evolvetoolanddie.comevolvetoolanddie.com/uploads/3/4/8/0/34803438/evolv… · Web viewLarger tapped holes for lifting might be required, please check the ratings. Sub plates must

Evolve Tool and Die Design and Build Standards / 001-905-962-6880 March 8 2018

EVOLVE Tool and Die Ltd.

Global Partnerships with Purpose.

Design and Build Standards

March 8 2018

Website: www.evolvetoolanddie.com

Email: [email protected]

Phone: 001-905-962-6880

Created by Evolve Tool and Die Ltd.

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Table of Contents

Terms and Conditions

Preface

Section 1) General Build Concepts and Rules

A) Tool Build Units of Measurement

B) Pocket and key Tolerance's

C) Line Up

D) Spotting in the Die

E) Die Lifting and Safety

F) Pilot, Location and Part Control

G) Stamps, Run Markers and Die Markings and Stenciling

H) Nitrogen Requirements and Positioning

I) Quick Change Die Location

J) Sensor's

K) Fasteners and Location

L) Outsourcing

M) Coatings

Section 2) Purchased Components

A)Punches, Pilots and Buttons

B) Nitrogen

C) Lifters

D) Run Markers

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E) CAM Units

F) Fastener's

G) Sensor's

Section 3) Die Construction

A) Die Set

B) Sub Plates

C) Strippers

D) Die Steels and Wire Punches

E)Form Steels

F) CAM Construction

G) Guides, Lifter and Feed Construction

H) Cut Off and Part Fall Off

I) Gag Punch Construction

J) Wear Plates

K) Down Stops

Section 4) CAD and Drawing Standards

A) CAD

B)Drawings

C)Title Block Information

Section 5) Simulation and Strip Process Development Requirements

A) Simulations

B)Process Development (Strip Concept and GDT Justification)

C) Tolerance Process Rules

D) Design Review Requirements

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E) Ordering Material Requirements

Terms and Conditions

Preface

This document is meant to commonize the build standards within Evolve Tool and Die Ltd. Each section of the Standard has been laid out to ensure simplicity in finding the information that you will require to successfully design and build a tool to Evolve Tool and Dies minimum standard. In all cases Evolves Tool and Die Customers design and build standards will over rides these standards. In the event Evolves customer does not dictate a particular design or build standard of process then Evolves Design and Build Standard will dictate the method required.

This Standard is the property of EVOLVE Tool and Die Ltd and is not to be copied in part or in whole without the written consent of EVOLVE Tool and Die Ltd.

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Section 1) General Build Concepts and Rules

A) Tool Design and Build Units of Measurement

All tools will be designed and built in Full Metric Units unless otherwise specified in writing or email at the time of kick off from Evolves Tool and Die or their customer.

All imperial or Inch tools will follow the North American sizing for Taps.

Examples of UNC (Unified national Course) tap sizes:

1/4"-20 UNC

5/16"-18 UNC

3/8"-16 UNC

1/2"-13 UNC

5/8"-11 UNC

3/4"-10 UNC

7/8"-9 UNC

1.00"8- UNC

1.25"-7 UNC

B) Pocket and Key Tolerance's

Pockets are to be machined in a manner that does not require the chamfering of corners to fit blocks into a pocket. The only time this rule does not apply is when the strength or integrity of the blocks function is in question.

All Pockets are to be Plus nothing / Minus .05mm. (Imperial Conversion Plus Nothing / minus .002")

So a pocket size would read for example: 100mm +0/-.05mm

This is being done to ensure that when blocks come in from outsourced parties the tools fit together with minimum issues.

Keys are to be designed and built at nominal sizes, all slots for the purpose of keys must be precisely machined in a manner that ensures a good fit.

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All Slots are to be Plus .03 / Minus .0mm. (Imperial Conversion Plus .001" / minus .000")

So a Slot width size would read for example: 10mm +.03/-.00mm

All pockets that can contain Lube or oils must have Drain holes. Ideally drain holes must be at least 10mm / .406" Diameter. (Anything smaller will require written approval)

CNC Pocket Corner Scallop Sizes

C) Line Up

In this day and age much of the lineup is done with the CNC and wire machines.

However to ensure good line up dowels should always have the ability to be increased by one standard size.

Line up checks must be done where crucial edges are required.

D) Spotting in the Die

All Dies must be spotted into a minimum of 80%

E) Die Lifting and Safety

All dies over 3.50 meters / 42" long must have Coffin handles for safe lifting and flipping.

Coffin Handle Sizes are as follows:

Depth from the side of the die shoe 152 mm / 6.00"

Length of Handle 152 mm / 6.00"

Diameter of Handle 38.1mm / 1.500"

Coffin handle and pocket radius' 32 mm / 1.250"

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All tapped holes for eyebolts for the purpose of lifting must meet the appropriate safety ratings.

Die Sets must have a minimum of a 24mm / 1.00"-8 UNC tapped hole in four places per plate evenly balanced. Larger tapped holes for lifting might be required, please check the ratings.

Sub plates must have a minimum of a 20mm / 3/4"-10 UNC tapped hole in four places per plate evenly balanced. Larger tapped holes for lifting might be required, please check the ratings.

Strippers must have a minimum of a 16mm / 5/8"-11 UNC tapped hole in four places per plate evenly balanced. Larger tapped holes for lifting might be required, please check the ratings.

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Tapped holes are to match the units of the build at kick off.

F) Pilot, Location and Part Control

Part and Strip control are very important features to a great running tool, as a general rule the more control the better.

Part and Strip control can be achieved in many ways. Some examples of this are as follows:

Piloting

Piloting must always occur after the first pilot pierce hole. Ideally two rows of pilots towards the outside of the strip will help to maintain good alignment.

Pilots are to always be a nominal size with a .1mm / .005" clearance hole for the button.

Evolves preferred method at the cut off for piloting is to have the second last pilot as close to the cut off as possible. This is done to ensure the parts being cut off are well located at the time of the shear cut.

The shear on your punches can also affect your part control. Always ensure that when applying shear to the cut off punch that you are cutting the parts off before the scrap.

False Flanges

False Flanges are required on all one sided carriers or single out dies that have a one sided carrier.

False Flanges can also be used to help control pull on the strip if it is required.

Draw Beads

Draw Beads are to be used or designed into all tooling based on the simulation requirements and or experience.

In all cases having the correct pressures behind the components also serve as a very important element to the control of the strip or part.

G) Stamps, Run Markers and Die Markings and Stenciling

All tools must have provisions for stamps in the tool, as a general rule all parts must have a minimum of two ARGON stamp holders for each tool. One stamp is for the Julian date and the second stamp is for the part number and revision level.

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In the design process the Part Number stamp can be placed throughout the die in any position that will not affect the clarity of the letters during the forming or cutting process, preferably after forming.

For the Julian Date it is preferred to be done at the very end of the tool when possible. This will save money on coil material during set up along with making the change over's a little easier.

If we cannot place the stamp at the end of the tool, we will place it at the very beginning of the tool. It will cost a little more for coil material, but it will make the access a little easier.

When designing the Julian Date stamp, a quick change application must be fully considered.

When possible design the stamps to be on the top side of the die.

When possible design the stamps to be interchangeable from the top side of the die to the bottom side of the die.

Always review the part print thoroughly to ensure there are not special considerations for the stamp information.

Die Engraving or Markings

On the top side of the bottom die shoe the following information must be present:

Part Number

Part Name

Coil Material Type

Coil Material Thickness

Coil Progression

Coil Strip Width

EVOLVE's Job Number

Customers Job Number

Customers Tags

When required Asset tags must be mounted to the appropriate location based on Customer Standards.

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Die Stenciling

Die Stenciling requirements will be dictated by the customer, however at a minimum:

Top Shoe Stenciling:

Die Number

Top Weight

Feed Direction

Part Number

Bottom Shoe Stenciling:

Die Number

Total Weight

Feed Direction

Part Number

The Die Color is to be supplied by Evolves Customer.

H) Nitrogen Requirements and Positioning

Nitrogen Requirements are based on the tonnage requirements of the specific material.

Stripper Nitrogen Requirements are 5% of the calculated Blanking requirements.

Self contained Nitrogen is preferred, however during drawing processes ensure that you use a linked system.

During drawing or Extruding processes create individual pads or strippers to ensure good control of the pressures. Also where required stand offs will be incorporated to ensure good control of the material flow.

All CAM units must have nitrogen placed over the working area of the part to ensure proper nesting and control.

Tonnage Calculations

Material Thickness X Length of Cut X Shear Strength = Y

Y / 2000 Tons = Blanking Pressures

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Blanking Pressure X .05% = Stripping Pressure

Stripping Pressure / .750 = Number of 3/4 ton Cylinders

I) Quick Change Die Location

Quick Die Change location is required in all tools and is dictated by Evolves customer requirements.

J) Sensor's

Micro Switches are required on all feed progression fingers

Proxy sensors are to be used at the end of the die as an anti buckle sensor. The sensor must be mounted into a self enclosed paddle bracket.

All CAM Trims and CAM Forms require brackets to hold a proxy sensor with a 6mm / .250" -20 UNC Socket Head Cap Screw on the CAM body for adjustment.

K) Fasteners and Location

All blocks must have a minimum of two Socket Head Cap Screws in all block. Four is preferred.

The bottom die assembly Form Steels and Die Steels must contain Socket Head Cap Screws

No smaller than 10mm / 3/8-16 UNC.

The Top die assembly Form Steels and Punches must contain Socket Head Cap Screws

No smaller than 12mm / 1/2"-13 UNC.

All Dowels must be positioned in a way that will allow the hole to be opened upto the next available dowel size

All blocks must have two jack Screws to allow for easy disassembly.

Large blocks over 10 kg / 22 Lbs must have balanced tapped holes for lifting.

Fasteners, location and lifting holes are to be set at nominal distances from the edge of blocks or in relationship to other holes in the blocks.

All holes must be a minimum of 6mm /.250" from the block edge.

Every block must be poke yoked or designed in such a manner that it will not fit into a different location of the die, or be rotated within the pocket.

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No hole shall be located within the periphery of the part, specifically in the forming operations. This is done to prevent marking on the parts.

All Fasteners must take into consideration where the force or pressure is coming from. Generally speaking Socket Head Cap Screws will tend to be closer to the working face with additional Socket Head Cap Screws at the back of the block for additional support and balance.

Key location is also important when considering placement.

Mount the keys to the block details and not the die set where possible.

Try and keep the keys located where they will do the most good relating to pressures or locations.

Treat Keys and Dowels the same always separate them as far apart on a block when using them for location to ensure good location of a block or subplate.

L) Outsourcing

Outsourcing is at the discretion of Evolve Tool and Die Ltd.

M) Coatings

Preferred Coating for general use is IonBond Concept 90, however different applications require different coatings that will be determined by Evolves customer at the time of Quoting. If Evolve Tool and Die has not received direction from their customer Concept 90 will be

applied. (www.ionbond.com)

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Section 2) Purchased Components

A)Punches, Pilots and Buttons

Punches, Pilots and Buttons must be purchased from Dayton or Tipco.

Punches, Buttons and Pilots are to be M2

Any punch piercing material over 3.2mm must use tough punches.

All die buttons must have slug retention designs built in.

All punches must have Ejectors.

All Shaving punches must be polished and coated.

All Pilots require a minimum of two ejectors on opposing sides of the pilot.

B) Nitrogen

All Nitrogen must be from Dadco or Kaller

No Nitrogen gas springs with a diameter less than 25mm / 1.00" will be accepted, unless it is being used for the sole purpose of part or strip ejection, such as in a stripper.

All nitrogen Gas Springs must be mounted correctly as per there catalogue mounting instructions.

Where possible have Nitrogen go through the die shoes and mounted with blocks that are press accessible in the event of a Nitrogen failure.

C) Lifters

Purchased Lifters can be purchased through Standard Lifters or Danley.

Ensure lifters in question of marking or deforming the part have opposing pads that travel to balance out the pressures to eliminate or minimize distortion of the part.

D) Run Markers

Purchased Run Markers can be purchased through Argon Stamp, Tipco or Enviro Engraving

E) CAM Units

Purchased CAM Units must be reviewed and agreed to by Evolves Customer prior to ordering

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F) Fastener's

Purchased Fastener's can be purchased through Fastenal.

G) Sensor's

All Fingers require a Micro Switch

All CAM's require CAM return Proxy Sensors Brackets

Where slugs have to be sensored the punch must penetrate the land on the die to ensure the slug falls through the die.

All Tools require H- shaped channels machined into the die shoe allowing for a fully protected cable. All Channels require drain holes throughout the trough.

Anti Buckle progression proxy sensors are required at the cut off.

Channel Size is

16mm Wide X 19mm Deep or .625" Wide X .750 "Deep

with a 3mm / .118" deep cover.

Drain holes must be at least 10mm / .406" Diameter

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Section 3) Die Construction

A) Die Set

Die Sets are to be Mild Steel

Die with offset loads require heeling, heels must be A-2 with Ampco wear plates.

All thickness adjustments are to be done on the A-2 to ensure the purchased Ampco 25 plate does not require adjustment upon replacement.

Die Sets are to have roller pins and bushings where allowed depending on manufactures specifications.

Please refer to Section K) Fasteners and Location for fastening information.

B) Sub Plates

Sub-plates are to be Mild Steel unless the material is more than 4.5mm thick, then we must use 4140 or P20.

Must be Keyed to the sub-plate in two directions.

Socket head cap screws must be 16mm minimum / .625"

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The lead edge of the sub-plate is to be cut on a 15 degree angle with a 30 degree lead in for coil loading. this lead should be 38.1mm deep / 1.50"

Pockets machined in the sub-plate must not exceed 45% of the overall thickness of the sub-plate

C) Strippers

Strippers are to be 4140 or P20

Strippers must be guided at all times with Pins and bushings or Heeled Keeper Blocks.

Standard Lifters are only to be treated as spools with no guidance expectations unless the part is flat. Only then no pins and bushing or Heeled Keeper blocks will be required.

All Keepers must have Grease Lines

Stripper Window are to be soft unless told in writing to be hardened

Stripper Windows are to be 16mm / .625" Thick Minimum.

Stripper Windows must be fastened with No smaller than 10mm / 3/8-16 UNC.SHCS.

Stripper Windows must also contain two Jack Screws equal to the size of the mounting SHCS.

Stripper Windows are to be 0-1 / 4140 / P20

D) Die Steels and Wire Punches

Die Steels are to be D-2 or Japanese DC53

38mm / 1.500" Thick at a minimum

No Weld is allowed on Die Steels or Wire Punches.


E)Form Steels

Working Form Steels are to be D-2 or Japanese DC 53

Non Working Form Steels are to be A-2 or Cr12MO1V1

All forming operations must be fully supported by opposing parallels.

All Forming or Extruding operations that will or can lock air pockets in the forming or Extruding process must have air venting in areas of the process that will not affect the part quality such as the corner of the female form.

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No Weld is allowed on form steels


F) CAM Construction

Wearing surfaces must be dissimilar metals,

Ampco 25 against A-2 is preferred for CAM Sliding motion.

In China / DC 53 against Cr12MO1V1 is preferred for CAM Sliding motion.

CAM Bodies are to be 4140 / P20 where possible.

CAM Slide Base is to be A-2 / Cr12MO1V1

CAM Arms are to A-2 or 0-1/ Cr12MO1V1

CAM Drivers are to be A-2/ Cr12MO1V1

All Grease traps rings must be placed on the upper contact face for easy application of grease when the die is fully loaded.

CAM Stripper material must be considered depending on the application based on forming or piercing refer back to those specific material requirements.

All CAMs must have Grease Lines

All Grease traps rings must be placed on the moving portion of the CAM to ensure the grease stays within the CAM.

No Graphite plugs are allowed in the tool, unless it is a Evolve Customer requirement.

Graphite plugs wear quickly and tend to pull out and jam CAM's

G) Guides, Lifter and Feed Construction

Guide Lifters are to be 4140 pre-hard / P-20 / 0-1

Guide Rails are to be A-2 Heat treated.

The first set of Guide Rails must be 1.5 times the progression for length and must be mounted to the sub-plate directly. (150mm / 6.0" Minimum Length)

One side must have an adjustable rail with a key for perpendicularity.

The opposing guide rail must be solid to the sub-plate and dowelled into position.

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All Leads must be 25mm / 1.00" in length X 15 degrees (Minimum)on Two faces

Notch punches and French cuts are required in all tools.


H) Cut Off and Part Fall Off

Part location at cut off is crucial and is often the largest problem at buy off.

Shear must be applied to ensure that the parts separate before the carrier.

Any lifter bars must contain the last possible pilot to ensure correct cut off location.

Shimmable cut off inserts are always preferred for adjustment.

Anti Buckle sensors and brackets must be adjustable in all directions and must be protected from damage.

Part chutes must be on a 45 degree angle minimum and must be protected from damage.

I) Gag Punch Construction

Gag Punches are required before the first forming operation to allow for correct set up of the tool to ensure half parts are not loaded into the die during CAM operations. and easier strip development.

For material that is from .1mm to 2.8mm thick a retractable punch design is required.

For material that is from 2.9mm and up a bottom side Vee -style Gag is to be used.

J) Wear Plates

Wear plates must be dissimilar metals

A-2 and Ampco 25 are preferred.

All Grease trap rings must be placed on the moving portion to ensure the grease stays within moving component. (Grease Rings must not break out of the perimeter of the block edges.)

All Grease traps rings must be placed on the upper die contact face for easy application of grease when the die is fully loaded.

No Graphite plugs are allowed in the too, especially on CAM units.

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Wear Plates are to be 16mm / .625" Thick Minimum.

Wear Plates must be fastened with No smaller than 10mm / 3/8-16 UNC.SHCS.

K) Down Stops

Down stops must be placed between opposing parallels

Down Stops must have 2X 10mm / 3/8" Socket head cap screws retaining them.

Lead Step is to be 13mm wide X 1.02mm Deep or .500" wide X .040" Deep.

.25mm / .010" Air gap for lead check

Section 4) CAD and Drawing Standards

A) CAD

Designs will be done in full 3D and will be supplied to the customer in Step format with the original native design files .

B)Drawings

All 2D drawings will be in DWG or PDF format.

2D Details will be minimal focusing primarily on consumable components with very basic information given on the prints.

2D Details will have the following basic information when required for the actual build:

Material Type

Datum with basic block dimension

Heat Treatment requirements

Component Name

Quantity

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C)Title Block Information

Title Blocks must include:

Component Name

Component Designer's Name

Scale of Drawing

Evolves Job Number

Detail Number

Quantity of Components Required

Section 5) Simulation and Strip Process Development Requirements

A) Simulations

Simulations are required for all parts with Forming operations that are more complex than a simple bend. (Or as per Evolves Customer Requirements.)

B)Process Development (Strip Concept and GDT Justification)

All Processes will only be approved by demonstrating that all tolerances have been considered on the print by using Evolves Process Development Method.

(Separate Evolve Process Development Design Standard is Required)

C) Tolerance Process Rules

(Separate Evolve Process Development Design Standard is Required)

General note for part development, parts tolerance should be built to a nominal or middle of the tolerance, with the exception of purchased punches where you are to use 75% of the upper tolerance.

D) Design Review Requirements

All Designs must be signed and approved by Evolve Tool and Die Ltd's Engineering Manager before ordering any Materials or Components.

E) Ordering Material Requirements

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All Designs must be signed and approved by Evolve Tool and Die Ltd's Engineering Manager before ordering any Materials or Components.

>>> END OF THIS PORTION OF THE OUR STANDARD <<<

Thank you for reviewing and following the EVOLVE Tool and Die Standard, If you have any questions or thoughts regarding the standard please contact us for further discussions. We

are always happy to EVOLVE and Improve the standard to ensure our customers full satisfaction of our products everytime along with keeping upto date with current and future

market trends.

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Documents

evolvetoolanddie.comevolvetoolanddie.com/uploads/3/4/8/0/34803438/evolv… · Web viewLarger tapped holes for lifting might be required, please check the ratings. Sub plates must