General Tooling Standard

Transcription

1 General Tooling Standard Plastic Injection Mould Standard v RA-OD-3

2 2 General Tooling Standard TABLE OF CONTENTS 1. OVERVIEW General Requirements ACCEPTANCE PROCESS General Guarantee Delivery Documentation GENERAL DESIGN Handling and Safety Tool Identification Schematic Drawings and Tool Markings Tool Loading and Maintenance Magnetic Plattens...12/ Tool Drawings Other Requirements STEELS AND BOLSTERS Bolsters Clamp Plates Cavities Cores and Inserts Tool Hardening Quality Assurance General SURFACE FINISH General Spark Erosion...17

3 3 General Tooling Standard 6. FEED AND HOT RUNNER SYSTEMS Hot Runner Systems Power Connectors/Thermocouple Connectrs...19/2 6.3 Gate and Runner Sprue Bush Ring Diameter Venting EJECTOR SYSTEM General Ejector Design MOULD COOLING / HEATING General Water Fittings Hose Requirements Staubli plates HYDRAULICS General Hydraulic Core Connectors Hydraulic Valve Gate Connectors MOULD APPROVAL PROCESS PRODUCT IDENTIFICATION General Spares Standard Forms...3 TOOLMAKER CHECKLIST...31 App. 1 Tooling Quotation Breakdown...32 App. 2 Quotation Request Specification Sheet...33

4 4 General Tooling Standard 1. OVERVIEW Rosti Automotive takes pride in the products that it supplies to its customers. The injection mould tool is at the heart of the manufacturing process and as such must be properly engineered and constructed to maximise productivity and ensure the components produced are fit for their intended purpose for the life of the tool (approximately 1 years). The following standards and guidelines are to be used in quoting, designing and the construction of injection moulding tools for Rosti Automotive. Any questions, clarifications, deviations etc. must be addressed to the Rosti Technical Representative and any changes documented. Whilst these standards are as comprehensive as possible at the time of issue, Rosti Automotive employs a continual improvement philosophy and will update standards as required. We welcome any ideas or thoughts for improvement that our suppliers may have. 1.1 General Requirements The mould tool must be designed and manufactured to run flash free and meet the requirements of volume production, assuming planned maintenance has been carried out. A target cycle time will be a requirement, details will be provided by the Rosti Technical Representative. It is important that we apply right first time principals to the design and manufacturing of the mould using historical information when appropriate. Technical aids e.g. Moldflow should be used as a tool to manage weld lines, back filling, and unbalanced flow etc. The mould tool construction should allow for component removal by robot. Unless otherwise specified (example: auto removal of parts down a chute). The mould tool construction should allow for tool change times of 3 minutes or less. Following receipt of authorisation to proceed, a timing plan detailing the manufacturing process must be supplied, with appropriate pictorial updates at an agreed interval with the Rosti Technical Representative. On an agreed basis the tool status sheet must be submitted indicating delivery status. Failure to comply with the above conditions could result in withheld payment of invoice.

5 5 General Tooling Standard 2. ACCEPTANCE PROCESS 2.1 General The mould tool cost should reflect provision for trialling the tool until parts are approved by the relevant Rosti Engineer at the suppliers cost. Tooling payments terms are agreed / adjusted at pre-nomination stage, these are negotiated on a tool by tool basis. 2.2 Guarantee The supplier is obligated to repair or replace at its sole cost and expense any part of the tool which fails due to defects attributable to faulty workmanship or materials. Minor adjustments to the gate and runner after the initial trial are the Toolmakers responsibility. The supplier shall warrant the tool for a minimum period of 12 months from the start of volume production date, as identified on the tool specification sheet (subject to maintenance). A full list of recommended spares must be supplied. 2.3 Delivery The tool will be delivered to one of the following Rosti sites or a location identified separately: Rosti Automotive Stamford Bridge Limited Bridge Works Stamford Bridge York YO41 1AL Rosti Automotive Pickering Limited Westgate Carr Road Pickering North Yorkshire YO18 8LX Rosti Automotive Larkhall Limited Baird Avenue Strutherhill Industrial Estate Larkhall ML9 2PJ

6 6 General Tooling Standard 2.4 Documentation Accompanying or prior to tool delivery to Rosti Automotive, the following information is required on the inbuilt USB memory stick. A full set of tool drawings. 3D/2D tool data in DXF format on USB memory stick to be included in the tool bolster Hasco type A58/n1. Hot runner drawings (if applicable). A full parts list, including details of bought out components, with the supplier contact details and references clearly identified. Recommended spares list. Maintenance plan. Last off problem follow up (PFU) sheets and Process Settings. Images showing lifting centre of gravity required for fixed half, moving half and full assembly. Hardness certificates where applicable.

7 7 General Tooling Standard 3. GENERAL DESIGN 3.1 Handling and Safety The tool construction must allow for pry bar disassembly and comply with the latest EU manual handling regulations. Lifting straps must not be used (unless approved) for lifting the tool. Lifting holes must be provided in the bolster plates to provide a centre of gravity lift. The lifting eyes should be placed so that the tool is balanced whether lifting out in two halves or all together. Eyebolt holes must be provided in all plates, including Risers and Ejector plates with the size stamped adjacent to the hole where practical. Direct fixing of lifting eyebolts to mould tool is preferred. If an intermediate plate is required, a test certificate (to UK safety standards) for this component would be required. Transit straps will be required to hold the two halves together front and back and are to be painted red. The mould tool should be painted blue (RAL 512). Transit straps and supplied eyebolts must be specified to perform well within the tool weight working limits and must take into account maximum load. For general transit strap design, small and medium sized tools require a minimum 2mm plate and M16 screws. For large tools a minimum 25-3mm plate and M2 screw should be used. Transit strap preferred design to be as shown below, to allow easy removal from the tool and storage. Position when tool is in transit. Quick release pin. Alternative design

8 8 General Tooling Standard 3.2 Tool Identification The tool must have the following stamped / marked on the outside: Rosti tool number Customer part number and description Number of impressions Tool dimensions Total tool weight of fixed and moving half Maximum ejection stroke Year of manufacture A customer asset tag is also to be provided Details to be provided by the Rosti Technical Engineer 3.3 Schematic Drawings and Tool Markings Top of tool must be marked on the tool. A schematic diagram of water circuits is required on the non-operator side. A schematic diagram of any electrical manifold systems will be required on the operator s side. Any special requirements or core sequences are to be identified on the operator s side. Air / water inlets and outlets to be clearly marked, adjacent to the hole affected.

9 9 General Tooling Standard Non-operators side Example of a correctly identified and marked tool All waterways to be labelled All hydraulic connectors to be labelled Operator s side Tool identification Electrical Injection moulding sequence Hydraulic circuit diagrams Hot runner information Water circuit diagram

10 1 General Tooling Standard Example of water and oil circuit diagrams Example of injection moulding sequence plaque Close VG Open VG Z1 Z13 Z12 Z15 Z14 Z6 Z17 Z16 Z4 Top mold Z19 Z3 Z18 Z8 VG2 VG3 VG4 VG1 Z2 Hydraulic & Cooling Connections Z1 Z21 Z2 Z5 Z23 Wiring type legend Coding pin legend (if present) Symbol Description No coding pin / Single connection* Male pin // Parallel connection - - Serial connection Female pin *if there are 2 heaters one is for spare part VG5 Electric Connections HEATERS A THERMOCOUPLES Example of electrical connections and schematic diagram H2O Out H2O In Z9 VG6 Z11 VG7 Operator side Z22 Z7 Z25 Z24 A C WIRING INFORMATION - TOTAL 25 ZONES - POWER INSTALLED (PEAK): 22W HEATERS DETAIL SPARE Controls Type Q.ty Wiring Watt (23V) Ohm (23V) Ampere Q.ty Code Watt (23V) Ohm (23V) Ampere Heater type at 2 C (23V) at 2 C (23V) Code Z1 INLET 2 // A A Z2 MANIFOLD 2 // B H83298.RX1 Z3 MANIFOLD 2 // B B Z4 MANIFOLD 2 // B H83298.RX2 Z5 MANIFOLD 2 // B H83298.RX4 Z6 MANIFOLD 2 // B H83298.RX3 Z7 MANIFOLD 2 // B H83298.RX5 Z8 MANIFOLD 2 // B B Z9 MANIFOLD 2 // B B Z1 MANIFOLD 2 // B B Z11 MANIFOLD 2 // B B Z12 NOZZLE 2 / A A Z13 NOZZLE 2 / A A Z14 NOZZLE 2 / A A Z15 NOZZLE 2 / A A Z16 NOZZLE 2 / A A Z17 NOZZLE 2 / A A Z18 NOZZLE 2 / A A Z19 NOZZLE 2 / A A Z2 NOZZLE 2 / A A Z21 NOZZLE 2 / A A Z22 NOZZLE 2 / A A Z23 NOZZLE 2 / A A Z24 NOZZLE 2 / A A Z25 NOZZLE 2 / A A B D Z1 1 9 Z2 2 1 Z Z Z Z Z Z Z17 Z18 Z19 Z2 Z21 Z22 Z23 Z24 HEATERS C B HEATERS THERMOCOUPLES - + Z Z1 9 1 Z1 2 1 Z9 9 1 Z2 1 2 Z Z1 1 2 Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z THERMOCOUPLES - + Z Z Z Z Z Z Z Z Z25 HEATERS D THERMOCOUPLES - + Z registration number IT /C.F ive Information (R.E.A.) Example of electrical limit switch connection diagram

11 11 General Tooling Standard 3.4 Tool Loading and Maintenance Provision for direct bolting to the platen rather than clamps must be allowed on both fixed and moving half. Direct bolt holes must be down the sides of the tool not on top and underneath. Allow room for Allen key head and tightening movement. Pry bar recesses on both split line and between the bottom ejector plate are required. Pry bar recesses required on all four corners of the split line and also between the ejector plate 12mm wide by 3mm deep. Protection must be provided on the bottom of the tool for any vulnerable areas e.g. cylinders, piping and also to aid in turning the tool over. Where possible the backing plates should be the same thickness so that the same length cap screws can be used. All external fittings and pipes must be inboard of the backing plates. Allow room for bolt head and Allen key Pry bar slots between plates Where possible the back plates should be the same thickness so the same length cap screws can be used Transport strap on both sides of the mold painted red

12 12 General Tooling Standard MAGNETIC PLATTENS Pickering F3 13 ton Engel Fixed Half Moving Half Larkhall proximity cell position by machine FIXED HALF FIXED HALF MOVING HALF MOVING HALF

13 13 General Tooling Standard 3.5 Magnetic Plattens The points below are requirements for tools which are going into machines with magnetic platens. Back plates of the tools must always be manufactured from magnetic steel (not stainless or high alloy nickel). Minimum wall thickness of back plate must be 3mm after machining any internal pockets. Insulation plate must be inboard of back plate. Back plates must be smooth (Ra 1.6) and free from oil / grease. No large holes allowed. No cap screws or holes at platen sensor locations. 3.6 Tool Drawings The tool G.A. must be submitted to the Rosti Technical Representative for approval prior to steel being ordered and must contain the following: Tool construction Component feed scope to include hot and cold runner systems Features in the mould to enable production e.g. inserts for the polishing of deep ribs, gas evacuation channels, inserts that are interchangeable to address the effects of material wear etc. Water cooling channels Component ejection system (together with machine coupling system) Hydraulic cores and sequence Feet to protect vulnerable areas e.g. Cylinders piping and to aid tool turnover The mould shown in closed and open positions. The base dimensions of the tool and bolster plates should be shown Sufficient views / sections should be given to allow universal understanding of tool function Tie bar positions for the machines as detailed in the specification sheet Other items as detailed in the specification sheet Overall tool dimensions

14 14 General Tooling Standard 3.7 Other Requirements No welding of die faces must be carried out unless approved by a Rosti Technical Representative, especially where grain or chrome plating of the finished part is concerned and in consultation with the texture company and steel supplier. Insulation plates are required on the fixed half of all tools (inboard of the back plate) and possibly on the moving half this is dependent on the engineering materials being used and will be at the Engineers discretion. The insulation should be on the underside of the backing plates to protect the insulation material and for magnetic platens insulation disc is required on the front of the hot tip. Cold sprue bushes to have separate water circuits. Water baffles or plugs must not be made of aluminium or any material that may be corroded by chemicals used in water treatment. Brass or plastic are acceptable. Provision to evacuate compressed air from the main dowel bushes required. A shot counter with security against tampering is required on all tools. All parts require auto de-gating where possible. The sub gate can be direct onto B surface wall section (a concession from the Rosti Technical Engineer must be gained to gate to ANY A surface), ejector pins, or if the previous are inappropriate review with the Rosti Technical representative. If the part cannot be sub-gated, the robot head must offer a de-gating solution. All sprue puller pins must have a hardened bush fitted. Any cap head screws on the shut off faces must be coppered over. All tools must have hardened pressure pads on the shut offs.

15 15 General Tooling Standard 4. STEELS AND BOLSTERS 4.1 Bolsters Standard bolsters should be used where appropriate. Where bolsters are made up they should be manufactured from standard Hasco equivalents. Highly stressed bolsters and supporting plates should be manufactured from 6 tons tensile steel such as high sulphur content P2 steel. Where side movers are necessary the preferred heel block construction should be in solid plates with large bore pockets and must be stress relieved prior to final machining. 4.2 Clamp Plates Standard plate thicknesses are required by press group to facilitate length bolts. The minimum requirements are: Press Range Plate thickness -1T 2-25T 35-4T 5-6T 8-12T 12-17T 27T 22 mm 36 mm 46 mm 56 mm 66 mm 76 mm 8 mm 4.3 Cavities Cores and Inserts Material requirements will be proposed by and agreed with Rosti Technical Representative and will take into account product quantities, surface finish, and hardness requirements.

16 16 General Tooling Standard 4.4 Tool Hardening Any heat treatment must be carried out in accordance with the steel manufactures recommendations, with differential hardness for sliding surfaces and shut off faces. 4.5 Quality Assurance Copies of steel certificates and hardening certificates must be available if requested from EU countries and must be supplied before tool completion in Asia Pacific Countries. 4.6 General Careful consideration should be given to the mechanical layout of the mould and any hot runner systems. The mould strength must be sufficient so as not to allow melt leakage in to the hot runner system and flashing of the part under dynamic forces.

17 17 General Tooling Standard 5. SURFACE FINISH 5.1 General Where a particular finish is required either spark eroded or acid etch, the appropriate steel must be selected in consultation with the Rosti Technical Representative (see also surface finish section). When a textured finish is required then details of the grain, gloss levels and the nominated etching company will be provided by the Rosti Technical Representative. The Rosti Technical Representative will state the type and area of grain required. Due note must be given to the following:- Draw taper requirement to the textured finish must be given careful consideration before machining starts. Even with the correct draw taper scuffing / pulling may still occur and undercuts may be required after graining. When selecting a tool steel consideration should be given to the abrasive nature of some materials, the life expectancy of the tool normally 1 years and parts per annum. Ensure that stresses are not induced during metal removal that would affect performance of the steel with subsequent effect of the grain on the finished moulding. That all machining marks are removed prior to etching, particularly spark erosion marks. 5.2 Spark Erosion This style of finish is introduced during tool manufacturing by the toolmaker, therefore some but not all of the comments and recommendations made above will also apply here. Consideration must be made to avoid slag build up (i.e. Good flow of dialectic.) and electrode materials to give best results.

18 18 General Tooling Standard 6. FEED AND HOT RUNNER SYSTEMS 6.1 Hot Runner Systems Hot nozzles and manifold systems must be HRS or Synventive unless otherwise agreed by the Rosti Technical Representative. Careful consideration should be given to water cooling around each individual tip with advice taken from the tip supplier. Consideration must be given to avoid dead spots within the manifold and allow for colour changes if required. Wiring must be routed to the top of the tool and be protected in a channel machined through the back plate. A copy of the wiring diagram should be supplied to project engineer prior to the tool delivery. The tool must be wired according to Euromap 14, example shown below. A plate with a schematic diagram of the manifold system should be on the operator side of the tool please (See Section 3.3 SCHEMATIC DRAWINGS & TOOL MARKINGS) Example schematic of Rosti specified layout Zone Position Area Sprue Bridge manifold Top Top/centre Bottom/centre Bottom Top Top/centre Bottom centre Bottom Sprue Manifold Manifold Manifold Manifold Manifold Nozzle Nozzle Nozzle Nozzle Example of how Rosti Automotive would like the heating zones to be laid out Starting at the Sprue with Zone 1. The lowest number Tip goes to the lowest number manifold as shown in the example.

19 19 General Tooling Standard 6.2 Power connectors Thermocouple connectors HARTING HARTING HARTING HARTING

20 2 General Tooling Standard 6.2 Power connectors Thermocouple connectors Pin numbers Zone Pin numbers Zone thermocouple to go to lowest number i.e.. 1,2,3

21 21 General Tooling Standard 6.3 Gate and Runner Full round runners are preferred. Trapezoidal are acceptable if it incorporates the full round section. With abrasive materials where possible gate inserts should be used. Any cold runners to be vented at the end of each branch to atmosphere. In all cases feed and runner systems must be balanced to ensure even filling patterns. Adequate venting to be incorporated at tool design stage and shown on the tool drawings. Cold slug bushes are required for sprue puller pins. The position and dimensions of feed gates and runners are to be agreed with the Rosti Technical Representative at the GA stage with inputs as required from FEA flow software and the nominated supplier. 6.4 Sprue Bush Ring Diameter This should be reviewed at the GA Stage. Various diameter location rings are used at Rosti Automotive. Requirement to be confirmed by a Rosti Technical Representative based on designated press specification. Sprue bush radius should be 12.7mm. 6.5 Venting Close attention to water cooling and venting will be required. All tools should be vented before sampling and primary vents should be polished. If the A surface is a cosmetic face or the parts are to be painted? All vents should be cut on the core side of the tool (where possible). Vent depth according to material recommendations.

22 22 General Tooling Standard 7. EJECTOR SYSTEM 7.1 General Tooling for press size above 15 ton must have provision for additional ejector bar positions other than centre ejection. These should be tapped to allow for ejection pullback. For additional ejector positions the Rosti Technical Representative is to advise. All ejector systems to incorporate push back. All tools in machine ranges 65t and above should use tool contained hydraulic ejection. Ejector location under side movers or which have to be sequenced must run on push pull and the ejector plate sequenced forwards / backwards with a Burgess 4BR micro switch. The tool must be clearly marked for the sequence and have pre-loaded push backs. Wiring of cores should be to Euromap pin 1amp male fitting (Harting socket N ). Deep surface mounting housing to be used with one sided entry (N ). Euromap 13 standard tool wiring Harting Pin Harting Pin 1 24v core 1 9 Core 1 out 2 24v core 1 1 Core 1 in 3 24v ejector 11 Core 2 out 4 24v core 3 12 Core 2 in 5 13 Ejector Back 6 14 Ejector Forward 7 15 Core 3 out 8 16 Core 3 in

23 23 General Tooling Standard 7.2 Ejector Design Use of blade ejectors must be carefully considered in situations where thin walls could cause the blade to dig in. Their use close to gates must be agreed by the Rosti Technical Representative. When parts are ejected using up and away movers, consideration should be given to the part riding with the up and away mover on ejection and provision made to keep the part central during ejection. For ejection actuated by hydraulic cylinders, the tool must be supplied with cylinders ready piped up to a manifold point utilising the bolster or risers when appropriate, to minimise any exposed pipe. Adjustable ejector stops required to limit the ejector stroke this is to prevent the moulding falling out of the press. 8. MOULD COOLING / HEATING 8.1 General Control of the tool temperatures is one of the most important areas of the tool design and the circuits should be given careful thought and discussion at the GA stage. The water circuit design should aim to maximise water flow to achieve a good heat exchange. Secondly turbulent flow is required, turbulence increases as volume increases and turbulent flow is also enhanced by sharp transitions or turns. Avoid flow restrictions at all costs. If water baffles are used these must be brass or plastic keyed in the correct orientation to prevent movement, aluminium must not be used. Inlets and outlets must be stamped IN & OUT and numbered. A schematic of the circuits should be shown on the GA. For circuits around hot tip bushes, these should be identified on the tool as hot tip bush Thermocouples may be requested for each half of the tool, if these are requested by the Rosti Technical Representative these should not be too close to runners or water ways. J type bayonet fitting required 1/8 BSP. Wiring should be terminated to a box mounted, RS components SKT ref N Each circuit must be pressure tested to 1 psi at 5c for 15 minutes no leaks should be evident. Max temperature 9c. All tools are to be supplied with the throughput per circuit in litres a minute in table format.

24 24 General Tooling Standard 8.2 Water Fittings Water connections are to be on the non operator side of the tool where possible. If connections are required on the bottom of the tool they must be recessed so to allow the tool to stand on legs provided on the tool no fittings to be placed on top of the tool. The tool must be capable of being loaded into the press without removal of the water connectors. Connectors to be used on the tool Connectors to be used on the pipe 1.3 Other equipment 1.4 Tool water fittings hot (3/8 BSP) RPL /KR 1.6 Tool water fittings hot RPL 8681/CN/RE/KR 1.5 Tool water fittings cold (3/8 BSP) RPL /KB 1.7 Tool water fittings cold RPL 8.681/CN/RE/KB Showing how female fitting is screwed into the mold and sits flush. Red denotes return water. 8.3 Hose Requirements 1mm or 13mm bore to be decided at toolmakers disc For Hot water i.e. return 1.8 Push fit hose 2m roll hot CALORLOCK 1/KR 1.9 Push fit hose 5m roll hot CALORLOCK 1/KR/5 For Cold water i.e. feed 1.1 Push fit hose 2m roll cold CALORLOCK 1/KB 1.11 Push fit hose 5m roll cold CALORLOCK 1/KB/5

25 25 General Tooling Standard 8.4 Staubli plates All tools designed to run in machines above 65 ton must be fitted with Staubli quick connectors. For any tool to fit in a machine of 65 ton and above Staubli plate water manifolds are to be fitted. For tools below 65 ton, DME N9 push fits (shown below) are to be used. If water plates are to be fitted to tools, consideration needs to be made with regards to adequate clearance to enable the tool to be lowered into the machine and machine side connectors to be attached. If the tool runs on a water heater the HR must have the ability to run on cold water. This will be achieved with the use of Staubli push fit connectors shown on slide 24 or N9 s if below 65 ton. 1 to 6 circuits (3/8 BSP) RMI /JV 9 self-lock adaptor (1mm hose) AF152.1/CN/RE 9 self-lock adaptor (13mm hose) AF152.13/CN/RE IN S OUT 9 self-lock adaptor (1mm hose) AF152.1/CN/RE 9 self-lock adaptor (13mm hose) AF152.13/CN/RE Extender RMF Main manifold attaches to the tool with 6 in s and 6 outs DME N9 s to be used with tools to run in machines of below 65 This spacer is used on the 6 inner most connectors of the above manifold. They allow the pipes to exit above the 6 outside pipes The below part screws into this extension

26 26 General Tooling Standard 9. HYDRAULICS 9.1 General All hydraulic cylinders fitted to tools are preferred with external micro switches signalled mechanically. All hydraulics equipment fitted to the mould should have a minimum rating of 3 psi. (27 bar) Hydraulic connection must be 1/4 or 3/8 BSP and fitted with quick release couplings. Multiple cylinders on the same circuit should preferably utilise bolsters and risers whenever possible to give one inlet and one outlet. All hydraulic cores must be fitted with limit / safety switches, Burgess 4BR. Termination of wiring should be to Euromap 13, 16 pin male fitting Harting socket (No ). Deep surface mounting housing for the socket is required (No ) Core sequence must be shown on the GA and stamped onto the tool. Traffic lights should be used for complicated core sequences that show the position of each core. All tools fitted with cylinders must have flow regulators on them. All cylinder shafts to have male threads. Staubli hydraulic valve gate quick connector Hydraulic core Staubli quick connector

27 27 General Tooling Standard 9.2 Hydraulic Core Connectors 1 circuit Induvidual plug (3/8 BSP) Induvidual socket (3/8 BSP) IN OUT 2 circuits RMP /JV 3 circuits RMP /JV

28 28 General Tooling Standard 1 gate Induvidual plug (3/8 BSP) CBX Induvidual socket (3/8 BSP) CBX IN OUT

29 29 General Tooling Standard 1. MOULD APPROVAL PROCESS On completion of the mould and in advance of tool shipment, the tool will need validating by one of the following options, this will be agreed with the Rosti Technical Representative in advance of the final tool trial:- 1. A single trial that requires the Toolmaker to produce a minimum of 5 lifts off the tool using free issue material, within the costed cycle time and off Robot. 2. A single trial that requires the Toolmaker to validate the tool by dry cycling the tool a minimum 1 times and locking over the tool every time. On completion of this trial the tool will require to be fully stripped down and all moving parts inspected for wear or pickup, all vents will need inspecting to ensure they are still evident and functioning at the correct depth. 11. PRODUCT IDENTIFICATION 11.1 General All products must be identified with the following information, taking into account change type inserts. All engraving to be agreed by the Project Engineer Part numbers. Including LH & RH if applicable. Part number suffix (e.g. AB) should be on a removable brass insert Customer logo Tool number Cavity number 5mm x 15mm insert with 2D bar code information on (to be supplied by Project Engineer if applicable) Image 22 Vendor code Material code e.g. >PC-ABS< Date grid/clock (depending on space available). For Date clocks, DME Date Pins OMN & OYN series preferred 1mm OD. Separate year and month clocks (6 year and above). Image 21. Date clocks format preferred Image 22. Typical 2D Bar Code grid

30 3 General Tooling Standard 12. SPARES Standard mold components should be used wherever possible. If this is not possible for any technical reason then a provision for spare should be allowed for. Cylinders New molds should be supplied with a spare set of cylinder seals for each different cylinder. i.e. if the tool has four identical ejector cylinders one set of spare seals is required. If however the tool has 4 different cylinders used for core movement then a set of spare seals is required for each. Ejector Pins If for any reason a non standard ejector pin has been used then spares should be supplied. This includes unusually long pins with long lead times. Overmoulded Pins If pins are overmoulded then spare interchangeable pins should be supplied and allow for exchange from the front of the mold. Hot Runner If for any reason non standard long lead-time parts are required for the hot runner system then spares should be supplied. If hydraulic valve gates are supplied then at least one spare set of seals are to be provided. 13. STANDARD DOCUMENTS Blank Timing Plans and PFU documents will be supplied by your Rosti Technical Representative. You will be expected to use these Rosti document templates.

31 31 General Tooling Standard TOOLMAKER CHECKLIST TOOL MAKER TO FILL IN AND RETURN WITH THE TOOL To Check 1. Tool number clearly identified on tool 2. Tool weight clearly identified on tool 3. Maximum ejection stroke clearly identified on tool 4. Maximum opening stroke clearly identified on tool (if applicable) 5. B surface correctly marked with component identification, date, pin year and month, material type and part numbers (including RH / LH of applicable) Supplier Rosti 6. Transit strap identified 7. Waterways identified in 1-out 1 in 2 out 2. A3 schematics al all water circuits required 8. All waterways checked and free of blockages 9. Tool has been completely tested and is free of leaks 1. All electrical circuits are wired correctly to Rosti Automotive standard and to euromap Grease grooves are machined onto relevant parts 12. Ejection operates freely 13. Slides operate freely 14. All vents, primary and secondary are completed 15. Any sub-gate along with sprue holes to be highly polished to prevent swarf 16. All sharp corners removed from plates etc. 17. Runners are smooth and burr free no sharpness 18. All gates are well polished 19. Hydraulic / pneumatic connectors are fitted and checked 2. Location ring fitted 21. All hot runner details have been supplied with the tool 22. All PFU issues have been addressed 23. All heel blocks have hardened and tempered wear plates and are let into a pocket 24. Any insulation plates must be asbestos free 25. Ensure that the tool location dowels locate before any side mover dowels and are vented to atmosphere Comments

32 32 General Tooling Standard Appendix 1 TOOLING QUOTATION BREAKDOWN Rosti Automotive Doc. No. RA-OD-5 Rev. 1 15/3/218 ROSTI AUTOMOTIVE Tooling Quotation Breakdown Company Representative name Vehicle model Approx IMM size Part description Component material Warranty period, shots / years Number of cavities Estimated tool weight Surface finish of tool Currency Part volume in mm 3 Approx tool dimensions No & Type of Nozzles Image of component Tool description Description CAM Cad modification Moldflow 2D-3D tool design Description Milling Drilling EDM Wire erosion Turning Grinding Description Assembly Polishing Bench work Design and Feasibility Hours Price/ H Total Machining Hours Price / h Total Manual Work Hours Miscellaneous Price/H Total Description Total Robot head cost All transport tool + parts Treatments Graining Tool trials Materials Tool Steel sizes for Cavity and Core Description Total Grade Height Width Depth Weight Hot runner Bought in standard components Steel Additional Comments Total amount of hours Total cost of hours CAD Revision Totals Miscellaneous Material costs Total tool cost Date of quotation

33 33 General Tooling Standard Appendix 2 QUOTATION REQUEST SPECIFICATION SHEET Rosti Automotive Doc. No. RA-OD-6 Rev. 1 15/3/218 Rosti Automotive (quotation request specification sheet) Part Number: Part Name: No. of Cavities: Type of mould: Production Prototype Cycle time Press Size: Material Spec: Shrinkage: Programme Quote reference TYPE OF MOULD CAVITY MATERIAL GATING Standard Hardness Rockwell Edge 3 Plate P2 Tab Fixed Half Ejection High Hard P2 Sub-gate onto part 2-shot mould Tool Steel H-13 Sub-gate onto ejector pin Cube tool Auminium Winklw gate MOULD BASE Cold sprue EN8 Valve gate P2 CORE MATERIAL Hardness Rockwell RUNNER MANIFOLD P2 Full Round Manufacturer:- High Hard P2 Trapezoidal Hot bush Tool Steel H-13 Direct Sprue Manifold No of drops Auminium Sequential Gating SPECIAL FEATURES FINISH EJECTION Guided Ejector System Cavity Core Ejector Pins Straight Parting Line Locks Standard Polish Ejector Blades S/movers - Mechanical Fine Polish Ejector Sleeves S/movers - Hydraulic Mirror Finish Ejector Bars S/movers with locking cylinders Texture MT Stripper Plates Interchangeable Inserts EDM Finish Up & Aways Runner Shut-offs 2 Stage Ejection Moulded in inserts COOLING Auto Unscrewing Cavity & Core Interlocked Drilled in Cavity Inserts Poppet Valves Inserted Core Drilled in Core Inserts Fixed Half Ejection Inserted Cavity Drilled in F/H Backplate Hyd Ejection presses 6T + Cycle Counter N9 (Jiffy Plugs) Hyd Faster fittings Date Grid/Clock Water Manifolds non-corrosive Engraving on Core Staubli Manifolds + fittings SMED Required Cavity Core OTHER DETAILS Tool Painted Bubblers Remove all EDM marks Thermal Pins Stress relieve core & cavity after machining TRIALING FEATURES APPROX. TOOL DIMENSIONS Texture preperation inc transport 4 tool trials including texture trial LENGTH-mm's Texture prep in UK inc transport 6 piece ISIR at all trials WIDTH-mm's Tool cost MUST INCLUDE DELIVERY Shipment of 3 parts at each trial HEIGHT-mm's TO: Rosti Automotive. site TBC (UK) Sufficient off site trials to validate the Tool, Parts and Process Enquiry to be sent to the following Toolmakers Any Other Details: All items checked on specification sheet MUST BE QUOTED FOR It will be assumed that the quote does include ALL of the above items