DIN AE Fo-4
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Translations of
DIN-Standards
Typescript translations
The attached typescript translation has not been checked by DIN-
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cannot, therefore, assume responsibility for its correctness or
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Beuth Verlag GmbH Berlin ¢ Wien e ZirichUDC 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 DINDIN 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 orDIN 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 shallDIN 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 accountDIN 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 2DIN 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
10DIN 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
nDIN 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
12DIN 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
13DIN 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
14DIN 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
15DIN 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
16DIN 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.
aqDIN 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
18DIN 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
19DIN 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
20DIN 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