KSS GLOBAL STANDARD Plastic Injection Tool Standard KSS 714portal.keysafetyinc.com/supplier_docs/09....

KSS Global Standard Plastic Injection Tool Standard

Doc. No: 1003746 Rev. 7

of 18 Uncontrolled copy printed: 21-Dec-2017

(KSS template no. 1033844 Rev. 2)

KSS GLOBAL STANDARD

Plastic Injection Tool Standard

KSS 714

Document No: 1003746

Author: Paul Ullrich

Approved by: Rodolfo Ventresca (electronic signature on file)

Tandi Mosier (electronic signature on file)

Kevin Gillis (electronic signature on file)

Document History

Revision: Release Date Change No. Modification

7 10. Feb. 2015 101381 Align with approved processes

6 18. Oct. 2013 63147 Added tool materials for EU Market, general updates

5 14. July 2011 46144 Revised Component Part Identification

4 07. May 2009 35695 Added Sections 10 and 11: Part and Tool I.D. requirements

3 09. Oct. 2008 32959 Amended as per SDE Global Tool Purchasing

2 15. Dec. 2006 26886 Amended 33: Part Identification Requirements

1 07. April 2004 83055A Release


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Table of Contents

1 INTRODUCTION ....................................................................................................................................... 3

2 PURPOSE ................................................................................................................................................. 3

3 SCOPE ...................................................................................................................................................... 3

4 SUPPLIER RESPONSIBILITY ................................................................................................................. 3

5 DESIGN APPROVAL ................................................................................................................................ 4

6 SAFETY REQUIREMENTS ...................................................................................................................... 5

7 MOLD BASE INFORMATION .................................................................................................................. 5

8 CORES AND CAVITIES ........................................................................................................................... 6

9 SLIDES AND LIFTERS ............................................................................................................................. 7

10 RUNNER SYSTEM ................................................................................................................................... 8

11 EJECTION SYSTEM ................................................................................................................................. 8

12 COOLING SYSTEM .................................................................................................................................. 9

13 REFERENCES (RELATED DOCUMENTS) ........................................................................................... 11

14 APPENDICES ......................................................................................................................................... 11

14.1 TOOL PROGRESS REPORT ................................................................................................................. 11

14.2 NEW INJECTION MOLD TOOL INFORMATION FORM .............................................................................. 12

14.3 TOOL TAG INSTRUCTION .................................................................................................................... 13

14.4 PREVENTIVE MAINTENANCE CHECK LIST ............................................................................................ 14

14.5 COMPONENT PART IDENTIFICATION .................................................................................................... 15

14.6 MOLD SAFETY STRAP INFORMATION .................................................................................................. 16

14.7 BALANCED RUNNER AND COLD SLUG WELL AND SPRUE ..................................................................... 17

14.8 DEVELOPMENT AND IDENTIFICATION OF MOLDING TECHNOLOGIES…………………………………………………..18


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1 Introduction

This document describes the requirements of Key Safety Systems (KSS) related to injection molding tools.

2 Purpose

The purpose of this Plastic Injection Tool Standard is to eliminate misunderstanding, promote thought and generate discussion on key tool development, tool design and tool building issues. Molds are required to produce finished parts that conform to: a. the 3D Model, including the geometric dimensional callouts and tolerances as

defined in the inspection documents (prints, notes and/or attribute files). b. the requirements for the first parts approval process. c. any other KSS Procedure or Requirement.

This specification and the specifications or procedures referenced herein are issued to: a. reduce the mold design and build costs by:

(1) standardization of design, which will decrease review time and expense. (2) using commercially available die components.

b. assure the safety of the operating personnel. c. promote superior tool design and consistent mold making practices based on

complexity and longevity of production and service requirements.

3 Scope

This document applies to all suppliers of injection molded parts to KSS and to all tool makers (supplier internal or external) who build tools for those suppliers or tool makers who build tools directly for KSS. This procedure defines the processes and requirements for conducting business with KSS.

4 Supplier Responsibility

All tooling must be designed and constructed to meet or exceed the guidelines set forth in this document. The supplier has the final responsibility to manufacture a mold that will produce parts that are within part print tolerances. If the subject parts are not made to part print tolerances, the necessary corrections and/or additions to the tool will be the supplier’s responsibility.


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In order to allow a common data transfer, the software used for the tool design needs to be able to generate PDF- and STP- files. The tool maker shall be responsible for the tool construction compliant to the part print Parts requiring texture shall be submitted for dimensional/surface approval prior to texturing the tool. KSS will determine the texturing source. The tool maker shall submit bi weekly tool progress report to the responsible Tool Engineer and Supplier Quality Engineer of KSS (see Appendix 14.1). The supplier shall furnish the material for all tooling tryouts. A completed tooling library portfolio shall be submitted prior to completion of payment: a. 3D models or drawings of final tool design b. Photos of completed mold / fixture including overall view from different sides,

cavities, details like sliders, lifters, runners, ejectors, tool tags, etc. c. New Injection Mold Tool Information Form (see Appendix 14.2) d. Tool dimensional layout e. Process sheet f. Tool Ownership Form (where applicable) Tool tags will be furnished by KSS and shall be completed and permanently affixed to the tool if not otherwise specified. If gages are supplied they shall be tagged as well. Tool tag instructions are listed in Appendix 14.3. The supplier shall assure a minimum tool life to be agreed with the business award. In order to reach this tool life, the supplier will execute a scheduled preventive maintenance plan (see Appendix 14.4). For further requirements please check the KSS Global Tool Purchasing Procedure Doc. Nr. 82018958.

5 Design Approval

A final design of the mold must be submitted for approval, and approved by the KSS Tool Engineer. The design shall include the following:

A. Plan View of Cavity B. Plan View of Core C. Section View thru long side of mold D. Section View thru short side of mold E. Part position F. Runner and Gate location G. Parting lines H. Waterlines


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I. Part Ejection J. Component Part Identification (per Appendix 14.5)

It is the tool makers responsibility to record all changes to the tool design during the manufacturing of the tool and to update the original design immediately upon sample approval. Note: Tool design approval by KSS Tool Engineering does not relieve the tool supplier of accountability for proper tool function.

6 SAFETY REQUIREMENTS

6.1 Safety straps are to be installed on each side of the mold, at the parting line. (see Appendix 14.6). 6.2 All slides must be equipped with a positive holding device to keep slides in position while the mold is open. 6.3 Molds with ejection elements below a slide shall have positive early ejector returns, to move the ejector plate to the retracted position before the slide is actuated. 6.4 All positive return details shall be included and detailed in the design.

7 MOLD BASE INFORMATION

7.1 A standard DME No. 2 steel mold base (or KSS approved equivalent) must be used. 7.2 DME standard Leader Pins and Bushings (or KSS approved equivalent) must be used. All tools must have four (4) leader pins. 7.3 One leader pin must be offset to prevent mold from being assembled backward 7.4 A minimum of two (2) pry-bar slots must be provided. 7.5 Tapped holes for mold handling must be provided on all sides of tool. Size of holes shall depend upon mold size and weight. 7.6 Standard DME die locks (or KSS approved equivalent) must be used on all molds designed with a flat parting line. 7.7 Stamp mold base front and back with the following information:

a. Part name and number b. Tool Number c. Material and shrink


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d. Number of cavities e. Tool builder and location f. Shut height and tool dimensions g. Weight of mold

8 CORES AND CAVITIES

8.1 Cores and Cavities shall be made as follows (unless otherwise required by KSS): Large cores and cavities: NAR (North America) AISI S7 tool steel/H13 AISI P20 pre hardened tool steel EUR (Europe): 1.2343 (X 37 CrMoV 5-1) 1.2767 (45 NiCrMo 16) when using PVC granules, altern. 1.2316 (X38CrMo16) for grained parts alternatively 1.2311 (40CrMnMo7) or 1.2738 (26MnCrNiMo6-5-4) Small cores and cavities: NAR: AISI S7 tool steel EUR: 1.2343 (X 37 CrMoV 5-1) 1.2767 (45 NiCrMo 16) 1.2379 (X153CrMoV12) when using PVC granules, altern. 1.2316 (X38CrMo16) for grained parts alternatively 1.2311 (40CrMnMo7) or 1.2738 26MnCrNiMo6-5-4) 8.2 Any substitutions must be approved by KSS Tool Engineering. 8.3 Cores and cavities must have adequate cooling (see Cooling System section for specific detail) to ensure optimum production capability of mold. 8.4 Cores and cavities to be designed with sufficient base size and fastening to ensure stability during the injection cycle. 8.5 Standard DME core pins (or KSS approved equivalent) must be used whenever possible. 8.6 All cores and cavities are to be individually inserted into the mold. 8.7 Small standing steel and/or critical areas are to be individually inserted. 8.8 All irregular shaped core pins must be keyed to prevent rotation.


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8.9 All part surfaces to be free of undercuts (unless approved by KSS Tool Eng.). 8.10 All final polishing to be in line of draw to allow maximum release of part. 8.11 All core and cavities must be properly vented to prevent gas trapping and/or to assure proper filling of the cavity. NOTE: At no time will cores and cavities be cast or made from castings.

9 SLIDES AND LIFTERS

9.1 Slides and lifters must be made as follows (unless otherwise approved by KSS): Large slides and lifters: NAR: AISI S7 tool steel /H13 AISI P20 pre hardened tool steel EUR: 1.2343 (X 37 CrMoV 5-1) when using PVC granules, altern. 1.2316 (X38CrMo16) for grained parts alternatively 1.2311 (40CrMnMo7) or 1.2738 (26MnCrNiMo6-5-4)

Small slides and lifters: NAR: AISI S7 tool steel EUR: 1.2343 (X 37 CrMoV 5-1) 1.2379 (X153CrMoV12 when using PVC granules, altern. 1.2316 (X38CrMo16) for grained parts alternatively 1.2311 (40CrMnMo7) or 1.2738 (26MnCrNiMo6-5-4) Any substitutions must be approved by KSS Tool Engineering. 9.2 All slides must be equipped with a positive locking device sufficient to eliminate movement during the injection cycle. 9.3 All slides must be equipped with a positive holding device to keep slides in position while the mold is open (Safety Requirement). 9.4 Wear plates should be considered for large sliders.


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9.5 A center key, in addition to the slide gib, is to be used to guide all slides whenever the width of the slide exceeds the length. 9.6 Wear plates and gibs must contain grease grooves. 9.7 Grease fittings are required to ensure adequate lubrication. 9.8 Large slides must have adequate cooling to ensure optimum production capability of the mold (see Chapter 12 “Cooling System” for specific detail) 9.9 All slides must be mechanically actuated. Hydraulic actuation is only to be used with KSS Tool Engineering approval. 9.10 Horn pins must be DME (or KSS approved equivalent). 9.11 Material combinations and hardness should be selected so that a seizure of moving parts (sliders and moveable cores) will be avoided.

10 RUNNER SYSTEM

10.1 All runner systems must be balanced (see Appendix 14.7). 10.2 Runners must be full round. Trapezoidal runners can be used only with the tool engineer’s approval. No other runner cross sections will be accepted. 10.3 A cold slug well for both the sprue and the end of runner must be present (see Appendix 14.7). 10.4 Runners must have adequate ejection for proper removal from mold. 10.5 A sprue puller must be used to ensure removal from sprue bushing. 10.6 A standard DME sprue bushing (or KSS approved equivalent) must be used. 10.7 Hardened runner bars must be used in all molds and are to be constructed of AISI S7 tool steel (NAR) or 1.2343, 1.2379 (EUR) hardened to 50-54 Rockwell.

11 EJECTION SYSTEM

11.1 Ejector pins must be DME standard (or KSS approved equivalent). 11.2 The ejector plate assembly must have DME Stop Pins (or KSS approved equivalent) to ensure minimum deflection during the injection cycle. 11.3 Ejector Guide Pins and Bushings must be used to ensure continued alignment of the ejector assembly.


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11.4 Ejection is required under all runners. 11.5 All molds must have ejection return springs.

12 COOLING SYSTEM

12.1 Waterlines must be dimensionally located in the design. 12.2 Water inlets and outlets must be stamped with the numbers for different zones. Example: 1 in 1 out, 2 in 2 out, 3 in 3 out, etc. 12.3 Locate all ‘in’ and ‘out’ waterlines on opposite sides of the tool wherever possible. 12.4 Standard DME quick disconnect water fittings (or KSS approved equivalent) must be used on all waterlines. 12.5 All water fittings must be recessed 1.5mm below mold surface to prevent damage. 12.6 All waterlines must be designed for turbulent flow of water through the mold. 12.7 All waterline quick disconnect fittings and related piping must be permanent parts of the tool. 12.8 Waterlines must never be located in the clamp slot areas of the tool. 12.9 Thermal insulation plates suggested.


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13 References (Related Documents)

• 82018958 Global Tool Purchasing Procedure

14 Appendices

14.1 Tool Progress Report


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14.2 New Injection Mold Tool Information Form


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14.3 Tool Tag Instruction

Key Safety Systems Tool Tag - Instructions

1

3

2

4

1 - engrave the Tool Number (assigned by KSS Tooling Engrg.)

2 - engrave PN (KSS number takes prioity – alternative numbers only with KSS approval)

3 – engrave Description of part produced by the tool (see KSS drawing).

4 – engrave Part Revision Level (per direction of KSS Tooling Engrg.)

The KSS tool tag must be completed and placed on the tool in a visible area, preferred on

the operator side. Eventual Property tag (OEM specific format) must be placed near to the

KSS tag.

Note: Tag size is approximately 102 X 38 mm


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14.4 Preventive Maintenance Check List


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14.5 Component Part Identification

1. All component parts require identification. 2. OEM specifications for component identification shall be applied if

applicable. 3. The following KSS component identification guidelines shall be used if no

OEM specifications exist. 4. The specific region for component identification shall be shown on the

applicable part print by a rectangular symbol. 5. The responsible Engineer shall ensure the part print contains the following

information:

• OEM or KSS guidelines to be used

• Allowable region for identification If space on the component is limited, the following guideline establishes priority for component identification requirements. INJECTION MOLDED PART GUIDELINE Parts shall be identified in the following priority order: A) ‘DD’ where: DD= CAVITY NUMBER B) ‘XXXXXXX X’ where: XXXXXXX X= KSS COMPONENT PART NUMBER

& REV LEVEL (Drawing Level is not to be shown) If space is limited, last 4 & Rev digits only can be used C) MATERIAL RECYCLABILITY CODE: ex. <PP> / <PA66> / <ABS> etc. D) DATE WHEEL – Indicating 2 digits of the year and arrow for the month. Alternative calendars may be applied on larger parts with KSS concurrence

identified in the design record (3D attribute sheets or drawings). E) ‘XX’ = SUPPLIER ID AS PER THE APPROVED SUPPLIER LIST.

F) ‘LD’ where: L= REGION (N – North America, E – Europe, A – Asia, I – India, S – South America, F – South Africa) and D= TOOL NUMBER NOTE: - KSS emblem/logo is optional but not required. - Supplier emblem/logo is optional but not required. - OEM emblem/logo should only be added as per Customer guidelines.


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14.6 Mold Safety Strap Information


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14.7 Balanced Runner and Cold Slug Well and Sprue


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14.8 Development and Identification of Molding Technologies Note: This specification shall not limit the development of additions to molds or processes that enhance robust manufacturing including but not limited to the following:

• Pressure gages for injection ports and mid-mold flow monitoring.

• Temperature gages for injection port and mid-mold thermal profile monitoring.

• Enhanced heat transfer features including coatings and/or thermal conducting inserts.

• Mold thermal profile data (IR Thermography Certification)

• Gates and vents

• Correlation documentation between mold performance and mold flow analysis.

Recommendations for features leading to improvements in molded part quality and variation reduction should be identified during the ESI process.

KSS GLOBAL STANDARD Plastic Injection Tool Standard KSS 714portal.keysafetyinc.com/supplier_docs/09....

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