This Injection Mold Standard is used for the design and fabrication of Plastic Injection Molds.

Transcription

1 This Injection Mold Standard is used for the design and fabrication of Plastic Injection Molds. 1. Mold Design 1.1. A preliminary mold design review will be conducted, preferably with the customer present, to review the mold design prior to ordering any materials Mold design requirements for the preliminary design review are to include, but not be limited to: Cavity plan view Core plan view Separate isometric views of the cavity half and core half Section view along the short axis of the mold Section view along the long axis of the mold All internal waterlines and water fittings, waterlines to be numbered An isometric view of the numbered waterlines, pulled out of the 3D mold design All slides and lifters A section through each unique slide and lifter Venting Dimensions for all plate and insert sizes All electrical and hydraulic connections Hydraulic and/or pneumatic cylinders, if used Tie bar locations in the cavity and core plan views All mold components (locks, guided ejection, springs, pins, etc.) Runners and gates, including sections through the gates Complete Bill of Materials that identifies material type, size, hardness, manufacturer, and manufacturer s part number Plastic material and shrink factor to be listed on 2D drawings Preliminary mold designs to be submitted in 2D DXF format and 3D STEP format. Native Pro-E or SolidWorks files can also be submitted If any mold design change arises from the preliminary design review, new mold design files will be submitted for approval by the customer Approval to order materials must be received in writing Approval to begin mold manufacture must be received in writing. 2. Reporting 2.1. An Project Manager dedicated to the management of the customer s projects will be provided A Mold Status Report in chart style will be supplied within 10 days of the order confirmation. Mold Status Reports will be submitted weekly until the first mold trial. The weekly Mold Status Report will be accompanied by digital pictures of cavities, cores, slides, and lifters, in JPG format, to verify progress as reported in the charts No deviation in the schedule will be acceptable unless authorized by the customer. The customer will be notified immediately of potential delays. Delaying notification of schedule changes is not acceptable. ~ 1 ~

2 3. Materials 3.1. Materials used must follow this document, the Injection Mold Standard and the document Injection Mold Specification that defines the part specific requirements for every Injection Mold Mold Bases Hardness of plates used for the mold base are not to be less than 270 Bhn Unless specified otherwise, AISI 4130, AISI 4140 and/or P-20 steels should be used for all mold base plates, including Clamp Plates, Ejector Box Rails, and Ejector plates When stainless steel mold bases are specified, the hardness of the stainless steel plates are not to be less than 270 Bhn Minimum acceptable steels for mold bases are: DME #2 steel, LKM P-20 steel Cavities and Cores Cavities and cores are to be of dissimilar materials and/or dissimilar hardness High Hard P-20 cavities are to be used with standard hardness P-20 cores H-13 cavities hardened to the 50-52HRc range are to be used with H-13 cores hardened to the HRc range Uddeholm, Assab, Finkl, LKM, Daido, and Brush Wellman are approved manufacturers of steels for use on cavities and cores. See the Injection Mold Specification for exact types and grades to use for the cavities and cores for a given part/mold Slides Uddeholm, Assab, Finkl, LKM, Daido, and Brush Wellman are approved manufacturers of steels for use on slides. See the Injection Mold Specification for exact types and grades to use for the slides for a given part/mold All gibs on the sides of slides, the wear plates under slides, and the wear plates on the locking back surface of slides are to be graphite impregnated bronze plates (greaseless) Lifters Uddeholm, Assab, Finkl, LKM, Daido, and Brush Wellman are approved manufacturers of steels for use on lifters. See the Injection Mold Specification for exact types and grades to use for the lifters for a given part/mold Unless otherwise specified all lifters are to be hardened tool steel Unless otherwise specified all lifters are to be nitrided All lifters are to have a bearing/guide block in the back of the core/support plate which is a minimum of 25mm thick and made from graphite impregnated bronze (greaseless) Manufacturer material certifications will be provided for all materials and mold components. Also, hardness certifications will be provided for the mold base, cavity, core, slides and lifters. Certifications to be provided with the final mold design documents. 4. Cooling 4.1. Drilled waterlines are to be 7/16 or 11mm minimum diameter. Deviations require approval When using 7/16, or 11mm, diameter waterlines, ¼ NPT water fitting thread size and 3/8 minimum I.D. water fittings, and ½ I.D. water hose to be used When using 11/16, or 17mm, diameter waterlines, ½ NPT water fitting thread size and 5/8 minimum I.D. water fittings, and ¾ I.D. water hose to be used Baffles to be sized such that they have equal volume per side as the size of the waterline that supplies them. Baffles are not to restrict the water flow All water fittings to be brass and are to be supplied with the mold. Water fittings are to be DME type or quality and design equivalent All water circuits are to be stamped IN x and OUT x on the mold base and correspond to the mold design. x is the circuit number. ~ 2 ~

3 4.7. All water fittings are to be recessed below the outside surface of the mold Use brass for all pressure plugs, cascade water junctions, bubbler tubes and plug baffles All O-rings are to be standard size. Manufacturer, description and part number to be on the BOM Whenever possible put waterlines in slides and lifters. 5. Mold Base 5.1. Leader pins and bushings to be grease less type graphite impregnated bronze bushings Eye bolt lift holes to be on all sides of all plates. Thread size and pitch to be stamped next to each hole Assembled molds are to hang level for mounting in the molding machine Sprue bushing off-set to be no more than 50mm straight parting line locks to be used on all molds one on each side of the mold. DME standard quality or equivalent Graphite impregnated bronze wear plates must be used on one of the interlock surfaces when the mold base cavity and core plates are interlocked via a tapered step in the parting line All molds to have a minimum of one safety strap across the parting line All mold bases to be engraved on all sides with the following information: Customer Name Part number and part name Cavity number(s) Mold Maker Company Name Mold Maker mold number Mold weight Shrink rate 5.9. The following mold plaques (engraved aluminum) are to be mounted on the mold: Water diagram with circuits numbered Hot manifold system wiring diagram Hot manifold zones and drop numbering Hydraulic and/or pneumatic diagram All four corners of all plates of the mold base to have pry slots All four corners between the ejector plates to have pry slots Leader pins to be vented out the ejector box rails. 6. Cavities and Cores 6.1. Machine a depression on the back side of all cavity and core and sub-inserts, engrave material type and hardness Cavity and core inserts to be held tightly in cavity and core plate pockets with tapered bar inserts on two sides of the cavity and core inserts. Tapered bar inserts to be bolted in from the parting line surface All cavities and cores should be inserted at high wear areas or where standing steel may be damaged No welding permitted on any surface without customer approval All parting line shut-off (cavity to core) angles to be equal to or greater than 3 degrees EDM and/or cutter marks not permitted on parting line shut-off surfaces Part number, material type, cavity I.D., and date code to be engraved / installed on all cores Cavity and core finishes will be according to the Injection Mold Specification for each part/mold. ~ 3 ~

4 7. Slides and Lifters 7.1. Angled Core Pin pull slides are to have pins on an angle of no more than 30 degrees. Angle pins to have an outside hardness of 65 HRc minimum and a core hardness of 30 HRc minimum All slides to have spring loaded slide retainers or springs that will hold them in the retracted position Lifters to have a maximum angle of 10 degrees. Lifters on angles greater than 10 degrees to be designed as guided lifters (parallel guide rod in the ejector assembly) All slide locks are to be hardened steel Machine a depression on the back side of all slides and lifters, engrave material type and hardness All lifter shafts are to be guided through their complete travel with a minimum of two bearing surfaces or bushings Lifters that accelerate or decelerate more than 10 degrees to be designed as guided lifters Lifter feet to be of T gib design or Progressive Components Uni-lifter design. 8. Ejection 8.1. Ejector pins and sleeves to be DME standard quality, sizes and hardness or equivalent 8.2. Flush mount ejection pucks to be included on all ejector plate machine tie-in locations Ejector plates to be supplied with a spring returned option Guided ejection rods and bushings required on all molds in four places Micro switch / thin switch for sensing ejector plate back position to be included on all molds Contoured ejector pins must be keyed Parts are to fall free of ejector pins and lifters, or be loose and free for robotic end of arm tooling to pick up No ejector pins under slides without customer approval No ejector pins on the parting line Positive, early return ejection system to be on all molds where lifter heads shut-off on the parting line All ejector pins and sleeves to be guided for a minimum of 25mm before the hole is relieved. 9. Mold Components 9.1. All mold components, parting line locks, guided ejection, pins, sleeves, air poppets, limit switches, date codes, etc. to be of DME standard quality and design or approved equivalent Progressive Components Cycle counter to be included on all molds All socket head cap screws to be ISO Class Hot Manifold Systems Hot manifold systems will be purchased per the Injection Mold Specification for each mold Mold with hot manifold systems to include insulator plates on the Top Clamp Plate Power and thermocouple connections are to be mounted on the Top of the Mold. DME PIC-12-G and DME MTC-12-G or exact equivalent connectors and boxes will be used unless the customer specifies otherwise Nozzle numbers, per the Manifold System Plaque on the mold, to be engraved on the core next to gate tip, or in the runner next to gate tip. ~ 4 ~

5 11. Mold Qualification and Inspection Reports Inspection Reports that include 100% dimension inspection of all part print requirements on five shots to be included with each mold sampling Steel inspections to be provided on all dimensions that use 80% or greater of the print tolerance A 3 hour minimum mold capability run to be performed for mold approval to ship % Inspection report on 5 parts to be provided from mold capability run parts Cp/Cpk report on a minimum of 30 parts and two dimensions to be performed on parts from the mold capability run Gage R&R study with 10 shots and 3 operators to be performed on the two dimensions of the Cp/Cpk study Tool maker will be allowed a maximum deviation in the steel from the nominal dimension (plus shrinkage) that is no greater than 25% of the print tolerance, and in no case to exceed +/-0.125mm (.005 ), without customer approval Customer to provide all plastic materials for mold sampling and capability run Injection molding process parameters to be fully documented and sent with each inspection report All mold sampling and capability runs are to be performed using the water fittings, hoses and water line routing for production molding. External looping of waterlines other than was is approved for production molding is not permitted. 12. Warranty Molds built with Pre-hardened P-20 or Pre-hardened Stainless Steel cavities and cores to have a warranty of 400,000 shots Molds built with hardened tool steel cavities and cores to have a warranty of 1,000,000 shots Mold warranty to cover quality of materials, material or component defect and/or failure, quality of design, and quality of workmanship. The Mold Maker is responsible for all costs associated with repairing and/or replacing the mold component or mold Warranty does not cover lost production costs or defective product molded The customer shall have free entry to the Mold Maker s facility at all times while design, fabrication and debugging is being performed on the mold. Periodic inspections may be performed to confirm adherence to the fabrication specifications and delivery schedules. 13. Mold Shipping Digital pictures of all 6 sides of the mold to be sent to the customer after mold cleaning and prior to applying rust preventative, prior to mold crating for shipping All mold surfaces to be clean and coated with rust preventative prior to shipping Molds to be fully enclosed in robust wooden crates for shipping Molds to be insured for full value during shipment At the time of mold shipment the following information will be sent via overnight carrier to the customer on a CD: A copy of this same CD is to be sent to the Ultimate Consignee (recipient) of the mold Full 3D design of mold in native CAD format and in STEP format All 2D drawings for the mold and components in DXF format Scanned copies of all material certifications Bill of materials Final 3D part file in native CAD format and in STEP format Mold pictures from item ~ 5 ~

6 All inspection reports and mold qualification data Molding Machine process parameter sheets All DFM history At the time of mold shipment the original material and component certifications, and hardness certifications will be sent via overnight carrier to the customer. ~ 6 ~