MAGNA CLOSURESiweb01ds.magnaclosures.com/web/closuresv3wfv2.0.nsf/images/Do… · Tool Manufacturer Tool Manufacturer Job Number (for reference and tracking purpose) 6.2.5 Mould Hang

MAGNA CLOSURES

INJECTION TOOLS/MOULDS STANDARD

Page 1 of 27 Revision 03-12-06-06

MAGNA CLOSURES INJECTION TOOLS / MOULDS STANDARD

TABLE OF CONTENT PAGE Preliminary Mould Design…………………………………………………………………………………………4 Mould Design and General Design Requirements…………………………………………………………………4 Water Lines / Cooling Circuits…………………………………………………………………………………….5 Hot runner / Supplementary Sketch / Diagrams……………………………………………………………………5 Mould Construction (General):

Safety Straps…………………………………………………………………………………………… 5

Mould Identification / Plaques…………………………………………………………………………. 6 Mould Handling Holes / Safety Hoist Rings..……………………………………………………………………..6 Waterline Design + Connectors……………………………………………………………………………………7 Hydraulic…………………………………………………………………………………………………………..8 Electronics………………………………………………………………………………………………………… 8 Mould Base, Preload, Dei Locks, Guide Pins, Leader Pins………………………………………………………. 8 Slides, Horn Pins, Welding, Wear Plates, Ejection Mechanism………………………………………………….. 9 Core Pins, Knockout, Pilot Pins………………………………………………………………………………….. 9 Ejection System:

Vent…………………………………………………………………………………………….……….9 Conventional Runners / Gases………………………………………………………………….………10 Miscellaneous……………………………………………………………………………………..…….10

Side, Action, Plating, Spruce Bushing, Cavity I.D………………………………………………………………..10 Engineering Changes……………………………………………………………………………………….…...…11 Cavity Finish……………………………………………………………………………………………………….11 Mould Texture, Specification………………………………………………………………………………..…....11 Mould Classification…………………………………………………………………………………………..….11 Tool Grade………………………………………………………………………………………………….…..…11 Specific Construction Requirement………………………………………………………………………..…..….12 Tool Preventative Maintenance………………………………………………………………………………….. 12 Mould Inserts……………………………………………………………………………………………………. 14


Tool Maintenance (Financial Liability)……………………………………………………………………………14 Inspection + General Maintenance……………………………………………………………………………...…15 Major Maintenance………………………………………………………………………………………………. 15 Stress Relieve……………………………………………………………………………………………………. 16 Forms: Check List…………………………………………………………………………………………..…. 17 Mould Design………………………………………………………………………………………..…. 18 Tool Maintenance, Completed by Supplier…………………………………………………………………….….20 Cost Break-down Form: Request For Quotation (Injection Mould)………………………………………………………………22 Mould Inspection Report……………………………………………………………………………………….....24 Incoming and Outgoing Mould Inspection Checklist……………….……………………..…..……....25 Appendix 1 – European-Specific Requirements……………………………………………………….26 Appendix 2 – Injection Compression Molds Recommendations………………………………………27


A. Preliminary Mould Design

a. The responsible tooling engineer (representative of Magna) shall review the preliminary design, providing recommendations / comments as required.

b. The final design shall be submitted to Magna for final review and recommendation(s) at a design conference or at designated meeting.

c. Preliminary mould designs should cover: d. Mould Flow Analysis e. Complete set of Tool Drawing

Plan of Cavity Plan of Core Longitudinal Cross Section Runner and Gate Location Parting Line Waterlines Part Ejection and / or Lifters Hot Runner (whenever, wherever applicable)

B. Mould Design

a. Mould design is the responsibility of the moulding supplier (and / or the party to which Magna awarded a purchase order for the construction of the tool).

b. The supplier will also be asked to supply design, process information, which includes: Press Size Anticipated Cycle Time / Cycle Time Actual Process Set-up Sheet

4.1 The mould design shall be available for review by the moulding supplier and the Magna representative, to ensure

minimum requirements are met and agreed upon before the tool construction starts. 4.2 The completed mould design and detailing will be made available for final review / comment(s) /

recommendation(s) upon completion. 4.3 It is the suppliers’ responsibility to record all changes to the design during the mould construction and to

subsequently update the original design tracings.

The supplier has the final responsibility for tool modifications or corrections in order to ensure that final operation and production produces part to print.

4.4 Tool suppliers are required to provide Magna with a “Tool Progress Report” on a minimum weekly basis. Note:

For expedited tooling work, tool progress report may be submitted more than once / week, pending Magna’s request.

4.5 Tool Design shall remain the property of Magna Closures. 4.6 Tolerances that are indicated as critical or significant characteristics (SC/CC) on the part drawing, must guarantee

acceptable Cp values and Cpk of 1.67, at a minimum. This requirement must be complied with for a minimum of 20,000 molding cycles before routine maintenance as specified in the Tool Preventative Maintenance (P.M.) section.

4.7 The supplier is required to keep the molds in good working condition for the entire life of the awarded program.

Any documentation related to maintenance and repair of tooling must be made available, upon request, to the Magna Closures Purchasing Office, or any related and authorized Magna Office.

General Drawing Requirements 5.0 All designs must have a plan of cavity, plan of core, longitudinal cross section, and typical cross sections

through all major areas of the mould as follows:


5.1 Waterlines - The mould design must include an isometric (three dimensional) drawing of the core and cavity

block, viewed from parting line surface with the location and I.D. of each

Cooling Circuit – The drawing is to include a notation for the minimum flow rate for all circuits to achieve efficient cooling as stated below. Waterline Diameter (Inches/mm) Minimum Flow Required (Gals/Liters. Per Minute)

0.25 / 6.35 0.6 / 2.136 0.375 / 9.525 0.9 / 3.2 0.500 / 12.70 1.2 / 4.27 0.625 / 15.875 1.5 / 5.34 0.750 / 19.050 1.9 / 6.764 1.00 / 25.40 2.5 / 8.90

5.2 Mould inserts are to be one hundred percent detailed.

Hot Runner – If the mould is fitted with a Hot Runner system, the mould design must include an isometric (three dimensional) drawing from the parting line system showing and identifying each location of the hot drops and manifold section(s). This drawing must be producible on an “A” size sheet of paper and labeled “Sheet 1 of 2”.

A second drawing is to be a wiring sketch applicable to mould equipped with Hot Runner/manifold to demonstrate the size and location of the heaters and thermocouples to the components of the system and a listing of heaters by size, wattage and manufacturer description. This drawing is to include how the heaters and thermo couples are wired to their appropriate receptacles.

5.3 Supplementary Sketches / Diagrams – Similar drawings as those related to section 5.1 and 5.2 are to be

submitted as supplementary for sub contracted mechanism that might require repair and maintenance. Example include, but are not limited to chain drive or hydraulic unscrewing mechanisms, Geneva movement mould sweep systems, air ejection or blow off mechanism, or other in-mould machines / mechanisms.

Construction of Moulds (General) 6.0 All moulds that are not inserts into master mould bases are to have the following items included in the design

and construction of the mould. 6.1. Safety Straps – All moulds must have two (2) C.R.S. Safety Straps permanently mounted to their sides to

prevent the mould from opening while being handled to follow standards. 6.1.2 The thickness of the strap shall be compatible with the mould weight. 6.1.3 The width of the strap shall be a minimum of three diameters of clearance holes drilled to receive the two

bolts that shall hold the strap in place. 6.1.4 The strap shall be permanently affixed to the stationary half of the mould by a standard socket head cap

screw, screwed into the mould base or plate leaving a minimum of 0.030 inch or 0.762 mm. clearance to swing freely. The screw is to be locked in place by a one point set screw threaded in at the parting line at a right angle to lock in the socket head screw in place. The socket head cap screw shall be made non-removable (fill the head with weld).

6.1.5 A hole on the moveable half of the mould shall be drilled and tapped to accept a socket head cap screw that

will hold the safety strap in place. A similar hole shall be drilled and tapped to accept a socket head cap screw that will hold the safety strap in place. A similar hole shall be drilled and tapped on the stationary half so that the strap could rotate 90 degrees and bolted to the stationary half when mould in use.


6.2 Mould Identification / Plaques – All moulds are to have the following identification clearly stamped on the

mould. Stamping is to be minimum of 0.005 inches or 0.127 mm. deep and use letters that are large enough to be readable.

6.2.1 “Top” must be stamped on the mould. 6.2.2 Each plate used must be numbered as defined by the mould drawing. 6.2.3 Each plate must also have the number “0” stamped on the upper top operator side corner in the position as

mould is hung in the press. All plates are to have the type of steel and hardness stamped on them.

Where standard mould bases are used, the mould base suppliers stamping system is to be followed consistently with any additional plates.

6.2.4 Two mould plaques are to be constructed and mounted on the operator and rear sides on the mould by being

screwed into a pocket of sufficient length and width to accept the plaque. The pocket is to be deep enough so that the plaque is recessed from the outer mould surface by a minimum of 1/16 inch or 1.575 mm. Each plaque to have minimum of the following information:

Part Name Part Number and Rev. Level Customer Name Tool I.D. Number Number of Cavities Weight Each Half (Pounds and Kilograms) Total Mould Weight (Pounds and Kilograms) Length Mould Ejector Stroke (Inches and Millimeters) Applicable Core Sequence Tool Manufacturer Tool Manufacturer Job Number (for reference and tracking purpose)

6.2.5 Mould Hang Assistance Plaques – Each sketch rendered in section 5.1 – 5.3 shall be modified to show the

hook-ups of the utilities to each circuit corresponding to the identification scheme developed in section 7.1 below. The modified sketched shall then be rendered in the form of a plaque mounted into a recessed pocket on the mould, positioned to be easily readable to assist in installing the utilities during mould set-up procedure.

7.0 Water, Hydraulic and air circuit identification 7.1 Waterlines – Each waterline is to be identified on each end of the circuit with a number such as “in1 – out 1”

in compliance with the waterline sketch in section 5.1 7.2 Hydraulic Circuits – Each hydraulic stamped on the mould surface or an accompanying I.D. plaque it’s

purpose such as “core 1” or “core 2”. The identification is to include a notation for the side that is pressurized, it’s forward position (designated with the letter “F”), and return position (designated with the letter “R”) along with the maximum operating pressure to avoid damage to the mechanism.

7.3 Compressed air circuit is to be identified as to its purpose (such as “poppet blow off”) and the required

pressure to assure proper action. Each circuit is to be fitted with a quick disconnect fitting and labeled “Air In”.

8.0 Painting section “A” of the mould steel. 8.1 The ejection box plates shall be painted bright orange to comply with the safety strap. 8.2 The safety strap shall be painted with bright yellow enamel paint. 8.3 Any moving member on the outside surface of the mould shall be painted bright orange and guarded, to

prevent damage.


8.4 Part / Component Selection – Wherever possible all components such as bolts, heaters, thermocouples, hydraulic cylinders and etc. are to be standard models and readily available from number of suppliers. Custom components are to be avoided.

Mould Handling Holes (Eye Bolt Holes) / Safety Hoist Rings 9.0 Each mould shall have sufficient handling holes drilled and tapped in size and depth as per table below. The

locations of these holes are to be placed with respect to the balance point of the plates or mould halves and to accommodate safety hoist rings.

Eyebolts must be in compliance with DIN580. Top and Bottom Sides

Weight to be lifted (Lbs/Kg)

Hole Size (In./mm)

Number of Holes (per half)

Hole Size (In./mm)

Number of Holes (per half)

Minimum Thread Depth of

Eye Bolts (In./mm)

0-500/1100 0.50 1 0.50/12.70 1 11/4 / 31.75 500/1100 – 2000/4400 0.75 1 0.75/19.05 1 11/2 / 38.1 2000/4400 – 4000/8800 0.75 2 0.75/19.05 2 11/2 / 38.1

4000/8800 – 8000/17600 1.00 2 1.00/25.4 1 11/2 / 38.1 8000/17600 – 12000/26400 1.00 2 1.00/25.4 2 11/2 / 38.1 12000/26400 – 20000/44000 1.50 1 1.50/38.1 1 3 / 76.2 20000/44000 – 40000/88000 1.50 2 1.50/38.1 2 3 / 76.2

G. Waterlines Designs and Connectors G1. Type – The mould shall be fitted with male quick disconnect waterline connectors. Teflon tape shall be used

on all connectors. G2. Orifice Size – The waterline size shall be equal to the orifice size of the connector to eliminate any restriction

of flow from the connector. G3. Installation - Waterline connectors shall be mounted below the surface of the mould in a counter bored hole

whose diameter is to be sufficient to allow the easy connection and disconnection of female connectors. Each connector is to be sealed during installation with pipe thread sealing compound or Teflon tape sufficient to prevent leakage under normal operating pressures.

G4. Waterline Size – Please see Table in 5.1 G5. Drain Gutters – The mould is to be fitted with a drain groove connecting each countersunk waterline

connector hole to allow for drainage of drips so that slight leakage will be directed away from the cavity surface.

G6. Waterline Location – Waterlines are to be located to produce even cooling throughout the part in both core

and cavity. These locations to be determined through thermal finite element analysis. Where this analysis is not determined to be practical, waterline are generally to be placed within three (3) diameter of each other and no further than 2.5 diameters from the surface of the plastic part.

G7. It is recognized that ideal cooling patterns in a mould are sometimes not possible. Every effort should be

made to assure even thermal cooling of the part and avoid creation of uneven heat exchange (is. Use of Brillium Copper and….)

G8. Valve / Flow Meters – Where required, the mould shall be fitted with valves that can be located in a set

position to thermally balance the flow where required, the mould shall be fitted with flow meters to assure proper flow can be monitored through the cooling circuits.


G9. Baffles, Bubblers – Baffles should be used in place of bubblers. Plastic baffle should be avoided. Stainless or brass baffle are preferred. Baffles should be keyed in place and held securely with a set screw and Teflon tape.

G10. Stripper plate, runner plates (on three plate moulds), back up plates - All plates in the mould base

system with exception of the clamp plates should be cooled. J. Hydraulics Each hydraulic circuit is to be plumbed with a male connection attached to the side that is pressurized in the

forward position and a female connection to the side that is pressurized with a return position. The mould should be supplied with appropriate hoses and with mating connectors that can be attached to the machine’s hydraulic manifold.

Where core sequences are required, the core sequence is to be described as to their action in the mould

design. K. Electronics All electrical mechanisms, including but not limited to limit switches cavity pressure sensors, hot runner

circuits, motor drive circuits etc., shall be installed in accordance with prevailing electrical wiring standards by a competent licensed electrician. All circuits are to be wired with grounding connections. All circuits are to be terminated in an appropriately approved housing and clearly labeled as to power requirements. All wires are to be insulated with a material sufficient to provide appropriate electrical insulation for its prescribed application (ex. Insulation on limit switches for hydraulics, should be oil and water resistance, where the heater is a circuit, mica / fiberglass insulation to provide sufficient insulation in a high temperature environment).

L. Mould Base Size / Cavity Preload L1. Mould Base Size – The size of the mould base shall be large enough to hold the cavities, leader pins, sliders

and other mechanisms with additional mould base material giving sufficient strength to prevent mould distortion or cavities shift with continued operation. The mould shut height shall be sufficient so that the mould clamps and other mechanism do not interfere with each other during installation and operation. Wherever possible, a standard mould base and mould component shall be used in preference to a custom base.

The mould design shall include in the plan views, a platen layout that shows the location of the recommended

machine tie rods and mounting hole locations to ensure the mould will fit in the machine easily and safely. The side view shall show the location of the clamps so that the installation of waterlines will not interfere with clamps.

L.2. Preload – The cavity and core inserts, shall be preloaded to stand 0.001 to 0.0015 inches or 0.025mm to

0.0377mm. higher than the overall parting line and external for 0.250 – 0500 inches or 6.35mm to 12.7 mm. The rest of the parting line is to be cleared 0.050 inch or 1.27 mm.

L.3. Standoff Pads – The height of the parting lines are to be around the guide pins so that the preload with exert

on the parting line but not to be crushed by the pressure from the platens. The standoff pads are to be of sufficient area to avoid crushing the preload shutoffs at maximum clamp pressure.

M. Die Locks, Guide Pins (Leader Pins), Stand offs M.1. Die Locks – Where the design of the part or the mould mechanisms result in substantial side loads during

production, the mould shall be fitted with die locks of sufficient size and placed in locations where shifting of cavities will be minimized or eliminated. Wear plates shall be made of bronze alloy material that will minimize galling.


M.2. Guide Pins, Leader Pins M.2.1 Presence – The mould shall be fitted with leader pins to obtain initial alignment during mould closed phase

of operation. The mould shall contain a minimum of 3 leader pins for small inserts and a minimum of 4 leader pins for any independent mould base. Leader pins shall be industry standard pins wherever possible.

M.2.2. Location Size – The leader pins shall be mounted in the corners of the mould. One pin shall be of a different

size to eliminate the possibility of mis-assembly of the two mould halves. The pin shall be of sufficient diameter to allow the mould half with the pins to be placed in a manner where the mould is standing on the pins without damage or distortion.

N. Slides – Slides shall be locked in place with double wedge locks to avoid movement after the mould is closed

during the mould operation. N.1. All Horn Pins - Actuated slides shall be spring loaded so that slide is held in position or mechanically latches

or both to accept the pin and not slide out of position if mounted vertically in the mould. N.2. All Welding Shall be Approved - Welding is to be done per welding procedure to avoid brittleness from

unstable welds. Supplier shall submit applied procedure if requested by Magna. N.3. Stop Buttons / Prying Mould Open with the Ejector Plate - The ejector plate shall be fitted with positive

stop buttons and all plates have pry slots to facilitate separation during maintenance. If the mould has slides that will be damaged by the premature action of the ejector plate, the moulds shall be fitted with a plaque on the side of ejector plate stating “damage will occur if ejectors are moved forward before mould is fully open”.

N.4. Wear Plates – All areas prone to wear are to have easily replaceable wear plates, hardened slides and be

fitted with a lubrication system, if required. N.5. Ejector Pins – All ejector pins should be nitrited or hardened. N.6.1 In the Ejector System all core pins inside sleeve ejectors shall be retained by a cap plate held in position by a

minimum of two screws. N.6.2 Core Pin Shut Offs or Pilot Pins – All core pins that shut off against steel or are piloted into a hole shall be

through hardened made of M-2 or CX steel. (Applicable only for North America and China) N.7 Ejector Systems Other Than Ejector Pins - All stripper plates, rings, or blades are to be case hardened or

nitrated. (For Europe) N.8 Pillar Support, Support Rails – Rails or Pillar support are to be 0.001 in / 0.025 mm. higher than the outer

housing rails supporting the ejector half of the mould. N.9 Knock out Pads – Pads are to be installed on the ejector plate to accept the knock out rods. Pads to be

recessed 1/16 in. / 1.59 mm. from platen, protruding through the clamp plate to accept knockout rods and keyed into the ejector plate.

O. Vents O.1. All ejector pins with more than “one” inch stroke shall be ground circumferentially 0.150 in. / 5.810 mm.

down from the top an amount consistent with the vent depth (appropriate to the material). An atmosphere vent shall be ground down to assure good venting. The detail and construction of these pins shall be noted separately on the drawing.

O.2 All cavities shall have full perimeter vents of a depth and land width appropriate to the material, then flowing

to a 0.100 inch wide by 0.100 inch deep, or 2.54 mm. wide by 2.54 mm. deep channel. This channel shall mate with a secondary channel of approximately the same dimensions that will vent to the parting line edge to the atmosphere.

O.3 Blind pockets or deep ribs may require passive vents or venting channels into blind areas to assure fill

without burning and elimination of any weak weld line.


P.1 Perishable Items – All items considered perishable should be noted as such. Q.1 Pry Slots – The mould shall be fitted with pry slots to facilitate opening the mould with pry bars if necessary.

All plates shall have additional pry slots to allow easy separation during maintenance. Minimum “1” in. / 2.54 mm. long by 5/8 in. / 15.875 mm. wide.

R.1 Rough Edges – The moulds outside edges shall be filed or radiused to be free of sharp edges on all sides by

1/8 inch radius. S. Conventional Runners, Gates S.1 Geometry / Size – Unless specified the runner shall be full round, each half in each side of the mould.

Maximum allowable mismatch 0.002 inches. The ideal diameter shall be 1.5 – 2 times the nominal wall stock. All runners are to have slug wells. Confirmation via mould Flow Analysis or similar tool design.

S.2 Runner Balance – The runners shall be balanced as to size or cavity pressure through physical balance or

computer simulation. S.3 Gates – The gate cross section shall be 80% of the nominal wall thickness unless otherwise specified. The

gate geometry shall be tunnel or submarine gate unless in agreement with Magna, to be different. The gate location shall be determine to optimize cavity fill either by computer simulation or experienced personnel.

S.4 Runner Plates / Gate Inserts – High volume tools, where excess wear and / erosion on the runner and gate

system is anticipated, runner plate and gate inserts in preference to cutting the runner and gate into the mould steel. Runner plates shall be hardened steel unless the abrasive nature of material requires the use of the machine-able ceramic.

T. Miscellaneous Construction Notes T.1 Use of Shims – No shims shall be used in tool construction, maintenance and repair. T.2 Blind Pockets – All blind pockets shall have 0.030 in. / 0.762 mm. minimum radius on all wall intersections. T.3 Hydraulic Cylinders – All hydraulic cylinders shall be fitted with a “T’ fitting in preference to a threaded

connection to the moving member it actuated. T.4 Plating Mould Plates - All mould plates that are not stainless steel shall be plated with electro less nickel or

chrome with a minimum plating thickness of 0.0007 in. / 0.0178 mm. per surface for corrosion resistance. T.5 Sprue Bushing – Orifice must be specified, bolted, to prevent rotation with a minimum of two screws.

Where required should be keyed to assure proper alignment with the gate and runner system. T.6 Side Action Mechanisms – All side action mechanisms must have positive holdbacks to avoid the

mechanism from accidentally moving forward. All side action mechanisms must incorporate wear plates and (where allowable) grease grooves, lubrication lines and grease fittings on the outside of the mould.

T.7 Hot Runner Moulds – Injection moulds equipped with hot runner, require insulating material to form a

thermal barrier between mould and platens. A second layer of thermal insulating material is to be designed into top of the mould to minimize heat loss from the mould.

Hot Runner / Hot Manifold moulds are to have separate insulation around the heated member of the mould to minimize heat transfer to the cooled mould plates. The manifold plate is to be slotted for easy removal of manifold without having to remove wiring.

As noted before, both mold halves (stationary & moveable) must be insulated to prevent heat loss. The

connectors must be embedded or protected. The electric wiring must run inside the external surface of the mold.

You must use 16 pin electric connectors for molds with hot runner systems (for Europe only).


T.8 Cavity Identification – When multi cavity tooling is built, each cavity must have identification on the cavity surface, moulded into the part. The size and location to be specified by the customer engineer.

T.9 Avoidance of Mechanical Breakage of Mechanisms - If mould has slides, pins, blades, sleeves or stripper

rings place in front of hydraulic mechanisms as such, but not limited to side cores, to avoid damage to mechanism should have some confirming safety mechanism (such as limit switch) to assure no interference or damage can occur in normal operation.

Where the ejector plate cannot be used to open the mould due to pins contacting a moveable feature, a plaque must be mounted on the mould, warning of the damage that will occur.

T.10 Engineering Changes – All changes are to be authorized by Magna Closures. Authorization includes a

formal drawing change, a written and authorized approval for the change, and/or purchase order. T.11 After the part engineering change approval (documented) the subsequent change to the mould design must

also be approved by Magna Closures and the tooling contractors. T.12 Cavity Finish – Unless otherwise specified, the cavity will be finished with an SPI # A3 finish with the final

polishing to be in line of draw. The core shall be finished to an SPI # B3 finish with the final polishing being done at 90 degrees to line of draw.

T.13 Mould Texturing – Cost of texturing shall be quoted separately from the construction of the tool. It is

recognized that the aesthetics of texturing is highly judgmental. However, the aesthetics of texture can vary depending on the processing technology, material moulded and

processing conditions. Because of this, the tooling source is held liable for the accuracy of the placement depth and finish of texture.

T.14 Texture Specifications – Wherever possible the texture is to be specified from a test plaque supplied by the

texturing source. U. Non Compliance / Deviations – Magna Closures must be notified in writing for the reasons of non-

compliance. V. All of the accessories (air, water, oil connections, spigots etc.) shall be considered an integral part of the

mold. W. All threads must have metric, course pitch threads type UNI453 (for Europe only). “Mould Classification”

Standards generally refer to moulds that run in machines whose clamp pressures are 400 tons or less and generally produce products with less than thirty-five square inches.

“Tool Grades” Grade 6 Mould:

Common Use: Prototype, Product Development Expected Life: Minimum 500 parts Tooling Agreement: Yes, if product life is more than two years. Specific Construction Requirements: None


Grade 5 Mould:

Common Use: Low production Expected Life: Minimum 10,000 cycles Tooling Agreement: No Usual Qualification Method: Functional and dimensional Characteristics / Unique Requirements: Limited production. Layout Design Required (detailed). Mould liaise

can be aluminum or mild steel. Cavity and core material can be of aluminum and mild steel or any other agreed upon materials or composites.

Specific Construction Requirements:

Layout for core, cavity, ejection and cooling Specification of materials for core and cavity Runner and gates are cut into the mould liaise / cavity insert

Grade 4 Mould:

Common Use: Low to medium production Expected Life: Minimum 50,000 cycles Tooling Agreement: Not usually Qualification Method: Dimensional Characteristics / Requirements: Most popular type of mould for medium production. Ideal for

general purpose open to tolerance moulding where design tolerances are relatively open and could sustain processing variation.


Layout design for entire mould Specification of materials for core and cavity Cavity back-up plates to be of a 35 RC hardness minimum Core and cavity plates or inserts are to be of a 54 RC hardness minimum Runners and gates are cut into the mould base and cavity inserts

Grade 3 Mould:

Common Use: Capable of close tolerance moulding, not candidate for statistical qualifications.

Expected Useful Life: Minimum 100,000 cycles Qualification Method: Functionality and dimensionally and statistical qualifications Characteristics / Requirements: Mould base, used for commodity resins, ideal for combination of

abrasion, heat or chemical exposure. Routine maintenance required design of mould base generic but cavity inserts subject to detailed design.


Detailed design for entire mould Specification of material for core and cavity Cavity back up plates to be of a 35 RC hardness minimum Core and cavity plates or inserts are to be if a 54 RC hardness minimum Ejector plate is to have guides with wear bushings to assure alignment Runners are cut into mould base, gate inserts optional

Grade 2 Mould:

Common Use: Medium to high volume tooling, materials that will erode the cavity steel / close tolerance moulding

Expected Useful Life: Minimum 500,000 cycles Tooling Agreement: Yes, tool maintenance required Qualification Method: Dimensional and statistical qualifications required

Characteristics / Requirements: Multi cavity, part production in millions, due to volumes, tolerance requirements and life of tool, built with extra features to minimize maintenance routine refurbishment / major maintenance to expand it’s productive life.


Ideally runner less such as hot tip insulated runners or full hot runner system. Pay back in the first year’s production.


Detailed design for entire mould Cavity back up plates 35 RC hardness minimum Core and cavity plates or inserts of H13 steel of 54 RC hardness minimum Ejector plate to have guides with wear bushings to assure alignment All moving component to be fitted with wear plates and lubrication systems where

necessary The area away from the cavity inserts or cavity area is to be cleared by 0.025 in. /

0.635 mm. minimum depth to allow for preload on the parting line of the cavity by 0.002 in. / 0.05 mm. The area around the leader pins is to be left as a standoff pad (0.002 inch lower than cavities) allowing the cavities to touch first, compress, then the standoff pads touch seconds to distribute the champ force

Core and cavity parting lines to be hardened Cavities are to be plates to protect against material abrasion and rust Waterlines to be coated / plated with electro less nickel or electro less chrome to

reduce corrosion or scale build up Runner bars / gate inserts incorporated into the design and made of hardened steel Confirm electrical sensors on all moving members to assure proper precision

alignment If mould uses independent hydraulic ejection, limit switch and hydraulic balancing

circuits are incorporated into the design to ensure even stroke of ejector plate. Cylinders double rod end with cushioned stroke.

Hot runner designs to assure a cooling circuit near the hot runner orifice, as well as air insulating areas around the manifold and tip. Clamp plate is fitting with insulating material to assure minimum heat loss to machine platens.

Grade 1 Mould:

Common Use: High volume tooling Expected Useful Life: More than 500,000 – material erodes steel and / close tolerance

moulding Tooling Agreement: Yes, tool designed for parts that will be running for long time and

tool maintenance is required Qualification Method: Multi-cavity, statistical and / dimensional Characteristics: Tools with all characteristic of grade 2 as basic set of requirements

but, subject to maintenance with the replacement of core and cavities. Tool extensive P.M. is required. Frequently using hot runner systems, guided ejection, easily replaceable wear plates and cavity pressure transducers to assure minimum mould wear, maximum part productivity and minimum material consumption


Detailed design for entire mould. The design is to incorporate front load parting features for each cavity to facilitate repair / replacement of cavities and core without the need for completed mould disassembly (is. Disassemble from parting line).

Cavity back up plates to be minimum 54 RC hardness. Cavity back-up plates to be plated or made of corrosion resistance steel

Core and cavity plates and / inserts H-13 steel (must triple draw H-13, RC 44 – 46) Ejector plate to be made of stainless steel or to be plated to avoid corrosion. Equipped

with ball bearing wear bushings and hardened steel guide pins to assure alignment (precision tooling)

All moving members to be fitted with wear plates and lubrication system, (where necessary)

The area away from the cavity insert or cavity area is to be cleared by 0.025 in. / 0.635 mm. minimum depth to allow for preload on the parting line of the cavity by 0.002 in. / 0.05 mm. The area around the leader pins is to be left as a stand off pad (0.002 in. / 0.05 mm) lower than cavities) allowing the cavities to touch first, compress, then the stand off pads touch second to distribute clamp force

Parting lines (all) to be hardened


Cavities to be plated to prevent wear against material abrasion and rust unless made of stainless steel (or choose correct material to prevent rust and wear)

Waterlines to be coated / plated with electro less nickel or electro less chrome Runner bars / gate inserts are incorporated into the design and made of hardened steel

(H-13 or D-2, gate inserts, should be replaceable) To unsure proper / precision alignment, electrical sensors on all moving members If independent hydraulic ejector to be used, incorporation of limit switches and

hydraulic balancing circuits are required cylinders to be double rod end with cushioned stroke

Tools with hot runner systems shall be equipped with cooling circuit near the hot runner orifice and air insulating areas around the hot runner manifold and tip. The clamp plate is lifting with insulating material to assure minimum heat transfer from the hot runner to the machine platen

“Injection Mould Inserts”

If supplier is instructed to build inserts to fit in a common mould base. Inserts are divided into these categories:

Grade 3 Inserts: Description: Low volume production (prototype)

Expected Useful Life: Less than 500 units / parts Qualification Method: Functional only Characteristics / Requirements: Inserts can be made of material that allows the part to be

produced. Inserts construction uses minimum of drawings and sacrifices the quality of material for the speed of construction. Common use of aluminum, epoxy, zinc, brass, low melt alloys, spray metal or electroformed cavities

Grade 2 Inserts: Description: Same as Grade 4 mould

Expected Useful Life: Less than 100,000 units Qualification Method: Functional and dimensional Characteristics / Requirements: Inserts made of aluminum or mild steel construction Construction Requirements: Same as Grade 4 moulds. The insert has cooling lines, I.D.

is stamped on the inserts

Grade 1 Inserts: Description: This insert is used for high volume production

Expected Useful Life: More than 500,000 units Qualification Method: Dimensional and Statistical Characteristics / Requirements: Inserts made of hardened steel Construction Requirements: Inserts use requirements of Grade 2 mould

Tool Preventative Maintenance (Level ) Tool maintenance, required and to be implemented by supplier:

Matter of record keeping and authorizing the work to be done in timely manner Disassemble the tool, clean and lubricate by competent and trained tool maker Decision making (what to be done) Who pays? How to qualify the tool Designate and empower person to do the job

The Financial Liability of Maintenance Once a mould has been qualified and accepted by Magna, the mould maker / manufacturer is liable for manufacturer’s defects such as, mis-assembled inserts, blocked water line, steel flaws, cavity crack(s), workmanship defects.


Routine Maintenance; Moulder’s Responsibilities: Replacement of broken / worn ejector pins Return ejector springs Rework of any scratch, dings, nicks Flash elimination,

are responsibility of the moulder in addition to those items were caused during production. Maintenance require as a result of (excessive) / wear, before anticipated life span, is the responsibility of the molder. The cost of general maintenance after anticipated life span, is subject to negotiation basis with moulder as re-investment in the mould. Wear and tear and the need for maintenance is determined by the level of quality expectation by Magna. Inspection Maintenance (Level 2) General maintenance consist of following recommendations are recognized as responsibility of moulder, performed by a qualified mould maker:

1. Any components missing or cavity blocked off. A sample from blocked cavity should be retained

2. Wash mould with safety solvent to remove the varnish and build up from the resin and moulding process

3. The gas vents should be checked for depth and width in a minimum of four clock-face places around the cavity face

4. Notations for work to be done during the general maintenance procedure and should be noted on the form for the future work

5. Bent, worn or broken ejector should be replaces immediately. Remove mould from production, replace pins

General Maintenance (Level 3) Note – This maintenance schedule should be performed by trained / certified tool room technicians.

1. All plates separated and their faces cleaned 2. All moving components are disassembled, checked for wear, cleaner, re-lubricated (when

/ if required) and re-assembled 3. Check all components for wear, note results of assessment on wear, notify production to

execute repair, replace or continue production, pending requirements 4. Eliminate any roughness outside the cavity details. Any dings, dents or other signs of

wear and abuse shall be worked out 5. Lubricate all moving parts 6. Check gas vents for depth, width and land as per tool drawing specifications. Create data

as recorded on the check list 7. Check “O” rings, seals and gaskets for integrity. Authorize replacement 8. Pressure test all waterlines for leaks and flow capacity. If waterlines have scale built up,

pressure clean with descalling agent 9. Examine ejector system for proper alignment. If holes have become egg shaped, re-drill

and bore larger ejector pin holes and replace the existing pins 10. Replace broke / collapsed return springs, re-plate or retexturing, as a result of the material

eroding the mould surface, replace gates or gate inserts, new runner blocks

Level 4 – Major Maintenance This maintenance should be performed by skilled tool and die personnel. This maintenance should be done due to:

1. Mould has reached number of cycles for maintenance 2. Damage to toll


3. Excessive wear Tool is subject to re-qualification procedure as outlined in mould qualification section of this manual. Supplier is required to keep records to determine tool condition, there should be four complete shots (Parts, Spring and Runners) with the tool for study. Two shots should be from the initial mould run as retained and labeled. This is to provide a visual record of what was new and fully functional. The second two shots should be labeled as last offs before the tool was pulled for maintenance comparison of before and after shots will determine wear and abuse the tool has suffered. Comparison of parts and maintenance log, should result in plan for maintenance of the tool.

1. All components determined and authorized to be replaced shall be removed and replaced with new components

2. Worn leader pins, bushings, all moving surfaces should be checked for wear, replaced / repaired as required.

3. Mould cavity surfaces and plates shall be checked for parrallelness and ground flat if required

4. Mould cavity surface shall be cleaned and polished to the original surface requirements. Galling, dings and dents should be worked until the surface is fully in compliance to the original print specification.

5. All components not meeting the part prints original specifications shall be repaired, replaces and re-qualify as required.

6. All plated components should be stripped and re-plated where required. All components that have had special surface treatments for corrosion resistance, lubricity, hardness and the like, shall be-retreated to ensure the original intent of the tool.

7. All moving components shall be checked for ease of movement. Adjustment shall be made as required. All return springs in the ejector. Plate shall be replaced with new springs to prevent fatigue.

8. Flush all water lines with descaling agent to remove build up. All “O" rings, internal plugs, seals and gaskets shall be replaced.

9. For high production tooling, the cavities should be removed and stress relieved to remove work hardening and material embrittlement per the attached welding, stress relieving procedure in this manual. After stress relief they should be re-hardened to the specific hardness. The entire mould / cavity set must be re-inspected and re-qualified as a new cavity.

10. The mould base shall be inspected for cracks, work hardening, corrosion etc. If the mould base is plated or painted for corrosion resistance, the coating shall be stripped, cleaned and reapply the coating. The mould’s ID is to be re-done indicating the tooling was re-built.

11. Inspect cavity surface for wear or erosion of plating or texturing. When determined to be necessary, the cavity surfaces are to be stripped or re-plated, or the texture is to be polished off and then new texture applied.

Stress Relieving for Moulds and Mould Plates All moulds and mould plates made of P20 or similar steels prone to a machining stresses or weighing more than 2000 pounds must be stress relieved after rough machining before the mould is finished. A1. Stress Relief Procedure Machine the core and cavity block to approximately within 1/8 inch of the final dimensions. Heat the steel at the rate recommended by the steel supplier to the stress relief temperature recommended by the steel manufacturer. Heat soak the steel for half an hour per inch of maximum thickness. Remove the steel and allow it to air cool. Air quenching and other steels should be stressed relieved per the steel manufacturer’s instructions.


DESIGN REVIEW

CHECK LIST FOR MOLDS

TO BE COMPLETED BY TOOL MAKER AND PART MANUFACTURER

PIECE PARTS 1) Is this piece part drawing approved? 2) Have you read all the notes pertaining to the job? 3) Is the type of plastic material indicated? 4) Are the function, location and use of the piece understood? 5) Can any changes be recommended to make a simpler or better piece? 6) Is the number of cavities correct? 7) Are tolerances indicated on all critical dimensions? 8) Can these tolerances be maintained? 9) Are the dimensions given including of excluding shrinkage? 10) What shrinkage factor is to be used? 11) Has adequate draft been specified? 12) Have tapers been specified? 13) Has the parting line been specified? 14) Has the gate location been approved? 15) Is the gate location in the best possible place for maximum physical properties? 16) Is the gate location in the best possible place for finishing? 17) In designing location of gate, will anticipated weld lines prove objectionable esthetically or 18) Will the piece price hang (stay) on the ejection side? 19) Has the ejector mechanism(s) been decided? 20) Have the location of the ejector mechanism(s) been approved? 21) Is the ejection mechanism(s) sufficient? 22) Has polish been specified by Magna Product Engineer? 23) Will the mold physically fit in the presses to be used? 24) Is the mold thicker than the minimum thickness required of the presses?


25) Is the ejection stroke of the machine long enough to allow for part removal (definite ejection to

remove the part from the mold) 26) Can the mold be clamped into the press? 27) Is the clamping capacity of the machine enough for the parts? 28) Is the injection capacity of the machine enough for the parts? 29) Do the ejector holes correspond with the ejection mechanism of the press? 30) Do we need knock out mechanism on injection side? 31) Are water lines located so that they will not both be in the way of or interfere with the operator? 32) Do water lines interfere with tie bars or other mechanism? 33) In the event of requirement for heating the mold, are the heating elements and control units placed

safety to be out of the operator’s way? 34) Have the dimension of the locating ring been shown?

MOLD DESIGN 35) Are the mold plates and component parts strong enough for the piece? 36) Is there sufficient steel surrounding the cavities and cores? 37) Are there sufficient support pillars? 38) Is one leader pin and bushing unsymmetrical? 39) Will the leader pin enter before any other part of the mold? 40) Is there ample clearance of leader pins in the other side of the mold? 41) Is there sufficient travel for the ejector plate? 42) Is the ejector plate strong enough? 43) If a stripper mold, is the stripper plate properly supported? 44) Have a push back pins been provided? 45) Does the sprue bushing fit the machine? 46) Have the dimensions of the sprue bushings been recorded? 47) Are there sufficient cooling channels in the mold and cavities? 48) Do the knockouts clear the water holes? 49) Are runners specified?


51) Have gates been specified? 52) Have run-offs been provided when required? 53) Has venting been specified? 54) In cam acting molds, have provisions been made for hardening moving parts? 55) In cam acting molds, have provisions been made for replacing worn parts and tightening cam? 56) In cam acting molds, can cam pins be replaced without removing the mold from the machine? 57) If there are electrical switches on the mold, have they been made safe? 58) Can the electrical parts be replaced without removing the mold? 59) Have provisions been made for closing, opening and depressions that might be filled up by flashed

shots? 60) Are all steel and metal specifications shown? 61) Have the heat treating specifications been shown? 62) Have the surface specifications been shown (including Chrome Plating)? 63) If the mold has to be heated, have provisions for difference in expansion been made? 64) Have eyebolts been provided on both halves of the mold? 65) Where there are expendable parts such as springs, ‘o’ rings and switches, has a specification chart

been provided? 66) Are bolt sizes specified? 67) Are mold parts (sprue bushings) standard? 68) Have any spare parts to be furnished with the mold designated? 69) Can mold and cavities be disassembly within a minimum of time? 70) Are all the component parts numbered so as to allow for proper re-assembly? 71) Has the mold been properly marked for identification? 72) Has Manifold zones identified on tool as schematics (Hard Stamped, Plague, engraved on

Electrical box)? 73) Are the dimensions on the prints the same as the dimensions on the mold? 74) Is there a schedule of completion dates for stages of the mold work?

Document Tool Progress on Tool Progress Report. "Tool Tracker.xls"


75) Are the mold components identified for type of steel and RC value? 76) Tool maintenance schedule established plus details? If yes, attach Maintenance Report for Daily,

Weekly, End of run plus when tool reaches its life as specified in Magna’s Tool Standard. 77) Is the tool equipped with a shot counter?

TOOL MAINTENANCE DAILY TOOL MAINTENANCE

1) Inspect / clean parting line for damage and blocked vents

2) Inspect taper locks for excessive wear or galling

3) Inspect surface finish in cavity – refer to part

4) Inspect leader pins and bushing for adequate grease

5) Inspect ejector pins for damage and surface finish

6) Inspect ejector guide pins and bushings for adequate grease

7) Inspect ejector system function

8) Inspect for water leaks and verify cooling flow rate COMPLETE BY: DATE: WEEKLY TOOL MAINTENANCE:

1) Items 1 through 8 listed under daily tool maintenance

2) Inspect ejector pins for wear

3) Inspect leader pins and bushings for wear

4) Inspect and thoroughly clean parting line and tapered interlocks COMPLETE BY: DATE:


End of run tool maintenance: NOTE: 2 LAST OFF SAMPLES REQUIRED FROM EACH CAVITY

1) All items listed under daily and weekly tool maintenance.

2) Inspect mold for loose screws

3) Inspect all seal offs and parting line for wear

4) Clean mold and prepare for next production run. COMPLETEED BY: DATE: NOTES: Tool room: Production: Engineering:


REQUEST FOR QUOTATION INJECTION MOLDS

Date Production Prototype Purchasing Agent Tool Engineer K (?) No. Quote due by Part No. Part Name Part print date Rev. Level Press size ton Press type Material Number of cavities

Number of molds Mold type Mold Material Gating (Always include manifold when required) Standard P-20 edge (self de-gating style)

3 plate H-13 inserted tunnel or cashew stripper BeCu inserts direct spruce reverse inj stainless steel hot drops (low vestige) insert mold other valve gate (Manufacturer)

H-13 TO BE 44-46 RC hot drop to cold runner S7 or Equivalent (include manifold if required + Manufacturer)

Mould Base Pressure transducer Ejection Action Finish Ej. Pins cavity core cavity core Ej. Blades mech. Slide texture Ej. Sleeves hydraulic cyl. Glass bead Stripper plate ej. Activated SPI Drop to conveyor spring activated Tool cost break down ($)


Eject to robot angled lifter Design $ Collapsible core Material $ Double action Labour $ Features Cooling Part Identification Ej. Guides cavity core Part No. Spring loaded ej Insert Material code Accelerated ej. Mold base Vendor code Positive ej. Return BeCu inserts Customer logo Hydraulic ej other inserted P.L locks Double ej. C.M.M. layout required (6 OR 30) parts Date code Insert Cost cycle time sec. (mold close to mold open) Per cavity in house or third party yes no Yes no Mold maker Magna Closures Note: All quotations must be based on Fully surfaced IGES file compliance with latest tooling standards. List all assumptions and Mold flow /cool analysis. disclaimers on quote. Mold tryout material . Mold tryouts Signed


INJECTION MOULD INSPECTION REPORT Date: (Please initial your comments) Mould Number: Customer: Part Description: Part Number: Machine Number: Mould Needs To Be Cleaned: Water Lines Plugged: Heater Probes Functioning: Side Seizing: Core Pull Hydraulic or Pneumatic Cylinder Damage: Core or Cavity Mold Damage: Excess Wear On Guide Rods or Bushings: Water Leaks ( In Mould or Water Lines): Comments:


Form To Be Used For Tool Design Review and Tool Transfer

INCOMING MOULD INSPECTION REPORT & OUTGOING MOULD INSPECTION REPORT

Y N O 1. ( ) ( ) ( ) K.O. Bars Available 2. ( ) ( ) ( ) K.O. Location (TC Suit Holes in Hydr .K.O. Mech. Of Large) 3. ( ) ( ) ( ) K.O. Pullback 4. ( ) ( ) ( ) K.O. Clearance Location 5. ( ) ( ) ( ) K.O. Plate Tapped 6. ( ) ( ) ( ) Ejector Plate Function 7. ( ) ( ) ( ) Ejector Plate Travel – Spring Compression and Return 8. ( ) ( ) ( ) Riser Operation – Ejection and Return (Confirm ejection mechanism function) 9. ( ) ( ) ( ) Return Pins 10. ( ) ( ) ( ) Cylinder Mountings Front and Rear 11. ( ) ( ) ( ) Cylinder Port Location 12. ( ) ( ) ( ) Safety Witch Function 13. ( ) ( ) ( ) Slides – Operation – Seal Offs – Water Connections Retainers – Safety Switches 14. ( ) ( ) ( ) Bent Horn Pins 15. ( ) ( ) ( ) Slide Hole Position To Stop Location 16. ( ) ( ) ( ) Hot Nozzle Length “Hot” 17. ( ) ( ) ( ) Hot Nozzle I.D. & Taper 18. ( ) ( ) ( ) Sprue Puller 19. ( ) ( ) ( ) Runner – Size – Vents – Corner Radii – Finish 20. ( ) ( ) ( ) Spruce Finish 21. ( ) ( ) ( ) Spruce “O: Diameter 22. ( ) ( ) ( ) Locating Ring Length and Diameter 23. ( ) ( ) ( ) Cavity Finish 24. ( ) ( ) ( ) Core Finish 25. ( ) ( ) ( ) Bent Core Pins 26. ( ) ( ) ( ) Vents – Depth –Size - Location 27. ( ) ( ) ( ) Gates – Size – Tunnel Finish – Tunnel Shape 28. ( ) ( ) ( ) Taper Parting Line Locks. 29. ( ) ( ) ( ) Bent Guide Pins 30. ( ) ( ) ( ) Eye Bolt Holes – Lifting Fixture 31. ( ) ( ) ( ) Stamp Top of Mould 32. ( ) ( ) ( ) Heater Connections 33. ( ) ( ) ( ) Test Heaters and Thermocouples 34. ( ) ( ) ( ) Check Air Systems – Valves – Cylinders – Leaks – K.O 35. ( ) ( ) ( ) Water Test – Pressure – Flow – Mould Temperature 36. ( ) ( ) ( ) Mark Water System & Mould Number 37. ( ) ( ) ( ) Hot Runner Controls Available and Heater Layout Properly I.D 38. ( ) ( ) ( ) Hydraulic Core Pull Sequences Available in Writing Maintenance Set- Up by Engineering. 39 ( ) ( ) ( ) Instruction Re – Flow Dividers 40. ( ) ( ) ( ) Instruction Re – Part Take Out Equip., (Conveyors, Chutes) 41. ( ) ( ) ( ) Spare Heater /Components available 42. ( ) ( ) ( ) Cavity Identification Number 43. ( ) ( ) ( ) Intier Identification 44. ( ) ( ) ( ) Add Color Code For Weight of Mould 45. ( ) ( ) ( ) Completed Date

V- Vendor T- Tool Room E – Engineering Distribution Tool Room: Production: Engineer: Vendor:


Appendix 1

European-Specific Requirements

In addition to meeting the General Magna Closures Standards as defined within the document, those tools built specifically for our European Divisions, must also comply with the additional requirements, below.

1. All moveable and sliding parts (carriages, slides, blades, guides etc.) must be made out of steel ,

type UNI:X40CrMoV511 KU, or similar, hardened to 54 – 58 HRC. They must also be subjected to an anti-seizing treatment.

2. Small dies and punches must be made of steel, type UNI:X40CrMoV511KU or similar. They must

be hardened to 50 – 54 HRC.

3. Large dies and punches must be made out of steel , type UNI:40CrMnMo7 or similar. The must be hardened to 50 – 54 HRC.

4. The counter locks must be made out of steel, type UNI:90MnCrV8KU, hardened to 54 – 62 HRC

with anti-seizing compound.

5. Mold holders and ejector plates for small molds may be made out of steel, type UNI:C45W,or similar.

6. Large mold holders must be made out of tempered steel, type UNI:40CrMnMo7, or similar.

7. Bushings, support pillars, expellers, spigots, guides, springs, injection sleeves, air valves, bleeders

etc. must be standard

8. Use custom-made pars only if it is impossible to use standardized material.

9. All internal parts, cavities, punches and carriages (if of adequate size) must be equipped with cooling circuits.

10. All carriages, slides and counter lock blocks must be equipped with grooves that allow correct

lubrication.

11. All carriages must have a stop mechanism suitable for keeping them in position even when the mold is open. They must be provided with a rear counter lock that prevents them from moving during the molding cycle and they must be activated mechanically or hydraulically. Movement by spring is not permitted.

12. Bleeders must be provided in all of the cavities, in the deepest points that gas can remain trapped.

This is in order to facilitate optimal filling of the form.

13. All of the cavities must me marked with numbers or letters to allow identification of origin of the molded component.


Appendix 2

Injection Compression Molds Recommendations. Shear Edge

1. Should have 1º angle, .001” (0.0254mm) gap, and min 1” (25.4mm) land (height). 2. One side should be hardened.

Safety Rings.

1. Should be minimum 1/8” (6.35mm) higher than shear edge land. 2. Painted same color as safety straps. 3. Placed over guide pins for transportation and storage to protect shear edge.

Pressure Pads.

1. All pressure pads should be identified with numbers correlated to same numbers o the mold, so will always be installed in required location.

2. They all should have identical set of shims. (e.g. .005” +.010” +.020”), which can not be substituted, such as two .005” in place of one .010”.

3. Pressure pads and set of shims should guarantee, when closed mold stops on them, part nominal wall thickness, and shear edge gap .001”.

Guide Plates.

1. All guide plate sets should be identified with numbers correlated to same numbers o the mold, so will always be installed in required location.

2. One plate in the set should be made of hardened steel, and other of wearable material, lamina or equivalent.

3. Should have lead in chamfer, and be spotted to zero gap. 4. Guide plate sets, and shims should guarantee, when mold closed, shear edge gap .001”.

Pressure Transducers.

1. Minimum two pressure transducers should be installed in cavity. Preferred brand is Kistler. 2. Location: one close to gate, “first to fill”, and second far from gate, “last to fill”. 3. If it is possible should be installed on stationary half of the mold.

Polishing: should be: Core 240, Cavity 320 emery. Manifolds. Unless otherwise specified, a Synventive or Husky hot runner system is to be used. Runners should be min. 25 mm in diameter and shut off nozzle orifice should be min 8 mm in diameter.


Documents

MAGNA CLOSURESiweb01ds.magnaclosures.com/web/closuresv3wfv2.0.nsf/images/Do… · Tool Manufacturer Tool Manufacturer Job Number (for reference and tracking purpose) 6.2.5 Mould Hang