: Work Instruction WI #: 7330-000-006-0 COR

Description: TOOL STANDARD / Tryout / Procurement Page: 1 of 4

Date Issued: 11/22/02 Revision Date: 03/10/03 Written By: Mike Burmesch Approved By: George Semrad

1 PURPOSE / SCOPE
This work instruction has been developed to establish tooling standards for Maysteel tools and dies

2 FORMS
Tooling Audit Identification Tag

3 INPUTS
Customer or Maysteel requirement for new tooling

4 PROCEDURE
4.1 Engineering receives procurement instructions from the Sales department which will contain all tooling for a
given customer project.

4.2 Engineering will determine where the tooling is to be made and completion dates. Purchase orders will be
placed or work orders for tool room are written by Engineering.

4.3 Pre-Design
4.3.1 All electronic file formats exchanged between Maysteel and the tool supplier must be
previously agreed upon.

4.3.2 Upon format agreement, the electronic files will be uploaded or downloaded to an agreed
upon Maysteel FTP site, at which time the supplier or Maysteel will be notified of the location
of such files for download. If the supplier does not have these capabilities for transferring
electronic files, the transfer must be completed in some other means agreed upon by both
involved.

4.3.3 Maysteel, the supplier and the customer (if applicable), have the opportunity to discuss the
following: tolerance issues, tooling processes, prints and electronic files, Maysteel
Manufacturing Tolerance Guidelines for non-specified dimensions, critical to function issues
and process control dimensions.

4.4 Basic conceptual design must be reviewed and approved by Maysteel and the customer representative(s) if
applicable before proceeding to build the tool or die

4.5 Unless otherwise specified, Maysteel furnishes the material for samples

4.5.1 Purchased tools / fixtures and dies are to include a minimum of 1 sample part for approval
prior to shipment of tools / fixtures if applicable.

4.5.2 If the supplier does not have the necessary equipment available for tryout, some other
arrangements must be made and agreed upon.

4.5.3 Maysteel representatives should be present to view the tool / fixture tryouts if applicable.

4.5.4 Upon verification the tool / fixture is released for tool / fixture tryout at Maysteel for process
evaluation, safety inspection, first article verification, etc.
 : Work Instruction WI #: 7330-000-006-0 COR
Description: TOOL STANDARD / Tryout / Procurement Page: 2 of 4
Date Issued: 11/22/02 Revision Date: 03/10/03 Written By: Mike Burmesch Approved By: George Semrad

4.5.4.1 The supplier or internal tool room will fill out and attach a tooling audit
identification tag to all tools / fixtures when released for try out at Maysteel, if
applicable. Reference the Tooling Tags work instruction.

4.6 All tools and dies must produce an acceptable part. Unless otherwise specified, tooling should consume no
more than 33% of the total print tolerance for all critical to function dimensions (CTF) and 50% of all non-
critical dimension and non-specified dimensions on forming location features. On cut-out feature sizes, print
tolerances apply, unless otherwise specified.

4.7 Unless otherwise specified, all dies are set for quick die change.
4.7.1 Top shoe clamping area to be 2.00 inches thick and bottom clamping area to be at 1.00 inch
thick. Clamping centers should be matched up to the press ram and bed prints.

4.7.2 Punch Press Shut Height Standard for Stamping and Forming Dies:
4.7.2.1 Dies designed for 275 Ton to 550 Ton presses are to have a shut height of
16.00 inches +.000 / - .040.
4.7.2.2 Dies designed for below 275 Ton presses are to have a shut height of
12.00 inches + .000 / - .040.
If there are any circumstances that this criteria cannot be achieved, please discuss with Maysteel personnel
during the design or design approval meeting

4.8 Unless otherwise specified, first piece documentation is required when submitting first part for approval.
Documentation on Maysteel forms with accompanying numbered print or print file.

4.9 Unless otherwise specified, spring, urethane, or nitro loaded strippers will be used wherever possible and
practical

4.10 Use only stock pushers at sufficient strength to keep the blank against the back gauges or equivalent

4.11 The material must be guided from the coil feeder to the work area using hook or inverted L guides unless
otherwise specified.

4.12 Ejection of parts must be provided for and agreed upon when the conceptual design is reviewed. Parts
must eject from the tool safely for the operator.

4.13 All areas of the die, which might contact the material in process, must have rounded corners, so that while
feeding, the material cannot catch on corners or protrusions in any way. Also, lifter pins must be provided by
cutting edges to bridge the gap

4.14 Punches are to have ejectors unless otherwise specified

4.15 All screws and dowels must be standard and of ample size. All form blocks must be either set into the die
shoe or keyed in place.

4.16 Unless otherwise specified, all dies to feed from right to left when facing die in operating position
 : Work Instruction WI #: 7330-000-006-0 COR
Description: TOOL STANDARD / Tryout / Procurement Page: 3 of 4
Date Issued: 11/22/02 Revision Date: 03/10/03 Written By: Mike Burmesch Approved By: George Semrad

4.17 When more than one die is required for a part, location points on all dies must be at the same location

4.18 Spring pushers must be provided to insure that the blank is held against gauges of die

4.19 Oil breaker pins are required on all dies

4.20 If the die is to be hand fed, it must be designed to eliminate the need for operator to place hands or fingers
within the point of operation while loading or unloading parts. Dies must be designed to be loaded with a
commonly available manual die feeding device.

4.21 Scrap cutters, ramps, chutes and drop-through holes should be used for scrap removal. Scrap must fall
away free with no hazard to the operator and eliminate the need for the operator reaching into the die to
affect its removal.

4.22 Dies must be marked in characters of minimum size to show:

4.22.1 Maysteel Tool Number
4.22.2 Maysteel Part Number
4.22.3 Shut Height
4.22.4 Tonnage
4.22.5 Upper & Lower Die Shoe Weight
4.22.6 Customer Tool Number
4.22.7 Customer Part Number
4.22.8 Supplier ID and job number, if applicable

4.23 Basic die protection is required. Consideration should be given during the design phase for prevention of
tool breakage (i.e.: short feed, mis-feed, part ejection, operator enhancement blocks).

4.24 Tool Classifications for Stamping Dies.

NOTE: Forming dies must be treated on an individual design basis, depending on the characteristics of the
part being formed.

4.24.1 Class A (Minimum Requirements)

Life Expectancy 1,000,000 hits

Die Set 2 inches thick top and bottom shoe

Punch Holder 1 inch thick / HRS
Tool Steel 1.25 inches thick / A2
Punches 2.25 inches long / A2
Strippers .750 inches thick / CRS
Bushings Bronze Plated
 : Work Instruction WI #: 7330-000-006-0 COR
Description: TOOL STANDARD / Tryout / Procurement Page: 4 of 4
Date Issued: 11/22/02 Revision Date: 03/10/03 Written By: Mike Burmesch Approved By: George Semrad

4.24.2 Class B (Minimum Requirements)

Life Expectancy 250,000 hits

Die Set 2 inches thick top and bottom shoe
Punch Holder .750 inches thick / HRS
Tool Steel 1 inch thick / A2
Punches 1.750 inches long / A2
Strippers .625 inches thick / CRS
Bushings Bronze Plated

4.25.3 Class C (Minimum Requirements)

Life Expectancy 50,000 hits

Die Set 1 inch thick top and bottom shoe
Punch Holder .500 inches thick / A2
Tool Steel .750 inches thick / A2
Punches 1.250 inches long / A2
Strippers .500 inches thick / CRS

5 OUTPUTS / RECORDS
Tool Tryout (first article report) to be maintained in the part number history file located in the Measurement Center.