General Tolerances

These tolerances apply as a general rule of thumb. Closer tolerances can be obtained depending on part design or the use of special procedures or secondary operations.
INDEX:
[ CASTING TOLERANCES | FLATNESS | STRAIGHTNESS ]
[ CONCENTRICITY | ROUNDNESS-SOLID BARS | ANGLES ]
[ HOLE POSITIONING | BLIND HOLES | PARALLEL SECTIONS ]
[ WALL THICKNESS | ROUNDNESS-HOLLOW TUBING ]
[ SURFACE FINISH ]

CASTING TOLERANCES

U.S.METRIC
Up to 1.000 in.±.005 in.Up to 25 mm±.127 mm
Up to 2.000 in.±.010 in.Up to 50 mm±.254 mm
Up to 3.000 in.±.015 in.Up to 75 mm±.381 mm
Up to 4.000 in.±.019 in.Up to 100 mm±.483 mm
Up to 5.000 in.±.022 in.Up to 125 mm±.559 mm
Up to 6.000 in.±.025 in.Up to 150 mm±.635 mm


FLATNESS

Flatness refers to single plane surface and is usually a function of volumetric shrinkage.

U.S.METRIC
ThicknessDish per 6 sq. inches of surfaceThicknessDish per 42 sq. cm of surface
Up to .250 in.insignificant Up to 6.5 mminsignificant
.251 in. to .500 in..004 in. TIR 6.5 mm to 13 mm.102 mm TIR
.501 in. to 1.000 in..008 in. TIR 13 mm to 25 mm.201 mm TIR
1.001 in. to 2.000 in..016 in. TIR 25 mm to 50 mm.406 mm TIR


STRAIGHTNESS

Tolerances for axial straightness: ±.005 in. per inch (±.127 mm per 25 mm) as cast.


CONCENTRICITY

  1. Concentricity of diameters in a shaft is also a function of straightness. Centers will be concentric within .005 in. per inch (±.127 mm per 25 mm) of maximum separation.
  2. Centers of I.D. to O.D. will be concentric within .003 in. per 1/2 in. (.076 mm per 13 mm) of wall thickness. This disregards out-of-roundness, and assumes measurements in the same plane If the concentricity is being measured in separate planes, the requirements of paragraph 1 above must be added.


ROUNDNESS-SOLID BARS

Roundness is a function of normal shrinkage variations in the metal. Shrinkage variation increases with diameter and the tolerance required increases proportionately. A general rule of ±.005 in. per inch (.127 mm per 25 mm) may be applied.

ANGLES

As-cast tolerances of angles depend on their location in casting. They range from ± 1/2° for well supported positions to ± 2° where inherent distortion could be expected. Inclusion of gussets and ribs often minimizes distortion and many sections can be mechanically straightened.

HOLE POSITIONING

±.005 in. per inch (.127 mm per 25 mm) from any single reference point.

BLIND HOLES

Blind holes can be cast if length does not exceed the diameter. In nonferrous materials, blind holes under 2 in. (6.5 mm) may be cast if length does not exceed twice the diameter.

PARALLEL SECTIONS

Controlling relationship is between length and width of the elements being checked. To establish a specific tolerance range for all combinations would be impossible, but a general tolerance of .010 in. TIR per inch (.254 mm per 25 mm) may be used.

WALL THICKNESS

U.S.
MINIMUM WALL
METRIC
MINIMUM WALL
MetalSmall AreaNormalSmall AreaNormal
Beryllium Copper.035 in..050 in..899 mm1.270 mm
Ductile Iron.035 in..050 in..899 mm1.270 mm
Aluminum.040 in..060 in.1.016 mm1.524 mm
300 Series Stainless.040 in..060 in.1.016 mm1.524 mm
Cobalt Chrome.040 in..060 in.1.016 mm1.524 mm
400 Series Stainless.045 in..070 in.1.143 mm1.778 mm
Carbon Steel.050 in..080 in.1.270 mm2.032 mm


ROUNDNESS-HOLLOW TUBING

As-cast tolerances are ± .005" per inch (± .127 mm per 25 mm). Tubular section out-of-roundness may be altered mechanically according to wall thickness and ductility. Tolerances are as follows:
U.S.METRIC
DiameterTolerancesDiameterTolerances
Up to 1 in..006 in. TIRUp to 25 mm.152 mm TIR
1 in. to 1 1/2 in..008 in. TIR25 mm to 37.5 mm .203 mm TIR
1 1/2 in. to 2 in..010 in. TIR37.5 mm to 50 mm .254 mm TIR
2 in. to 3 in..015 in. TIR50 mm to 75 mm.381 mm TIR


SURFACE FINISH


Metal
MICRO-INCHES
Average RMS value
MICRO-METERS
Average Ra value
Aluminum60-1001.50-2.50
Beryllium Copper60-1001.50-2.50
Cobalt Chrome80-1002.00-2.50
300 Series Stainless90-1252.25-3.20
Carbon Steel90-1252.25-3.20
400 Series Stainless100-1252.50-3.20


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