1、 WORLDWIDE ENGINEERING STANDARDS General Specification GMW15850 Injection Mold Tool Standards Copyright 2011 General Motors Company All Rights Reserved October 2011 Originating Department: North American Engineering Standards Page 1 of 52 1 Introduction Note: Nothing in this standard supercedes appl
2、icable laws and regulations. Note: In the event of conflict between the English and domestic language, the English language shall take precedence. 1.1 Scope. This standard applies to the design and construction of injection mold tools that will produce thermoplastic vehicle parts globally. 1.2 Missi
3、on/Theme. This standard enables the global production of high quality injection mold tools at the lowest investment cost. Essential part specific concessions to this standard must be agreed upon by the Global Paint and Polymers Center (GPPC) engineer (when resources are allocated), the GM Product De
4、velopment Design Engineer (DE), the molding supplier and the tool source. Note: Report to GM Engineering when GPPC Engineer is not allocated. 1.3 Classification. Not applicable. 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Sp
5、ecifications. ANSI B151.1 ISO 11469 ASTM A681 NAAMS4512 FCD5506 2.2 GM Standards/Specifications. GM7400M GMW15188 GMW3059 GMW16355 GMW15187 GMW16375 2.3 Additional References. Atlas Bronze Ampco () D-M-E Components Catalog () Materion Corporation - MoldMAX (http:/) Molders World Inc. Porcerax () RJG
6、, Inc. Pressure Transducers () Society of Plastics Engineers/Society of the Plastic Industry (SPE/SPI) Bolt Patterns Statement of Requirements (SOR), Appendix E8 3 Requirements 3.1 Design Standards. 3.1.1 General Information. 3.1.1.1 All designs must be marked PROPERTY OF GENERAL MOTORS. 3.1.1.2 Too
7、l designs may be distributed in order to facilitate regional tool construction for global vehicle platforms (construction of multiple tools to the same design). Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW158
8、50 Copyright 2011 General Motors Company All Rights Reserved October 2011 Page 2 of 52 3.1.1.3 All designs must be available in the English language. 3.1.1.4 All General Motors molded parts should be marked as a minimum to the ISO 11469 specifications unless regional callouts are different. All mate
9、rials processed through General Motors tools should have a material data sheet that follows the GM7400M specification as a minimum. The injection molds built for General Motors should run in equipment that has minimum compliancy to ANSI B151.1. 3.1.1.5 Tool designs as solid models (compatible with t
10、he current GM version of Unigraphics (UG) software) must be retained at the tool sources for the life of the program. The tool source should provide a catalog of the tool drawings/math data files and their locations to the molding supplier. Access to this data must be immediately made available to G
11、M upon request. 3.1.1.6 All part engineering changes will require revision to the original tool design math file. 3.1.1.7 Tool design changes must be documented and added to the tool math file provided to GM and the molding supplier for final design submission. 3.1.1.8 A log of all as-built tool cha
12、nges (including those made during validation) must be kept by the molding supplier and made available to GM upon request. 3.1.1.9 All changes made on tool designs after designs have been released to the molding suppliers manufacturing floor must have the changes recorded in the Change Notice column
13、in the tool math file. 3.1.1.10 No tool shall be released for construction without a formal signed Approval to Tool form (see example in Appendix A, Table A1) when an Appendix E8 attachment document is present in the SOR. 3.1.2 GM Part Math Information. 3.1.2.1 The GM Design Engineer (DE) will provi
14、de the part math file including, but not limited to the following layers of data found in Table 1 and Table 2. In Table 2, the data can start in any layer but must be consecutive layers (the tool sources may collaborate directly in design development of these layers, but GM is responsible to approve
15、 them). Table 1: Sequence Layers Layer Number Data Provided on these Layers 1 Part/Solid 2 Wireframe 3 Center Line Data 4 Theoretical 5 Sections 6 Developmental 7 Mate/Datum 8 Criteria 9 Mid-surface Table 2: Layering Sequences Six Consecutive Layers Contents Layer X Data Provided on these Layers X +
16、 1 Die Vectors for Cavity and Core X + 2 Action Vectors, Lifter and Slides X + 3 Parting Lines, All Areas, Transitions X + 4 Grain Surfaces with Full Grain X + 5 Grain Surfaces with less than Full Grain and Grain Washout X + 6 Painted Surfaces Provided by IHSNot for ResaleNo reproduction or networki
17、ng permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15850 Copyright 2011 General Motors Company All Rights Reserved October 2011 Page 3 of 52 3.1.2.2 The molding supplier and tool source are responsible for comparing the GM part math file to Design for Manufacturability (
18、DFM) criteria and proposing solutions to conflicting criteria. 3.1.2.3 Potential damage to fragile tool components determined by the product design must be identified by the molding supplier and tool source prior to tool construction. Appropriate countermeasures and Total Productive Maintenance (TPM
19、) measures for these items must be given to the GM engineer and GM DE. 3.1.3 Tool Math Information. 3.1.3.1 The tool source must provide the tool math file including, but not limited to (as layers with a legend provided): 3.1.3.1.1 Stock list of components. 3.1.3.1.1.1 Vendor. 3.1.3.1.1.2 Catalog nu
20、mber. 3.1.3.1.1.3 Description (sufficient descriptive information for ordering including vendor address and phone number). 3.1.3.1.2 Core weight. 3.1.3.1.3 Cavity weight. 3.1.3.1.4 Shrinkage information. 3.1.3.1.5 Material to be molded. 3.1.3.1.6 Tool identification tag information/illustration. 3.1
21、.3.1.7 Part identification information. 3.1.3.1.8 Hot runner manifold schematic (with zones, gate sizes, gate lands, and runners labeled with dimensions). 3.1.3.1.9 Change block. 3.1.3.1.10 Electrical schematic. 3.1.3.1.11 Water schematic (including all manifolds). 3.1.3.1.12 Hydraulic schematics an
22、d diagnostic diagrams. 3.1.3.1.13 Part layout (with the items 3.1.3.1.13.1 through 3.1.3.1.13.4 indicated). 3.1.3.1.13.1 Parting lines. 3.1.3.1.13.2 Lifter lines. 3.1.3.1.13.3 Slide lines. 3.1.3.1.13.4 Insert lines. 3.1.3.1.14 Block sizes (cavity and core). 3.1.3.1.15 Lifters/slides. 3.1.3.1.16 Lift
23、er/slide pockets. 3.1.3.1.17 Quick Mold Change (QMC) plates (if necessary) and clamp plates. 3.1.3.1.18 Ejector system (all ejector and return pins not detailed must have catalog numbers and nominal lengths given). 3.1.3.1.19 Vent schematic (with vent sizes and lands labeled with dimensions). 3.1.3.
24、2 The hot runner manufacturer must provide the math data (as layers) in the manifold math file for direct input to the tool math file. 3.1.3.2.1 Hot runner manifold assembly layout. 3.1.3.2.2 Complete detailed component layouts. 3.1.3.2.3 Schematic of the hot runner construction. 3.1.3.2.4 Heater la
25、yout. 3.1.3.2.5 Thermocouple zone layout. 3.1.3.2.6 Heater wattage and resistance requirements for zones. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15850 Copyright 2011 General Motors Company All Rights Res
26、erved October 2011 Page 4 of 52 3.1.3.2.7 Heater and thermocouple components list (including the type, wattage, resistance, current, and quantity of each device with part number and manufacturer for ordering). 3.1.3.3 At GMs request, A3 drawings should be made available of all tool construction and
27、manifold design. 3.1.4 Design Direction. 3.1.4.1 Tool Construction Design Direction. The tool designer should provide tooling solutions that meet the requirements for tool construction items including, but not limited to: 3.1.4.1.1 Die line. 3.1.4.1.2 Die locks/undercuts. 3.1.4.1.3 Part draft/open a
28、ngle. 3.1.4.1.3.1 Special condition. Grain specific draft/open angle. 3.1.4.1.4 Seal off angles. Avoid three way seal offs. 3.1.4.1.5 Part/tool radii. 3.1.4.1.6 Part thickness. 3.1.4.1.7 Part layout in tool. 3.1.4.1.8 Tool size/mass. 3.1.4.1.9 Tool materials (steel versus castings). 3.1.4.1.10 Parti
29、ng lines, variations and options. 3.1.4.1.11 Hot runner manifold and gating (gate inserts). 3.1.4.1.12 Lifters (maximum angles). 3.1.4.1.13 Slides (cavity dropout). 3.1.4.1.14 Core pulls. 3.1.4.1.15 Collapsing core (if applicable). 3.1.4.1.16 Inserts (Porcerax, MoldMAX, etc.) 3.1.4.1.17 Wear plates/
30、Ampco (when needed). 3.1.4.1.18 Match inserts (for parting lines). 3.1.4.1.19 Support pillars. 3.1.4.1.20 Mold locks. 3.1.4.1.21 Part ejection and removal from mold. 3.1.4.1.22 Cooling. 3.1.4.1.23 Venting. 3.1.4.1.24 Serviceability. 3.1.4.1.25 Tool finish (polish, coatings, etc.) 3.1.4.1.26 Steel sa
31、fe validation/optimization (i.e., for backside features). 3.1.4.1.27 Local (production region) electrical equipment voltage limits. 3.1.4.1.28 Noise Level. Noise level produced by the molding system must not exceed 70 db (a) (decibels, a-weighted) and peak c-weighted sound pressure at work stations.
32、 3.1.4.1.29 Stress/Strain. The compressive yield stress and compressive ultimate stress values will be considered equivalent to the tensile stress values. Shear yield stress, modulus of rigidity, and ultimate shear stress will be calculated utilizing 0.4 of the proportional limit using stress-strain
33、 ultimate strength data. 3.1.4.1.30 Deflection. To avoid parting line damage, the tool design must not exceed 0.0508 mm (0.002 in) total deflection (Figure 1). Actual dynamic deflection in the molding machine may vary (from the design deflection) providing it does not cause parting line flash or cor
34、e steel mismatch. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15850 Copyright 2011 General Motors Company All Rights Reserved October 2011 Page 5 of 52 Note: Die liners and mold interlocks should be used to k
35、eep the cavity and core aligned. This movement will vary between large and small tools. Figure 1: Deflection Diagram 3.1.4.2 Part DFM Design Direction. The tool design must seek to eliminate or minimize common molding defects including, but not limited to the following: 3.1.4.2.1 Parting lines on Cl
36、ass A surface (core or cavity extraction). Tool design should seek to remove all parting lines from Class A surface. Multiple parting line solution sets with associated cost and quality impacts must be provided to the GM engineer and GM Design Engineer. 3.1.4.2.2 Alternative tooling, molding and pro
37、cess approaches to achieve a zero parting line condition must be identified in the part supplier proposal for GM Engineering. 3.1.4.2.3 If parting lines are required on interior and exterior Class A surfaces, the supplier must present data that supports the requirement for parting lines. The appeara
38、nce is to be minimized and maintained using cavity match slides as defined in this standard. 3.1.4.2.4 Parting Lines. The Tier 1 part supplier will be responsible for directing their selected tool source to design and build an injection mold that minimizes the appearance of parting lines on Class A
39、surfaces. These lines, called Match Lines require both pre-texturing and post texturing matching of tool steel mechanisms to ensure a perfect fit/match. Minimizing the appearance of match lines will also be achieved by applying full depth texture continuously across all affected tool steel at the sa
40、me time. See Figure 2. Figure 2: Garnish Trim Tool Layout Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15850 Copyright 2011 General Motors Company All Rights Reserved October 2011 Page 6 of 52 3.1.4.2.5 To ach
41、ieve the best possible match lines, the tool design will ensure that all tool mechanisms creating the match line are designed to be nested and locked/bolted into the cavity steel, in the position it will be in during the molding process. See Figure 3. Figure 3: Best Possible Match Line Strategy 3.1.
42、4.2.6 For fascia parts, the part supplier will be required to provide a primary tooling feasibility study that will remove all match lines from Class A part surfaces between mold tooling cavity and core that lead to parting line surface conditions. The part supplier is responsible to initiate an esc
43、alation process for part design issues that are not technically feasible to accommodate hidden parting lines. The Tier 1 supplier will be responsible to ensure that their selected tool source executes all parting line locations as defined in the GM released part math data file. 3.1.4.2.7 Sink marks,
44、 backside feature read through. 3.1.4.2.8 Flash. 3.1.4.2.9 Distortion during ejection. 3.1.4.2.10 Ejector marks. 3.1.4.2.11 Flow marks. 3.1.4.2.12 Gate blush. 3.1.4.2.13 Splay. 3.1.4.2.14 Unintentional sticking in cavity or core. 3.1.4.2.15 Trapped gas. 3.1.4.2.16 Warpage. 3.1.4.2.17 Weld (knit) lin
45、es. 3.1.4.2.18 Lifter line read-through. 3.1.4.2.19 Incorrect part thickness for material. 3.1.4.2.20 Dimensional issues. 3.1.4.2.21 Assembly issues (i.e., clearance issues). 3.1.4.3 Prior to approval of tool, a review of the tool design and part DFM tradeoffs must be held. The GM engineer, GM DE, m
46、olding supplier, tool source, material supplier, hot runner manufacturer and Moldflow source must agree to these tradeoffs. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15850 Copyright 2011 General Motors Comp
47、any All Rights Reserved October 2011 Page 7 of 52 3.1.5 Tool Dimensions. 3.1.5.1 The following tool stack-up and dimensions must be shown in the tool math file (see Figure 4): 3.1.5.1.1 Overall shut/stack height. 3.1.5.1.2 Dimension from main parting line to front of ejector plate. 3.1.5.1.3 Dimensi
48、on from the highest parting line to the back of core. 3.1.5.1.4 Ejector travel distance. 3.1.5.1.5 Action (slide, lifter) travel distance. Figure 4: Tool Dimensions 3.1.5.2 Travel of all moving parts must be dimensioned. Moving parts must be shown with phantom lines in the mold open position on all
49、sections or on a separate layer of the tool math file. 3.1.5.3 The part must be verified and documented in full ejector forward position with phantom lines as molded in the molding supplier production press for the part unloading mechanism. 3.1.5.4 All tool and part dimensions must be in millimeters. C
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