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IS 10604-1 (1983): Machining allowances and tolerances for
open die steel forgings, Part 1: carbon and low alloy steel
forgings [MTD 16: Alloy Steels and Forgings]






(Reaffirmed 2001)
IS : 10604 ( Part 1) - 1983
I ndian Standard
SPECI FI CATI ON FOR MACHI NI NG
ALLOWANCES AND TOLERANCES FOR
OPEN DI E STEEL FORGI NGS
PART 1 CARBON AND LOW ALLOY STEEL FORGINGS
Steel Forgings Sectional Committee, SMDC 21
Chairman Representing
SHRI B. K. ANA-AH WG Forge & Allied Industries Ltd, Thane
Members
ADDITIONAL DIRECTOR ( MET ),
RDSO, LUCKNOW
Ministry of Railways
SENIOR CHEMIST & METALLURGIST,
WHEEL & AXLE PLANT, BANGALORE ( Alternate )
SHRI BRIJESH K. AGGARWAL All India Metal Forging Association, New Delhi
SHRI D. P AGGARWAL ( Alternate )
SHRI B. CHA~~~RJI Hindustan Aeronautics Ltd. Bangalore
Smtr P. P. CHOPRA HMT Ltd, Bangalore
SHRI A. SHANTHARAM ( Alternate )
SHRI S. K. JAIN Directorate General of Technical Development,
New Delhi
Smu K. C. P. NAIR ( Alternate )
SHRI H. A. JAISINGHANI Mahindra & Mahindra Ltd, Bombay
Smu A. R. RANADIVE ( Alternate )
SHRI R. JAYARAMAN Hindustan Shipyard Ltd, Vishakhapatnam
SHRI A. SESIUGIRI RAO ( Alternate )
!Q-m R. C. JHA Alloy Steels Plant ( SAIL ), Durgapur
SHRI P. L. TALWAR ( Alternate )
SHRI V. V. KAVISHWAR Bhilai Steel Plant ( SAIL ), Bhilai
SHRI B. M. K. BAJPAI ( Alternate )
SHRI V. B. KHANNA Dire&o;:; General of Supplies and Disposals, New
SHRI D. K. PAUL ( Alternate )
SHRI S. S. LAKKUNDI Bharat Forge Co Ltd, Pune
SHRI K. C. G~GATE ( Alternate )
SHRI P. MEHRA
Association of Indian Drop Forging and Stamping
Industries, Bombay
SHRI O.B. DIAS ( Alternate )
( Continued on page 2 )
0 Copyright 1984
INDIAN STANDARDS INSTITUTION
This publication is protected under the Indian Copyright Act ( XIV of 1957 ) and
reproduction in whole or in part by any means except with written permission of the
publisher shall be deemed to be an infringement of copyright under the said Act.





IS:10604(Partl)-1983
( Continuedfrom page 1 )
Members Representing
DR T. MUKHERJEE Tata Iron and Steel Co Ltd, Jamshedpur
SHRI S. A. HAQUE ( Alternate )
SHRI S. B. PAL Ministry of Defence ( DGOF )
SHRI B. BANDYOPADHYA ( Alternate )
SHRI B. RADHAKRJSHNAN Ashok Levland Ltd, Madras
SHRI U. JAIKRISHNA ( Alternate )
DR G. RAI
Research and Development Centre for Iron and
Steel ( SAIL ), Ranchi
DR S. K. MUKHERJEE ( Alternate )
SHRI S. P. RAO
WG Forge & Allied Industries Ltd, Thane
SHRI B. N. SAHA Ministry of Defence ( DGI )
SHRI N. R. PAUL ( Alternate )
SHRI S. SATHYANARAYANA Bhardt Heavy Electricals Ltd
SHRI U. MOHAN RAO ( Alternate I )
SHRI A. K. MITTAL ( AZfernate II )
DR R. SHARAN National Institute of Foundry and Forge Techno-
loav. Ranchi
SHRI N. P. SAKSENA ( Alternate )
&RI S. R. SHARhfA Tata Engineering and Locomotive CO Ltd,
Jamshedpur
SHR~ P. P. PURANIK ( Alternnte )
SHRI S. R. SRINIVAWN Shardlow India Ltd, Madras
SHRI R. S. K. RAMAN (, Alternate )
SHRI A. D. SUR
Heavy Engineering Corporation, Ranchi
SHRI S. MAZUMDAR ( Alternate )
SHRI SUIUNDRA KUMAR Central Boilers Board, New Delhi
SHRI K. RAGHAVENDRAN,
Director General, IS1 ( Ex-officio Member )
Director ( Strut & Met )
Secretary
SHRI S. D. CHOIJDHRY
Deputy Director ( Metals ), IS1
Panel for Heavy Steel Forgings, SMDC 21 : PI
Convener
SHRI U. MOHAN RAO
Members
Bharat Heavy Electricals Ltd, Hyderabad
SHRI R. N. MAHENDRU ( Alternate I
to Shri U. Mohan Rao )
SHRI UMA KANT ( Alternate II
to Shri U. Mohan Rao )
SHRI R. C. JHA
Alloy Steels Plant ( SAIL ), Durgapur
SHRI R. C. MODI ( Alternate )
SHRI S. S. LAKKUNDI
Bharat Forge Co Ltd, Pune
SHRI P. N. LAXMINARAYAN ( AZternate )
( Continued on page 15 )
2





IS : 10604 ( Part 1) - 1983
Indian Standard
SPECI FI CATI ON FOR MACHI NI NG
ALLOWANCES AND TOLERANCES FOR
OPEN DI E STEEL FORGI NGS
PART 1 CARBON AND LOW ALLOY STEEL FORGINGS
0. FOREWORD
0.1 This Indian Standard (Part 1 ) was adopted by the Indian Standards
Institution on 18 May 1983, after the draft finalized by the Steel Forgings
Sectional Committee had been approved by the Structural and Metals
Division Council.
0.2 The tolerances for open die steel forgings were earlier covered in IS :
3469-1966. However, when the standard was revised it was agreed to pre-
pare separate standards covering tolerances for open and closed die steel
forgings. Accordingly the following standards covering the tolerances for
closed die steel forgings have already been published:
IS : 3469 ( Parts 1 to 3 ) - 1974 Tolerances for closed die steel forgings
(first revision ).
0.3 This standard ( Part 1 ) deals with tolerances for open die steel forgings.
Part 2 of this standard covers forgings made from high alloy steels.
0.4 Additional allowances due to warpage and twist (circular and rectangu-
lar ) have not been covered for the present and if required may be agreed to
between the purchaser and the supplier.
0.5 For the purpose of deciding whether a particular requirement of this
standard is complied with, the final value, observed or calculated, express-
ing the result of a test, shall be rounded off in accordance with IS : 2-1960t.
The number of significant places retained in the rounded off value should
be the same as that of the specified value in this standard.
1. SCOPE
1.1 This standard ( Part 1 ) covers the machiningallowancesand tolerances
for open die steel forgings made from carbon and low alloy steels.
2. MACHINING ALLOWANCES AND TOLERANCES
2.1 These shall be as given in Tables 1 to 7.
*Tolerances for steel drop forgings, upset forgings, press forgings and forged bars.
fRules for rounding off numerical values ( revised ).
3















TABLE 2 MACHI NI NG ALLOWANCES AND FORGI NG TOLERANCES ON LENGTH FOR FREE-FORGED
PLAI N OR STEPPED SHAFTS (PRESS FORGI NGS )
All dimensions in millimetres.
DIAMETER
LENGTH I OF THE FINISHED PRODUCT, mm
& oF THp_
FINISHED
r________-500__-1000_-----h__-----~---
------_)
OVER+ - 1 600 2 500 3 750 5 400 7 500 10 000 13 000
PRODUCT UP TO + 500 1000 1 600 2 500 3 750 5 400 7 500 10 000 13 000 16 000
ALLOWANCES ON LENGTH
$15 +20 +25 +30 +35 +40 +45 +50
+55 $60
up to 500 30 35 40 45 50 60 70 80 90 100
-10 -10 -15 -20 -25 -30 -35 -40 -45 -50
+20 5 +30 +35 +40 +45 $50 +55 $60 -1-65
501 to 1 000 35 40 45 50 60 70 80 90 100 110
-10 -15 -20 -25 -30 -35 -40 -40 -50 -55
+25 +30 +35 +40 1-45 +50 +55 $60 +65 +70
Above 1000 40 45 50 60 70 80 90 100 110 120
-15 -20 -25 -30 -35 -40 -45 -50 -55 -60
NOTE - Machining allowances and forging tolerance are:
a ) applicable for both circular and rectangular shafts, and
b ) upper limit of tolerance will be 40 percent more for stepped sections.





IS : 10604 ( Part 1) - 1983
TABLE 3 MACHI NI NG ALLOWANCES AND FORGI NG TOLERANCES ON
LENGTH FOR FREE-FORGED PLAI N OR STEPPED SHAFTS
( HAMMER FORGI NGS )
All dimensions in millimetres.
DIAMETER~&OF LENGTHI) OFFINISHED PRODUCT, mm
THE FINISHED
PRODUCT
r----
_____A-_----_--_~
OVER-f - 500 1000 1600 2500
uPTO-+ 500 1000 1600 2500 3 750
ALLOWANCESONLENGTH
up to loo
+8 +10 +15 +20 +25
20 25 30 35 40
-4 -5 -8 -10 -15
101 to 250
+15 +20 f25 +30 +35
30 35 40 45 50
-8 -10 -15 -20 -25
NOTE - Machining allowances and forging tolerances are:
a ) applicable for both circular and rectangular shafts, and
b ) upper limit of tolerance will be 40 percent more for stepped sections.
TABLE 4 FORGI NG ALLOWANCE AND TOLERANCE ON FLAT SECTI ONS
u, b and i are machined sizes
-5
FORGIN~ALLOWANCEANDTOLERANCEON a AND b
<1:7
Normal working allowance and tolerance according to Tables I ,2
and 3 for size a and b
< 1:s
For size a, increase allowance and tolerance by 15 percent
<1:9
For size a, increase allowance and tolerance by 30 percent
< 1: 10 For size a, increase allowance and tolerance by 75 percent
> 1: 10 To be decided by the technologist on individual basis
NolIZ - Forging allowance and tolerance on a and b will be determined separately
according to a and I and b and I respectively.
7





IS : 10604 ( Part 1) - 1983
2.2 Additional forging allowance due to eccentricity in stepped shafts
including rolls shall be calculated as given in Fig. 1. The value so calculated
shall be added to the diameter when I> 8dl and di/ dz or dt/ ds > 16.
u
iij
5 20 - - 25 . - 30
' i i
5 15 . - 20 - - 25
s
$ 10 - - 15 - - 20
z! 5 - - 10 . - 15
a - 5 - - 10
E
%
0 0 0
1. 6 2. 0 2. 5 3. 0 3. 5 6. 0
ddd2
FIG. 1 METHOD OF CALCULATING ADDITIONAL FORGING ALLOWANCE
DUE TO ECCENTRICITY IN STEPPED SHAFTS INCLUDING ROLLS
3. TECHNOLOGICAL INSTRUCTION FOR FORGING STEPPED
FLANGED AND NECKED SHAFTS
3.1 In case of stepped shafts ( round or square > where ratio between two
adjacent dimensions of any step, for example, dl/dz or dl/ds or dz/ ds ( Fig. 2 )
< 16, allowance and tolerance for dl, dz and da, I I , 12 and 23 and I will be
on the basis of dl and 2 as per Tables 1, 2 and 3.
8
--





IS : 10604 ( Part 1 ) - 1983
T.aLE 5 MACHLilNG ALLOW.+NCE ,AND FORGLYG TOLF&%MXS FOR FREE-FORCED
I. SOLID BLAXKS. 2. HOLLOW EL&-KS
(whersh<d,d,$!3d)
---- flNlSHE0
PROOUCT
- FORGING
-.
OUTSIDE
HGNT h OF THE FINISHED Pno~ucr
DIAMFIFR r_____-___-----~_-___~- __________L_----------------
d OP nw OVFR + - 40 63 loo 160 200 250 31s
FINISHED UP TD AND
PRooun INCLUDING- .40 63 100 160 200 250 315 Jo0
ALLOW.~NCE ON
From To d h d h d h d h d h d h d h d h
63 100 8 L? 7 -2 8%2 7i2 9 z2 ar2 - - _ _ _ - - - - _
101 160 813 7.72 9_t3 8+2 9:3 8+2 IO-3 9-3 - - _ _ _ _
161 200 9 L-3 8f3 973 8z3 llz4 9t3 13 A:4 I2 :3 15-4 13+4 - - _ _ _ _
201 250 1014 9-?3 12 i-4 9+3 14I4 IO 4 1x5:5 14x.4 18 I5 16-4 20~5 IRA5 - _
251 315 126 IO-4 14 -6 10?~4 17-6 12L4 20+7 IS--5 22e.7 IS -6 22 -7 xl fi 24. 8 22 7 _ _
316 400 - - 16 ~6 12:4 19-7 13 L5 22+8 16-6 24-~8 18 --6 25 9 to-7 x-10 22:~s 27 -1, 25J.0
401 so - - 22LR 14-6 25+9 1677 25-10 22-7 29.11 24LR 30112 25-9 32 -13 !n+lC
- _ _ _
- _ _
- _ _ _
- _
- _ __
501 630
631 800
ROI loo0
IO01 I250
15-13 72711 - _
_ - - - 2519 17.1 30+10
2258 32-11 26.-8 3~12 SO+) 36~13 32ilO 37-13 _ 3371n 75-14 34fll JO=l5 35713
- -
29-10 21 :-8 34i1l 2759 36tl2 30~9 3Brl3 33+lfl 4OtI4 34111 42*l5 35:11 43 -16 3712 Wtl 38513
-
- 34Ll2 28+9 38i12. 33tl0 401-13 35110 42~14 3R:l1 44+15 38+12 46516 39~12 48-_17 41~~13 51+19 41tll
- 40~13 35~10 43*13 38511 45*14 39111 47tl5 4l+l? 49+16 41+13 5111: 43Ll3 53:1x W=ll 55-_19 44LI5
_ _
_ __ _ _
_ _ _
_ _ _
_ _
_
_
$518 39tl4 - -
52.19 41+\5 53+X 4ltl6
57--x 44tl6 55 --21 45-17
1251 1600
-
- 49514 42+12 52&15 44-12 53~16 441-13 54~17 45514 56ClS 46514 58-c19 46.:IS 6liO 47_16 62=2l 47--l 63,22 47-1s
NOTE - In case of hollow blanks allowances on d, are ID be taken 50-A mote than that on d.
9










IS : 10604 ( Part 1) - 1983
TABLE 7 ADDI TI ONAL MACHI NI NG ALLOWANCE FOR FREE-FORGED
THI N WALLED RI NGS
All dimensions in millimetres.
( Over the Allowance for Ring >
OCJ TSIDE DIAMETER
WALL THICKNESS OF m PRODUCT
d OF THE
_-__------A_---___-__
FINISHED PRODUCT OVER-+ 6.3
UPTO AND -4 63 10 :6 24 ::
FROM To INCLUDING+
ADDITIONAL MACHINING ALLOWANCE, PERCENT
Whenh$d,d,>-$d
1:: 160 100 :: Z8 G z I - -
I 61 200 50 40 30 20 - -
201 250 251 315 ix % :: :: 20 -
316 400
t: 2:
40 30 20
401 500 50 20
501 630 I O 60 50
% ::
20
3.2 Eccentricity Allowance - Additional machining allowance has to be
provided to take care of the eccentricity between the steps.
3.2.1 In case of shafts where d/d2 or dzld3 or dl/h ( Fig. 2 ) 3 16 and
08 dl < I < 8 dl, provision for eccentricity allowance has to be considered
in the sections where the condition satisfies.
Eccentricity allowance = (dl - dz) 005 or (d2 - ds) 003
3.2.1.1 In case of multistepped shafts this allowance has to be considered
for each step where the above condition satisfies and the maximum of the
eccentricity allowance to be provided on sections by the technologist keeping
in view the economics of material and process.
3.2.2 In case of shafts where I > 8 dl and dl/dz or dlld3 > 16 eccentricity
allowance has to be provided as per Fig. 1.
4. SHAPE OF FORGING
4.1 Stepped Shafts - See Fig. 3.
4.1.1 Minimum Height of Steps
Hmin=( TL+Tu) ( l-&) >
where
3
TL = lower tolerance, and
TV = upper tolerance.
11
5 mm for Di < 100, and
10 mm For Dr > 100





Is:10604( Part 1 ) - 1983
c
L
+dl
W2
\
--,- --__ .$,dj __ ._
1
f
f
1
r
1
1
12
I_
3 _
I
W
c
2A Stepped Shaft
26 Flanged Shaft
+%I
+
J
Wl _._-.Ad2
-l
1 3
I f
C--[l-r--
? _
1
rr
5
I
2C Necked Shaft
NOTE - Dimensions indicate machined size only.
FIG. 2 FIXING OF FORGING ALLOWANCES AND TOLERANCES
TO THE SHAPE OF FORGINGS
ACCORDING
- - - - - g;y:f
- FORGING
NOTE - After providing allowances and tolerances as per 3.1 and 3.2, the above
forging sketch is prepared.
FIG. 3 STEPPED SHAFT
12





IS : 10604 ( Part 1) l 1983
4.1.2 Maximum Range of Steps
-$- < 25;
-$- < 25;
In case the ratio of steps is more than the permissible maximum ratio,
suitable technological allowance has to be provided to bring the ratio within
limit.
4.1.3 Minimum Length of EndStep
0:
1
hm,n=04 7 2 011 B -
D3
2 width of pallet
4.1.4 Minimum Distance Between Steps
(DI -Dz)
a) kmin= 12 3
b) 120: + I3D: > 040:
4.2 Flanged Shaft ( see Fig. 4 )
where
DE
a) zor ~1
DM > 15 but < 25, and
b) LE < O~DE or LM < 05 DM
FIG. 4 FLANGED SHAFI
4.2.1 Minimum Width of End Flange
LEmin 5
DE- DI
2 + 007& > 70 mm
4.2.2 Minimum Width of Middle Flange
LMmin =
[
D+ + 007&,f
I
07 > 70 mm
4.3 Necked Shaft ( see Fig. 5 >
13





IS : 10604 ( Part 1) - 1983
FIG. 5 NECKED SHAFT
D2mimin = DI
WP
J-
-
12
where
WP = width of pallet, and
Dl = smaller of the end diameters of the neck in case the flange
diameters are not equal.
In case D2 < D2min, technological allowance has to be provided.
14





Is : 10604 ( Part 1) - 1983
( Continued from Page 2 )
Members
Representing
SHRI P. MAITRA
Mahindra Ugine Steel Co Ltd, Bombay
SHRI K. A. MANDANNA
Visvesvaraya Iron & Steel Ltd, Bhadravati
SHRI S. S. VEERABHADRARADHYA ( Alternate )
DR G. RAI
Research and Development Centre for Iron and
Steel ( SAIL ), Ranchi
REPRESENTATIVE
National Metallurgical Laboratory ( CSIR )
Jamshedpur
SHRI J. B. SAXENA
Ministry of Defenct ( DGOF )
SHRI D. K. DAS G~PTA ( Alternate )
SHRI A. D. Sun
Heavy Engineering Corporation, Ranchi
Srinr S. MAZUMDAR ( Alternate )
15