:Work Instruction WI #: 7330-000-006-0 COR
Description: TOOL STANDARD / Tryout / ProcurementPage: 1 of 4
Date Issued: 11/22/02 Revision Date: 03/10/03 Written By: Mike Burmesch Approved By: George Semrad
1PURPOSE / SCOPE
This work instruction has been developed to establish tooling standards for Maysteel tools and dies
2FORMS
Tooling Audit Identification Tag
3INPUTS
Customer or Maysteel requirement for new tooling
4PROCEDURE
4.1 Engineering receives procurement instructions from the Sales department which will contain all tooling for a given customer project.
4.2Engineering will determine where the tooling is to be made and completion dates. Purchase orders will be placed or work orders for tool room are written by Engineering.
4.3Pre-Design
4.3.1All electronic file formats exchanged between Maysteel and the tool supplier must be previously agreed upon.
4.3.2Upon format agreement, the electronic files will be uploaded or downloaded to an agreed upon Maysteel FTP site, at which time the supplier or Maysteel will be notified of the location of such files for download. If the supplier does not have these capabilities for transferring electronic files, the transfer must be completed in some other means agreed upon by both involved.
4.3.3Maysteel, the supplier and the customer (if applicable), have the opportunity to discuss the following: tolerance issues, tooling processes, prints and electronic files, Maysteel Manufacturing Tolerance Guidelines for non-specified dimensions, critical to function issues and process control dimensions.
4.4Basic conceptual design must be reviewed and approved by Maysteel and the customer representative(s) if applicable before proceeding to build the tool or die
4.5Unless otherwise specified, Maysteel furnishes the material for samples
4.5.1Purchased tools / fixtures and dies are to include a minimum of 1 sample part for approval prior to shipment of tools / fixtures if applicable.
4.5.2If the supplier does not have the necessary equipment available for tryout, some other arrangements must be made and agreed upon.
4.5.3Maysteel representatives should be present to view the tool / fixture tryouts if applicable.
4.5.4Upon verification the tool / fixture is released for tool / fixture tryout at Maysteel for process evaluation, safety inspection, first article verification, etc.
4.5.4.1The supplier or internal tool room will fill out and attach a tooling audit identification tag to all tools / fixtures when released for try out atMaysteel, if applicable. Reference the Tooling Tags work instruction.
4.6All tools and dies must produce an acceptable part. Unless otherwise specified, tooling should consume no more than 33% of the total print tolerance for all critical to function dimensions (CTF) and 50% of all non-critical dimension and non-specified dimensions on forming location features. On cut-out feature sizes, print tolerances apply, unless otherwise specified.
4.7 Unless otherwise specified, all dies are set for quick die change.
4.7.1 Top shoe clamping area to be 2.00 inches thick and bottom clamping area to be at 1.00 inch thick. Clamping centers should be matched up to the press ram and bed prints.
4.7.2Punch Press Shut Height Standard for Stamping and Forming Dies:
4.7.2.1Dies designed for 275 Ton to 550 Ton presses are to have a shut height of
16.00 inches +.000 / - .040.
4.7.2.2Dies designed for below 275 Ton presses are to have a shut height of
12.00 inches + .000 / - .040.
If there are any circumstances that this criteria cannot be achieved, please discuss with Maysteel personnel during the design or design approval meeting
4.8Unless otherwise specified, first piece documentation is required when submitting first part for approval. Documentation on Maysteel forms with accompanying numbered print or print file.
4.9Unless otherwise specified, spring, urethane, or nitro loaded strippers will be used wherever possible and practical
4.10Use only stock pushers at sufficient strength to keep the blank against the back gauges or equivalent
4.11The material must be guided from the coil feeder to the work area using hook or inverted “L” guides unless otherwise specified.
4.12Ejection of parts must be provided for and agreed upon when the conceptual design is reviewed. Parts must eject from the tool safely for the operator.
4.13All areas of the die, which might contact the material in process, must have rounded corners, so that while feeding, the material cannot catch on corners or protrusions in any way. Also, lifter pins must be provided by cutting edges to bridge the gap
4.14 Punches are to have ejectors unless otherwise specified
4.15 All screws and dowels must be standard and of ample size. All form blocks must be either set into the die shoe or keyed in place.
4.16Unless otherwise specified, all dies to feed from right to left when facing die in operating position
4.17When more than one die is required for a part, location points on all dies must be at the same location
4.18Spring pushers must be provided to insure that the blank is held against gauges of die
4.19Oil breaker pins are required on all dies
4.20If the die is to be hand fed, it must be designed to eliminate the need for operator to place hands or fingers within the point of operation while loading or unloading parts. Dies must be designed to be loaded with a commonly available manual die feeding device.
4.21Scrap cutters, ramps, chutes and drop-through holes should be used for scrap removal. Scrap must fall away free with no hazard to the operator and eliminate the need for the operator reaching into the die to affect its removal.
4.22Dies must be marked in characters of ¼ “ minimum size to show:
4.22.1Maysteel Tool Number
4.22.2Maysteel Part Number
4.22.3Shut Height
4.22.4Tonnage
4.22.5Upper & Lower Die Shoe Weight
4.22.6Customer Tool Number
4.22.7Customer Part Number
4.22.8 Supplier ID and job number, if applicable
4.23Basic die protection is required. Consideration should be given during the design phase for prevention of tool breakage (i.e.: short feed, mis-feed, part ejection, operator enhancement blocks).
4.24Tool Classifications for Stamping Dies.
NOTE: Forming dies must be treated on an individual design basis, depending on the characteristics of the part being formed.
4.24.1 Class A (Minimum Requirements)
Life Expectancy / 1,000,000 hitsDie Set / 2 inches thick top and bottom shoe
Punch Holder / 1 inch thick / HRS
Tool Steel / 1.25 inches thick / A2
Punches / 2.25 inches long / A2
Strippers / .750 inches thick / CRS
Bushings / Bronze Plated
4.24.2 Class B (Minimum Requirements)
Life Expectancy / 250,000 hitsDie Set / 2 inches thick top and bottom shoe
Punch Holder / .750 inches thick / HRS
Tool Steel / 1 inch thick / A2
Punches / 1.750 inches long / A2
Strippers / .625 inches thick / CRS
Bushings / Bronze Plated
4.25.3Class C (Minimum Requirements)
Life Expectancy / 50,000 hitsDie Set / 1 inch thick top and bottom shoe
Punch Holder / .500 inches thick / A2
Tool Steel / .750 inches thick / A2
Punches / 1.250 inches long / A2
Strippers / .500 inches thick / CRS
.
5 OUTPUTS / RECORDS
Tool Tryout (first article report) to be maintained in the part number history file located in the Measurement Center.