitted from a plane and consists o f the distance between two parallel planes within which the entire surface so toleranced must lie. SandTolerance I For castings over 24 inches (WO.mm), consult foundry. Checking for flatness will be performed only on those surfaces specified. On castings of such configuration and/or alloy where it becomes impossible or impractical to straighten, exceptions to the above tolerances are required. In such cases the foundry should be consulted. Tolerances closer than the above can at times be obtained. Special gauges and fixtures requiring extra costs may be needed. STRAIGHTNESS: Straightness is that condition which, when matched with a true straight edge af a true flat surface, will permit full line contact along the full length. Tolerance should be discussed with foundry. 9 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 03:27:32 MDTNo reproduction or networking permitted without license from IHS -,-,- NOTE Thevalues shown herein represent normal production practice a t the most economic level. Greater ac- curacy involving extra close work or care in production should be specified only when and where necessary since additional costs may be involved. Conversely, more liberal values should be indicated, when accept- able, as these tend to keep cocts to a minimum. Any variations in these valuesshall not be binding on the bun- dry unless accepted in writing. (a 1 í b) PARTING Holes and pockets in sand castings may be produced either by incorporation as integral features of the pattern equipment (provided size limitations, draft requirements and direction of draw are satisfactory), or by insertion of separately made sand cores. These sand cores will give a flexibility of design to the pattern equipment (see figure above), but generally at a higher production cost. The limiting factors in casting holes and pockets are depth, degree of draft and the narrowest dimension across the hole. The table below lists limiting sizes, depths and draíts for holes as produced with or without separate sand cores. Note that as in the above figure, “a” refers to the shortest dimension across the base of the hole or pocket. a BaseHole diameter or Minimum dimension of recess in., mm 10 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 03:27:32 MDTNo reproduction or networking permitted without license from IHS -,-,- ENGINEERING SERIES AA-CS-E7-2000 HOLES AND POCKETS-PERMANENT MOLD Standards For Aluminum Sand and Permanent Mold Castings NOTE: The values shown herein represent normal production practice ai the most economic level. Greater ac- curacy involving extra close wdn o r care in production should be specified only when and where necessary since additional costs may be involved. Conversely, more liberal values should be indicated, when accept- able, as these tend t o keep costs to a minimum. Any variations in these values shall not be binding on the foun- dry unless accepted in writing. MINIMUM bAA DIAMETER _IBASE L=(BASE DIMENSION D I AM ETER BASE DIMENSION IN CASE OF INTERNAL CHAMBER SLOT OR POCKET FORMED BY SAND CORE INTERNAL CHAMBER FORMED BY COLLAPSIBLE STEEL CORE Holes and pockets in permanent mold castings are preferably produced by steel cores which are so incorpo- rated in the mold design that they can be withdrawn manually or mechanically during the casting cycle. Such cores require drafî for withdrawal. Sand cores may be used where normal draft cannot be tolerated, OF where internal chambers are requir