INTEVA

TOOLING MANUAL

INTEVATM, Rev G; 01/04/2013 Page 1

Contents
Section 1 - GENERAL INFORMATION.

Section 2 - NEW TOOL SPECIFICATIONS.

1. General Points.
2. Injection Molding.
3. Stamping Tools.
Section 3 – CURRENT PRODUCTION TOOLING
1. Modifications and Refurbishments.
2. Tooling Maintenance.
3. Tooling Condition.
4. Prototype Tooling.

Appendices’
Appendix 1 – Tooling Contact Details.

Appendix 2 - Tool Terminology Injection Molding.

Appendix 4 – Recommended Mould Tool Steels.

Appendix 5 – Tooling Manual Form Usage.

Revision Index

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Section 1 - GENERAL INFORMATION
1 Scope
The purpose of this document is to ensure proper communication necessary to ensure mutual understanding of
criteria used in construction of a High quality tool
It is understood that die making practices commensurate with high quality dies and molds will be used in
unspecified matters.
All documents referenced in this manual are available on request and shown in Appendix 5 where they are to
be used.

2 Performance Requirements
All tools will be capable of production for the anticipated life of the component with the supplier being
responsible for their maintenance, using a preventative maintenance plan to ensure that the tool is kept in good
working order at all times.
Records of all maintenance will be kept by the supplier and available for audit. A tooling DFMEA and process
FMEA will be used to aid tool design.

3. Supplier Responsibility
3.1. All tooling to be designed and constructed to meet and/or exceed the standards contained in this ‘Tooling
Manual’ (TM). In addition, tooling shall be free from defects in materials and workmanship and free from
all liens and/or claims.

3.2. The supplier will be responsible for the submission of weekly progress reports to the Tooling Specialist
(TS).

3.3. Any changes in delivery and/ or cost of a tool, requested by the tool supplier, shall be communicated in
writing immediately to the Buyer and TS.

3.4. Any request for information pertaining to the tool being built shall be directed to the TS.

3.5. All aspects of prototype and production tooling are to be kept in good mechanical and quality condition
throughout the life of the product.

3.6. Inteva approval must be given before welding and all areas that are welded in order to correct errors or in
the normal course of tool building. A log must be kept throughout tooling development of any welded
areas showing location, size and type of weld and rod material used. These records must be provided at
tool buy-off.
A copy of the log shall also be reviewed prior to sending the tool out for texturing (if required).
No shimming or repair/salvage of tool components will be allowed unless authorization from Inteva TS is
given.

3.7. The Supplier is urged to recommend any revisions, during construction or design, which they feel would
provide a better tool, an equivalent tool at a lower cost or improved delivery dates.

3.8. The Supplier agrees to obtain and maintain adequate insurance for any tooling in the Supplier’s
possession and/or sub-contractor including during transportation. The tooling shall be insured for its full
value against damage from loss, fire, flood, theft, explosion and other insurable risks.

3.9. All tools which are used for Inteva products (owned and/or not owned) when not used to produce
parts, are stored in a fire protected area which is physically separated from the production floor and not
fitted with any fire sprinkler system.

3.10. No tool construction or material ordering should be done without formal Inteva purchase order and design
approval from TS. Any work undertaken without approval is at the supplier’s liability.

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Section 2 - NEW TOOL SPECIFICATIONS.

1. General Points
1. Scope
The following are standards considered to be necessary by Inteva for construction of high quality Injection
Molding and Stamping Tools and are to be adhered to unless specifically waived in writing by the signatory.

2. Tool Costs
All tool cost quotations are to be submitted on the Inteva ‘Tool Cost Breakdown’ sheet.

3. Tool Makers
3.1. Inteva reserves the right to assess the toolmaker and any sub-contractors using the tooling assessment
format. Supplier is to state toolmakers at time of quotation.

3.2. The tool manufacture must not be sub-contracted without the prior agreement of Inteva.

3.3. If schedule demands are such, that the original Tool Maker (if sub-contracted by Supplier) cannot
complete the tool, work will be resourced upon agreement/approval with Inteva to an alternate Tool
Maker.
All related cost will be the responsibility of the Supplier.

4. Design Requirements
4.1. The tool design must be carried out in accordance with all information supplied in this document.
See Appendix 1 for Inteva ‘Tooling Contacts’.

4.2. Any deviation from this procedure must be agreed in writing with the Tooling Specialist.

4.3. Complete tool designs must be supplied with each new tool. The final tool design is to be provided
electronically in native format. The final design must accurately reflect the condition of the tool as
delivered and provide in full detail, including but not limited to, sections, details, schematics and material
list (BOM).

4.4. The tool design is to be submitted to the relevant Tooling Specialist at Inteva as per the requirements
detailed in the ‘Tool Design Approval Document’.
The tool design is subject to review before being sign-off by an Inteva Tooling Specialist.

4.5. Approval or comments to the submission will be given by the Inteva TS prior to any tool manufacturing
being started. Any work done or parts purchased without approval is at the suppliers liability. The
approval given by the document does not accept liability for the tool construction and the subsequent life
guarantee; it merely shows compliance to the Inteva standards.

4.6. During the design review process all critical features are to be inserted and manufactured steel safe.

4.7. After any tool modification or engineering change, the tool design must be promptly and accurately
updated.

4.8. All tool designs, tooling aids, programs etc. are the property of Inteva and will not (in total or in part) be
shared with any company, secondary tool source etc. without the written approval from Inteva.
Tooling aids include duplicating casts, check fixtures, EDM electrodes, CAD data, drawings and any
special tooling that was necessary to produce the tool and have no capital asset value to the Supplier.

5. Construction Requirements
5.1. See Appendix 2 + 3 for Terminology References

5.2. Tool operation: Where practical, all tools to be designed to run fully automatic, with due consideration
given to robot unloading / part ejection of the components to minimize labor requirements, all to be
agreed with Inteva TS.

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 5.3. Part Identification: To be included on multi-impression tooling, position to be mutually agreed.

For subsequent tools, back-up duplicate, the numbering sequence will be a continuation of the preceding
tool.
Example:
If tool #1 is an eight-cavity tool, the numbering sequence will be 1 through 8.
For tool #2, the sequence will be 9 through 16,
For tool #3, 17 through 24, etc

5.4. Mold Steels: Steel Grade and Hardness to be agreed with Inteva TS.

5.5. Die Plates to be manufactured from Pre-hardened tool steel (1.2311 or 1.2312) from a standard supplier.
See Appendix 4 for Steel Recommendations.

5.6. Tool frame to be purchased from approved supplier and specified on the General assembly drawing.
Approved suppliers are:-
 Hasco
 DME
 DMS
 LKM (China)
All other suppliers to be approved by Inteva.

5.7. Heat treat specifications/certifications for all fabricated components (core, cavity, inserts, lifts, etc.) shall
be included at buy-off. Main cavity and core steel certifications from the manufacturer for no porosity
and/or cracks should also be included for pre-hardened.

5.8. Where standard plates are not possible bolster plates to be machined from tool steel (1.1730) from
standard suppliers, see item 5.6.
Plate thickness, hole centers and details to be to suppliers specification.

5.9. Any alternatives to the above specified grades/suppliers are to be agreed with Inteva TS.

5.10. If required cost of chroming, ion implanting and etched finishes should be itemised at the quotation stage,
this must not be implemented without authorisation.

5.11. Tools should be designed to make use of standard tool components, i.e. ejectors, sleeves, guide pillars
etc are to be as standard from the chosen supplier as point 5.6.
In the event standard components cannot be used, the tool builder is expected to provide a list of
recommended spare parts for items, which are considered perishable, along with a list of suppliers.

6. Clamping, Lifting straps & Eye Bolts.

6.1. Tools will have a safety strap which, when attached to the tool, will prevent the tool halves from
separating during handling. The straps should be attached in such a manner as to remain attached to
either half at all times.

6.2. On all tools, it is essential that eyebolts (Minimum 4 per tool) are positioned so the tool hangs correctly
when suspended on the lifting mechanism using the chart below as reference.

6.3.
IMPERIAL
METRIC SIZES
SIZES WEIGHT ( KG ) WEIGHT ( LBS. )

5/8 M16 -625 -1375

¾ M20 630 - 945 1386 - 2079
1 M24 950 - 1495 2090 - 3289
1¼ M30 1500 - 2250 3300 - 4950
1½ M36 2300 - 3350 5060 - 7370
1¾ M42 3400 - 4450 7480 - 9790
2 M48 4500 - 6750 9900 - 14850
2½ M64 6800 - 14000 14960 - 30800

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 6.4. On Tools over 1 Ton, lifting holes required on each bolster plate, to aid assembly and maneuverability.

6.5. Tool Clamping: Tools are to be designed with extended clamp plates for direct clamping to the machine
platens. A minimum, of four direct fixing holes are required per half of tool.

7. Identification
7.1. Tool marking: Inteva specific plaque is to be issued for each new tool and should be engraved by the
supplier with the relevant information.

7.2. In the event of no plaque being issued on tool completion the following minimum information must be
stamped on the tool :-
 Customer
 Component Name
 Component No.
 Closed Height
 Ejection Stroke:-
 Tool No:-
 Weight:-
 Press Size / Tonnage :-
 Revision Level:-
All stamping, plaques and tool tags to be shown on tool operator side in press position

8. Miscellaneous
8.1. CMM Report on New Molds. This shall include all KPC/SPC/PST points as designated by OEM
manufacturer pertaining to the part. It will also include all attachment flange locations, net surfaces,
mating surfaces of the part to other components and any other areas of concern as determined by Inteva
engineering.
Reference diagrams must be included to reflect points checked

8.2. Keying: When inserts require to be keyed, they should be keyed in such a way the insert can only be
replaced in one direction.

8.3. Chamfers: All sharp edges which are not product related must be broken.

8.4. Inserts: Where interchangeable inserts are required, each insert must be clearly identifiable and stored in
a durable container. Where possible, die inserts to be engraved on underside with tool number & item
number reference.

9. Spares/Detail Drawings
9.1. A full set of tool drawings reflecting the PPAP parts submission to be held at suppliers location at all
times.

9.2. It is the supplier’s responsibility to ensure that the drawings are up to date following any modifications etc.

9.3. On receipt of PPAP approval the supplier is to send a copy of the latest up to date tool drawings, on CD,
to Inteva for the attention of the Tooling Specialist.

9.4. On receipt of PPAP approval the supplier is to send a completed ‘Tool Identification Form’ to Inteva for
the attention of the Tooling Technician.

9.5. A stock of spares as identified by the DFMEA as necessary will be held at the supplier’s plant.

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2. Injection Molding
1. Scope
The following are standards considered to be necessary by Inteva for construction of high class Injection Molding
Tools and are to be adhered to unless specifically waived in writing by the signatory.

2. General Instructions
2.1. Shut out angles must be a minimum of 3 degrees, faces bedding out must be manufactured from
dissimilar materials with differing hardness to avoid any interference. If this is not possible due to design
constants it is to be agreed at the ‘Pre-award’ meeting by all parties.

2.2. Maximum draft angles must be incorporated on textured parts.

Texturing per Tenebac-Grafion: 1 ½ degrees on wall per .025mm of depth of stipple. 1 degree on wall for
every degree after that.
 #2 - .050mm deep - 3 degrees minimum.
 #3 - .075mm deep - 4 ½ degrees minimum.
 #5 - .125mm deep - 7 ½ degrees minimum.

2. Cooling, Insulating & Temperature Control

2.1. Cooling: All water circuits to be designed for maximum control over cores and cavities. Water channels
should be minimum 5mm from the tooling surface / molding surfaces.

2.2. All cavity inserts must contain separate water circuits, where practical.

2.3. For tools with more than one cavity cut into solid steel – each cavity should have its own set of circuits.
When the cavities are identical the circuits should be also kept identical.

2.4. All mechanical devices that form part of the cavity should be cooled (e.g. slides, lifters, etc.)

2.5. Ins and Outs are preferred on side opposite the operator or bottom of mold.

2.6. All temperature control channels to be numbered, for example: - 1in, 1out, 2in, etc.

2.7. General assembly drawings to incorporate schematic water diagram. Cooling piping diagram to be
supplied with tool.

2.8. It is recommended that water connectors to be 10mm Diameter waterways for machines 100 Tons and
above and 8mm Diameter waterways for machines below 100 Ton. For large tools would need 19mm dia
w/ 24mm baffles.

2.9. All water circuits to be pressure tested to 2 bar minimum.

2.10. Standard water line plugs should be used as per suppliers in item 4.6.

2.11. Protection feet: Tools must be furnished with feet to prevent damage of water connectors, when located
on the underside of the tool.

2.12. Walker’s standard specification mechanical rubber seals to be used on all tooling. All seals must remain
undamaged and compressed whilst the tools are being assembled. All ‘O’ Rings must be pocketed on
three sides. For high temperature tools use Viton seals.

2.13. Insulation plates: All thermoplastic tools to be fitted with Sindanyo-L21 (asbestos free)
insulation plates on the fixed half clamp plate.

2.14 Temperature Control: - Thermocouple holes to be positioned in fixed and moving half die plates for
additional temperature control.

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3. Gating, Runners & Shrinkage
3.1. Gate position agreement to be given by Inteva Engineering in ‘Pre-Award’ meeting.

3.2. Supplier to identify the gate positions, number, size, type and configuration of gate on the general
assembly drawings. Details to reference any tool flow undertaken.

3.3. Runners: All runners should be totally balanced. Runners should never run on and parallel to insert lines.
Whenever a runner must cross an insert line, it should cross as near to 90 degrees as possible.

3.4. Shrinkage: This is to be as per the material manufactures recommendations.

3.5. Sprue bush: Are to be standard from an approved supplier. Unless otherwise authorized, sprue length is
not to exceed 130mm. All tools to have hardened sprue bush with radii to suit machine nozzle.

3.6. When runners are cut into the tip of the sprue bushings, the bushing is to be keyed to prevent rotation.

3.7. All tools to have hardened sprue bush with radii to suit machine nozzle.

3.8. Feed gate inserts require fitting for glass filled tools. Replaceable gates must be provided in all tools that
will run corrosive or abrasive materials.

3.9. All sprues and runners to be automatically de-gated in the mold. Sub gate puller pins should be used on
all sub gates. All gates must be removed from the tool automatically upon opening of the tool and ejection
of the part.

3.10. All runners will have cold slug wells machined at the end of each run and will have proper venting. Cold
slug wells should extend ½ the diameter of the runner past the end of the run.

4. Ejection
4.1. Ejector position agreement on position to be given by Inteva Engineering in ‘Pre-Award’ Meeting or by
written confirmation from Inteva Engineering.

4.2. Ejection system must be designed to eject the component from the tool free from ejector stress and
distortion.

4.3. Ejector positions and type i.e. (push/pull, spring return, two stage, stripper plate, etc.) are to be identified
on General assembly drawings.

4.4. Formed ejector pins must be locked into the ejector plate per Inteva agreed method.

4.5. All bosses’ deeper than 12mm must have sleeve ejection. If it is not feasible, it must be discussed with
the TS prior to manufacture.

4.6. Ejector systems: Support pillars are to be located close as possible to high load areas, such as runners,
under cavities and part trim lines.
Preload is to be at a rate of 0.0125mm per 25mm distant from the nearest parallel but not exceeding
0.125mm.

4.7. All Ejector systems to be fitted with return pins.

4.8. Where larger ejection plates are used multiple connections to the machine platen are to be reviewed to
eliminate ejector plate twist.

4.9. Ejection plate will have a minimum of two (2) guide pins and will be equipped with bronze-plated bushings
with lubrication grooves or Self lube bushings.
Large tools and tools with adequate space must have a minimum of four ejection guide pins.

4.10. Ejector plate stop buttons are to be located directly below all return pins and in areas around groups of
ejector pins and/or lifters.

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 4.11. Ejector pins shall never be placed under moving cores or slides unless approved by the TS and
mechanical, hydraulic, or electrical early returns are incorporated.

4.12. On occasions when blade ejectors are required, if blades are very narrow use maximum body length
possible.

4.13. Rising Ejectors: Manufactured from a different material to the block into which it is sliding, also to be a
variation in hardness. Secure rising ejectors by adding a cross dowel pin running between hardened base
plate and rails.

4.14. Rising ejectors to be fully guided in guide blocks secured in cavity backing plates.

4.15. A cover plate is to be on the top of the tool to cover the ejection box to prevent sprues etc dropping into
the tool.

5. Moving Cores
5.1. Side cores: All side cores must slide on at least one hardened wear plate and grease grooves machined
into the surface.

5.2. Heel blocks: Where heel blocks are incorporated into a design and are subjected to cavity pressure,
where practical they must be cut from the solid die plate and fitted with a hardened wear plate.

5.3. Side cores are to be located with side rails and are to be retained in the open position by adequately
sized spring loaded ball catches. Side cores which operate vertically downwards must be held in the out
position by a spring when the tool is open, the cores should also be fitted with stops to prevent them from
falling out of the tool.

5.4. Side cores measuring 100mm or wider must be fitted with two angled dowel pins. Where hydraulic cores
are required, the manufacture is to be specified. Where Cylinders are used. The cylinder must be
connected to the side core via a tendon nut.

5.5. Sequence protection: Where a tool design incorporates the use of side cores, a method of preventing
damage from incorrect sequencing must be included, mechanically or electrically. The recommended
type is micro switch sensors.

5.6. Protection feet / cage: When cylinders or mechanical coring protrude from the underside of a tool, they
must be protected by fitting feet or a cage.

5.7. Tool sequencing must be stamped on the side of the tool in a position which can be viewed by the
operator i.e.
 Tool opens (side core out)
 Hydraulic Cylinder back (core out).
 Ejection forward
 Ejection back
 Hydraulic cylinder forward (core in).
 Tool closes side core in.

6. Hot Runners
6.1. Hot runners: Systems or hot tipped bushes are to be from an agreed supplier and supplier specification is
to be sent with general assembly drawing for approval. All suppliers to be approved by Inteva.

6.2. Hot runner thermocouples and heaters: To be terminated in suitable Harting plug and sockets and
secured to the tool.

6.3. Wiring: All wiring to pass through adequate sized channels and to be retained by fixing plates.
Boxes to be located on the top of tool (or if not feasible on the rear of the tool) but not in areas with water
connectors.

6.4. Wiring diagrams to be added to the tool design.

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7. Miscellaneous
7.1. Venting: All tools will be vented per the material manufacturer’s specifications (parting line, ejector pins,
and sleeves, cores, etc.) and should be shown in the tool designs.

7.2. Machine Location: All tools to be fitted with a fixed half location ring, to suit the designated press details.
To be shown on general assembly drawing.

7.3. Date inserts to be on all parts where possible and to be standard parts as item 4.6. All tools must have
component manufacturing date traceability. A date table or a standard circular date code must be
included on the component. Location and type to be agreed upon with Inteva.

7.4. Fittings & connectors: All tools to be supplied, with necessary fittings: hydraulic, pneumatic and electrical
connectors.

7.5. Guide pillars: To avoid incorrect assembly of tools, one guide pillar is to be of a smaller diameter than the
other three.

7.6. Tool Dis-assembly: Notches scalloped from the sides of the bolster L32 x W16 x D6.5, or optional 45
degrees across corners to avoid damage.

7.7. Split Line Location Interlocks: On tool faces that shut out, SSI straight interlocks or cone locators must be
used unless the product design incorporates this.

7.8. Keying: When inserts require to be keyed, they should be keyed in such a way the insert can only be
replaced in one direction.

7.9. Chamfers: All sharp edges which are not product related must be broken.

7.10. Inserts: Where interchangeable inserts are required, each insert must be clearly identifiable and stored in
a durable container. Where possible, cavity & core inserts to be engraved on underside with tool number
& item number reference.

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3. Stamping Tools
1. Scope
The following are standards considered to be necessary by Inteva for construction of high class progressive and
single stage dies and are to be adhered to unless specifically waived in writing by the signatory.

2. General Instructions
2.1. Die set is to be four (4) post precision ball bearings with demountable bushings.

2.2. Stock feed is to be from right to left, unless otherwise specified. Starting point shall be clearly marked
and tagged so as to be visible to the operator.

2.3. Die clearance is to be the accepted industry standard, ten percent (10%) and to be reviewed at Design
Review.

2.4. On progression dies, as a minimum there is to be one idle station for every fifth working station.

2.5. On single stage tooling there must be provision made in the initial quotation for the addition of one
additional operation if required to achieve part quality.

2.6. Flattening and re-strike sections are to be provided, as dictated by part configuration and part print
specification.

2.7. As a minimum, all sector blank dies shall have a flattening (re-strike) station.

2.8. All dies containing a re-strike station shall have a minimum shoe thickness of 90mm. Part thickness of 3.2
mm and over shall require a minimum shoe thickness of 100 mm.

2.9. All dies containing coining stations shall have a minimum 20 mm hardened plate under each station for
support and a minimum of 90 mm thick shoe.

2.10. Dies with push back in the strip part designs are NOT acceptable.

3. Part Ejection
3.1. Part ejection on progressive dies is to be accomplished by either free drop or mechanical ejection off the
front of the die.

3.2. All single stage dies are to have mechanical part ejection fitted.

3.3. Slug die clearance to be tapered at a minimum of 1 degree following the first 3mm of land.

3.4. Maximum slugs in the lower die to be 3 x material thickness. Slugs to fall freely to lower plate.

3.5. All scrap and slugs coming from the die must be capable of being moved out the back of the die, without
interference from parallels, blocks, nitrogen units or any other obstructions.

3.6. Part must be probed in cutoff station to ensure part and scrap have properly ejected from die.

4. Material Guiding
4.1. Vertical stop blocks are to be permanently set to the proper shut height, and have a 0.75 mm x 12.5 mm
slot on the top surface. Add compression holes as needed.

4.2. Provide heal blocks on die shoes to equalize forming pressure. (Die review).

4.3. All dies are to have a micro-switch actuated pitch-notch stop. If the die does not have a pitch-notch stop,
a spring loaded pilot actuated micro-switch will be used. This will need to be discussed at the die review.

4.4. Dies are to have one permanent and adjustable stock rail. Rails are to be staggered at the start to aid in
starting and hardened throughout the die.

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 4.5. Moveable positive stops for starting the strip are to be installed wherever possible.

4.6. Strippers are to be spring loading with guides. They must have windows for access to ball-lock retainers.
They must also have keepers or spools for stripper retainment. All springs, Danley spring retainers or
equivalent. Springs are not to extend out through the top shoe. All strippers are to have tapped handling
holes, and be a minimum 1-1/4” (31.75 mm) thick. (Nitr. Cylinders use is highly recommended)

4.7. Pilots are to be hardened Rc 58-60 and tempered. They are to be ball-lock type. A double row is to be
used wherever possible and maintained as long as possible.

5. Dies and Punches

5.1. All top cutting steels (outline punches) are to be hardened to Rc 58-60 and ground. Slug ejectors are to
be used wherever possible.

5.2. Standard pierce punches are to be hardened to Rc 60-62 and ground with a slug ejector wherever
possible.

5.3. Punch and die button retainers are to be hardened and jig ground with a 1/4” (6.35 mm) minimum thick
hardened back-up plate.

5.4. Die buttons are to be straight press fit into counter bored holes.

5.5. All cutting sections are to be separate from any form steel. This is to eliminate the problem of regrinding
forms when sharpening and shimming die steels.

5.6. All bottom die steels are to be hardened to Rc 60-62 and ground with a minimum of 3/8 (9.525 mm) die
life and have a 1/4 degree minimum ground taper relief. Insert for cut-off where possible.

5.7. All forms are to inserted and adjustable without disassembly of the die wherever possible and
adjustable with the press.

5.8. All form steels are to be finished with a TD coating process (P.V.D.) to ensure long-life and eliminate
wearing.

5.9. All cutting and forming sections must have jack-screw holes to necessitate removal from die for
maintenance purposes.

5.10. All die matrixes (buttons) used in piercing holes shall be mounted in counter bored retainer for ease of
shim placement under buttons after sharpening.

5.11. The following details should be accessible through stripper if possible: stripper retainment, spools, form
blocks, punch sections, etc.

5.12. All cam slides are to have a positive return if possible. If not possible, use nitrogen or double springs.

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Section 3 – CURRENT PRODUCTION TOOLING
1. Modifications and Refurbishments.
1. Scope
All modifications done to Inteva owned or supplied tooling is to be done in line with the tool design
recommendations in this manual.

2. Performance Requirements
Modifications should be done in line with best practices and must ensure that there is no effect on the
anticipated life of the component.
Any effects on the initial quoted life of component must be highlighted at time of quotation.

3. Tool Costs
All tool cost quotations for modifications and refurbishments are to be submitted on the correct forms,
‘Modification Cost Breakdown Sheet’ or ‘Refurbishment Cost Breakdown Sheet’.

4. Tool Replacement
4.1 When replacement of tools is required, the previous tool design must be reviewed.
4.2 If the present tool was not built to these standards, the tool should be redesigned to conform.
4.3 Repair history of the tool, part quality problems, processing problems and tool flow analysis (if required)
will be analyzed and the appropriate tool design will be updated.

2. Tooling Maintenance.
1. Scope
Inteva requires that all suppliers undertake regular tooling and machine preventative maintenance programs.

2. Performance Requirements
2.1. Evidence of written procedures is to be submitted as requested. (Duplicate from above)

2.2. Schedules and records showing actual maintenance undertaken for any tooling is to include as a minimum
the following points:-
 Condition and capability of tooling or equipment.
 Tooling storage and tool handling plus set-up system.
 Record of daily maintenance performed:-
 Daily check list.
 Operator’s responsibility.
 Operator’s training.
 Record of scheduled maintenance performed:-
 Master schedules.
 Work undertaken.
 Corrective actions taken

3. Tooling Condition.
1 Scope
To monitor the condition and expected tool life.

2 Performance Requirements
2.1 Inteva requires the completion of a ‘Tool Condition Report Form’ when requested.
It is the supplier’s responsibility to ensure that all aspects of both prototype and production tooling are
kept in good mechanical and quality condition throughout the life of the product.

2.2 A list of all Inteva owned tooling currently at the supplier is to be listed on the Tool Detail form and is to be
sent to Inteva for the attention of the Tooling Specialist

4. Prototype Tooling.
1. Scope
To ensure that all quotations for prototype tooling are as is required based on timescales, volume etc. All
quotations are to be submitted on a ‘Prototype Tool Breakdown Sheet’.

INTEVATM, Rev G; 01/04/2013 Page 13

Appendix 1 – Tooling Contact Details.

Name Position Contact No. Email Address

Sr Director
Pierre Blanchard Advanced Manufacturing +33 682816417 Pblanchard@intevaproducts.com
Engineering

Stephen Leyland Tooling Group Manager +44 7919 328731 sleyland@intevaproducts.com

Constantin Fetelea Tooling Specialist - Americas +1 313 587 9037 Cfetelea@intevaproducts.com

Patrick Hilaire Tooling Technician +33 329 522020 Philaire@intevaproducts.com

Justin Wu Tooling Specialist - Asia +86 511 88885702 Jwu2@intevaproducts.com

Naveen Kumar Tooling Specialist - India +91 9900785676 nkumar@intevaproducts.com

Paval Dvorak Tooling Specialist - Europe +420730181028 PDvorak@intevaproducts.com

Iulian Nani Tooling Specialist - Europe +40725353673 inani@intevaproducts.com

INTEVATM, Rev G; 01/04/2013 Page 14

 Appendix 2 - Tool Terminology.
Hot Runner
Harting Plug

Cavity Inserts
Core Inserts
Guide Pillars

Insulation Plate

Insulation Plate

Support Pillars
Bolster Plate

Ejection Plates Hot Tip

Location Ring
Ejection Return

Bolster Plate

Hot Runner
Ejector Pins Manifold

Guided Ejection

Cavity Plate

Core Plate
Cooling
Channels
Ejection Return Pins

INTEVATM, Rev G; 01/04/2013 Page 15

Appendix 3 - Typical Progression Tool Layout.

INTEVATM, Rev G; 01/04/2013 Page 16

Appendix 4 – Recommended Mold Tool Steels.

Recommended Mould Tool Steels & Alloys

Werkstoff ?? BS4659 AISI Supplier Code Applications (Recommended
Number Number Number Hardness)
1.2767 Carrs P576 Mold steel:-Cores, cavities etc
Inman HCNC Hardness 52-54 Rc
Cooks Benum Plus
1.2344 BH13 H13 Carrs 53S Mold steel :- Cores, cavities etc
Uddeholm Orvar Supreme Gives a good polished finish.
Can be Nitrided
Hardness 50-52 Rc
1.6747 Carrs P552 Mold steel :- Cores, cavities etc
EN30B Hardness 52-54 Rc
Uddeholm Calmax Mold steel :- Cores, cavities etc
Very tough, good wear resistance.
Good dimensional stability in
hardening
Hardness 56-58 Rc
1.2379 BD2 D2 Carrs 69S Gate inserts. Compression tools
Aurora D2 Very hard wearing
Uddeholm Sverker 21 Hardness 58-62 Rc
1.2510 B01 01 Carrs O9B Angle Pins / Wear plate
Uddeholm Arne Hardness 54-62 Rc
Gauge Plate
1.2083 420 Carrs P1008 Stainless mold steel :-
Uddeholm Stavax ESR Good resistance to corrosion
Gives good polish
Hardness 48-53 Rc
1.2738 P20 HH P20
Hardness 40-42 Rc
1.2711 Pre-hard
1.2311 BP20 P20 Carrs P20 Pre hardened mold steel :-
Used for soft tooling, Bolster plates
Can be spark eroded (sulphur free)
Can be nitrided
Supplied Hardness 30-33Rc
1.2312 Carrs P20S Pre hardened mold steel :-
Bolster plates. Unsuitable for spark
erosion. Can be nitrided
Supplied hardness 30-33Rc
1.1730 Medium carbon steel
Suitable for Backplates Risers
Ejector plates etc
Supplied Hardness 10 Rc
Carrs Ampcoloy 940 Alloy used where heat dissipation is
(Be Cu critical. Can be nitrided
replacement) Not suitable where wear is critical.
Supplied Hardness 18 Rc

INTEVATM, Rev G; 01/04/2013 Page 17

Appendix 5 – Tooling Manual Form Usage

Supplier To Complete Inteva To Complete

RFQ TO SUPPLIER

QUOTATION
SUBMITTED BY Tool Cost Breakdown Sheets.
SUPPLIER

PURCHASE ORDER
PLACED WITH
SUPPLIER

TOOL DESIGN
Tool Design
SUBMITTED Approval Document.

NO
OK

YES

TOOL
MANUFACTURE
STARTED

FINAL DESIGN
APPROVAL
SUBMITTED

TOOL SAMPLING

Tool Design Approval Document.

PPAP SUBMISSION

INTEVATM, Rev G; 01/04/2013 Page 18

Revison Index
Rev. # Date Revision Change Changed Approved
By
A 23-06-2007 New Document S.Leyland J.Persa
B 26-10-2007 Formal document number added. S.Leyland J.Persa
Section 2 – Item 5.9 changed from 2 bat to2 bar minimum.
C 01/04/2008 Janos Persa replaced by Pierre Blanchard S.Leyland Pierre Blanchard
D 1/5/2010 Added Stamping Standards S.Leyland Pierre Blanchard
E 03/01/2011 ArvinMeritor replaced with Inteva S.Leyland Pierre Blanchard
F 12/5/2011 Terminology changed – added to SRM S.Leyland Pierre Blanchard
G 04/01/2013 New Tooling Specialist Added S.Leyland Pierre Blanchard

INTEVATM, Rev G; 01/04/2013 Page 19