DIN AE Fo-4 Ubersetzungen von DIN-Normen Manuskriptibersetzungen Die in Kopie beigefiigte Rohiibersetzung wurde vor DIN-Sprachendienst nicht auf ihre Richtigkeit gepriift. Deshalb schlie&t das Deutsche Institut fir Normung e.V. (DIN) ausdriicklich jegliche Haftung fir deren Richtigkeit bzw. Vollstandigkeit aus. Translations of DIN-Standards Typescript translations The attached typescript translation has not been checked by DIN- Sprachendienst for its accuracy. Deutsches Institut fir Normung e.V. (DIN) cannot, therefore, assume responsibility for its correctness or completeness. Onno account shall the translation be considered authorized by DIN. Beuth Verlag GmbH Berlin ¢ Wien e ZirichUDC 621.74.002.63-034: DEUTSCHE NORMEN October 1980 621.753-1 Rough Castings Dn General tolerances and machining allowances; 1680 General Part 1 1. Scope This standard contains all the general information concerning the general tolerances (general casting tolerances) and machining allowances to be taken into consideration in the design, production and inspection of rough castings of netallic materiale. Tads general information is applicable in conjunction with standards of the series DIN 1683 to DIN 1688 and supplements the numerical values stipulated therein in relation to the respective casting materials (see also the Explanations). 2. Other applicable standards DIN 1680 Part 2 Rough castings; General tolerance system DIN 1690 (still in draft form) General technical supply specifications for metal castings 3. Nominal dimensions and nominal dimension ranges Yor the general tolerances, the nominal dimensions and nominal dimension ranges relate to the dimensions of the blank casting. The nominal dimensions of surfaces on blanks which are to be machined alsu include the machining allowance. Standards Committee on Casting (GINA) of DIN Standards Committee on Length and Shape (NGL) of DINDIN 1680 Part 1 The machining allowance to be selected is governed by the largest external dimension of the rough casting and shall be selected from the corresponding nominal dimension range. 4. General tolerances 4.1 General tolerances for rough castings (referred to in the following text ao "general casting tolerances", abbreviation: GT) are tolerances for dimensions on unmachined faces for which no special details on the required dimensional accurecy are given in the drawing. 4.2 The values of the general casting tolerances shall be taken from the standardsquoted in Section 1 in accordance with the selected degree of accuracy. If special values for wall thicknesses are not necessary for particular materials and production methods, these shall be allocated to the degree of accuracy for length dimensions. Wall thicknesses also include the Lhickuess of fillets and fins. In accordance with DIN 7182 Part 1, the degree of accuracy describes the combination of tolerances for all nominal dimensions into a tolerance series. 4.3 If, for individual nominal dimensions of the rough casting, other tolerances than those of the selected degree of accuracy are required or permitted then these shall be given in the drawing of the rough casting as numerical values at the dimension concerned. In this event, the numerical values shall where possible be selected froma different degree of accuracy stipuleted for the relevant material. 4.4 The complete range of general tolerances may bo appliod for shape and position tolerances. In the event of disadvantageous shaping of the rough casting orDIN 1680 Part 1 special requirements on the shape and position, agreement shall be reached between the client and the manufacturer regarding restricted shape and position tolerances. 4.5 In the case of a finished dimension between an unmachined and a machined face on a casting for which no individual tolerance is specified, the general casting tolerance shall be applicable provided that it is greater than the general tolerance according to DIN 7168 Part 1 given in the drawing- 5. Mould-dependent and _mould- independent dimensions The dimensional deviations on a rough casting are, amongst other things, dependent upon the positon of the mould division. Nould-dependent dimensions are dimensions in the sane nould section (upper or lower section of mould). They remain unaffected by the mould division as regards its effect on dimensional deviations (see Figure 1). Fig-1 - Mould-dependent dimensions Dimensions which are independent of the mould are formed from two or more mould sections which may lead to greater dimensional deviations than for mould-dependent dimensions.DIN 1680 Part 1 Mould-independent dimensions also include dimensions affected by cores, loose parts, extractors and dies (see Figure 2). YU Ze KL \ Fig.2 - Mould-independent dimensions The distinction made between mould-dependent and mould- independent dimensions shall only be taken into account for manufacturing methods in which they result in substantial differences in tolerances. ‘This shull be specified in the relevant standards. 6. Mould draft (conicity Mould drafts are necessary shape alterations in order to be able to separate pattern and casting mould or rough casting and permanent mould from each other. The changes in dimensions and shape due to mould drafts in relation to the nominal shape of the rough casting are not considered the same as exceeding the tolerances, see Figures 3 to 6. Fig.3 - Rough casting (nominal shape)DIN 1680 Part 1 Fig.4 - Mould draft + (material addition compared to nominal shape) Fig.5 - Mould draft - (material deduction compared to nominal shape Pig-6 - Mould draft + 8 i = internal dimension a = external dimension hs the general casting tolerances are applicable to the nominal dimensions entered, the drawing shell specify whether mould draft is to be added (mould draft +, see Figure 4), deducted (mould draft -, see Figure 5) or averaged (mould drafl +, see Figure 6). In the case of surfaces to be machined, the mould drefte shallDIN 1680 Part 1 be positioned on the rough casting so that the finished dimensions can be achieved. The size of required mould drafts shall be stipulated in the drawing, e.g. by means of reference to DIN 1511. 7. Machining allowances BZ A machining allowance BZ on rough castings is e material allowance provided in order to remove imperfections on the surface caused by the casting technique and to achieve the desired surface condition and the required dimensional accuracy by means of subsequent machining. The actual amount of material to be removed is furthermore dependent upon the actual dimensions on the rough casting which may vary within the range of the specified general casting tolerances given for an individual dimension. The machining allowance BZ.ohall be considered as a cutting allowance, i.e. in the case of rotating bodies or the machining of two mutually-opposed sides it shall, accordingly, be taken into account twice. The values of the machining allowances shall be taken from the standards quoted in Section 1. As a general rule, only one machining allowance is applicable to the whole rough casting and this shall be selected in accordance with the largest external dimension from the nominal dimension range. In drawings of rough castings, the machining allowance shall be taken into account when stipulating the nominal dimensions of the rough casting, see also Section ll. In the case of chain dimensioning - which shall however be avoided whenever possible - the machining allowance shall be stipulated under consideration of the fact that the finished part is capable of being manufactured when taking into accountDIN 1680 Part 1 all the tolerances. In the case of drawings of finished parts the machining allowance shall be specified in the drawing, see Section 8. It shall then be taken into consideration when producing the pattern. For sone material groups, two different machining allowances are standardized up to certain nominal dimension ranges. The lower value shall however only be used in such cases in which, e.g. in the case of series production, the client and manu- facturer have between them achieved optimization of the pattern apparatus, the casting method and the machining es regards the clamping faces and working faces. If machining ellowances other than the standard ones are required for individual faces of the rough casting, they shall be specified in the drawing on the appropriate face (see Figure 1). RE Fig-7 - Specification of the machining allowance and the symbol according to DIN ISO 1302 in finished part drawings (may be supplemented by the surface quality). In some cases, e.g. on steel castings, the casting manufacturer carries out pre-machining on particular faces. The faces to be pre-machined and the machining allowances required for the final machining shall be specified by the client in the drawing. The machining allowances required in order to achieve the pre- machined condition are the concern of the casting manufacturer.8. DIN 1680 Part 1 Drawing entries When dimensioning castings in the blank or finished part drawings or combinations of these, special attention shall be paid to the effects of general casting tolerances or casting tolerance, machining allowances, tolerances for the machining, datum and clamping faces, location faces, mould divisions and mould drafts. The documents forming the basis of the order, e.g. drawings, should contain the following details: a ) b) e ) Degree of accuracy Only one degree of accuracy may usually be stipulated for a casting. Deviating degrees of accuracy, e.g. for a special accumula- tion of dimensions, shall be agreed upon by the client and the manufacturer. Machining allowance Only one standardized machining allowance may usually be stipulated for casting faces to. be machined. It is governed by the largest external dimension of the rough casting, and for some material groups also by the position of the face in the casting mould. Deviating machining allowances for individual faces shall be indicated in the drawing, see Figure 7. Mould division The mould division shall be specified if the client requires the mould position to be in a particular position. It shall be indicated by means of the symbol "X" on a fine dot-dash line (see Figure 8).DIN 1680 Part 1 x Pig.8 - Indication of the mould division in drawings d) Mould drafts lf one uniform would draft io poesible for the entire rough casting, then this shall be specified in the vicinity of the title panel, e.g. mould draft +. Individuel deviating mould drafts shall be indicated on the respective faces using a reference arrow. In the case of faces to be machined, mould draft + is elwaye applicable. A special.entry is not required. e) Machining faces If finished part drawings are used to order @ rough casting, thon the machining faces, shall be indicated with symbols according to DIN ISO 1302 (see Figure 7). If it is necessary to refer to machining faces in a blank drawing, then the contour of the finished part (see DIN 15, Part 1 and Part 2) shall be indicated by means of @ fine dot-dash line, see Figure 9. Pig.) - Indication of the contour of the finished part in blank casting drawings according to DIN 15 Part 2DIN 1680 Part 1 f) Datum faces, clamping faces, location faces In the case of rough castings subjected to machining it is advisable to indicate the datum face relating to the first machining procedure. In series production it is also useful to specify the clamping and location faces. 9. Designation of general casting tolerances and machining allowances Example 1 Casting made of cast steel, without machining allowance; selected degree of accuracy GTB 18 according to DIN 1683 Part 1: Tolerance DIN 1683 - GTB 18 Example 2 Casting made of lamellar graphite cast iron, largest external dimension of the rough casting 380 mm, with machining allowance; selected degree of accuracy GTB 17 according to DIN 1686 Part 1, machining allowance BZ according to DIN 1686 Part 1 of 2.5 mm for faces at the bottom or sides of the casting mould, 3 um for upper faces: Tolerance and allowance DIN 1686 - GTB 17 - BZ 2.5/3 Example 3 For a combination of a standardized general casting tolerance (degree of accuracy) and a machining allowance not contained in the relevant material standard, the following designation is recommended: Tolerance DIN 1686 - GTB 17 Machining allowance: 6 om 10DIN 1680 Part 1 10. Testing and complaints The testing of dimensions and complaints about general casting tolerances being exceeded are regulated in DIN 1690 "General technical supply specifications for castings made of netallic materials" (still in draft form). Note: Until publication of DIN 1690, the provisions printed in the Explanations, transferred from the previous edition of DIN 1680 Part 1, August 1974 editaon, are applicable. 11. Caleulation of the nominal dimensions of rough castings The rough casting nominal dimensions (R) which are necessary in order to obtain the required finished part dimensions (F) on machining faces taking into account the general casting tolerances end the machining allowances, can be defined as follows; see also Figure 15 and Table 1. 11.1 for two-sided machining (this also includoe diameter dimensions) with addition of mouid draft Houle arate Fig.10 - for external dimensions: Ry for internal dimensions: Ry nDIN 1680 Part 1 11.2 for one-sided machining Fig.11 - for external dimensions: R, = F, + 1 x BZ for internal dimensions: Ry - 1x BZ fr Note: Attention shall be paid to the fact that in the case of parts to be machined on one side eccording to Paragraph 4.5, the general casting tolerance applies to the finished dimension if this is greater than the general tolerance according to DIN 7168 Part 1 (see also dimension 1, in Figure 15). When stipulating the nominal dimensions of rough castings it can therefore be necessary to provide an additional allowance in the region of half the general casting tolerance if the dimension may not fall short of the nominal dimension. 11.3 for step dimensions The external face of the casting shall be considered the datum face for the step dimension. 11.3.1 for two-sided machining R ——£L ler a az or ner Z ‘a s Fig.22 12DIN 1680 Part 1 11.3.2 for one-sided machining on the external face R=F+1XBZ Fig.13 Note: see also Paragraph 11.2 11.3.3 for one-sided machining on the internal face Bz ReF-1XBZ Fig. 14 Note: see also Paragraph 11.2 13DIN 1680 Part 1 11.3.4 Calculation of the nominal dimensions of rough castings using the exemple of a flanged shaft Rl Fi Fh Rh hy i Pig-15 - Flanged shaft 14DIN 1680 Part 1 Table 1 Een face! so oven casting Fermte, tor Picension! oe largest Supple: | Celculsting the er | finished |external |Smallesty Norinaly Largest! nominal dimensions Sante" |Sisenotonfecorene [aizens” | Uicens | eumen= Sette castings guetoriesgneee [tite | ten” [sion dy | 250 - £44 2456 | 250 254.4 Rd, = Fdy ~ T tr — oF @ | m0 | sar | ns [aaa | vse | 2x | rege rt +2xez+S |— \ a L | ] { or 4 | 0 | [ssa | ve | ara | ae | 2x | rayerag+2xez-St ! L 2 4 ot a | 7% | | sxe | 52 | se5 | 62 [2x | Ren ree-2X02 g i i or | 50 | [sz | ase | sea | a2 | 2x | resera-2xe2-F T CT h as | za} oa | a | 3 | ax [ryern+exereS | nn | 20 | « | sae | cape | 2m | 290 | 1x | = r+1xez j oF 6 «o | saz | 9 | rr7 | 1054 | ax | gery +2xez+ T we | «| sae | sez] ors | os urn 15DIN 1680 Part 1 Further standards DIN 15 Part 2 Lines in drawings; Examples of application DIN ISO 1302 Technical drawings; Indication of surface features in drawings DIN 1511 Foundry patterns and accessories; Manufacture and quality DIN 7168 Part 1 General tolerances (undimensioned tolerances); Length and angular dimensions DIN 7182 Part 1 Tolerances and fits; Basic concepts DIN 7184 Part 1 Shape and position tolerences; Concepts, indication in drawings Explanations In conjunction with the standards DIN 1680 Part 2 and DIN 1683 to DIN 1686, Part 1 respectively, as well as DIN 1687 and DIN 1688, Parts 1, 3 and 4 respectively, this standard concerns the general tolerances (undimensioned tolerances) and machining allowances on rough castings of various metallic materials. DIN 1680 Part 1 contains all the details which are identical for the different materials. DIN 1680 Part 2 describes the general tolerance system for rough castings whilst the other standards merely contain the numerical values of the general tolerances and machining allowances specific to different materials. This format avoids the same subject matter being dealt with in different standards. The explanations to DIN 1680 Part 2 now contain all the details on the tolerance system and its history. Concepts The previously standardised concept "undimeneioned tolerance" has now in general been replaced by the concept "general 16DIN 1680 Part 1 tolerance", so this designation has also been adopted for rough castings. Specification of the relevant DIN number, e.g. DIN 1683, indicates that it concerns general casting tolerances. This is also indicated by means of the letters "GT" in the abbreviation of the tolerance, e.g. GTB 18. After thorough consultation, the committee have altered the concept "minimum machining depth By ,3,,", still stipulated in the draft of December 1977. According to the definition of "machining allowance BZ" given in DIN 7162 Part 1 this corres- ponds exactly to the minimum machining depth. In practice this means that BZ is a desired allowance whorese the resultant actual amount of material to be machined off (cutting depth) varies in relation to the resultant deviation from the nominal dimension of the rough casting. General tolerances The general casting tolerances are combined into degrees of accuracy over a series of nominal dimensions. Allocation to particular castings is not yet possible due to insufficient research. It is expedient to specify the same degrees of accuracy for eimilar parts within a production programme. In order to prevent the tolerances from becoming disproportion- ately high in the lower nominal dimension ranges, it has been stipulated that the tolerance shall be restricted to 4 25 % of the respective nominal dimension. This is of particular importance for vall thicknesses, fine and fillets es the previously provided tolerances were in some cases as great as the nominal dimension. The rule stipulated in Paragraph 4.5 complies with previous specifications in accordance with DIN 7168. They signify that when the designer is stipulating blank dimensions he shail consider whether it is necessary to specify tighter tolerances on the finished dimension in the case of one-sided machining in order to actually achieve the finished dimension required. aqDIN 1680 Part 1 Machining allowances Machining allowances are necessary on rough castings in order to remove imperfections in the upper layers of the rough casting resulting from the casting technique and to achieve the desired surface quality and finished dimensions. Tn the standards relating to specific materials, in addition to the generally applicable machining allowance a second series has been added which can be used in cases where a smaller machining allowance is possible as a result of special agreements between the client and the manufacturer, e.g. in the case of series production, for economic reasons etc. Stipulation of this second series should if possible prevent the production of numerous works standards with restrictions on the standardized machining allowances. Shape and position tolerances Due to insufficient information from industry, the committee was still unable to standardize any details concerning shape and position tolerances. Therefore, the entire dimension tolerance range may he considered applicable. Accordingly, the surface of the rough casting may not exceed the imaginary envelope of the geometrically ideal shape and position with maximum-material-dimensions and minimum-material-dimensions (see Figure 16). Calculation of the nominal dimensions of rough castings On faces to be machined, calculation of the nominal dimensions of the rough casting is connected with a computer programme. Unfortunately it was not possible to illustrate in a summarized form the calculated results which the machining allowance and the general tolerance have to take into account. Tests by the Austrian Standards Institute have shown that by means of appropriate programmes this kind of table can be produced. If possible, such documents will be published as a supplement to 18DIN 1680 Part 1 naterial dinension Rough casting Rough - casting Wo _ —_—-a Envelope Min-material dimension e = coaxiality tolerance t roundness tolerance Fig.16 - Shape and position tolerance the present standard at a later date. Testing and complaints The stipulations concerning testing of dimensions, test certifi- cation and complaints contained in the August 1974 edition were no longer retained. They have been transferred into DIN 1690 "General technical supply specifications for castings made of metallic materials" (still in dreft form). Pending approval of the final version of DIN 1690, the following 19DIN 1680 Part 1 is applicable: a) Testing of dimensions Dimension tests shall in general be carried out by the manufacturer within the scope of the production. An additional dimension test by representatives of the client at the manufacturer's works shall however be the subject of special agreement in the order. b) Test certification When placing an order, the client and manufacturer can agree upon the issueing of a certificate concerning completed dimensional tests, e.g. in accordance with DIN 50 049. c) Complaints Complaints may only be made regarding exceeded general tolerances on rough castings if they prejudice the treatmont and use appropriate to the type of material and casting mould to any considerable extent. The client shall give the supplier the opportunity to satisfy himself that the complaint is justified, wherever possible by presenting the rejected casting and documentation concerning the castings supplied. The client shall ultimately decide upon the usability of rough castings which exceed general casting tolerances, after consulting the manufacturer. Drawing entries The section "Drawing entries" governs not only the indication of standardized general casting tolerances and machining allowances but, in addition, also how to enter tolerances and allowences other than the standardized ones on the drawing in substentiated cases. As it is undeniable that-a reduction of both tolerances and 20DIN 1680 Part 1 machining allowances is possible assuming a precise knowledge of the manufacture and processing of rough castings, the committee considers it expedient to take this fact into account and to stipulate details conforming to standards in order to avoid individual works stipulations. ar