Mold Design Specifications Note: This mold design specification document is meant to serveas a guide to requirements for molding tools operated at CommScope Omaha. However, not all jobs will have the same requirements and so it is understood that each job will be accompanied with a mold design specification individuallymarked by the product engineer reflecting the specificrequirements of his job. All requirements will apply unless specifically deleted by the product engineer.CommScope Mold planning Worksheet 12000 I st.Omaha, NE 68137Engineer Try out to be performed at Comm Vendor phone # * Capability Study required yes noFax # * First article inspection required yes noE-Mail SLA Model Available yes no Description / part name Proto Type Part yes no Piece Part Comcode # Tool Design available yes no Tool # / CT- XXOHXXXXPurchase Order No. * Refer to 8.1 & 8.2 mold spec.Delivery RequirementRaw Material / PlasticMold Cavities RequiredEstimated cycle timeUG or Pro - E Rev #H frame inserts Other FinishCOMMSCOPE - OMAHAISSUE 31 E-7251 1/04/99The tool shall be designed for full automatic operation.1.0 Mold bases / Mold Component Steels:1.1Unless otherwise specified, small (<1.5" square) cores and cavity details subject to seal-off shall be constructed of AISI S-7 steel,hardened to Rc:54-56. Larger cores and cavities shall be constructed of AISI H-13 steel, hardened to Rc 52-54. Either detail is tohave an equivalent Charmiles Std. EDM Finish No. 24, polished to facilitate parts removal.Note:If the material to be molded is corrosive, such as polyvinyl chloride (PVC) or polyphenylene sulfide (PPS or Ryton), the coresand cavities shall be Armco 17-4-PH from Armco Steel Corp., hardened to 44 R.C., or Type 440C, hardened and finished as above.Cavities shall not be machined directly into the mold plates.1.2Unless otherwise specified, cavity retainer sets ("A" & "B" Plates) shall be constructed of 4130 (DME #2) steel, 280 - 320 BHN. or AISI H-13 steel, hardened to 40-45 RC.Note: If the material to be molded is corrosive, the cavity retainer set ("A" & "B" Plates) shall be Type 420 stainless steel, hardened and finished as above.1.3Cam-actuated slide details, if required shall be constructed of AISI*H-13steel, hardened to Rc:52-54 with a Charmiles Std. EDMFinish No. 24, polished to facilitate parts removal.Note: If the material to be molded is corrosive, the slide details shall be Type 440a stainless steel, hardened and finished as above. 1.4If a stripper ("C") plate is required, it shall be constructed of AISI A6 steel, hardened to RC:54-56.Note: If the material to be molded is corrosive, the stripper plate shall be type 440C stainless steel, hardened to RC:54-561.5All other mold plates (base, ejector pin retainer, back-up plates, ejector housing, etc.) shall be constructed of AISI4140 steel, pre-hardened to a minimum of 300 BHN.1.6If the material to be molded is corrosive, sprue bushing and runner system shall be constructed of Type 420 stainless steel. Otherwise, standard sprue bushings shall be used. All sprue bushings shall be polished.1.7Standardized mounting plates shall be AISI Type 41534, 300BH.Natalloy 2H or equivalent.Note: S-7 tool steel - oil quench section sizes over 1-1/2 thick.1.8Female side locks should be embedded in the movable half of the mold. The preferred type locks are the DME straight side interlocks or equivalent. If stripper plate design is applicable use DME X - style straight side interlocks or equivalent.1.9Components such as core pins, ejector pins, leader pins and bushings, etc. shall be standard off-the-shelf items wherever possiblewith the supplier for each component listed on the drawing stock list.1.10All exterior edges are to be broken approximately 1/16 by 45 degrees1.11Leader pin lengths to engage a minimum of ½” before force and cavity engagement, and ¼” before angle pins.1.12Pry bar slots ¼” deep to be provided in all four corners of mold plates on parting line. Leader pin bushings must be adequatelyvented through lower plate to allow air and debris to escape as pin enters.1.13Provide safety strap connecting A and B plates on top side of mold; strap to remain with tool. On runnerless tools, a strap will beprovided to separate the mold plates for purging.1.14The following information (shall be stamped on the tool.)•CommScope Tool No. Ct- (Refer to mold planning work sheet.)•description - (Refer to mold planning work sheet.)•weight - (To be determined by tool builder)•piece part cc# - (Refer to mold planning work sheet.)To be stamped in 1/4 to 3/8-inch characters on the “operator viewed” side of tool.1.15The mold nozzle seat shall be 3/4" spherical radius.1.16Eyebolt holes shall be provided on all 4 sides of each major component plates. Major component plates include: "A" plate, "B" plate, clamp plate, support plate, ejector housing, manifold housing (hot runner tools) and stripper plates.•Use: 1/2 - 13 = up to 300 lbs. total tool weight.•3/4 - 10 = from 300 to 2500 lbs. 1 - 8 = over 2500 lbs.1.17All conventional runner multi cavity tools shall be designed with runner shut offs which can be activated without removing the toolfrom the press. DME runner shut off inserts or equivalent to be used on both A & B side of tool . ( part # MRS - 0013 thru 00261.18Ejector return pins shall not lie within the path of falling, ejected parts2.0 Mold Design2.1Drawings, Manual design or Cad designs will be completely detailed and dimensioned. All designs will have all details called out on the main plan stack up views. A bill of material with complete component specifications will be included2.2Shrinkage allowance shall be determined by the tool manufacturer, and noted on the preliminary drawings.2.3General arrangement and cavity details of proposed design shall be submitted for COMMSCOPE Engineering approval prior tocutting metal for the mold. This approval is for general arrangement only. Any exceptions to this specification should be noted onthe quotations.Note: ELECTRONIC DRAFTING:E.D.S. U.G.-II version 13 or later. or P.T.C. Pro-Engineer version 18or later. Drawing procedures are available at the Omaha; however, if neither system is available, contact Harvey Ma rx’s in MoldDesign. Department JT11A1200 for instructions. Data may be exchanged through magnetic storage media or via modem. QIC-150,3.5 inch diskette and TCP/IP Network transmission could be used in these instances.2.4Final design information in complete detail on paper shall be furnished, after approval of samples by COMMSCOPE . These tracings will be made in accordance with COMMSCOPE COMMUNICATION (Omaha) Tool and Gage Drafting Standards Spec. SU-316dated12-14-98. For databases please refer to preceding note.2.6A standard numbering system will be followed on all multi-cavity tools. The cavity numbering system will be to start with the upperleft hand corner of the injection half of the tool as it will hang in the molding press and proceed in a counterclockwise rotation. The identification should include both a letter and number to completely identify the part. The cavity numbering system should coincide with and runnerless wiring layout.2.7Tool prints shall have tie bar location drawn both on preliminary and final designs.3.0 Tolerances3.1Tool shall be designed to nominal part dimensions, not to high side of tolerance.3.2All part projections, such as locking tabs, feet, etc. which must be ejected from a cavity shall be designed with 1/2 deg. (min.) which must angle unless otherwise specified on the piece part drawing.3.3All tool drawings shall contain a tolerance box to read:Four-Place Dec.= +/-.0005Three-Place Dec.= +/-.001Two-Place Dec.= +/- .01One-Place Dec.= +/-.05Dimensions requiring a tighter tolerance shall be notedindividually.Note: All dimensions shall be tolerance such that all same parts are completely interchangeable; any dimension not -tolerance shall be box tolerance.4.0 Cavities4.1Highly-detailed, close-tolerance cavities shall be constructed in segments, including end segments and center segments, the number of the latter to be determined by the length of the parts.4.2If cam-actuated details are required, the following designs shall apply:•Slide wear surfaces shall be hardened to RC-54-56.• Tool shall be designed so that slides can be removed without removing the tool from the press.• Hydraulic core pull shall not be used without written engineering approval.•Slides are to run horizontally in the tool as it hangs in the press . the slides must have spring forced retention.4.3All cavity, core and slide details shall be Armoloy or chrome plated with .000050/.000075 thickbuild-up per side on all surfaces with no edge build-up. All detail dimensions shall be designed to allow for this plating build-up.Note: Any areas which will not allow chrome plating shall be specified on the detail print as a "restricted area" not to be plated. Any cavity, core, or slide detail which is not chrome plated shall require previous written CommScope Engineering approval.Approved source: Armoloy of Illinois, 118 Simonds Avenue, DeKalb, IL 60115 Attention: Jerome Bejbl ph # 1-815-758-66914.5All E.D.M. surfaces shall be retempered after final machining at 50 deg. F to 100 deg. F under the original tempering temperature to minimize any untempered martensitic surface layer formed during the E.D.M.process.4.6Details will be stamped or etched with detail number and type of steel.4.7Scissors / Bypass shut-offs are to be a minimum 5 degree angle unless otherwise approved.4.8Spare details shall be provided equivalent to 25% of the total required for a complete tool. Spare details will be provided to replace one of each of the details which are deemed vulnerable to short-term damage. Spares will becoated and ready for installation into any cavity.4.9Cooling lines shall be located as close to cavities and runners as possible and shall be labeled "IN or OUT" as required. Lines shall be recessed for flush mounting DME "Jiffy-Tite" plugs or stand-off legs provided. “Jiffy-Tite plugs,1/4”NPT, 3/8” thru hole, DME part no. JP352 or JP352F shall be installed in all cooling line openings. All water lines should enter and exit the bottom of the tool with no water connection on the top of the tool ,If it is required to have multiple waterlines a manifold for the "A" and "B" mold halvesshall be provided. The manifolds shall be either mounted to the standardized clamp plates or incorporated into the tool.The manifold shall have a single inlet and outlet per CITCO Products Inc. (North 8779, Highway X, Watertown, Wisc. 53094) or equivalent. 5.0 Venting5.1Vents will have a relief .030 deep extending .100 - .125 from the edge of the cavity to out side of the mold. Vent width to be 1/8” - 1/2” wide depending on part size and material to be molded. The distance from the end of t he relief to the cavity will be the effective vent depth.5.2All vents to be draw stoned to ensure self cleaning.Provide ejector pins or inserts in deep pockets and rib areas for venting purposes as necessary.5.3Runner system to be vented.6.0 Ejector Systems6.1If the part design required multiple thin-walled sections, two-stage ejection shall be used. As an example, the cores may be ejected first, clearing the parts from the cavities, and the part subsequently ejected from the cores.6.2Guided ejector systems shall be used wherever possible.•Ejector plates shall have a minimum of four guide posts and four return pins.•Guide posts must be secured to the clamp plate and not telescoped into or attached to the cavity plate.6.3A micro switch shall be mounted between the ejector housing and ejector plate to verify the ejector pins are in the full returnedposition before allowing the molding press to close. Switch to be used is "MICRO SWITCH" 1CH32-R6.4Ejector plate shall use die spring return and spring ratings shall be specified on drawings.6.5Ejector plate stop pins (DME or National) shall be provided.6.6Unless otherwise specified, standard SPI knockout pattern shall be provided.6.7Ejector guide post bushings shall be Lamina bronze or equivalent. (DME standard leader pins and guided ejector bushing series.) 6.8All ejector plates shall be provided with hardened riser pads. They shall be mounted to the ejectorplate for the purpose of maintaining a standardized clearance of .050" from the ejector pad to the back of the "B" clamping plate.This is to allow COMMSCOPE to standardize the molding press K.O. rods.6.9All tools using a submarine gate shall also be designed with a ejector pin adjacent to / or as close to the gate as possible to eject any partial shot without damaging the tool.7.0 Hot Runners7.1All runnerless tools shall be designed to provide the ability to purge through the hot runner system by separating the cavity retainer plate from the hot manifold while in the molding press.7.2All tools equipped with a hot sprue bushing shall use a 115 volt controller.7.3Thermoplastic hot runner will have an insulator sheet mounted to the stationary side clamp ½ “ thic k and parallel with in .002. DME High Temperature Insulator sheets or equivalent.7.4Final design information in complete detail on paper and cad shall be furnished, after approval of samples by COMMSCOPE .These tracings will be made in accordance with COMMSCOPE (Omaha) Tool and Gage Drafting Standards Spec. SU-316 issue 2dated 2-19-967.5All runnerless tool drawings shall include a complete wiring diagram similar to CT-80OH3109, sheet 47. The diagram is to includea complete bill of materials. With D.M.E./Moldmaster/Husky type runnerless tools use the following DME catalog number electricalplugs:Power: PIC-12-G Thermocouple: MTC-12-G Terminal mounting box: PTC-12-TB-G8.0 Sampling and Inspection of Mold / Process Capability8.1The completed mold shall be sampled by the tool manufacturer and samples from each cavity shall be produced. Samples submitted to COMMSCOPE Engineering for approval shall be obtained during this continuous run, which shall duplicate normal productioncycles as determined and observed by COMMSCOPE Engineering. Parts shall be taken from consecutive shots during the run and tagged or numbered in the order in which they were produced.8.2The tool manufacturer shall furnish inspection data certifying that sample parts meet the part drawing requirements. Final acceptance of the mold will be based upon the conformance of molded parts from each cavity to the part requirements.8.3Any parts produced in advance of sample approval by COMMSCOPE Engineering shall be the responsibility of the tool manufacturer.8.4The tool shall be observed in operation by COMMSCOPE Engineering and/or Purchasing personnel at the tool manufacturer's plant.8.5COMMSCOPE is to supply plastic (no charge) unless otherwise specified in the purchase order.8.6Try outs that are performed @ the tool vendors will be required to supply the molding engineer with complete sample shots including runner (quantity to be determined by molding engineer). Also there shall be a sample that is a fill only shot that is approximately 95% to 99% full at the last place to fill. This will serve as an indication of runner balance and mold pressure transducer location.9.0 Other Information9.1The tool shall not be shipped without written approval by COMMSCOPE (Omaha) Purchasing Department.9.2The attachment pertaining to patents and technical information shall apply.9.3The mold maker is responsible for:•Insuring that mold conforms to specifications supplied by CommScope•Utilizing sound tool practices in the construction of the mold.•seek prior approval for non - desirable practices. (shim, weld, etc.)•Meeting promised completion dates.9.4The following has been adopted from the society of plastic engineers mold classification system and is used in reference to mold life and warranties . Actual mold construction details will be specified on the mold engineering planning worksheet.9.5The following document is a new tool check list that is required to be completed and returned to CommScope molding engineersdepartment at completion of mold building project.New Tool Check ListN/A OKVerify tool ID stamped on mold base CT_ _ OH _ _ _ _Verify sprue bushing spherical radius to equal ¾”.Verify gate size is indeed what final tool prints call-out.Verify all gate sizes on multi-cavity tools do not vary more than .001”.Verify all water passages have been pressure tested @ > 80 psi.Verify mold base water inlets have been recessed on bottom of tool to accept 200 series JiffyTight fittings.Verify safety strap has been provided and stamped same as mold base.Verify Cavity ID has been engraved on each individual cavity / ejector pin per mold designspecs.Verify mold transducer slot has been included.Verify transducer ejector pin size stamped on mold base.Verify tool switch components have been attached to mold base topside and offset to avoidinterference of eyebolts / hoist rings.Verify transducer slot is on topside of tool unless otherwise specified.Verify latest mold design has been electronically transferred with hard copy to follow.Verify molding tool has been sprayed and secured for shipment (¾” plywood box and skid).Verify company logo “CommScope” to be engraved on removable tool detail inse rt.Tool # / Mold ID: CT-___________________________________Description: ________________________________________________Toolmaker Initials: ______________________________________Date Approved: ________________________________________Two Copies Needed!One copy of this checklist shall be transported with the tool in crate.(Should not be included in the packing list!).The second copy will need to be faxed to CommScope engineering 402-691-3465.。