Casting, Dimensional Tolerances/Visual Inspection Specification (Characteristics) 16701

Engineering
Standards
Engineering Standard Number
Name CASTING,DIMENSIONAL TOLERANCES/VISUAL
INSPECTION SPECIFICATION 16701

Identifier
(CHARACTERISTICS)
Abstract
This specification establishes requirements for identification, dimensional accuracy and as-cast
condition of rough castings.
Current Release Number Std. Revision Level

122021-120 001 Page 1 of 18
CUMMINS CONFIDENTIAL
This document (and the information shown thereon) is CONFIDENTIAL AND PROPRIETARY and shall not be disclosed to others in hard copy
or electronic form, reproduced by any means, or used for any purpose without written consent of Cummins Inc.
Engineering
Standards

Identifier
(CHARACTERISTICS)
Table of Contents
Heading Page Number
Abstract .....................................................................................................................................1
Table of Contents ......................................................................................................................2
1. Scope....................................................................................................................................3
2. Applicable Documents.........................................................................................................3
3. Definitions............................................................................................................................3
4. Specifications.......................................................................................................................6
4.1. Significance and Use ...................................................................................................6
4.2. Pattern and Casting identification................................................................................6
Table 1: Casting Identification ............................................................................................6
4.3. Dimensional Tolerances ..............................................................................................7
Table 2: Cored Passage Size Tolerance ...............................................................................8
Table 3: Wall Thickness Tolerance .....................................................................................8
Table 4: Fillet and Round Tolerance ...................................................................................8
Table 5: Total Casting Tolerance.........................................................................................9
4.4. Draft .............................................................................................................................9
Table 6: Draft on Sand Casting not Defined by Master CAD Model................................10
4.5. Machining Stock ........................................................................................................10
Table 7: Machining Stock for Aluminum/Iron Castings ...................................................10
Table 8: Machining Stock for Steel Castings ....................................................................11
4.6. General Casting Appearance Requirements ..............................................................11
Figure 1: C-9 Cast Microfinish Comparator......................................................................13
Figure 2: Example of Ejector Pin Mark.............................................................................14
Figure 3: Example of Vent Mark .......................................................................................15
Table 9: Surface Cavity Acceptance Limits ......................................................................15
Figure 4: Example of Cold Shut (2 Views of Same Defect) .............................................16
Figure 5: Grinding of Hose Beads that Cross Parting Lines..............................................17
4.7. Chaplet Usage ............................................................................................................17
Appendix A: Recommended Practices for Casting Date Codes..............................................18
Table A1: Month Code ......................................................................................................18

122021-120 001 Page 2 of 18
Engineering
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Identifier
(CHARACTERISTICS)
1. Scope
This specification establishes requirements for identification, dimensional accuracy and as-cast
condition of rough castings. This specification applies to sand and permanent mold castings of all
metals and provides dimensional tolerances for castings having standard accuracy.
2. Applicable Documents
Applicable documents listed below may be obtained from the respective organizations listed in
CES 10054, Standards Organizations Addresses.
a. CES 10012, Listing, Approved Source

b. CES 10054, Standards Organizations Addresses
c. CES 10056, Glossary
d. CES 16048, Particle, Magnetic
e. CES 16136, Penetrant, Cylinder Blocks
f. CES 18111, Identification, Prod Item
3. Definitions
Terms used in this standard that have a general definition for usage in Cummins Engineering
Standards are defined in CES 10056, Glossary.
3.1. Borescope
A borescope is an instrument using rigid or flexible optical fibers for the visual inspection of
narrow cavities. The image is typically observed through an eyepiece or displayed on a screen.
3.2. Cast Dimensions
Cast dimensions are to theoretical sharp corners and the draft is additive to those dimensions.
3.3. Cavity
A cavity, in the context of this specification, is any depression or hole on the internal or
external surface of a casting. This includes, but is not limited to, gas porosity and surface
shrinkage porosity.

122021-120 001 Page 3 of 18
Engineering
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Identifier
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3.4. Cold Shut
A cold shut is an area of incomplete mold fill or a defect caused by un-fused metal. The defect
appears as a line on the surface with no metal fusion across the line.
3.5. Combustion Face
The combustion face is the surface of a cylinder head that is exposed to pressure and temperature
from engine cylinders. It is identified by the presence of intake and exhaust port openings on a
flat surface.
3.6. Cored Passage Tolerance
Cored passage tolerance is the variation from nominal between two cast surfaces produced by the
same core or mold section.
3.7. Discontinuity
A discontinuity, in the context of this standard, is any condition where the cast metal does not
exhibit a smooth, continuous cast surface. Discontinuities include, but are not limited to, cold
shuts, misruns, and cracks.
3.8. Fin
A fin is a thin, irregular ridge of metal on an external or internal surface of a casting resulting from
seepage of the molten metal into a crack in the mold or the joint between separate components of
the mold (cores, mold sections).
3.9. Flash
Flash is a thin, irregular ridge of metal on an external or internal surface of a casting, resulting from
seepage of the molten metal into the joint between separate components of the mold (cores,
mold sections).
3.10. Largest Overall Cast Dimension
The largest overall cast dimension is the largest linear dimension of the casting, including
machining stock. Addition of several drawing dimensions and machining stock may be necessary
to determine the largest overall cast dimension, but diagonal calculations do not apply.

122021-120 001 Page 4 of 18
Engineering
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Identifier
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3.11. Loose Fin
A loose fin is a thin projection from the cast surface which can be removed readily with a probe,
wire brush, chisel, or other hand-held instrument using hand pressure.
3.12. Master CAD Model (MCM)
A Master CAD Model is a Cummins controlled Computer Aided Design (CAD) model of the cast
component which includes all casting features such as parting lines, machining stock, draft, rounds
and fillets.
3.13. Permanent Mold Casting
Permanent mold casting is a metal casting process that utilizes reusable molds (e.g. “permanent
molds”) usually made from metal. Permanent mold casting may also be referred to as gravity die
casting or low pressure die casting.
3.14. Projection
A projection is any material that projects above the adjacent nominal cast surface. Projections
include, but are not limited to, fins, flash, and burned-in sand.
3.15. Smooth and Flat
Local areas on castings may be designated as “smooth and flat” to accommodate machining
locators, clamps, or for other functions that are sensitive to surface roughness or angularity. These
areas are subject to more stringent surface quality requirements than general cast surfaces.
3.16. Surface Cavity
A surface cavity is an imperfection that appears as a depression in relation to the adjacent cast
surface. Surface cavities include surface porosity and depressions formed by the casting mold.
3.17. Total Casting Tolerance
Total casting tolerance is the maximum deviation of cast surfaces from nominal location.
Generally, these are measured from initial machining locators (cast datums); however, tolerances
applied to each cast surface are not additive. Any two cast surfaces shall be within total casting
tolerance of each other.

122021-120 001 Page 5 of 18
Engineering
Standards

Identifier
(CHARACTERISTICS)
4. Specifications
4.1. Significance and Use
4.1.1. This specification applies to most cast components. Part specific standards referenced
on the component drawing take precedence over this standard.
4.1.2. This specification is intentionally general, without reference to specific components or

product families. Special sections referencing common, colloquial product names shall not be
added to this specification.
4.1.3. If more restrictive requirements are needed for a particular component, the
requirements should be noted on the drawing or in a different specification that is referenced by
the component drawing.
4.1.4. Tolerances, identification, and other acceptance criteria for exceptional parts such as
very large, pit molded castings should be specified on the drawing or a separate specification.
4.1.5. This specification applies to as-cast components. It does not address casting
imperfections exposed on machined surfaces. Acceptance levels for imperfections on machined
surfaces should be defined in specifications addressing the particular function of the machined
surface (mounting, sealing, etc.).
4.2. Pattern and Casting identification
4.2.1. All castings shall have information identified on the casting in accordance with Table 1:
Casting Identification on page 6.
Table 1: Casting Identification
All Castings Critical Castings (1)
Part number CES 18111 CES 18111

Engineering revision level Recommended Recommended
Pattern number Required Required
Note (1): Critical castings are identified by reference to CES 10012 on the drawing.

122021-120 001 Page 6 of 18
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Identifier
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Table 1: Casting Identification (Continued)
All Castings Critical Castings (1)
Supplier identification per Required Required

CES 18111
Cast date Required Required
Shell mold date Required Required
Mold cavity number Required Required
Core box cavity number Recommended Required
Heat code Optional Required
Note (1): Critical castings are identified by reference to CES 10012 on the drawing.
4.2.2. Lettering sizes from 5 mm (0.2 in.) to 15 mm (0.6 in.) raised up to 1.5 mm from the
adjacent cast surface are acceptable. Lettering should be sized appropriately for the size of the
casting. Sharp-faced Gothic letters are recommended.
4.2.3. Recommended practices for date codes are described in Appendix A: Recommended
Practices for Casting Date Codes on page 18.
4.3. Dimensional Tolerances
In determining tolerance for a specific cast dimension, one, and only one, of the Sections 4.3.1.
Cored Passage Size Tolerance on page 7 through 4.3.5. Total Casting Tolerance on page 9 will
apply to each dimension.
4.3.1. Cored Passage Size Tolerance
The variation from nominal between any two cast surfaces formed by the same core or mold
section shall be in accordance with Table 2: Cored Passage Size Tolerance on page 8.

122021-120 001 Page 7 of 18
Engineering
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Identifier
(CHARACTERISTICS)
Table 2: Cored Passage Size Tolerance
Nominal Size of Cored Dimension Tolerance
0 - 250 mm (0 - 9.8 in) ± 0.8 mm (0.032 in)

Over 250 - 450 mm (9.8 - 17.7 in) ± 1.2 mm (0.047 in)
Over 450 mm (17.7 in) ± 1.5 mm (0.059 in)
4.3.2. Wall Thickness Tolerance
Cast-to-cast wall thickness tolerance, independent of how the wall is formed, shall be in
accordance with Table 3: Wall Thickness Tolerance on page 8. The tolerance is determined by the
largest overall casting dimension, independent of the local wall thickness.
Table 3: Wall Thickness Tolerance
Largest Overall Cast Dimension Tolerance
0 - 450 mm (0 - 17.7 in) ± 0.8 mm (0.032 in)

Over 450 mm (17.7 in) ± 20% of specified wall thickness
4.3.3. Fillet and Round Tolerance
Fillets and rounds shall be in accordance with Table 4: Fillet and Round Tolerance on page 8.
Table 4: Fillet and Round Tolerance
Fillet or round size Tolerance
0 - 8mm (0.32 in) radius 0.8x radius to 1.3 x radius

Over 8 mm (0.32 in) radius ± 2.5 mm (0.1 in)

122021-120 001 Page 8 of 18
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Identifier
(CHARACTERISTICS)
4.3.4. Angular Tolerance
a. Angular tolerance for all dimensioned angles on castings shall be ± 1 deg.

b. Angular tolerance for draft is ± 0.5 deg.
4.3.5. Total Casting Tolerance
For characteristics not specified in Sections 4.3.1. on page 7 through 4.3.4. on page 9, the tolerance
shall be in accordance with Table 5: Total Casting Tolerance on page 9. Any two cast surfaces shall
be within total casting tolerance of each other. The tolerance in all directions is determined by the
largest overall cast dimension.
Table 5: Total Casting Tolerance
Largest Overall Cast Dimension Total Casting Tolerance
0 - 150 mm (0 - 5.9 in) ± 1.0 mm (0.039 in)

Over 150 - 600 mm (5.9 - 23.6 in) ± 1.5 mm (0.059 in)
Over 600 - 1200 mm (23.6 - 47.2 in) ± 2.0 mm (0.079 in)
Over 1200 mm (47.2 in) ± 2.5 mm (0.098 in)
4.4. Draft
4.4.1. When a Master CAD Model is available, the drafted cast surface shall be within the
appropriate tolerance of the nominal surface defined by the model. See Section 4.3. Dimensional
Tolerances on page 7.
4.4.2. If a Master CAD Model is not available, draft shall be applied such that it adds material
to the nominal casting dimensions.
4.4.3. If a Master CAD Model is not available, draft angle shall be in accordance with Table
6: Draft on Sand Casting not Defined by Master CAD Model on page 10. Larger angles are
permitted only when necessary to match surfaces from different mold halves at the parting plane.

122021-120 001 Page 9 of 18
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Identifier
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Table 6: Draft on Sand Casting not Defined by Master CAD Model
Length of Draw Maximum Allowable Draft
0-25mm (0-1 in) 2°

Over 25mm (1 in) 1°
4.5. Machining Stock
4.5.1. If a Master CAD Model is available, the casting geometry shall be in accordance with
the Master CAD Model. Machining stock shall not be added to the cast dimensions.
4.5.2. If a casting drawing is available, the casting geometry shall be in accordance with the
casting drawing. Machining stock shall not be added to the cast dimensions.
4.5.3. If a combined drawing (machining and casting) or a machined component drawing is

used, machining stock shall be added to the nominal machined dimensions according to Table 7:
Machining Stock for Aluminum/Iron Castings on page 10 or Table 8: Machining Stock for Steel
Castings on page 11 as applicable. Machining stock is constant for all casting surfaces to be
machined, regardless of individual feature size.
4.5.4. For components machined before delivery to Cummins, alternative machine stock may
be used subject to agreement between the casting supplier and the machined component supplier.
Table 7: Machining Stock for Aluminum/Iron Castings
Largest Overall Cast Machining Stock Machining Stock

Dimension Sand Cast Permanent Mold
0 -150 mm (0-5.9 in) 1.8 mm (0.070 in) 1.2 mm (0.047 in)

Over 150 - 300 mm 2.5 mm (0.098 in) 1.8 mm (0.070 in)
(5.9-11.8 in)
Over 300 - 450 mm 3.0 mm (0.118 in) 2.0 mm (0.079 in)
(11.8-17.7 in)

122021-120 001 Page 10 of 18
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Identifier
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Table 7: Machining Stock for Aluminum/Iron Castings (Continued)
Largest Overall Cast Machining Stock Machining Stock

Dimension Sand Cast Permanent Mold
Over 450-750 mm 3.8 mm (0.150 in) 2.5 mm (0.098 in)

(17.7-29.5 in)
Over 750 mm (29.5 in) 5.0 mm (0.197 in) 3.8 mm (0.150 in)
Any disk ground 0.8 mm (0.032 in) 0.8 mm (0.032 in)
surfaces
Table 8: Machining Stock for Steel Castings
Largest Overall Cast

Machining Stock
Dimension
0-300 mm (0-11.8 in) 4.5 mm (0.177 in)

Over 300 mm (11.8 in) 6.5 mm (0.256 in)
4.6. General Casting Appearance Requirements
4.6.1. Visual Inspection Method

4.6.1.1. Visual inspection shall be conducted without magnification and with sufficient
lighting to evaluate the exterior and interior surface of the casting.
4.6.1.2. Task lighting, flashlights, flexible lights, mirrors, rigid borescopes, or flexible/
articulated borescopes may be required for inspection of internal passages.
4.6.1.3. Surface quality limits of acceptability in this specification apply to all surfaces of the
casting as shipped from the foundry, including internal and external cast surfaces as well as
surfaces ground during the casting cleaning process.

122021-120 001 Page 11 of 18
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Identifier
(CHARACTERISTICS)
4.6.2. Appearance and Cleanliness
4.6.2.1. Castings shall be free of rust, corrosion and/or other surface scale.
4.6.2.2. Castings shall be free of loose sand, shot and other foreign material.
4.6.2.3. Castings having a generally unacceptable appearance shall be cause for rejection
independent of the other provisions in this specification.
4.6.3. Surface Roughness
4.6.3.1. Cast surface roughness should not exceed Ra of 18 um (720 micro-inch) when
determined using visual and tactile comparison to a C-9 Cast Microfinish Comparator.
4.6.3.2. Machining locator surfaces specified on drawings shall be smooth and flat.
4.6.3.3. Surfaces specified to be smooth and flat shall be free of parting line fins; shall be
drafted 1.25 degrees or less when draft is applied, shall have a surface flatness of 0.2/25 X 25, and
shall have a surface roughness not greater than Ra 11µm (420 micro-inch) when determined using
visual and tactile comparison to a C-9 Cast Microfinish Comparator (Figure 1: C-9 Cast
Microfinish Comparator on page 13).
Note: The C-9 Cast Microfinish Comparator is available from the American Foundry Society at
www.afsinc.org.

122021-120 001 Page 12 of 18
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Cast smooth and flat. General cast surface.
Figure 1: C-9 Cast Microfinish Comparator

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4.6.4. Fins, Flash, and Other Projections
4.6.4.1. Castings shall be free of sharp edges caused by fins, ground surfaces or other features
that could cause injury during handling.
4.6.4.2. Loose projections which can be removed readily with a probe, wire brush, chisel, or
other instrument, using hand pressure, shall be removed before the casting is shipped to the casting
customer.
4.6.4.3. Fins and flash shall be ground within 1.5 mm of flush with the adjacent casting
surface. The height of the allowable flash is in addition to the dimensional tolerance of the adjacent
casting surface. All sharp edges or flash shall be removed from the casting.
4.6.4.4. Blow tube, vent, and ejector pin witness marks shall be ground flush with the adjacent
casting surface within 0.8 mm (0.03 in). See Figure 2: Example of Ejector Pin Mark on page 14
and Figure 3: Example of Vent Mark on page 15.
Figure 2: Example of Ejector Pin Mark

122021-120 001 Page 14 of 18
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Figure 3: Example of Vent Mark
4.6.5. Cavities
4.6.5.1. Surface cavities deeper than one half of the local designed wall thickness are
not allowed.
4.6.5.2. Surface cavities shall conform to the acceptance limits documented in Table 9:
Surface Cavity Acceptance Limits on page 15
Table 9: Surface Cavity Acceptance Limits
Cavity Depth Acceptance Criteria
Less than ¼ local wall thickness, up to 3 mm deep Acceptable

Greater than ¼ local wall thickness Not acceptable
Greater than 3mm deep, independent of wall thickness Not acceptable
Surface cavities on machined surfaces that will be Acceptable
removed during machining.

122021-120 001 Page 15 of 18
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4.6.6. Discontinuities
4.6.6.1. No cold shuts or folds are allowed. Examples of cold shuts are shown in Figure 4:
Example of Cold Shut (2 Views of Same Defect) on page 16.
Figure 4: Example of Cold Shut (2 Views of Same Defect)
4.6.6.2. Cracks
Cracks detectable by visual inspection without magnification are not acceptable.

122021-120 001 Page 16 of 18
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Identifier
(CHARACTERISTICS)
4.6.7. Other Surface Quality Conditions
Hose beads that cross a parting line may be ground flat for a width not to exceed 5 mm (0.2 in.)
(Figure 5: Grinding of Hose Beads that Cross Parting Lines on page 17).
Figure 5: Grinding of Hose Beads that Cross Parting Lines
4.7. Chaplet Usage
4.7.1. Chaplets should be avoided or minimized to the extent possible. Where required
usage is subject to approval by Cummins Supplier Quality Improvement (SQI) and Plant
Product Engineering.
4.7.2. Chaplets shall not be used on the combustion face of cylinder head castings unless the
machining process removes them. Cummins Supplier Quality Improvement and product
Engineering shall approve any use of chaplets on cylinder head castings.
4.7.3. If a Master CAD Model is available and includes chaplet pads, the chaplet pads shall
be in accordance with the model geometry. If the Master CAD Model does not include chaplet
pads, chaplet pads may be added subject to approval by Cummins Supplier Quality Improvement
(SQI) and Plant Product Engineering.
4.7.4. If a Master CAD Model is not available, the foundry may add chaplet pads not to
exceed 15 mm diameter and 2 mm height on each side of the wall supported by the chaplet.

122021-120 001 Page 17 of 18
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Identifier
(CHARACTERISTICS)
Appendix A: Recommended Practices for Casting Date Codes
Option 1 (preferred)
The first digit(s) specify the day of the month on which the castings were poured. The day is
followed by a letter (A to M) indicating the month of the year in accordance with Table A1: Month
Code on page 18. The last digit indicates the year.
Example: 18H7 is 18th August 2007.
Table A1: Month Code
A - January G - July
B - February H - August
C - March J - September
D - April K - October
E - May L - November
F - June M - December
Option 2
A four digit number where the first three digits indicate the day of the year and the fourth digit
indicates the year.
Example: 0068 = 6th Jan 2008; 2898 = 15th Oct. 2008

122021-120 001 Page 18 of 18

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Engineering

INSPECTION SPECIFICATION 16701

Current Release Number Std. Revision Level

INSPECTION SPECIFICATION 16701

Heading Page Number

Current Release Number Std. Revision Level

INSPECTION SPECIFICATION 16701

a. CES 10012, Listing, Approved Source

3.2. Cast Dimensions

Current Release Number Std. Revision Level

INSPECTION SPECIFICATION 16701

3.4. Cold Shut

3.5. Combustion Face

3.6. Cored Passage Tolerance

3.10. Largest Overall Cast Dimension

Current Release Number Std. Revision Level

INSPECTION SPECIFICATION 16701

3.11. Loose Fin

3.12. Master CAD Model (MCM)

3.13. Permanent Mold Casting

3.15. Smooth and Flat

3.16. Surface Cavity

3.17. Total Casting Tolerance

Current Release Number Std. Revision Level

INSPECTION SPECIFICATION 16701

4.1.2. This specification is intentionally general, without reference to specific components or

4.2. Pattern and Casting identification

All Castings Critical Castings (1)

Part number CES 18111 CES 18111

Current Release Number Std. Revision Level

INSPECTION SPECIFICATION 16701

Table 1: Casting Identification (Continued)

All Castings Critical Castings (1)

Supplier identification per Required Required

4.3. Dimensional Tolerances

4.3.1. Cored Passage Size Tolerance

Current Release Number Std. Revision Level

INSPECTION SPECIFICATION 16701

Table 2: Cored Passage Size Tolerance

Nominal Size of Cored Dimension Tolerance

0 - 250 mm (0 - 9.8 in) ± 0.8 mm (0.032 in)

4.3.2. Wall Thickness Tolerance

Table 3: Wall Thickness Tolerance

Largest Overall Cast Dimension Tolerance

0 - 450 mm (0 - 17.7 in) ± 0.8 mm (0.032 in)

4.3.3. Fillet and Round Tolerance

Table 4: Fillet and Round Tolerance

Fillet or round size Tolerance

0 - 8mm (0.32 in) radius 0.8x radius to 1.3 x radius

Current Release Number Std. Revision Level

INSPECTION SPECIFICATION 16701

4.3.4. Angular Tolerance

a. Angular tolerance for all dimensioned angles on castings shall be ± 1 deg.

4.3.5. Total Casting Tolerance

Table 5: Total Casting Tolerance

Largest Overall Cast Dimension Total Casting Tolerance

0 - 150 mm (0 - 5.9 in) ± 1.0 mm (0.039 in)

Current Release Number Std. Revision Level