TOOL DESIGN & MANUFACTURE

Issue 8 - 21st June 2002

SECTION 1 - DESIGN
General
1.16 All tooling to be of sufficient design and quality standard that production volumes
for a period of 10 years can be maintained. -

Weekly production volumes will be provided at quotation stage. -

1.17 All dowels used in tooling construction must be standard metric or "extracta" type in
blind holes. (Threaded Dowels) -
1.18 All screws used in tooling construction must be standard metric only. -
1.19 All screws should enter tapped holes a minimum of '2½ D' (2½ times the diameter of
thread).
1.20 On press tools, one sheet must contain all information required for tool maintenance. This
will include a drawing showing the relative heights or lengths
of all punches, dies, forming sections etc, for regrind purposes.-
1.21 On press tools all wear/replaceable parts must be capable of being removed from inside the
tool whilst the tool is in the press where practical.

1.22 Where blank development on press tools has to take place, a fully detailed blank
development drawing must be provided.-

SECTION 2 - GENERAL ASSEMBLY DRAWINGS (G.A.)

2.4 All details will be clearly identified on the G.A. with their reference (detail) number, which
shall correspond to the parts list.-
This also applies to screw and dowels and other proprietary items which are used in the
construction of tools.-

The reference number shall be clearly shown in a balloon with a leader to the relevant
detail.-
2.5 The parts list shall contain:-

i) Detail reference number. -

ii) Description-
iii) Material type or BO part -
iv) Material size with allowance for machining or BO part number -

SECTION 4 - PRESS TOOL SPECIFICATIONS

General
4.1 Die sets will conform to meet the press specification. With respect to Press / Component. –

4.2 Length of pillars is determined by stroke requirements, however, number of variable lengths
must be kept to a maximum of four. -

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 TOOL DESIGN & MANUFACTURE
Issue 8 - 21st June 2002

4.3 All press tools must be fitted with Misumi demountable type pillars and bushes or
alternatives specified at the time of order or roller ball cage to be specified at time of quote. -

4.4 When press tools are fully closed, pillars must be clear of the press by at least 5 mm. –
4.5 All press tools must incorporate depth stops, (at least two, set diagonally), stops must be
dead-size. The diameter of the stops will be as per the pillar size in the tool. -

4.6 All top and bottom die sets must have 4 off tapped holes to suit M16 or M20 eye bolts.

4.7 All tools to carry, riveted on,:-

i) Operation Number -
ii) Component Number -
iii) Material Size (First Operation Tools) -
iv) Tool Shut Height -
v) Press Tonnage -
vi) Month and Year of Manufacture -
vii) Weight of Tool & Top Die Weigh -
Viii) Pitch (where applicable) -

4.11 Nitrodine gas springs will be used where appropriate. Musumi. -

4.14 It is preferred that springs have a dowel through the centre to protect the tool in the event of
spring breakage or spring retainers or sleeve. -

Always build units using the same springs. -

4.20 Where high pressures are required on pressure plates, self contained nitrogen cylinder are to
be used in preference to springs. -

4.21 Tool protection - a mis-feed sensor / sensors to be fitted at a convenient stage in the
progression sensor
SECTION 5 - MANUFACTURE
5.1 All dowels to be 'Extracta' type. –

5.2 All guarding to be painted yellow. -

5.3 All setting stops to be painted red. -

5.4 All tools to be painted to suit Magal colour coding (see specification). -

5.6 All tools containing gas springs to be fitted with a 'warning' plate on the front of
the tool. -

5.8 It is imperative that all location systems are positively mistake proofed to avoid incorrect
component location. Tool makers must prove capability of locations at
try out stage

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5.9 (Pierce Punches to be "Tin" coated). -

Use slug ejector punches wherever possible. -

5.11 Pierce punches to be readily replaceable whilst tool is in press where practicable (punch
plate and strippers to be easily removable). Musumi. -

5.14 Die sections to be keyed or recessed into bolster plates. -

SECTION 6 - PIERCE AND BLANK TOOLS

6.1 All pierce and blank tools to be four pillar type. All pillars to be the same diameter with one
pillar offset to foolproof tool assembly. -
6.2 Pierce and blanking punch and die sections will be 'D2' material, hardened and tempered to
RC 58-60. In all cases the material must be triple tempered to afford maximum die life. -

6.4 Lifters will be placed in the die to ensure the material will flow over the cutting edges. -

6.5 All piercing punches will be fitted with slug ejectors unless prior written approval is given
to deviate. -

6.7 all punches to be "tin" coated. -

6.22 Welding of any die edges or punches is not permissible. -

6.23 Progression feed pilots must be long enough to accurately locate the strip or coil before any
cutting or forming takes place. -

6.24 Fixed stripper plates must be made sufficiently thick enough to overcome material
stripping loads without permanent deformation. -

6.30 Ensure pierce lacing gives maximum material utilisation. -

6.31 Provide setting stops. -

6.35 Recommended list of spare punches and dies to be supplied with costs. -

6.37 Always use spring loaded top strippers - no fixed strippers to be fitted unless authorised by
Magal Engineering in writing. -

SECTION 7 - PROGRESSION TOOLING

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Issue 8 - 21st June 2002

7.1 For progression provide strip layout to include:

(a) tool number-

(b) press size-
(c) pitch-
(d) coil width-
(e) stops-
(f) denote direction of component and scrap fall away.

7.6 Side crop first stage to provide coil/hand feed facility. - Ok

7.7 Use D2 tool steel when blanking/notching. - Ok

SECTION 8 - FORMING TOOLS

8.2 Forming dies and punches to be "Toyota diffusion" coated.
(Consider Plasma Nitriding in some cases).
8.3 It is imperative that all location systems are positively mistake proofed to avoid
incorrect component location.

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