INTEVA TOOLING MANUAL

Transcription

1 INTEVA TOOLING MANUAL INTEVATM, Rev F; 7/6/2011 Page 1

2 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 INTEVATM, Rev F; 7/6/2011 Page 2

3 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 The supplier will be responsible for the submission of weekly progress reports to the Tooling Specialist (TS) 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 Any request for information pertaining to the tool being built shall be directed to the TS All aspects of prototype and production tooling are to be kept in good mechanical and quality condition throughout the life of the product 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 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 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 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 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. INTEVATM, Rev F; 7/6/2011 Page 3

4 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 The tool manufacture must not be sub-contracted without the prior agreement of Inteva 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 Any deviation from this procedure must be agreed in writing with the Tooling Specialist 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) 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 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 During the design review process all critical features are to be inserted and manufactured steel safe After any tool modification or engineering change, the tool design must be promptly and accurately updated 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 for Terminology References INTEVATM, Rev F; 7/6/2011 Page 4

5 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 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 Die Plates to be manufactured from Pre-hardened tool steel ( or ) from a standard supplier. See Appendix 4 for Steel Recommendations 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 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 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 Any alternatives to the above specified grades/suppliers are to be agreed with Inteva TS If required cost of chroming, ion implanting and etched finishes should be itemised at the quotation stage, this must not be implemented without authorisation 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 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 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. INTEVATM, Rev F; 7/6/2011 Page 5

6 6.3. IMPERIAL SIZES METRIC SIZES WEIGHT ( KG ) WEIGHT ( LBS. ) 5/8 M ¾ M M ¼ M ½ M ¾ M M ½ M On Tools over 1 Ton, lifting holes required on each bolster plate, to aid assembly and maneuverability 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 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 Chamfers: All sharp edges which are not product related must be broken 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. INTEVATM, Rev F; 7/6/2011 Page 6

7 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 It is the supplier s responsibility to ensure that the drawings are up to date following any modifications etc 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 On receipt of PPAP approval the supplier is to send a completed Tool Identification Form to Inteva for the attention of the Tooling Technician A stock of spares as identified by the DFMEA as necessary will be held at the supplier s plant. INTEVATM, Rev F; 7/6/2011 Page 7

8 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 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. # mm deep - 3 degrees minimum. # mm deep - 4 ½ degrees minimum. # mm 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 All cavity inserts must contain separate water circuits, where practical 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 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 All temperature control channels to be numbered, for example: - 1in, 1out, 2in, etc General assembly drawings to incorporate schematic water diagram. Cooling piping diagram to be supplied with tool 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 All water circuits to be pressure tested to 2 bar minimum Standard water line plugs should be used as per suppliers in item Protection feet: Tools must be furnished with feet to prevent damage of water connectors, when located on the underside of the tool 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 Insulation plates: All thermoplastic tools to be fitted with Sindanyo-L21 (asbestos free) insulation plates on the fixed half clamp plate. INTEVATM, Rev F; 7/6/2011 Page 8

9 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 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 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 Shrinkage: This is to be as per the material manufactures recommendations 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 When runners are cut into the tip of the sprue bushings, the bushing is to be keyed to prevent rotation All tools to have hardened sprue bush with radii to suit machine nozzle Feed gate inserts require fitting for glass filled tools. Replaceable gates must be provided in all tools that will run corrosive or abrasive materials 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 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 Ejection system must be designed to eject the component from the tool free from ejector stress and distortion Ejector positions and type i.e. (push/pull, spring return, two stage, stripper plate, etc.) are to be identified on General assembly drawings Formed ejector pins must be locked into the ejector plate per Inteva agreed method All bosses deeper than 12mm must have sleeve ejection. If it is not feasible, it must be discussed with the TS prior to manufacture 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 mm per 25mm distant from the nearest parallel but not exceeding 0.125mm All Ejector systems to be fitted with return pins Where larger ejection plates are used multiple connections to the machine platen are to be reviewed to eliminate ejector plate twist. INTEVATM, Rev F; 7/6/2011 Page 9

10 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 Ejector plate stop buttons are to be located directly below all return pins and in areas around groups of ejector pins and/or lifters 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 On occasions when blade ejectors are required, if blades are very narrow use maximum body length possible 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 Rising ejectors to be fully guided in guide blocks secured in cavity backing plates 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 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 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 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 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 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 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. INTEVATM, Rev F; 7/6/2011 Page 10

11 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 Hot runner thermocouples and heaters: To be terminated in suitable Harting plug and sockets and secured to the tool 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 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 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 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 Fittings & connectors: All tools to be supplied, with necessary fittings: hydraulic, pneumatic and electrical connectors Guide pillars: To avoid incorrect assembly of tools, one guide pillar is to be of a smaller diameter than the other three 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 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 Keying: When inserts require to be keyed, they should be keyed in such a way the insert can only be replaced in one direction Chamfers: All sharp edges which are not product related must be broken 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. INTEVATM, Rev F; 7/6/2011 Page 11

12 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 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 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 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 Flattening and re-strike sections are to be provided, as dictated by part configuration and part print specification As a minimum, all sector blank dies shall have a flattening (re-strike) station 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 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 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 All single stage dies are to have mechanical part ejection fitted Slug die clearance to be tapered at a minimum of 1 degree following the first 3mm of land Maximum slugs in the lower die to be 3 x material thickness. Slugs to fall freely to lower plate 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 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 Provide heal blocks on die shoes to equalize forming pressure. (Die review). INTEVATM, Rev F; 7/6/2011 Page 12

13 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 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 Moveable positive stops for starting the strip are to be installed wherever possible 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 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 and ground. Slug ejectors are to be used wherever possible Standard pierce punches are to be hardened to Rc and ground with a slug ejector wherever possible 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 Die buttons are to be straight press fit into counter bored holes 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 All bottom die steels are to be hardened to Rc 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 All forms are to inserted and adjustable without disassembly of the die wherever possible and adjustable with the press All form steels are to be finished with a TD coating process (P.V.D.) to ensure long-life and eliminate wearing All cutting and forming sections must have jack-screw holes to necessitate removal from die for maintenance purposes All die matrixes (buttons) used in piercing holes shall be mounted in counter bored retainer for ease of shim placement under buttons after sharpening The following details should be accessible through stripper if possible: stripper retainment, spools, form blocks, punch sections, etc All cam slides are to have a positive return if possible. If not possible, use nitrogen or double springs. INTEVATM, Rev F; 7/6/2011 Page 13

14 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 Spare parts 3. Tooling Condition. 1. Scope To monitor the condition and expected tool life. 3. Performance Requirements 3.1. 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. INTEVATM, Rev F; 7/6/2011 Page 14

15 3.3. 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. INTEVATM, Rev F; 7/6/2011 Page 15

16 Appendix 1 Tooling Contact Details. Name Position Contact No. Address Pierre Blanchard Sr Director Advanced Manufacturing Engineering Pblanchard@intevaproducts.com Stephen Leyland Tooling Group Manager sleyland@intevaproducts.com Constantin Fetelea Tooling Specialist - Americas Cfetelea@intevaproducts.com Patrick Hilaire Tooling Technician Philaire@intevaproducts.com Justin Wu Tooling Specialist - Asia Jwu2@intevaproducts.com Kiran Kumar Tooling Specialist - India kkumar@intevaproducts.com INTEVATM, Rev F; 7/6/2011 Page 16

17 Appendix 2 - Tool Terminology. Hot Runner Harting Plug Core Inserts Cavity Inserts Guide Pillars Insulation Plate Insulation Plate Support Pillars Bolster Plate Ejection Plates Hot Tip Ejection Return Location Ring Bolster Plate Ejector Pins Hot Runner Manifold Guided Ejection Cavity Plate Core Plate Ejection Return Pins Cooling Channels INTEVATM, Rev F; 7/6/2011 Page 17

18 Appendix 3 - Typical Progression Tool Layout. INTEVATM, Rev F; 7/6/2011 Page 18

19 Appendix 4 Recommended Mold Tool Steels. Recommended Mould Tool Steels & Alloys Werkstoff?? Number BS4659 Number AISI Number Supplier Code Applications (Recommended Hardness) Carrs Inman Cooks BH13 H13 Carrs Uddeholm P576 HCNC Benum Plus 53S Orvar Supreme Carrs P552 EN30B BD2 D2 Carrs Aurora Uddeholm B01 01 Carrs Uddeholm Carrs Uddeholm Mold steel:-cores, cavities etc Hardness Rc Mold steel :- Cores, cavities etc Gives a good polished finish. Can be Nitrided Hardness Rc Mold steel :- Cores, cavities etc Hardness Rc Uddeholm Calmax Mold steel :- Cores, cavities etc Very tough, good wear resistance. Good dimensional stability in hardening Hardness Rc 69S D2 Sverker 21 O9B Arne Gauge Plate P1008 Stavax ESR Gate inserts. Compression tools Very hard wearing Hardness Rc Angle Pins / Wear plate Hardness Rc Stainless mold steel :- Good resistance to corrosion Gives good polish Hardness Rc P20 HH P20 Hardness Rc Pre-hard 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 Carrs P20S Pre hardened mold steel :- Bolster plates. Unsuitable for spark erosion. Can be nitrided Supplied hardness 30-33Rc 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 INTEVATM, Rev F; 7/6/2011 Page 19

20 Appendix 5 Tooling Manual Form Usage Supplier To Complete Inteva To Complete RFQ TO SUPPLIER QUOTATION SUBMITTED BY SUPPLIER Tool Cost Breakdown Sheets. PURCHASE ORDER PLACED WITH SUPPLIER TOOL DESIGN SUBMITTED Tool Design Approval Document. NO OK YES TOOL MANUFACTURE STARTED FINAL DESIGN APPROVAL SUBMITTED TOOL SAMPLING PPAP SUBMISSION Tool Design Approval Document. INTEVATM, Rev F; 7/6/2011 Page 20

21 Revison Index Rev. # Date Revision Change Changed By Approved A New Document S.Leyland J.Persa B 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 INTEVATM, Rev F; 7/6/2011 Page 21