INTEVA TOOLING MANUAL - Inteva · PDF fileAll stamping, plaques and tool tags to be shown on tool operator side in press position 8. Miscellaneous 8.1. CMM Report on New Molds

INTEVATM, Rev G; 01/04/2013 Page 1

INTEVA TOOLING MANUAL


Contents Section 1 - GENERAL INFORMATION. Section 2 - NEW TOOL SPECIFICATIONS.

1. General Points. 2. Injection Molding. 3. Stamping Tools.

Section 3 – CURRENT PRODUCTION TOOLING 1. Modifications and Refurbishments. 2. Tooling Maintenance. 3. Tooling Condition. 4. Prototype Tooling.

Appendices’ Appendix 1 – Tooling Contact Details. Appendix 2 - Tool Terminology Injection Molding. Appendix 4 – Recommended Mould Tool Steels. Appendix 5 – Tooling Manual Form Usage. Revision Index


Section 1 - GENERAL INFORMATION 1 Scope

The purpose of this document is to ensure proper communication necessary to ensure mutual understanding of criteria used in construction of a High quality tool It is understood that die making practices commensurate with high quality dies and molds will be used in unspecified matters. All documents referenced in this manual are available on request and shown in Appendix 5 where they are to be used.

2 Performance Requirements All tools will be capable of production for the anticipated life of the component with the supplier being responsible for their maintenance, using a preventative maintenance plan to ensure that the tool is kept in good working order at all times. Records of all maintenance will be kept by the supplier and available for audit. A tooling DFMEA and process FMEA will be used to aid tool design.

3. Supplier Responsibility 3.1. All tooling to be designed and constructed to meet and/or exceed the standards contained in this ‘Tooling

Manual’ (TM). In addition, tooling shall be free from defects in materials and workmanship and free from all liens and/or claims.

3.2. The supplier will be responsible for the submission of weekly progress reports to the Tooling Specialist

(TS). 3.3. Any changes in delivery and/ or cost of a tool, requested by the tool supplier, shall be communicated in

writing immediately to the Buyer and TS.

3.4. Any request for information pertaining to the tool being built shall be directed to the TS.

3.5. All aspects of prototype and production tooling are to be kept in good mechanical and quality condition throughout the life of the product.

3.6. Inteva approval must be given before welding and all areas that are welded in order to correct errors or in

the normal course of tool building. A log must be kept throughout tooling development of any welded areas showing location, size and type of weld and rod material used. These records must be provided at tool buy-off.

A copy of the log shall also be reviewed prior to sending the tool out for texturing (if required). No shimming or repair/salvage of tool components will be allowed unless authorization from Inteva TS is

given.

3.7. The Supplier is urged to recommend any revisions, during construction or design, which they feel would provide a better tool, an equivalent tool at a lower cost or improved delivery dates.

3.8. The Supplier agrees to obtain and maintain adequate insurance for any tooling in the Supplier’s

possession and/or sub-contractor including during transportation. The tooling shall be insured for its full value against damage from loss, fire, flood, theft, explosion and other insurable risks.

3.9. All tools which are used for Inteva products (owned and/or not owned) when not used to produce

parts, are stored in a fire protected area which is physically separated from the production floor and not fitted with any fire sprinkler system.

3.10. No tool construction or material ordering should be done without formal Inteva purchase order and design

approval from TS. Any work undertaken without approval is at the supplier’s liability.


Section 2 - NEW TOOL SPECIFICATIONS. 1. General Points 1. Scope

The following are standards considered to be necessary by Inteva for construction of high quality Injection Molding and Stamping Tools and are to be adhered to unless specifically waived in writing by the signatory.

2. Tool Costs All tool cost quotations are to be submitted on the Inteva ‘Tool Cost Breakdown’ sheet. 3. Tool Makers

3.1. Inteva reserves the right to assess the toolmaker and any sub-contractors using the tooling assessment format. Supplier is to state toolmakers at time of quotation.

3.2. The tool manufacture must not be sub-contracted without the prior agreement of Inteva. 3.3. If schedule demands are such, that the original Tool Maker (if sub-contracted by Supplier) cannot

complete the tool, work will be resourced upon agreement/approval with Inteva to an alternate Tool Maker.

All related cost will be the responsibility of the Supplier.

4. Design Requirements 4.1. The tool design must be carried out in accordance with all information supplied in this document.

See Appendix 1 for Inteva ‘Tooling Contacts’.

4.2. Any deviation from this procedure must be agreed in writing with the Tooling Specialist.

4.3. Complete tool designs must be supplied with each new tool. The final tool design is to be provided electronically in native format. The final design must accurately reflect the condition of the tool as delivered and provide in full detail, including but not limited to, sections, details, schematics and material list (BOM).

4.4. The tool design is to be submitted to the relevant Tooling Specialist at Inteva as per the requirements

detailed in the ‘Tool Design Approval Document’. The tool design is subject to review before being sign-off by an Inteva Tooling Specialist.

4.5. Approval or comments to the submission will be given by the Inteva TS prior to any tool manufacturing

being started. Any work done or parts purchased without approval is at the suppliers liability. The approval given by the document does not accept liability for the tool construction and the subsequent life guarantee; it merely shows compliance to the Inteva standards.

4.6. During the design review process all critical features are to be inserted and manufactured steel safe.

4.7. After any tool modification or engineering change, the tool design must be promptly and accurately

updated.

4.8. All tool designs, tooling aids, programs etc. are the property of Inteva and will not (in total or in part) be shared with any company, secondary tool source etc. without the written approval from Inteva. Tooling aids include duplicating casts, check fixtures, EDM electrodes, CAD data, drawings and any special tooling that was necessary to produce the tool and have no capital asset value to the Supplier.

5. Construction Requirements 5.1. See Appendix 2 + 3 for Terminology References

5.2. Tool operation: Where practical, all tools to be designed to run fully automatic, with due consideration

given to robot unloading / part ejection of the components to minimize labor requirements, all to be agreed with Inteva TS.


5.3. Part Identification: To be included on multi-impression tooling, position to be mutually agreed.

For subsequent tools, back-up duplicate, the numbering sequence will be a continuation of the preceding

tool. Example:

If tool #1 is an eight-cavity tool, the numbering sequence will be 1 through 8. For tool #2, the sequence will be 9 through 16, For tool #3, 17 through 24, etc

5.4. Mold Steels: Steel Grade and Hardness to be agreed with Inteva TS.

5.5. Die Plates to be manufactured from Pre-hardened tool steel (1.2311 or 1.2312) from a standard supplier.

See Appendix 4 for Steel Recommendations.

5.6. Tool frame to be purchased from approved supplier and specified on the General assembly drawing. Approved suppliers are:-

Hasco DME DMS LKM (China)

All other suppliers to be approved by Inteva.

5.7. Heat treat specifications/certifications for all fabricated components (core, cavity, inserts, lifts, etc.) shall be included at buy-off. Main cavity and core steel certifications from the manufacturer for no porosity and/or cracks should also be included for pre-hardened.

5.8. Where standard plates are not possible bolster plates to be machined from tool steel (1.1730) from

standard suppliers, see item 5.6. Plate thickness, hole centers and details to be to suppliers specification.

5.9. Any alternatives to the above specified grades/suppliers are to be agreed with Inteva TS.

5.10. If required cost of chroming, ion implanting and etched finishes should be itemised at the quotation stage,

this must not be implemented without authorisation.

5.11. Tools should be designed to make use of standard tool components, i.e. ejectors, sleeves, guide pillars etc are to be as standard from the chosen supplier as point 5.6. In the event standard components cannot be used, the tool builder is expected to provide a list of recommended spare parts for items, which are considered perishable, along with a list of suppliers.

6. Clamping, Lifting straps & Eye Bolts.

6.1. Tools will have a safety strap which, when attached to the tool, will prevent the tool halves from separating during handling. The straps should be attached in such a manner as to remain attached to

either half at all times. 6.2. On all tools, it is essential that eyebolts (Minimum 4 per tool) are positioned so the tool hangs correctly

when suspended on the lifting mechanism using the chart below as reference. 6.3.

IMPERIAL SIZES

METRIC SIZES

WEIGHT ( KG ) WEIGHT ( LBS. )

5/8 M16 -625 -1375

¾ M20 630 - 945 1386 - 2079

1 M24 950 - 1495 2090 - 3289

1 ¼ M30 1500 - 2250 3300 - 4950

1 ½ M36 2300 - 3350 5060 - 7370

1 ¾ M42 3400 - 4450 7480 - 9790

2 M48 4500 - 6750 9900 - 14850

2 ½ M64 6800 - 14000 14960 - 30800


6.4. On Tools over 1 Ton, lifting holes required on each bolster plate, to aid assembly and maneuverability. 6.5. Tool Clamping: Tools are to be designed with extended clamp plates for direct clamping to the machine

platens. A minimum, of four direct fixing holes are required per half of tool. 7. Identification

7.1. Tool marking: Inteva specific plaque is to be issued for each new tool and should be engraved by the supplier with the relevant information.

7.2. In the event of no plaque being issued on tool completion the following minimum information must be

stamped on the tool :- Customer Component Name Component No. Closed Height Ejection Stroke:- Tool No:- Weight:- Press Size / Tonnage :- Revision Level:-

All stamping, plaques and tool tags to be shown on tool operator side in press position

8. Miscellaneous 8.1. CMM Report on New Molds. This shall include all KPC/SPC/PST points as designated by OEM

manufacturer pertaining to the part. It will also include all attachment flange locations, net surfaces, mating surfaces of the part to other components and any other areas of concern as determined by Inteva engineering. Reference diagrams must be included to reflect points checked

8.2. Keying: When inserts require to be keyed, they should be keyed in such a way the insert can only be

replaced in one direction. 8.3. Chamfers: All sharp edges which are not product related must be broken. 8.4. Inserts: Where interchangeable inserts are required, each insert must be clearly identifiable and stored in

a durable container. Where possible, die inserts to be engraved on underside with tool number & item number reference.

9. Spares/Detail Drawings

9.1. A full set of tool drawings reflecting the PPAP parts submission to be held at suppliers location at all times.

9.2. It is the supplier’s responsibility to ensure that the drawings are up to date following any modifications etc. 9.3. On receipt of PPAP approval the supplier is to send a copy of the latest up to date tool drawings, on CD,

to Inteva for the attention of the Tooling Specialist. 9.4. On receipt of PPAP approval the supplier is to send a completed ‘Tool Identification Form’ to Inteva for

the attention of the Tooling Technician. 9.5. A stock of spares as identified by the DFMEA as necessary will be held at the supplier’s plant.


2. Injection Molding 1. Scope The following are standards considered to be necessary by Inteva for construction of high class Injection Molding Tools and are to be adhered to unless specifically waived in writing by the signatory. 2. General Instructions

2.1. Shut out angles must be a minimum of 3 degrees, faces bedding out must be manufactured from dissimilar materials with differing hardness to avoid any interference. If this is not possible due to design constants it is to be agreed at the ‘Pre-award’ meeting by all parties.

2.2. Maximum draft angles must be incorporated on textured parts.

Texturing per Tenebac-Grafion: 1 ½ degrees on wall per .025mm of depth of stipple. 1 degree on wall for every degree after that.

#2 - .050mm deep - 3 degrees minimum. #3 - .075mm deep - 4 ½ degrees minimum. #5 - .125mm deep - 7 ½ degrees minimum.

2. Cooling, Insulating & Temperature Control

2.1. Cooling: All water circuits to be designed for maximum control over cores and cavities. Water channels should be minimum 5mm from the tooling surface / molding surfaces.

2.2. All cavity inserts must contain separate water circuits, where practical. 2.3. For tools with more than one cavity cut into solid steel – each cavity should have its own set of circuits.

When the cavities are identical the circuits should be also kept identical. 2.4. All mechanical devices that form part of the cavity should be cooled (e.g. slides, lifters, etc.) 2.5. Ins and Outs are preferred on side opposite the operator or bottom of mold. 2.6. All temperature control channels to be numbered, for example: - 1in, 1out, 2in, etc. 2.7. General assembly drawings to incorporate schematic water diagram. Cooling piping diagram to be

supplied with tool. 2.8. It is recommended that water connectors to be 10mm Diameter waterways for machines 100 Tons and

above and 8mm Diameter waterways for machines below 100 Ton. For large tools would need 19mm dia w/ 24mm baffles.

2.9. All water circuits to be pressure tested to 2 bar minimum.

2.10. Standard water line plugs should be used as per suppliers in item 4.6. 2.11. Protection feet: Tools must be furnished with feet to prevent damage of water connectors, when located

on the underside of the tool. 2.12. Walker’s standard specification mechanical rubber seals to be used on all tooling. All seals must remain

undamaged and compressed whilst the tools are being assembled. All ‘O’ Rings must be pocketed on three sides. For high temperature tools use Viton seals.

2.13. Insulation plates: All thermoplastic tools to be fitted with Sindanyo-L21 (asbestos free)

insulation plates on the fixed half clamp plate. 2.14 Temperature Control: - Thermocouple holes to be positioned in fixed and moving half die plates for additional temperature control.


3. Gating, Runners & Shrinkage 3.1. Gate position agreement to be given by Inteva Engineering in ‘Pre-Award’ meeting. 3.2. Supplier to identify the gate positions, number, size, type and configuration of gate on the general

assembly drawings. Details to reference any tool flow undertaken.

3.3. Runners: All runners should be totally balanced. Runners should never run on and parallel to insert lines. Whenever a runner must cross an insert line, it should cross as near to 90 degrees as possible.

3.4. Shrinkage: This is to be as per the material manufactures recommendations. 3.5. Sprue bush: Are to be standard from an approved supplier. Unless otherwise authorized, sprue length is

not to exceed 130mm. All tools to have hardened sprue bush with radii to suit machine nozzle.

3.6. When runners are cut into the tip of the sprue bushings, the bushing is to be keyed to prevent rotation.

3.7. All tools to have hardened sprue bush with radii to suit machine nozzle. 3.8. Feed gate inserts require fitting for glass filled tools. Replaceable gates must be provided in all tools that

will run corrosive or abrasive materials. 3.9. All sprues and runners to be automatically de-gated in the mold. Sub gate puller pins should be used on

all sub gates. All gates must be removed from the tool automatically upon opening of the tool and ejection of the part.

3.10. All runners will have cold slug wells machined at the end of each run and will have proper venting. Cold

slug wells should extend ½ the diameter of the runner past the end of the run.

4. Ejection 4.1. Ejector position agreement on position to be given by Inteva Engineering in ‘Pre-Award’ Meeting or by

written confirmation from Inteva Engineering. 4.2. Ejection system must be designed to eject the component from the tool free from ejector stress and

distortion.

4.3. Ejector positions and type i.e. (push/pull, spring return, two stage, stripper plate, etc.) are to be identified on General assembly drawings.

4.4. Formed ejector pins must be locked into the ejector plate per Inteva agreed method. 4.5. All bosses’ deeper than 12mm must have sleeve ejection. If it is not feasible, it must be discussed with

the TS prior to manufacture.

4.6. Ejector systems: Support pillars are to be located close as possible to high load areas, such as runners, under cavities and part trim lines. Preload is to be at a rate of 0.0125mm per 25mm distant from the nearest parallel but not exceeding 0.125mm.

4.7. All Ejector systems to be fitted with return pins.

4.8. Where larger ejection plates are used multiple connections to the machine platen are to be reviewed to eliminate ejector plate twist.

4.9. Ejection plate will have a minimum of two (2) guide pins and will be equipped with bronze-plated bushings

with lubrication grooves or Self lube bushings. Large tools and tools with adequate space must have a minimum of four ejection guide pins.

4.10. Ejector plate stop buttons are to be located directly below all return pins and in areas around groups of

ejector pins and/or lifters.


4.11. Ejector pins shall never be placed under moving cores or slides unless approved by the TS and mechanical, hydraulic, or electrical early returns are incorporated.

4.12. On occasions when blade ejectors are required, if blades are very narrow use maximum body length

possible. 4.13. Rising Ejectors: Manufactured from a different material to the block into which it is sliding, also to be a

variation in hardness. Secure rising ejectors by adding a cross dowel pin running between hardened base plate and rails.

4.14. Rising ejectors to be fully guided in guide blocks secured in cavity backing plates. 4.15. A cover plate is to be on the top of the tool to cover the ejection box to prevent sprues etc dropping into

the tool. 5. Moving Cores

5.1. Side cores: All side cores must slide on at least one hardened wear plate and grease grooves machined into the surface.

5.2. Heel blocks: Where heel blocks are incorporated into a design and are subjected to cavity pressure,

where practical they must be cut from the solid die plate and fitted with a hardened wear plate. 5.3. Side cores are to be located with side rails and are to be retained in the open position by adequately

sized spring loaded ball catches. Side cores which operate vertically downwards must be held in the out position by a spring when the tool is open, the cores should also be fitted with stops to prevent them from falling out of the tool.

5.4. Side cores measuring 100mm or wider must be fitted with two angled dowel pins. Where hydraulic cores

are required, the manufacture is to be specified. Where Cylinders are used. The cylinder must be connected to the side core via a tendon nut.

5.5. Sequence protection: Where a tool design incorporates the use of side cores, a method of preventing

damage from incorrect sequencing must be included, mechanically or electrically. The recommended type is micro switch sensors.

5.6. Protection feet / cage: When cylinders or mechanical coring protrude from the underside of a tool, they

must be protected by fitting feet or a cage. 5.7. Tool sequencing must be stamped on the side of the tool in a position which can be viewed by the

operator i.e. Tool opens (side core out) Hydraulic Cylinder back (core out). Ejection forward Ejection back Hydraulic cylinder forward (core in). Tool closes side core in.

6. Hot Runners

6.1. Hot runners: Systems or hot tipped bushes are to be from an agreed supplier and supplier specification is to be sent with general assembly drawing for approval. All suppliers to be approved by Inteva.

6.2. Hot runner thermocouples and heaters: To be terminated in suitable Harting plug and sockets and

secured to the tool. 6.3. Wiring: All wiring to pass through adequate sized channels and to be retained by fixing plates.

Boxes to be located on the top of tool (or if not feasible on the rear of the tool) but not in areas with water connectors.

6.4. Wiring diagrams to be added to the tool design.


7. Miscellaneous 7.1. Venting: All tools will be vented per the material manufacturer’s specifications (parting line, ejector pins,

and sleeves, cores, etc.) and should be shown in the tool designs. 7.2. Machine Location: All tools to be fitted with a fixed half location ring, to suit the designated press details.

To be shown on general assembly drawing. 7.3. Date inserts to be on all parts where possible and to be standard parts as item 4.6. All tools must have

component manufacturing date traceability. A date table or a standard circular date code must be included on the component. Location and type to be agreed upon with Inteva.

7.4. Fittings & connectors: All tools to be supplied, with necessary fittings: hydraulic, pneumatic and electrical connectors.

7.5. Guide pillars: To avoid incorrect assembly of tools, one guide pillar is to be of a smaller diameter than the

other three. 7.6. Tool Dis-assembly: Notches scalloped from the sides of the bolster L32 x W16 x D6.5, or optional 45

degrees across corners to avoid damage. 7.7. Split Line Location Interlocks: On tool faces that shut out, SSI straight interlocks or cone locators must be

used unless the product design incorporates this. 7.8. Keying: When inserts require to be keyed, they should be keyed in such a way the insert can only be

replaced in one direction. 7.9. Chamfers: All sharp edges which are not product related must be broken. 7.10. Inserts: Where interchangeable inserts are required, each insert must be clearly identifiable and stored in

a durable container. Where possible, cavity & core inserts to be engraved on underside with tool number & item number reference.


3. Stamping Tools 1. Scope The following are standards considered to be necessary by Inteva for construction of high class progressive and single stage dies and are to be adhered to unless specifically waived in writing by the signatory. 2. General Instructions

2.1. Die set is to be four (4) post precision ball bearings with demountable bushings.

2.2. Stock feed is to be from right to left, unless otherwise specified. Starting point shall be clearly marked and tagged so as to be visible to the operator.

2.3. Die clearance is to be the accepted industry standard, ten percent (10%) and to be reviewed at Design

Review.

2.4. On progression dies, as a minimum there is to be one idle station for every fifth working station.

2.5. On single stage tooling there must be provision made in the initial quotation for the addition of one additional operation if required to achieve part quality.

2.6. Flattening and re-strike sections are to be provided, as dictated by part configuration and part print

specification.

2.7. As a minimum, all sector blank dies shall have a flattening (re-strike) station.

2.8. All dies containing a re-strike station shall have a minimum shoe thickness of 90mm. Part thickness of 3.2 mm and over shall require a minimum shoe thickness of 100 mm.

2.9. All dies containing coining stations shall have a minimum 20 mm hardened plate under each station for

support and a minimum of 90 mm thick shoe.

2.10. Dies with push back in the strip part designs are NOT acceptable.

3. Part Ejection 3.1. Part ejection on progressive dies is to be accomplished by either free drop or mechanical ejection off the

front of the die. 3.2. All single stage dies are to have mechanical part ejection fitted.

3.3. Slug die clearance to be tapered at a minimum of 1 degree following the first 3mm of land.

3.4. Maximum slugs in the lower die to be 3 x material thickness. Slugs to fall freely to lower plate.

3.5. All scrap and slugs coming from the die must be capable of being moved out the back of the die, without

interference from parallels, blocks, nitrogen units or any other obstructions.

3.6. Part must be probed in cutoff station to ensure part and scrap have properly ejected from die. 4. Material Guiding

4.1. Vertical stop blocks are to be permanently set to the proper shut height, and have a 0.75 mm x 12.5 mm slot on the top surface. Add compression holes as needed.

4.2. Provide heal blocks on die shoes to equalize forming pressure. (Die review).

4.3. All dies are to have a micro-switch actuated pitch-notch stop. If the die does not have a pitch-notch stop,

a spring loaded pilot actuated micro-switch will be used. This will need to be discussed at the die review.

4.4. Dies are to have one permanent and adjustable stock rail. Rails are to be staggered at the start to aid in starting and hardened throughout the die.


4.5. Moveable positive stops for starting the strip are to be installed wherever possible.

4.6. Strippers are to be spring loading with guides. They must have windows for access to ball-lock retainers. They must also have keepers or spools for stripper retainment. All springs, Danley spring retainers or equivalent. Springs are not to extend out through the top shoe. All strippers are to have tapped handling holes, and be a minimum 1-1/4” (31.75 mm) thick. (Nitr. Cylinders use is highly recommended)

4.7. Pilots are to be hardened Rc 58-60 and tempered. They are to be ball-lock type. A double row is to be

used wherever possible and maintained as long as possible. 5. Dies and Punches

5.1. All top cutting steels (outline punches) are to be hardened to Rc 58-60 and ground. Slug ejectors are to be used wherever possible.

5.2. Standard pierce punches are to be hardened to Rc 60-62 and ground with a slug ejector wherever

possible.

5.3. Punch and die button retainers are to be hardened and jig ground with a 1/4” (6.35 mm) minimum thick hardened back-up plate.

5.4. Die buttons are to be straight press fit into counter bored holes.

5.5. All cutting sections are to be separate from any form steel. This is to eliminate the problem of regrinding forms when sharpening and shimming die steels.

5.6. All bottom die steels are to be hardened to Rc 60-62 and ground with a minimum of 3/8 (9.525 mm) die

life and have a 1/4 degree minimum ground taper relief. Insert for cut-off where possible.

5.7. All forms are to inserted and adjustable without disassembly of the die wherever possible and adjustable with the press.

5.8. All form steels are to be finished with a TD coating process (P.V.D.) to ensure long-life and eliminate

wearing.

5.9. All cutting and forming sections must have jack-screw holes to necessitate removal from die for maintenance purposes.

5.10. All die matrixes (buttons) used in piercing holes shall be mounted in counter bored retainer for ease of

shim placement under buttons after sharpening.

5.11. The following details should be accessible through stripper if possible: stripper retainment, spools, form blocks, punch sections, etc.

5.12. All cam slides are to have a positive return if possible. If not possible, use nitrogen or double springs.


Section 3 – CURRENT PRODUCTION TOOLING 1. Modifications and Refurbishments. 1. Scope

All modifications done to Inteva owned or supplied tooling is to be done in line with the tool design recommendations in this manual.

2. Performance Requirements Modifications should be done in line with best practices and must ensure that there is no effect on the

anticipated life of the component. Any effects on the initial quoted life of component must be highlighted at time of quotation. 3. Tool Costs All tool cost quotations for modifications and refurbishments are to be submitted on the correct forms,

‘Modification Cost Breakdown Sheet’ or ‘Refurbishment Cost Breakdown Sheet’. 4. Tool Replacement

4.1 When replacement of tools is required, the previous tool design must be reviewed.

4.2 If the present tool was not built to these standards, the tool should be redesigned to conform.

4.3 Repair history of the tool, part quality problems, processing problems and tool flow analysis (if required) will be analyzed and the appropriate tool design will be updated.

2. Tooling Maintenance. 1. Scope

Inteva requires that all suppliers undertake regular tooling and machine preventative maintenance programs.

2. Performance Requirements 2.1. Evidence of written procedures is to be submitted as requested. (Duplicate from above)

2.2. Schedules and records showing actual maintenance undertaken for any tooling is to include as a minimum

the following points:- Condition and capability of tooling or equipment. Tooling storage and tool handling plus set-up system. Record of daily maintenance performed:-

Daily check list. Operator’s responsibility. Operator’s training.

Record of scheduled maintenance performed:- Master schedules. Work undertaken. Corrective actions taken

3. Tooling Condition. 1 Scope

To monitor the condition and expected tool life.

2 Performance Requirements 2.1 Inteva requires the completion of a ‘Tool Condition Report Form’ when requested.

It is the supplier’s responsibility to ensure that all aspects of both prototype and production tooling are kept in good mechanical and quality condition throughout the life of the product.

2.2 A list of all Inteva owned tooling currently at the supplier is to be listed on the Tool Detail form and is to be

sent to Inteva for the attention of the Tooling Specialist

4. Prototype Tooling. 1. Scope

To ensure that all quotations for prototype tooling are as is required based on timescales, volume etc. All quotations are to be submitted on a ‘Prototype Tool Breakdown Sheet’.


Appendix 1 – Tooling Contact Details.

Name Position Contact No. Email Address

Pierre Blanchard Sr Director

Advanced Manufacturing Engineering

+33 682816417 [email protected]

Stephen Leyland

Tooling Group Manager

+44 7919 328731

[email protected]

Constantin Fetelea

Tooling Specialist - Americas

+1 313 587 9037 [email protected]

Patrick Hilaire Tooling Technician

+33 329 522020

[email protected]

Justin Wu

Tooling Specialist - Asia

+86 511 88885702 [email protected]

Naveen Kumar

Tooling Specialist - India

+91 9900785676 [email protected]

Paval Dvorak

Tooling Specialist - Europe

+420730181028 [email protected]

Iulian Nani

Tooling Specialist - Europe

+40725353673 [email protected]

mailto:[email protected]




Appendix 2 - Tool Terminology.

Ejection Return Pins

Ejection Return

Insulation Plate

Cavity Plate

Cooling Channels

Bolster Plate

Ejector Pins

Guided Ejection

Ejection Plates

Core Plate

Support Pillars

Insulation Plate

Hot Runner Manifold

Location Ring

Hot Tip

Bolster Plate

Guide Pillars

Hot Runner Harting Plug

Cavity Inserts

Core Inserts


Appendix 3 - Typical Progression Tool Layout.


Appendix 4 – Recommended Mold Tool Steels.

Recommended Mould Tool Steels & Alloys

Werkstoff ?? Number

BS4659 Number

AISI Number

Supplier Code Applications (Recommended Hardness)

1.2767 Carrs Inman Cooks

P576 HCNC

Benum Plus

Mold steel:-Cores, cavities etc Hardness 52-54 Rc

1.2344 BH13 H13 Carrs Uddeholm

53S Orvar Supreme

Mold steel :- Cores, cavities etc Gives a good polished finish. Can be Nitrided Hardness 50-52 Rc

1.6747 Carrs P552 EN30B

Mold steel :- Cores, cavities etc Hardness 52-54 Rc

Uddeholm Calmax Mold steel :- Cores, cavities etc Very tough, good wear resistance. Good dimensional stability in hardening Hardness 56-58 Rc

1.2379 BD2 D2 Carrs Aurora

Uddeholm

69S D2

Sverker 21

Gate inserts. Compression tools Very hard wearing Hardness 58-62 Rc

1.2510 B01 01 Carrs Uddeholm

O9B Arne

Gauge Plate

Angle Pins / Wear plate Hardness 54-62 Rc

1.2083 420 Carrs Uddeholm

P1008 Stavax ESR

Stainless mold steel :- Good resistance to corrosion Gives good polish Hardness 48-53 Rc

1.2738 P20 HH P20 Hardness 40-42 Rc

1.2711 Pre-hard

1.2311 BP20 P20 Carrs P20 Pre hardened mold steel :- Used for soft tooling, Bolster plates Can be spark eroded (sulphur free) Can be nitrided Supplied Hardness 30-33Rc

1.2312 Carrs P20S Pre hardened mold steel :- Bolster plates. Unsuitable for spark erosion. Can be nitrided Supplied hardness 30-33Rc

1.1730 Medium carbon steel Suitable for Backplates Risers Ejector plates etc Supplied Hardness 10 Rc

Carrs Ampcoloy 940 (Be Cu

replacement)

Alloy used where heat dissipation is critical. Can be nitrided Not suitable where wear is critical. Supplied Hardness 18 Rc


Appendix 5 – Tooling Manual Form Usage

Supplier To Complete Inteva To Complete

RFQ TO SUPPLIER

QUOTATION SUBMITTED BY

SUPPLIER

PURCHASE ORDER PLACED WITH

SUPPLIER

TOOL DESIGN SUBMITTED

PPAP SUBMISSION

TOOL SAMPLING

FINAL DESIGN APPROVAL

SUBMITTED

TOOL MANUFACTURE

STARTED

OK

YES

NO

Tool Cost Breakdown Sheets.

Tool Design Approval Document.

Tool Design Approval Document.


Revison Index Rev. # Date Revision Change Changed

By Approved

A 23-06-2007 New Document S.Leyland J.Persa

B 26-10-2007 Formal document number added. Section 2 – Item 5.9 changed from 2 bat to2 bar minimum.

S.Leyland J.Persa

C 01/04/2008 Janos Persa replaced by Pierre Blanchard S.Leyland Pierre Blanchard

D 1/5/2010 Added Stamping Standards S.Leyland Pierre Blanchard

E 03/01/2011 ArvinMeritor replaced with Inteva S.Leyland Pierre Blanchard

F 12/5/2011 Terminology changed – added to SRM S.Leyland Pierre Blanchard

G 04/01/2013 New Tooling Specialist Added S.Leyland Pierre Blanchard

Documents

INTEVA TOOLING MANUAL - Inteva · PDF fileAll stamping, plaques and tool tags to be shown on tool operator side in press position 8. Miscellaneous 8.1. CMM Report on New Molds