Royal Technologies Corporation
SPECIFICATIONS: PREPARED BY: APPROVED BY: Mold Mold Engineering Dave Radecki NUMBER: REVISION: PAGE: ISSUE DATE: SP-0001 Rev 9.0 1 of 22 3/10/10
>PURPOSE: To document and outline Royal Technologies minimum expectations for mold construction. They are also to be used as quotation guidelines. SCOPE: These specifications are designed to insure that all molds are built to a consistent level of quality expected by Royal Technologies and to allow us to deliver consistent, quality parts to our customers. The scope of responsibility for adherence to these standards is the Tool Engineering Department, the project engineer assigned to the mold, and the mold supplier. REFERENCES: Mold Launch Kickoff Procedure
ROYAL TECHNOLOGIES Mold Engineering Group
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PURPOSE AND EXPECTATIONS MOLD DRAWING REQUIREMENTS GENERAL MOLD BUILD CRITERIA EJECTION COOLING GATES, SPRUES & RUNNERS SLIDES & LIFTERS MOLD AND CAVITY IDENTIFICATION HYDRAULIC CYLINDERS HOT RUNNER SYSTEMS VALVE GATES MUD UNIT SPECIFICATIONS MULTI SHOT MOLDS CAVITY PRESSURE SENSORS HI TEMP MOLDS/GAS ASSIST/LENS MOLDS/INSERT MOLDS SHIPPING AND RECEIVING INTERNATIONAL CHANGE LOG
1. PURPOSE AND EXPECTATIONS
The purpose of these mold standards is to give our mold suppliers the minimum requirements and expectation for any molds built for Royal Technologies. These standards are to be used as guidelines on quotations. These standards as well as all quotations should be kept strictly confidential. Adherence to only the following standards does not constitute an acceptable mold. Royal Plastics expects its suppliers to use generally accepted mold-building standards for quality and performance. Any questionable mold conditions should be identified in the preliminary mold design review. Although we do not expect our suppliers to "redesign" the part, we do expect that any design alteration, which could simplify the mold build or create a better mold conditions, will be identified and submitted to Royal Technologies. These standards have been developed to reduce product development times, reduce cost, and provide a basis for continuous improvement in these areas as they relate to mold building. Royal Technologies expects each mold to arrive on time and run without incidence. Nonconformance to these criteria may result in removal from Royal Technologies preferred supplier list. These standards may only be deviated from with Royal Technologies Mold Engineering written approval.
2. MOLD DRAWING REQUIREMENTS
All molds must have 2D CAD designs. Mold designs must have Royal Technologies tool engineering approval before mold build can start, unless otherwise instructed by Royal Technologies tool engineering. Corrected mold designs are to be delivered to Royal Technologies before continuing mold build. Molds are to be designed to preliminary tooling details given on the purchase order issued by Royal Technologies tool engineering. Mold designs must have the following in order to be approved by Royal: 2.4.1 2.4.2 2.4.3 2.4.4 2.4.5 2.4.6 2.4.7 2.4.8 2.4.9 Location of water lines Location of ejector pins Location of gate with a gate detail section Mold base size dimension (L x W x Stack) Sections through all slides and lifters; Lifter and slide travel identified Sections showing Parting Line location. (Typically through center line) Location of vents Location of appropriate press tie bars, K.O. holes, and clamp bolt holes. Specifications of Hot Runners\ Sprues
2.5 2.6 2.7
Standard items must be called out on mold drawings in Bill of Material (stock list) format . Non standard items should be detailed to facilitate easy reproduction. Interchangeable inserts must be keyed to prevent improper installation. They also should be designed for removal while mold is in press. All inserts must be identified with insert number and part number A 2D final mold design, along 3D CAD of the mold, and a completed mold design checklist should be provided to Royal, no later than the mold receipt at Royal.
3. STANDARD MOLD BUILD CRITERIA
All molds up to 500 lb. are to have a minimum of one safety strap. All molds over 500 lb. must have at least 2 safety straps. All standard mold bases are to have a minimum of a centered and balanced eyebolt hole on all 4 sides of each mold half. All MUD molds to have one centered and balanced eyebolt hole on the top of each half of the mold. Use the following as size to weight guidelines for eyebolt sizes. When in doubt use the bigger size. Additional handling holes are required as needed. 3.22 3.23 3.24 3.25 3.26 3.27 0-200 lb. = 3/8" 200-500 lb. = 1/2" 500-2000 lb. = 3/4" 2000-5000 lb =1" 5000-10,000 lb = 1 ?” 10,000-20,000 lb = 1 ?”
Each mold should be supplied with one or two eyebolts sized per the above installed on the top of each half of the mold. In addition, any mold larger than 1000 lb., or designed for a 170 ton or larger press should have four eyebolt holes in the top and bottom clamp plate; two at each end (against the press platen) for ease in handling and disassembly. Holes should be sized per above. All standard mold bases are to have 7/8" wide by 5/8" deep clamp slots, 7/8” height from platens. Slots should be long enough to allow at least 4 clamps per half of mold, in relation to bolt pattern. Slots may be required on all four sides of the mold Leader pins must engage guide sleeves 1/2" min. before any part of core enters cavity. Leader pins are to be mounted in the cover half of the mold. Leader pins to have tapered lead. All leader pins should enter their bushings at the same time. If this is not possible the longer pins should have taper relief to allow them to engage at the same time. NO welding is permitted on any cavity surface without prior approval from Royal Plastics. All exposed edges of mold must be broken. All cored bosses to have standard sleeve ejector or equivalent whenever possible Otherwise Core Pins are to be used whenever possible Pry slots are to be provided on all mold parting lines to permit ease of disassembly.
3.7 3.8 3.9
All leader pins, slides, horn pins, return pins, ejector pins and other moving components must be greased before delivery to Royal Technologies. DAC#2 RED grease All molds and inserts must be clean and dry from any oils or EDM fluid; the parting lines should be sprayed with a dry mold saver. Molds with diamond turned inserts should be clean of all oils; and noted on the outside of the mold not to wipe or touch the inserts. All molds should have an extended lead locating ring. (Ref DME #6521) All molds should be properly vented; Vent relief should be cut with .04-.08” land, the relief should be .125” wide; .015” deep and extend as long as practical. . A .125-.250” relief should be .015” deep extending to atmosphere. Core pins, ejector pins, slides and inserted areas should be vented where practical and follow the same guidelines. Static vents required more relief to atmosphere Any mold containing a “porcerax” insert should be stamped on the operator side of the mold half containing the insert stating ?This mold has porcerax inserts? There should also be an air connector to the insert to allow back cleaning. Any mold 300ton press or larger shall have bronze bushings. All stripper plates or threeplate mold shall also have bronze bushings. Standoffs are required to protect all items extending outside the mold. They must be robust enough to support the mold, and strong enough to roll molds over when required. Interchangeable inserts must be easily accessible from the face of the mold, and identified by part number whenever possible, they also must be robustly keyed to prevent improper assembly
Toenail pins, or lifters that shut off on parting line require spring loaded return pins. A thin switch may also be required. Both items to be approved by tool engineering. All molds are to have guided ejection All molds to use DME/PCS brand pins and sleeves or equivalent. Press knock out holes are to be as follows: All holes a MINIMUM of 1.250" in diameter. Molds designed for 230 and 300 ton presses require 1.500" diameter holes. Molds designed for 400 ton and above require 2.00" diameter holes. Positive return mechanisms are required whenever slide cores extend over ejector pins. (Suicide slides) or whenever springs cannot be feasibly designed into the mold. Threaded positive return holes may be added to the ejector return plate. They should be as follows: ?-13 up to 400 ton 5/8-11 500 ton-770 ton using 2 x 8” pattern ?-10 650 or 770 ton using 3 x 14” pattern All tapped holes should be FLUSH with the back of the mold. Threaded return rods may require the use of a thin switch Alba type connectors (series 400 female) may be required on 750 ton Toyo machines to aid in KO rod installation Any mold (except MUD dies and small molds with permanent pressure transducers) that has an open ejector box as top of mold must have a removable cover over the ejector box. Use Parker Hannifin style H3C male connectors for all air poppet lines.
4.2 4.3 4.4
5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8
All water line disconnects to be recessed flush with mold. Use DME Series 300 type connectors. Solid brass only, plated fittings are not allowed. Water line diameters must be consistent with fittings used to minimize pressure drop. Water lines connectors must be marked on mold surface with a number and "in" or "out". O-rings are vigorously discouraged from being used. All molds will be pre plumbed prior to arrival at Royal; per mold engineering direction All baffles should be one size larger than the waterline they intersect When bubbler tubes are used they should be stainless steel and must be on a separate water circuit, labeled ?bubbler in? and ?bubbler out? Water lines should not exit top of mold whenever possible, especially inserted, or hot runner molds Whenever possible waterlines should exit the mold non-operator side, and/or bottom of the mold Slides and lifters should have water whenever practical When additional cooling is required; High hard mold max sub inserts should be used, and they should have a water circuit to them
6. GATES, SPRUES & RUNNERS
All molds use 3/4" radius sprue bushings. Offset sprue bushings are to be discouraged. Tools are not to be designed with an offset sprue without Royal Technologies Mold Engineering approval. Any tools requiring an offset of more than 2.00" shall also require a support bracket to be made. Sprue bushings cannot be recessed more than 2.00" without Royal Technologies tool Engineering approval, and are to be keyed or pinned to prevent rotation Gate location and size to be approved by Royal Technologies tool engineering. Runners and gates must be designed to facilitate a BALANCED fill pattern. Subgates and cashew gates must have one ejector pin on the part surface near the gate and at least one ejector pin on the runner. All gates are to be polished and free of cutter marks and EDM. All gate to runner transitions are to be radiused. All cashew gates should use pre-manufactured inserts whenever possible (I-mold/PCS) All sprue and subgate “puller” pins are to be undercut (back-drafted). Whenever possible edge gates should be chiseled and designed to be self de-gating Jump style gates are to be designed to break off with minimum vestige on the part. All sprue/runner transitions should be radiused. All subgate/cashew gate ?pusher? pins should be cored out into pad about 3/8” with 5? draft on core.
6.4 6.5 6.6
6.8 6.9 6.10 6.11 6.12 6.13
7. SLIDES & LIFTERS SLIDES 7.10 7.11 Slides should be removable from mold while mold is still in press. All slides are preferred to have springs to ensure positive location before mold closes. Slide springs should be designed for 40% maximum compression Superior Die Corp. or equivalent slide lock latches should also be used. "Ball type spring plungers" are not acceptable and are NOT to be used. Slides should have gibs and wear plates either Ampco material or be at least 60 Rc. Slides should have either a wear plate or removable lock block on the locking surface for adjustability Guide Pins are to be longer than angle pins All slides should have positive stops, and be easily removable from the face of the mold Slide lock surfaces must be sufficient to overcome the injection pressure on the slide face
7.15 7.16 7.17
LIFTERS 7.18 7.19 7.20 7.21 7.22 Lifters are to be Ampco/HH mold max, or nitrided to 60RC, or coated for wear. Lifters are to have adequate travel to release part, including shrink Guide plates or bushings are required( Ampco or 60Rc.) Lifters greater than 12 degrees require a ?partner rod? Access to bolts required to allow lifters to be removed easily
8. MOLD AND CAVITY IDENTIFICATION
Multi-cavity molds must have each cavity identified by a stamped or engraved number. Where space prohibits a number, dots or ticks may be used in the core steel, not on an ejector pin. Where possible a stamped number should be placed on the parting surface, near the cavity. All part cavities are to be engraved with the Part Number and Royal Tool number unless otherwise specified. When required by the customer, the Revision Level and Recycle Code and other required information must also be engraved in the part cavity. The outside of mold, preferably operator side, must be stamped or engraved with the following information.
8.3.1 Royal Mold Number 8.3.2 Part Number 8.3.3 Part Name 8.3.4 "Property of ¨ " Asset Number (if required) Mold Builder 8.37 Shrink 8.38 Wt. of mold 8.4 All components of mold are to be labeled to facilitate ease of disassembly and assembly. Type of steel and Rc hardness must be marked on each piece. All molds are to be stamped and painted with TOP of mold. Date Clocks when specified are to be changeable from the face of the mold. (PCS Type.) All molds should have the Royal Mold Number painted on two sides at least 1” Tall The weight of the mold is to be painted on one side of the mold at least 1” Tall
8.5 8.6 8.7 8.8
9. HYDRAULIC CYLINDERS
All cylinders and related limit switches should be protected with frames or pillars or brackets.
9.2.1 Use Parker cylinders with EPS-6 type internal proximity switches. Order the correct length wire. Turck 3RKM5-11-lgth cables can be substituted. Run the appropriate wires to an electrical box as detailed below. 9.2.1 Other cylinders must be approved by Royal tool engineering 9.2.2 Allen Bradley or other STANDARD limit switches may be used with Royal Technologies tool engineering approval 9.3 All molds require an electrical box. The box should be mounted in a protected, easily accessible location. It must be sized appropriately for the number of cylinders on the mold. Cylinder switches should not be wired. Royal Technologies will connect wiring. Simply run the correct wires to the electrical box. Minimum cylinder rating must be 2000 PSI. (Parker series 2H or 3H.). IF this must be deviated from a pressure relief valve will be required Quick disconnects for hydraulic core pull lines are Parker Hannifin to be supplied as follows: 9.6.1 Core 1: CORE SET: H3-63 male disconnect. CORE PULL: H3-62 female disconnect 9.6.2 Core Two: CORE SET: #H4-63 male disconnect. CORE PULL: # H4-62 female disconnect 9.6.3 Core Three: CORE SET: #6602-8-10 male disconnect. CORE PULL: #6601-8-10 female disconnect
NPT threads are required for all hydraulic component oil ports (not O-Rings). Whenever possible cores driven by cylinders should be mechanically locked in set position; Royal Tool Engineering must approve non-locked cylinders.
10. HOT RUNNER SYSTEMS
Wiring for hot runners to be 220 Volt, single phase, All wiring and connectors should be to top of mold, or non operator side and protected from damage Power & Thermocouple receptacles are to be as follows: THERMOCOUPLE POWER 1 or 2 zones DME CKPTIC -1, 1 per zone: power & thermocouple 3-5 zones DME MTC-5-G or equivalent DME PIC-5 or equivalent 6-8 zones DME MTC-8-G or equivalent DME PIC-8 or equivalent 9 12 zones DME MTC-12-G or equivalent DME PIC 12 or equivalent 12 or more Multiple DME -MTC-12-G?s Multiple DME PIC 12?s Maximum wattage per 15 amp zone should be 2000 watts, 1 or 2 zones may be 3600 watts with tool engineering approval All wiring channel edges to be broken & smooth. All wiring should be mounted and complete before shipping mold to Royal. Follow DME wiring standards All hot runner molds should have an insulated plate (non-steel) mounted on the top clamp plate of the mold. All Hot runner molds are to have a schematic of the heater/thermocouple zones attached to the operator side of the mold. Nominal orifice size should be no larger than .375
11.1 11.2 11.3
Pneumatic valve gates are preferred Valve gates fittings should be mounted on the TOP or Non-operator side of mold. Pneumatic Valve Gate Disconnects are: Parker Hannifin connectors #W68PL-4-4 for poly tubing. 1/4” dia ?B? port CLOSED. #W68PL-5-4 for poly tubing 5/16 dia ?A? port OPEN. Quick disconnects for hydraulic valve gates are to be supplied as follows: H2-62 FEMALE fitting on FOWARD. H2-63 MALE fitting on BACK
Any portion of the valve gate outside the mold base must be protected. Valve gate molds require an additional limit switch mounted on the parting line. A thin switch limit switch (DME #TSW2220) should be used. “Thin switches” used with a valve gate should be wired (black, white) to a small Hubble connector #HBL-7486N which is to be recessed into the mold or mounted in a box on the mold.
12.MUD UNIT SPECIFICATIONS
The following types of MUD (Master Unit Die) inserts may be supplied to Royal Plastics as specified on the RFQ form: 12.1.1 84/90 UF Inserts: Must have ? sprue radius Center K.O. 12.1.2 10/12 UF Inserts: Must have ?” sprue radius and 3.5” K.O. pattern 12.1.3 13/16 UF Inserts: Must have ?” sprue radius and 3.5” K.O. pattern All MUD molds to have one centered and balanced eyebolt hole on the top of each half of the mold. All MUD units must have guided ejection systems All MUD molds must have positive stops to prevent ejector plate from being accidentally pulled out of cavity. (Use shoulder on pillar supports). Water lines for MUD inserts should be out the top of the mold and the connectors must be recessed. MUD units should have one safety strap on the top of the mold. Four leader pins are required on MUD units
12.5 12.6 12.7
13. MULT SHOT MOLDS
All second shot ?soft? material runners to have pullers designed as follows; 14.1 13.11 Ejector pin, .060 minimum wall, .250/.312 into puller 13.12 No draft on sidewalls
Use ?free flow? hot drop tips on second shots; NO low vestige drops. All drops to have cold slug wells under drops
“CORE BACK” MOLDS 13.4 Molds to have adequate clearance on top to allow mold to be removed easily from press with out raising 2nd shot nozzle Hydraulic Cylinders that are buried inside the mold require a set screw to stop cylinder rods from unthreading. Avoid slides that shut off flat on the cover
ROTARY PLATEN MOLDS 13.7 13.8 13.9 All rotary molds to have 4 Hasco #Z05/26 locators on ejector All rotary molds to have extended KO rods Molds are to be designed to have a minimum of .100 crush area.
13.10 Molds to have adequate clearance for clamp bolts and wrenches 13.11 Molds to have clearance for sprues, runners and gates on second shot 13.12 Certain flat parts may require cover half ejection 13.13 All molds to have cylindrical parting line locks for alignment between halves
14. CAVITY PRESSURE SENSORS
Transducer model to be used is called out on the mold build PO, or be supplied by Royal. RJG transducers require an E-dart reader, DME transducers can be used direct with Milicron Robo shot machines All transducers should be protected with frames or pillars. Sensor installation machining instructions are available at the RJG website:http://www.rjginc.com/resources/sensor_solid_models or at DME.com
14.3.1 Place a punch prick on each ejector pin that will have sensor capability. 14.3.2 Label the ejector plate by each transducer as follows: PS#1; GATE CAV#1 ?PIN DIA? 14.4 14.5 PS#2; EOF CAV#1 ?PIN DIA?
140 F + temp molds require an insulating mounting plate. 250F + temp molds require high temp sensors
15. HI TEMP MOLDS/GAS ASSIST/LENS MOLDS/INSERT MOLDS
GAS ASSIST 15.1 Gain connectors (swag lock type) are to be used to attach to the gas pin.
LENS MOLDS 15.2 Lens molds are to be built with greaseless pins, slide wear plates, pins and bushings, and are to have a label on the mold stating that it is a greaseless mold. Locator pins, ?” rounded ejector pins may be required on top clamp plate 6” or 12” on C/L Diamond turned optic lenses require a label stating: ?This mold has diamond optics, do not touch or wipe these optics?
GLASS FILLED NYLON/ HIGH TEMP MOLDS 15.5 15.6 15.7 Molds running GFN (200?) may require insulating plates on the top H-13 steel or harder is required LN series sprue busing should be used. Where not possible standard sprue bushings may be used, but they must be nitrided for wear. ?Z? type sprue pullers may be required. The sprue puller pin should be keyed Molds running very High Temperatures (300?) High temp require insulating plates on the top and bottom clamp plates
15.10 Hi Temp molds (200+) will require JIC standard water fittings and braided metal hoses INSERT MOLDS 15.11 Insert molds may require two locator pins, ?” rounded ejector pins, on top clamp plate 6” or 12” on C/L for alignment
16. MOLD SHIPPING AND RECEIVING
All molds shipped to Royal Technologies must be protected as follows: 16.1.1 The parting surfaces of the mold must be clean and dry, then sprayed with a dry type mold saver. 16.1.2 The mold (other than small MUD units) must be banded securely to a skid. 16.1.3 The skid must be in good shape and of sufficient construction to support the mold. 16.1.4 The mold must be covered during shipment in inclement weather. Each mold must be shipped one to a skid to facilitate their return to the proper manufacturing location at Royal Technologies. Each mold should be returned to the plant location it was shipped from. New molds must be delivered to the plant specified dock unless otherwise instructed. Molds are to be shipped with pins and bushings and other moving mechanisms protected with DAC#2 RED Grease. Molds are not to be shipped with any oils, EDM fluid, spotting blue on them. Molds are not to be shipped without safety straps.
16.3 16.4 16.5
17. INTERNATIONAL TOOLING TERMS
This section documents the terms and conditions required of International mold suppliers quoting molds for Royal Plastics, Inc. Exceptions to these terms must be noted in writing on the returned quote. 17.1 Tooling terms are: FOB Hudsonville MI, USA by ocean freight. Duties and import fees are the responsibility of the supplier. Shipping the mold is the responsibility of the supplier? unless otherwise noted. Air freight, if required is to be quoted as a separate line item. All molds are to be built using US measuring systems, NO Metric components. The supplier will provide at least one sample pre-texture and one sample post texture of up to 100 shots per mold. Additional samples, pilot runs etc. will be quoted to Royal Plastics, Inc., as required, these must be quoted to include any and all shipping charges If sample is required due to supplier created mold issues, all costs incurred in the sample, including shipment will be the supplier?s responsibility 1st Article package to include the following: ? A short shot analysis of all cavities showing even fill, and part weight, Verification of NO more than two percent variation between high and low cavities. ? Completed Mold steel verification sheet if supplied by Royal at mold kickoff ? Material Certification on plastic used for samples. (If not supplied by Royal) Royal MUST approve this. Tooling work required to correct any issues arising from any of the following issues will be completed at the suppliers expense at a Royal Technologies approved local supplier: 17.10.1 Unapproved deviations from Royal Plastics Mold Standards 17.10.2 Damage in shipping 17.10.3 Mold failure due to poor workmanship. 17.8 The supplier will be billed at the rate of $65.00/hr to complete the corrections. This will include Royal Technologies? engineering and coordination time. There will also be a sampling charge of $350.00 per mold per occurrence to resample any mold needing corrections. NO changes to cost, timing, mold design or construction, or part design will be done without direction from Royal Technologies ONLY. ALL communication will be to and come from Royal Technologies.
17.2 17.3 17.4.
18. CHANGE LOG
2/24/10 Extensively reworked and revised released REV 9.0