Manual for a Cooperative Partnership with WAFIOS AG · supplier procures the required standards and...

Manual for a Cooperative Partnership with WAFIOS AG

Machineryfor Wire and Tube

Contents

1. Foreword

2. Areas of application

3. Cooperation with suppliers

3.1. Communication

3.2. Enquiries

3.3. Selection of suppliers

3.3.1. Supplier questionnaire

3.3.2. Purchasing / ordering

3.3.3. Framework contract, scheduling agreement

3.4. Logistics

3.4.1. Packaging

3.4.2. Empty packaging management

3.5. Quality assurance agreement

3.5.1. Quality management

3.5.2. Deviation in quantity of delivery

3.5.3. Deviation in quality of delivery

3.5.4. Supplier assessment

3.5.5. Non-disclosure agreement

3.6. Data exchange

4. Indications on drawings

4.1. General tolerances

4.2. Surface treatment

4.3. Chamfered edge

4.3.1. Size

4.3.2. Sharp-edged

4.3.3. Free of burrs

4.4. Scallop height

4.5. Labeling

4.6. Labeling in pairs

4.7. Return of drawings

4.8. Heat treatment

Copyright by WAFIOS AG 2013

Contents

5. Entries in work schedules

5.1. Abbreviations

5.2. Grinding allowances

5.3. Parts to be supplied / mounted

5.4. Work schedules (subcontracting)

6. Other regulations

6.1. Arrival of provided goods

6.2. Abrasive burning

6.3. Protection of components

6.4. Inspection/acceptance/delivery/operating instructions

6.5. Provided testing equipment and installations

7. Continuous improvement process

8. Annex:

Abbreviations in work schedules

WAFIOS Standard W 121 Drawing and engraving

WAFIOS Standard W 819 Grinding allowances

WAFIOS Norm W 854 Coatings – Painting

WAFIOS Standard W 1148 Threaded inserts

WAFIOS Standard W 2405 General Tolerances

Version:- Status July 2009 - Ammendment Chapter 3.3.1. Part 2

- Status May 2010 - Ammendment - W 2405, Sheet 5, Chapter 4 - Page 28

- Status July 2010 - Data Exchange W 2405

- Status August 2010 - Data Exchange W 0121

- Status July 2011 - Data Exchange W 2405

- Status April 2012 - Data Exchange W 0121

- Status July 2012 - Ammendment W 1148

- Status July 2013 - Ammendment W 0854


Dr. Bartz, G. Kocher, R. Müller, Dr. Schürmann, E. Walz, H. Weinmann, Th. Winkler, B. Zwiesele

19.07.13

1. Foreword

The market leadership of the WAFIOS AG requires our products to be of top quality. Our suppliers can make an important contribution to assure this quality. The quality of their pro-ducts has a great impact on our capability to meet our customers’ requirements. Our capa-bility is therefore based on a cooperative and trusting relationship with our suppliers.

For this reason, the common goal of WAFIOS AG, suppliers, and customers must be: “Zero errors” in quality, logistics and adherence to delivery dates!

This Supplier Manual is meant to further improve the successful cooperation with our suppliers. We strive for a true partnership based on fairness and efficiency.

Only motivated suppliers will help us to sustain our market leadership. Continuous improve-ments and the will to develop new things together and economically pave the way for a successful, long-term cooperation.The goals of the magic triangle of costs, quality and time can only be reached, if all parties involved collaborate. Therefore, we seek an open dialog with our suppliers.

The following pages describe our basic principles as they are applied by WAFIOS. They will show you, as our supplier, the measures, procedures and performances required togain the status of a “Class A” supplier”.

These regulations are meant to help you deliver functioning, top-quality products and services free from errors and in accordance with our orders within the stipulated deliverytime to ensure the high quality of our machines that is connected with the name of the WAFIOS AG.

Reutlingen, September 12, 2008

Executive Board Head of the Materials Adm. Dpt. Head of the Quality Man. Dpt.


2. Areas of application

These basic principles inform our suppliers about the minimum requirements concerning services and/or products that have to be delivered to WAFIOS AG within the duration of thecontract between WAFIOS AG and the supplier.Individual clauses of this agreement are only valid as long as they do not contradict otheragreements that have been made with the supplier. These other agreements must be madein writing.

3. Cooperation with suppliers

3.1. Communication

We recommend that our suppliers generate a separate email address for communication purposes (enquiries, questions, etc.) with a delegate function that allows several people to open and write emails from this address in case our contact person is sick or on vacation. Changes regarding our contact person must be transmitted immediately to WAFIOS AG to ensure continuous communication.

3.2. Enquiries

WAFIOS AG makes enquiries via fax, email, phone or our sourcing platform Techpilot. The supplier procures the required standards and guidelines (DIN, EN, ISO, VDA, etc.) mentio-ned in our enquiry on his own account. In case of parts that have to be produced accordingto drawings, the supplier is obliged to regularly make sure that all documents are still up to date, especially when it comes to changes (index, version).Before submitting a quotation, the supplier makes a feasibility study in which his technical and capacitive possibilities are considered. Possibilities of improvements regarding technical, quality and other subjects as well as possible problems can be mentioned in the quotation or discussed with the responsible purchasing agent. Useful suggestions as well as quality, service and adherence to delivery dates are considered in our assessment of suppliers.Please send quotations for the requested batch sizes.

3.3. Selection of suppliers

The supplier for a certain product or service is selected from our list of authorized suppliers.

3.3.1. Supplier questionnaire

New suppliers must be authorized by the WAFIOS AG. You are required to fill in a question-naire which gives us detailed information about contact persons, your factory size, produc-tion strategy, insurance policies and quality management system. Please return this question-naire to WAFIOS AG, signed by your Business Management and the Head of your Quality Management Department. Our suppliers must update this questionnaire and automatically send it to WAFIOS every two years.


Questionnaire: Supplier Self-Assessment

Part 1: General Information

1. Company name:

2. Address:

3. Phone no.:Fax no.:Email:Mobile phone:

4. Company data:Founding year:Legal form of company:Independent/Parent or subsidiary company:Turnover:Export share:Market volume:Number of employees:

5. In-house product development?

6. Quantity delivered per year to WAFIOS AG?

7. Your most important customers?

8. Your most important suppliers?

9. Production site(s):

10. Responsible salesperson:Name:Phone/fax:Email:Mobile phone:

11. Quality manager:Name:Phone/fax:Email:Mobile phone:

............................................ .........................................................Business Management Quality Management


Part 2: Quality Assurance

1. Is your QM system certified?If yes, please only answer questions 10 - 14and add the certificates

2. Have you been audited by external companieswith positive results? If yes, please only answer questions 10 - 14

3. Do you have a QM manual or another descriptionof your QM system?

4. Do you work with quality control plans?

5. Can you provide initial sample reports?

6. Do you make regular goods inwards inspections?

7. Do you have regular production controls installed?

8. Do you make systematic final checks?Do you document these checks?Can we access these documentations?

9. Is there a regular control of all production units?

10. Do you record quality-related costs?

11. Do you have a product liability insurance?

12. Is the documentation written in such a way that aproof of exoneration can be submitted in case ofa product liability claim?

13. Can you ensure the retraceability to your supplier?

14 Do you use your own vehicles for delivery?


Yes No

Yes, by the following company/-ies (submission of audit results):

No

Yes No

Yes No Partially

Yes No Partially

Yes No

Yes No

Yes NoYes NoYes No

Yes No

Yes No Partially

Yes No Partially

Yes No Partially

Yes No Partially

Yes No

3.3.2. Purchasing / ordering

As a matter of principle, WAFIOS AG places orders always in writing. We order and you deliver goods and services, mutually waiving all conditions of purchase and sale, granting awarranty period of 24 months in accordance with EU guidelines. This warranty period startsat the final acceptance date, at the latest 36 months after delivery. To ensure that all project-related requirements concerning quality, costs and delivery date are met by the supplier, WAFIOS AG can request the preparation and submission of a project plan. Besides this manual, the following documents are an integral part of the contract:- In case of purchased parts, the order/order text and drawing- In case of external processing jobs, the order/order text, text of processing order

and drawingFor external processing jobs, always drawings and production orders are provided. The drawing is only a valid production document, if it is marked with the number of the order. Only the processes indicated on the order must be carried out. The notes given in the order text have to be considered. These notes take precedence over the drawing.In case of ambiguities, the processor must contact WAFIOS AG for clarification.All processing documents (e.g. drawings, shop floor papers) have to be returned to WAFIOS AG after completion of order.

3.3.3. Framework contract, scheduling agreement

Framework contracts can be made for our serial orders of recurrent identical items. We reserve the right to change quality requirements.

3.4. Logistics

On the basis of the contracts concluded, delivery schedules are transmitted in writing or viaelectronic data exchange. A schedule is regarded as confirmed if there is no immediate written objection. Please send any written objection to the responsible purchasing agent atWAFIOS. Delivery of the required quantity in accordance with the current delivery schedule.Moreover, the delivery schedule informs you about the corresponding go-aheads for the purchase of input materials or for production. Please only deliver the quantity indicated onthe delivery schedule.

3.4.1. Packaging

Part-related packaging in accordance with logistics, quality, environmental and economical specifications is required. Avoid transport damages by correct packaging. Please make an appropriate packaging suggestion and consult WAFIOS. Always preserve all parts to avoid corrosion / flash rust also in case of unfavorable weather conditions. No wetness-absorbing materials must be used for packaging (e.g. corrugated cardboard, newspaper, etc.). Preferably use oil paper and protective sleeves.


3.4.2. Cargo management

For incoming and outgoing goods, the type and number of loading aids (pallets, iron-barredboxes, barrels, gas bottles) used by the supplier is recorded. All loading aids always have tobe taken back. Loading aids can only be invoiced, if WAFIOS AG accepts an invoicing.

3.5. Quality assurance agreement

3.5.1. Quality management

The cooperative relations between WAFIOS AG and suppliers result from the quality of the goods and services delivered as well as from the compliance with certain technical specifi-cations and requirements, adherence to delivery dates, cost responsibility and reliable deliveries. The supplier himself must take all necessary measures to reach our commongoal of “zero errors”. WAFIOS AG has the right to carry out an audit – after a corresponding advance notice – toensure that all agreed quality measures are taken. The transfer of jobs to sub-suppliers (except retailers) is only admitted with the prior consentof WAFIOS AG. If, compared to previous deliveries, dimensions or technical aspects have been changed, these changes have to be disclosed.Quality assurance contracts have to be observed.

3.5.2. Deviation in quantity of delivery

All parts declared to be faulty by WAFIOS AG are rejected. To avoid production downtimes at WAFIOS AG, the delivery of faultless parts must be top priority. Therefore, appropriate measures have to be taken as soon as possible to correct or substitute faulty parts. In especially urgent cases, if, for example, there is a risk of a production downtime, WAFIOS AG can correct the faulty parts themselves (after consulting the supplier) or ask a third partyto make the correction. The supplier pays the costs for these corrections.

In case of external processing jobs, the number of pieces to be delivered must be met exactly. Deviations (e.g. in order to use up remaining material), are not permitted without theprevious consent of WAFIOS AG. Rejected parts must not be invoiced.Moreover, the exact number ordered of purchased parts must be delivered. An overdeliveryis not desired.


3.5.3. Deviation in quality of delivery

If the supplier doubts the feasibility of the services ordered by WAFIOS AG, immediate clarification is required (with quality management of WAFIOS AG).If the supplier detects quality deviations from the required specifications, a special approval can be requested from the Quality Management Department of the WAFIOS AG. At least the following specifications have to be made:- Material number and version number- In case of external processing jobs: production order number and material number - In case of purchased parts: order number and material number - Number of parts to be delivered- Number of faulty parts- If available: consecutive number of faulty parts (serial number) - Description of deviationThe description of the deviation should be prepared in such a way that the WAFIOS quality management (QM) can make a decision without any more information. The description can be made by means of drawing extracts with inscriptions, digital photos, and/or detailed descriptions.The supplier has to make a suggestion for correction and indicate the name, position, phone, and fax number and email address of the contact person at the supplier. We also expect information on the error’s cause, correction measures, and effectiveness tests. A special approval does not count as approval for future deliveries.The decision about a special approval from the Quality Management Department is made in writing. This response has to be added to the delivery and the faulty or repaired parts must be identified clearly (tag, label).If the WAFIOS incoming goods inspection detects a deviation, the supplier is informed by the WAFIOS Material Administration Department in writing. The supplier checks the defects report and contacts WAFIOS AG immediately if there is a need for clarification. The number of the defects report, the order number or the production order number and if necessary theWAFIOS material number have to be indicated on all further correspondence.The supplier searches for the reason of the error and why it has not been detected and informs WAFIOS about the result. He determines correction and preventive measures as well as an appropriate effectiveness test.

3.5.4. Supplier assessment

WAFIOS AG regularly makes a supplier assessment of key suppliers. The following criteria are used for assessment:

Delivery / Packaging / Quality / Adherence to delivery dates / Service (flexibility, know-how and innovation, communication, cost-reducing measures, competitiveness) / Price-performance ratio

If you are classified as a B or C supplier, we expect to receive your comments and suggestions for improving your status and for being classified as an A supplier within 14 days.


3.5.5. Non-disclosure agreement

In accordance with our WAFIOS company philosophy, we cultivate an open and construc-tive contact with our suppliers. Therefore, we must be sure that our know-how or the know-how we compiled together with you is not passed to third parties. Our business partners areobliged to not pass internal WAFIOS information on to third parties without prior consent. In individual cases, non-disclosure agreements are made.

3.6. Data exchange

WAFIOS AG prefers the Tiff, DXF, and PDF format for the exchange of technical documents. Only if Tiff is not available, email or in special cases also a conventional data medium can beused. For reasons of secrecy, no confidential development data must be transmitted via email. If requested, WAFIOS will make the specification sheet for electronic data interchangeavailable.

4. Indications on drawings

4.1. General tolerances

Basically, the general tolerances (DIN ISO 2768, W 2405) indicated in the title block of the drawings are valid.

4.2. Surface treatment

Indications on drawings have to be observed.

4.3. Chamfered edge

4.3.1. Size

The chamfered edge is indicated on the drawing. In case of subcontracting jobs, an additio-nal grinding allowance might have to be observed, if the chamfered edge has to be made in accordance with the work schedule.

4.3.2. Sharp-edged

This notation means that the edge must be sharp-edged and without burr. Sharpening withan oil stone under 45° would mean the immediate rejection of the part.

4.3.3. Free of burrs

Sharpening under 45° with an oil stone is possible. The generally accepted chamfering edge of the drawing must not be used here.


4.4. Scallop height

A minimum scallop height indicated on the drawing must be observed.

4.5. Labeling

Manufacturer’s data (company name, logo) require the approval of WAFIOS AG.As far as there are no special indications on drawings, always the following designations have to be applied.- WAFIOS order number- WAFIOS material numberAs long as there is no other agreement, WAFIOS standard 121 must be applied. In case of questions, please contact our Quality Management Department.

4.6. Labeling in pairs

If labeling in pairs is required, the components have to be combined to pairs and they have to be delivered in pairs.

4.7. Return of drawings

After carrying out all work requested, the drawings have to be returned to WAFIOS AG together with the delivery. (See 3.5.3.)

4.8. Heat treatment

The hardness penetration depth and the surface hardness apply to the finish-processed component. Machining allowances have to be considered accordingly.Moreover, the hardening ranges indicated on the drawings have to be especially observed by the heat treater when partial hardenings are made. In case of doubts, contact WAFIOS AG.

5. Entries in work schedules

5.1. Abbreviations

Please see annex.

5.2. Grinding allowances

Grinding allowances have to be indicated as absolute value. The allowances indicated on the work schedule have to be applied. As long as not otherwise indicated, WAFIOS stan-dard W 819 has to be applied (s. annex).


5.3. Parts to be supplied / mounted

The parts mentioned in the work schedule have to be delivered by the supplier and are thusan essential part of the delivery.

5.4. Work processes (subcontracting)

According to the work schedule, work processes must not be started before the work schedules have been checked for completeness and correctness by the subcontractor. In case of any doubts, please contact WAFIOS AG before starting any work.

6. Other regulations

6.1. Arrival of provided goods

If goods are provided by WAFIOS AG (e.g. in case of subcontracting jobs), these goods have to be checked for obvious defects (e.g. rust, transport damages). If such a defect is detected later on, WAFIOS AG must be immediately informed about this defect. Otherwise, the goods are regarded as approved despite of this defect.

6.2. Abrasive burning

During grinding processes, abrasive burning must be avoided. Abrasive burning is inadmissible.

6.3. Protection of components

The supplier has to deliver and pack all parts in such a way that no transport damages can occur.

6.4. Inspection/acceptance/delivery/operating instructions

The supplier is responsible for the quality, date and quantity of the delivery. WAFIOS reser-ves the right to change the given delivery date. The supplier is informed about this change in writing.At least two copies of the delivery note are required. Besides the designation of the goods and the quantity, the delivery note must include the WAFIOS order and material number.All goods have to be clearly labeled. For clear labeling, an additional delivery note can be attached to the goods, for example. The delivery of purchased parts and subcontracted parts must be separated if there is no other agreement. Subcontracted parts must always be returned in original WAFIOS containers in case of defects. Subcontracted parts must always come with their according original production order and drawing.When the delivery is accepted, the number of pieces delivered is not immediately checked.A quality control of incoming goods does not release the supplier from his responsibility for defects that are detected later on.


If the delivery scope requests the delivery of operating instructions, these operating instruc-tions must be included in German and English language in every delivery. Moreover, WAFIOS must be provided with the corresponding information in digital form or via internet.Proof of final inspection before delivery of goods to WAFIOS. Besides, number 8 of part 2 ofthe supplier self-assessment questionnaire applies.

6.5. Provided testing equipment and installations

Check provided testing equipment and installations immediately upon receipt and inform WAFIOS AG about possible damages in writing. They must only be used for their designated purpose and must be treated with care.Provided testing equipment and installations must be returned after their use in separate packaging and with a separate delivery note. If they are not returned or if they are damaged,WAFIOS AG sends the supplier a corresponding invoice for this equipment.

7. Continuous improvement process

The supplier must make sure that all processes that are connected with the production sequence are continuously analyzed and optimized. Our aim is to use the results for improvements and to control the efficiency of these improvements.


Zu 5.1. Abbreviations in work schedules

Plans. Schedule page

Pl. Schedule

Lg. Length

Hinterdr.Hinterfrs. Relief groove

Hals-D.Naben-D.Zapfen-D.Zentrier-D. Graduated diameters

Gzld Limit plug gauge

Hgzld Auxiliary limit plug gauge

GGzld Thread limit plug gauge

GGzrl Thread caliper gauge

Passg. Fit

Stae./Stä. Thickness

Brt. Width

Abs. Offset, step

Aussp. Cut-out

Anschr.fl. Mounting surface

Rad. Radius

Zug. Allowance

Schl.Zug. Grinding allowance

Anfrs. Milling off/facing

Egal. Leveling

Passbo. Precision bore

Topfbo. Stepped drilling

Senkbo. Counterbore

Durchg. Through bore

AU Job instruction

Schmierl. Lubrication hole/lubrication bore


W 121 Sheet 1

Marking and Engraving

General work pieces

signed: Gminder rev.: UG consists of 1 pages

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WAFIOS Aktiengesellschaft - Precision machinery for wire and tube -

D – 72764 Reutlingen

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200

8.

Smallest dimension of

the work piece Font size Font

up to 50 mm 2 50 - 80 mm 3 over 80 mm 4

Standard

This company standard must be applied to new drawings and such drawings which are currently being altered.

WAFIOS marks every work piece with a material number (MATNR). Therefore, every work piece requires an indication on the drawing.

The indication on the drawing contains location and font size.

The marking must not be applied to ground surfaces nor to burnished surfaces

No marking must be applied to a functional surface!

The writing is applied by a laser, a burin or by engraving etc. (for hard metal only laser!).

Ø-dependent tools are additionaly marked with their wire Ø or their wire Ø range.

If possible, the MATNR should be visible at the machine without having to disassemble anything (except adhesive labels).

All order parts are additionally marked with the WAFIOS order number (except for sheet-metal plates)

The MATNR has the following format: Y Y Y Y - 5 - Y Y Y Y Y Y (the letter Y is used to make sure that the writing is never upside down).

General work pieces

The indication on the drawing: marked with MATNR

and order number font size 3mm With this indication admits producing in-house and externally.

W 121 Sheet 1


General work pieces


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8.

Painted work pieces and bodies

Painted parts are marked with adhesive labels. When the part is installed in the machine, the adhesive label must not be seen.


and order number on a adhesive label font size 3mm With this indication admits producing in-house and externally.

Very small work pieces

Work pieces that are very small, are stored in bags which are marked with adhesive labels.


and order number on a adhesive label font size 3mm With this indication admits producing in-house and externally.

Tools Tools that are produced in-house must be marked with the MATNR and the production order number. Tools that are produced externally, must be marked with MATNR and order number. The indication on the drawing: marked with MATNR

and production order number/ order number

font size 3mm With this indication admits producing in-house and externally. When producing in-house the production order number will be also marked. Furthermore the Wafios lettering and the Wafios logo will be added (look at the next page). Ø-dependent tools are additionaly marked with their wire Ø or their wire Ø range.

W 121 Sheet 1


General work pieces


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Smallest dimension of

the work piece

Logo size

Font

up to 60 mm 4 over 60 mm 6 over 200 mm 8

WAFIOS-Logo

WAFIOS Logo for tools

All tools are marked with the WAFIOS lettering and the WAFIOS-Logo and therefore, every work piece requires an indication on the drawing.

The indication on the drawing contains location and font size.

must be applied to new drawings and such drawings which are currently being altered.

Thr same condictions as the Matnr applied to the Wafios logo (for examble laser, burin or engraving etc., for hard metal only laser!).

Generelly the Wafios logo must be seen.

Not with browning combinable. The indication on the drawing: marked with Wafios

lettering and Logo Logo size 6mm

For small tools or if there is too less room, the Wafios logo is enough.

The indication on the drawing: marked with Wafios logo font size 4mm .

W 121 Sheet 2


Marking examples

signed: Gminder rev.: UG consists of 1 page

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Marked with MATNR on adhesive label Font size 3mm

Marking example In-house produced part or ordered part:

--------------------------------------------------------------------------------------------------------------------------------------- Marking example Tool: --------------------------------------------------------------------------------------------------------------------------------------- Marking example Sheet-metal part: --------------------------------------------------------------------------------------------------------------------------------------- Marking example Bag part:

Marked with MATNR and order no.

Font size 4mm

Marked with wire dia.

Font size 2mm

Marked with MATNR and production order / order no.

Font size 2mm

Marked with MATNR and order no. on adhesive label Kept in bags

W 121 Sheet 3


Feed rollers


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Diameter of feed roller Font size Font

up to 50 mm 2 50 - 60 mm 2.5 60 - 85 mm 3 over 85 mm 4

Standard (agrees to

OCR-B ISO 1073-2)

marked with Ø range marked with MATNR

Grooves Number of sides

Side

without grooves 1 opposite the face-ground side opposite the face-ground sidewith one groove 1 opposite the face-ground side opposite the face-ground side

with two similar grooves 1 face-ground side face-ground side

with two different grooves 2 large groove on face-ground side face-ground side

Feed rollers Feed rollers must always have an indication on their drawing that says where exactly the writing should be positioned. The general position of MATNR and Ø range is on the side of the groove or of the pin hole. Make sure that no writing is applied to the surface that contacts the collar of the feed shaft. The spring washer must not cover the writing on the feed roller on the front side when the feed roller is installed.

Feed rollers have a face-ground side and a flat-ground side. The face-ground side is ground with the diameter and is therefore the more exact side. If the feed roller has two different grooves, the larger one is always positioned on the face-ground side (determined in job instruction).

Feed rollers with two grooves always wear the wire diameter marking on the side next to the groove that has to be used. Note for the user: This can cause ambiguities, if the rear groove is the working groove. In this case, the wrong wire diameter would be visible on the front side.

W 819

Grinding Allowances

For hardened and unhardened parts


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Grinding allowances for bore holes in mm

Bore hole length

Bore hole diameter

up to 1xD up to 3xD

Receiving bore hole HGZLD

up to 7 0.1-0.15 0.1-0.15 0.1 >7-9 0.15-0.2 0.15

>9-13 0.15-0.25 0.2 >13-17

0.15-0.2 0.2-0.3 0.25

>17-30 0.2-0.25 0.25-0.35 0.3 >30-58 0.35-0.45 0.4 >58-75

0.25-0.35 0.45-0.6 0.5

>75-90 0.4-0.5 0.55-0.7 0.6 >90-98 0.5-0.6 0.7-0.9 0.7

>98-108 0.8

>108-114 0.9 >114

0.6-0.8 0.8-1.0 1.0

Grinding allowances for shafts in mm

Shaft length Shaft

diameter

up to 75 >75-100 >100-250 >250-500 >500-750 >750-1100 >1100-1500

up to 10 >10-18

>18-30 0.2-0.3 0.25-0.35

>30-50

0.25-0.35 0.3-0.4

0.45-0.55 >50-80 0.3-0.4

0.3-0.4 0.35-0.45 0.4-0.5

0.5-0.6 0.5-0.6

>80-120 0.35-0.5 0.4-0.55 0.4-0.55 0.45-0.6 0.55-0.7 >120-180 0.4-0.55

0.45-0.6 0.45-0.6 >180

0.45-0.6 0.55-0.7 0.55-0.7 0.55-0.7 0.65-0.8

Coatings

Painting

W 854

signed: Gminder checked: UG

WAFIOS Aktiengesellschaft - Precision Machinery for Wire and Tube -


consists of 3 pages

Page 1

Date: Aug 2013

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8.

RAL 7045 RAL 7035 RAL 3000 RAL 9005 RAL 1018 RAL 5002 RAL 7043 RAL 7047

Procedure Color RAL Coating type**

Quality *by Frei

Coating thickness

[µm]

Priming

[µm]Application

Wet coating tele gray I 7045

S, D GS 914180–150

18-30 Standard for machine frames and parts (MATNO 501700) Powder coating D PL 1033 0

Wet coating light gray 7035

F GS 9141 80–150 0 Oil chambers with gearbox paint, resistant to chemicals (MATNO 501614)

Wet or powder coating G KP 1618 18-30 18-30 Priming (= reaction primer),

(MATNO 501635) Wet coating

flame red 3000 F GS 9141

80–150

18-30 Safety + transport device (MATNO 500560) Powder coating PL 1033 0

Wet coating black 9005 S, D

GS 9141 18-30 Optional devices (MATNO 501585) Powder coating PL 1033 0

Wet coating signal yellow 1018 F

GS 9141 18-30 Warning about obstacles, protective and safety devices (MATNO 501654) Powder coating PL 1033 0

Wet or powder coating

ultramarine blue 5002 D GS 9141 PL 1033 80–150 Special colors (GBL release) traffic gray B 7043 D

tele gray 4 7047 D

Advantages of painting: Decorative surfaces Corrosion protection Improved functional

characteristics

Standard and Priming are self-explanatory. Design parts are parts that are on the exterior of the machine and have a particular smoothness to the base coat, which may need to be prepared accordingly. Coating type D is also permitted for type S. Function parts are parts in oil chambers, suspension equipment, etc.

The RAL color and coating type are plotted on the drawing when requested. They can also be found on the goods receipt slip.

Coating substances primarily consist of binding agents, color pigments, and, in some cases, solvents. Solvent-free paint coatings are described as powder coatings and solvent-based ones as wet coatings. Depending on the reaction, a distinction is made between two-component and powder coatings.

Depending on the geometry of the parts, various application techniques (painting, rolling, spraying) are used.

* To achieve uniform quality, only paints from Frei are used. Refer to the table for information on quality. Work instructions for pre-treatment, application, etc. are attached to this standard. ** A uniform structure and gloss level (silk gloss according to DIN EN ISO 2813) for the coated parts must be guaranteed. For this reason, sample boards (see image) are coated, which meet our quality requirements. Sample boards with the Standard or Design coating type in RAL 7045 are made available to the paint shops and are templates for all other RAL colors.

Coating type: S = Standard G = Priming

D = Design F = Function

Drawing information for coating:

No information on the drawing

Exception: marking of oil rooms on machine frames

Coating information in the SAP material master:

Complete the "RAL color" and "Coating type" fields

Coatings

Painting

W 854




consists of 3 pages

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Non-coated areas

Pre-treatment To achieve an optimum undercoat and enhanced corrosion protection underneath the coat of paint, the surface of all systems must be carefully prepared in accordance with DIN EN ISO 8504-1 and the RAL-RG 631 quality guidelines. See attached work instruction. Priming See attached work instruction, point 7. Particular care must be taken especially with respect to design parts (coating type D). A priming coat is a mandatory requirement for the treatment of welded and cast bodies. Polyurethane wet paint coating A 2-component system with a base and hardener, is also described as DD or PUR coating. It is applied by spraying the paint in one or two coats. The characteristics include very good resistance to chemicals, high abrasion resistance, excellent resistance of the gloss level with a low chalking tendency. High elasticity and color constancy, high level of rigidity (damage can be touched up with a high level of color accuracy without impairing quality). Powder coating This type of plastic coating is also known as electrostatic powder coating (EPC). The synthetic resins are applied dry, generally in one coat, in an electronic spraying procedure. The coating fuses and hardens at 160 °C. The characteristics include high chemical resistance and rigidity, high thermal and mechanical durability, very good gloss and color retention, and optimum weather resistance. Can only be touched up with two-component coating. Repairs are not possible with powder. Contact materials Adhesive tapes, sealants, plastic profiles, and cleaning agents must be matched to the corresponding coating system to prevent damage to the coating due to plasticizer migration or flaking. For example, benzine has proved successful in removing adhesive residues that have not yet hardened.

Machined areas and machined bores and threads must not be coated! They must be covered prior to coating. Oil rooms, machined areas that occur due to large unmachined size dimensions, and bores that are used to save weight must be marked on the drawing.

Drawing information for coating specific areas or bores: Coating area/bore

Drawing information for coating oil rooms: Coating oil room

Coatings

Painting

W 854




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Following paints are used: Standard colour:

0000-0-501700 Paint RAL7045 grey 2C-textured paint satin-finished mixture ratio 10:1 HU0010 FREI EFEDUR-order-no. GS9141 HW2062 Optional paints:

0000-0-501614 Paint RAL7035 grey Acryl paint paint oil resistant 0000-0-501635 Paint RAL7035 grey 2C-acryl paint satin-finished mixture ratio 10:1 HU0010 FREI EFFEDUR-order-no. GS1041 HRA735 0000-0-500560 Paint RAL3000 flame red 2C-textured paint satin-finished mixture ratio 10:1 HU0010 FREI EFDEDUR-order-no. GS1041 HRA300 0000-0-501585 Paint RAL9005 black 2C-textured paint satin-finished mixture ratio 10:1 HU0010 FREI EFDEDUR-order-no. GS1041 HRA905 0000-0-501654 Paint RAL1018 zinc yellow 2C-textured paint satin-finished mixture ratio 10:1 HU0010 FREI EFDEDUR-order-no. GS1041 HRA118 Special paints:

0000-0-501618 Paint RAL5002 ultramarine 2C-textured paint satin-finished mixture ratio 10:1 HU0010 FREI EFEDUR-order-no. GS1041 HRA502 0000-0-501703 Paint RAL7043 grey 2C-textured paint satin-finished mixture ratio 10:1 HU0010 FREI EFEDUR-order-no. GS1041 HRA743 0000-0-501609 Paint RAL7047 grey 2C-textured paint satin-finished mixture ratio 10:1 HU0010 FREI EFDEDUR-order-no. GS1041 HRA747

Date: 15.05.2013 Company: WAFIOS Aktiengesellschaft Emil Frei GmbH & Co.KG

Am Bahnhof 6 78199 Bräunlingen

1. Subject

Processing and drying of: : FREIOPLAST-Adhesion Primer KP1618MRU735 (primer) and EFDEDUR-System-Structure Coating GS9141 10:1 by weight with EFDEDUR-Hardener HU0010 (top coat)

2. Pretreatment

The substrate has to be free of adhesion-impairing substances such as oil, grease or tensides (surfactants, detergents, etc.). These requirements have to be secured by chemical (e.g. phosphatising, chromatising) or by mechanical (e. g. shot blasting) pretreatments.

3. Coatings

Primer: 1Component FREIOPLAST-Adhesion Primer KP1618MRU735 Top coat: 2Components EFDEDUR-System-Structure Coating GS9141 10:1 by weight with

EFDEDUR-Hardener HU0010

4. Application

Application: by conventional air spraying (e.g. cup gun) or by high pressure equipment (e.g. airless, airmix) The appearance oft he coating depends on the way of application and the equipment which has been used.

5. Viscosity

All coating materials can be applied in the viscosity as supplied. In case thinning is necessary, use thinners as follows:

EFD-Thinner 400424 for KP1618MRU735

EFD-Thinner 400320 for GS9141

6. Additional processing parameters

During the usage the temperatures of paint, ambient and part should be the same. The temperature of the substrate has to be above the dew point of the surrounding air during the application.

7. Drying and thickness

Primer: 1Component FREIOPLAST-Adhesion KP1618MRU735 18-30 microns Intermediate drying (time until GS9141 can be applied): 40 minutes at least (depends on the dry film thickness) Top coat: 2C EFDEDUR-System-Structure coating GS9141 10:1 HU0010 50-90 microns Drying: dry to touch after 5 hours at 20°C ambient temperature (depends on the dry film thickness)

8. Health & Safety guidelines at work

The standard personal safety precautions must be observed when handling painting materials. Detailed information about dangerous goods, safety data and recommendations concerning Health & Safety at Work and environmental protection can be found in the corresponding safety data sheet.

Working instruction

Prepared by: C. Hossmann

Date: 15.05.13 Company: WAFIOS Aktiengesellschaft Emil Frei GmbH & Co.KG

Am Bahnhof 6 78199 Bräunlingen

1. Subject Processing information of FREOPOX-Pulverlack PL1033A

2. Pretreatment

The substrate has to be free of adhesion-impairing substances such as oil, grease or tensides (surfactants, detergents, etc.). These requirements have to be secured by chemical (e.g. phosphatising, chromatising) or by mechanical (e. g. shot blasting) pretreatments.

3. Coating

FREOPOX-powder coating, Tribo PL1033A Satin gloss, coarse structure

4. Application

Processing / charging: Tribo- as well as Corona-Application Application equipment: manual and automatic gun

5. Working parameters

The processing and application of powder coatings depends on the application equipment and the parts, to be coated, in a high grade.

6. Baking parameters

The object baking temperature of PL1033A is 10 minutes at 160°C at least (see also baking window in the Technical Data Sheet of PL1033A). In case there are deviations in time and / or temperature compared to the baking window it can happen that variations of appearance, gloss and colour shade will occur.

7. Thickness

In order to achieve an equal structure appearance 80 to 120 microns have o be applied

8. Health & Safety guidelines at work

The standard personal safety precautions must be observed when handling painting materials. Detailed information about dangerous goods, safety data and recommendations concerning Health & Safety at Work and environmental protection can be found in the corresponding safety data sheet.

Working instruction

Prepared by: C. Hossmann

W 1148 Sheet 1

Threaded inserts

Application and indication on drawing

Signed: Gminder Checked: consists of 1 Page

Page 1

Date: June 2012



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In the past, there have always been problems with small threads on processing centers and during assembly. To avoid the breakage of drills, alternatives to the original thread-cutting technique have been examined.

Eventually, threaded inserts that are driven in by according tools have been tested and deemed to be the best option.

Application: The threaded inserts shall be used for thread sizes M3 - M6 and shall be employed as fastening threads - not only in large machine-bodies but also in small components, like strips etc. Even rails for linear guides can be fastened with these inserts.

Thread sizes M3 and M4 can be fully loaded (the screw was torn in half during the traction test). Thread sizes M5 and M6 came lose during the traction test and therefore must not be fully loaded (2/3 of the screws' load bearing capacity max.).

Work pieces must have a minimum wall thickness of 8 mm.

Inserts are used in steel, cast and aluminum materials. If inserts are driven into hardened steel, inserts are deformed. Therefore, they cannot be used with hardened steel. Compared to the traditional processing technique, threaded inserts are more cost-efficient because the inefficient manual thread-cutting process is not needed anymore during assembly. An uninterrupted flow of the organizational process chain in the manufacturing and assembly hall is guaranteed because there are no more breakages of drills and no time-consuming erosion work is needed anymore.

Moreover, threads do not have to be covered anymore as the threaded inserts are driven in after the painting process. Indication on drawing of threaded inserts that are to be driven in:

Can be executed with a threaded insert acc. to W 1148

This indication is available as CAD symbol. Select ± 0.1mm as distance tolerance. More accurate tolerances cannot be produced. As external production may be used, threaded inserts cannot be made compulsory. At WAFIOS, however, always threaded inserts according to W 1148, page 2, are used, if this indication is given on the drawing. The inserts are bulk goods for the Assembly Department and therefore must not be added to the parts list.

After the painting process, there will be the work step "Driving in of threaded insert" added to the work schedule.

W 1148 Sheet 2

Threaded inserts

To be driven in

according to Daetwyler


Page 1

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These threaded inserts are driven into the work piece by means of special tools. Thus no more small threads have to be cut on large processing centers anymore and the breakage of drills is avoided.

Designation of a threaded insert W 1148 with thread size M5 and L=8mm: Threaded insert to be driven in, size M5x8, knurled, MATNO 253815

Material: Stainless steel X6CrNiTi18-10 (former des.: X10CrNiTi1810) Version: Knurled with grooves parallel to the axis, spacing 0.6 mm. RAA 0.6 according to DIN 82 or 34060-0.6 according to VSM (Swiss standard) Supplier: Kurt Bläsi Mechanical Workshop Bielstrasse 11 CH 4512 BELLACH (Solothrun) Phone: +41 (032) 6182177 Telefax: +41 (032) 6182424

Bore hole for insert Minimum distance

from edge to center of thread

MATNOThread ØD P Ø L

Drilled Laser-cut Steel Alu

M3 0.60 253813

M4 0.70 253814

M5 0.80 253815

M6 1.00

8.75 8.0 8.5 ± 0.1 8.5 ± 0.1 6.0 7.0

253816

The inserts according to W 1148 are bulk goods for the

Assembly Department and therefore must not be added to the

parts list!

W 1148 Sheet 3

Threaded inserts

Driving-in tools

according to WAFIOS


Page 1

Date: June 2012



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These threaded inserts according to W 1148 page 2 are driven in by means of special tools in the Assembly Department. They are color-marked to differentiate the thread size.

Designation of a driving-in tool W 1148 for thread size M5: Driving-in tool for M5 MATNO 253825 Driving-in tool: For driving in threads, there are driving-in tools for four thread sizes available:

Threaded inserts are driven in after the painting process. Therefore, they do not have to be covered.

Thread P MATNO Driving-in tool

Threaded pin

MATNO Threaded pin

Color

M3 0.60 253823 M3x16 230953 blue M4 0.70 253824 M4x16 225709 red M5 0.80 253825 M5x20 229410 black M6 1.00 253826 M6x20 209644 white

The tools should be available in every assembly group.

W 2405 Sheet 1

General Tolerances

For general components (starting at 4mm thickness)

similar DIN ISO 2768

signed: Decker rev.: UG consists of 1 page

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This standard serves for the simplification of drawings. It contains the following general tolerances and must be applied to general components, except for welded constructions, sheet-metal parts (thinner than 4mm) and cast parts. General tolerances apply to measurements which do not contain any special indications on drawings regarding the required dimensional accuracy.

General tolerance for Tolerance category

Lengths and angle dimensions DIN ISO 2768 m Beveled edges DIN ISO 2768 m Straightness and planeness DIN ISO 2768 K Rectangularity DIN ISO 2768 K Radial and axial runout DIN ISO 2768 - Symmetry DIN ISO 2768 K Thread and bore distances similar DIN 7168 -

General tolerances for non-welded components starting at 4 mm thickness are determined in accordance with: ISO 2768- mK If smaller tolerances are required or larger tolerances are permitted and more economical, they must be indicated on the drawing. Tighter tolerances than the general tolerances mentioned here must only be applied in special cases as they increase production costs. The following tables contain tolerance values which can be achieved easily in the production process and which must be met. A. General tolerances for length and angle measures, edges and bore distances 1. Tolerances for length dimensions

Length ranges 0.5 - 6

over 6 - 30

over 30 - 120

over 120 - 400

over 400 - 1000

over 1000 - 2000

over 2000- 4000

Tolerances ± 0.1 ± 0.2 ± 0.3 ± 0.5 ± 0.8 ± 1.2 ± 2.0 2. Tolerances for angle dimensions

Length ranges of the shorter leg up to 10 over 10

- 50 over 50 - 120

over 120 - 400 over 400

Tolerances ±1º ± 0º 30’ ± 0º 20’ ± 0º 10’ ± 0º 5’ 3. Tolerances for beveled edges, curve radii and bevels

Length ranges up to 0.4

0.5 - 3

3 - 6 over 6

Tolerances +0.2 ± 0.2 ± 0.5 ± 1.0

The inner radius is produced with a tolerance of ± 25% of the nominal value (except for tools). If really exact radii are required, a tolerance value has to be added to the indication of the radius. 4. Tolerances for distances of threads, bores and counterbores

Nominal Ø up to 7 over 7 - 11

over 11 - 22 over 22

Tolerances ± 0.1 ± 0.2 ± 0.3 indication on drawing

Fit bore distances always have a tolerance value indicated on the drawing.

W 2405 Sheet 1

General Tolerances




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B. General tolerances for shape and position 5. Tolerances for straightness and planeness

Length ranges up to 10 over 10 - 30

over 30 - 100

over 100 - 300

over 300 - 1000

over 1000 - 3000

Tolerances 0.05 0.1 0.2 0.4 0.6 0.8

The length of the corresponding line applies to straightness tolerances and the larger side length of the surface applies to the planeness tolerances. 6. Tolerances for rectangularity

The longer leg of the two legs that make up a right angle, serves as reference element. 7. Tolerances for radial runout

d is the diameter at the measuring point. Diameter D, which is proportionate to the length, is the biggest diameter at the tool (not considering the collars).

8. Tolerances for axial runout

d is the diameter at the measuring point. Diameter D, which is proportionate to the length, is the biggest diameter at the tool (not considering the collars).

Length ranges of the shorter leg

up to 100

over 100 - 300

over 300 - 1000

over 1000 - 3000

Tolerances 0.4 0.6 0.8 1.0

Work piece Ø d up to 6 over 6 - 16

over 16- 40

over 40- 100

over 100- 250

L<10*D 0.005 0.008 0.012 0.02 0.032 L<16*D 0.008 0.012 0.02 0.032 0.04 Tolerances

L<25*D 0.012 0.02 0.03 0.04 0.05

Work piece Ø d up to 6 over 6- 16

over 16- 40

over 40- 100

over 100- 250

L<10*D 0.05 0.07 0.1 0.14 0.2

L<16*D 0.08 0.11 0.16 0.22 0.32 Tolerances

L<25*D 0.125 0.18 0.25 0.36 0.5

W 2405 Sheet 1

General Tolerances




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9. Tolerances for symmetry

Length ranges up to 100

over 100 - 300

over 300- 1000

over 1000 - 3000

Tolerances 0.6 0.8 1.0

The longer one of the two shape elements is the reference element. If the shape elements have the same nominal measures, each shape element can serve as reference element. The general tolerances for the symmetry apply if:

- at least one of the two shape elements has a center plane or - the axes of the two shape elements are positioned in a right angle.

Example of a drawing

Reference: longer shape element (l2) Reference: longer shape element (l1)

Reference: longer shape element (l2)

W 2405 Sheet 2

General Tolerances

for flame-cut parts

similar DIN V 32540


Page 1

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8.

This standard serves as information on flame-cut parts. It states tolerances which can be achieved in the autogeneous flame-cutting, plasma cutting and laser cutting process without any extra work.

When producing flame-cut parts, you have to consider that long work pieces expand more than short pieces when exposed to heat.

A. Autogeneous flame-cut parts A ring-shaped oxy-fuel gas flame heats up the work piece locally until it reaches the ignition point. From the middle of the burner nozzle oxygen is emitted under high pressure and burns the steel and extracts the cutting slag (oxyde and melting) from the seam. Following CAD symbol ’flame-cut’ will be used on the drawings of flame-cut parts:

The meaning of 331 in EN ISO 9013 is:

Range Tolerances for rectangularity [mm] 3 0,4 + 0,01a a=plate thickness

Range average peak-to-valley-height Rz [µm]

3 70 + 1,2a a=plate thickness

With DIN EN 10029 cl. A values following tolerances for the plate thickness:

Length ranges [mm] Tolerance class plate thickness

35 - 125 125 - 315 315 - 1000 1000 - 2000 2000 - 4000 10 < a < 50 ± 0,7 ± 0,8 ± 1,0 ± 1,6 ± 2,5

50 < a < 100 ± 1,3 ± 1,4 ± 1,7 ± 2,2 ± 3,1 100 < a < 150 ± 2,0 ± 2,1 ± 2,3 ± 2,9 ± 3,8 150 < a < 200 ± 2,7 ± 2,7 ± 3,0 ± 3,6 ± 4,5

1

200 < a < 250 - - ± 3,7 ± 4,2 ± 5,2

class A plate thickness

low size high size

≥ 3 < 5 - 0,4 + 0,8 ≥ 5 < 8 - 0,4 + 1,1 ≥ 8 < 15 - 0,5 + 1,2 ≥ 15 < - 0,6 + 1,3

class A plate thickness

low size high size

≥ 25 < - 0,8 + 1,4 ≥ 40 < - 1,0 + 1,8 ≥ 80 < - 1,0 + 2,2 ≥ 150 < - 1,2 + 2,4

Brennschni t t Schnittqualität EN ISO 9013-331

Grenzabmaße für Nennmaße

Tole

ranz

-kl

asse

Blech- dicke

35 <125

125 <315

315 <1000

1000 <2000

2000 <4000

>10-50 ± 0,7 ± 0,8 ± 1,0 ± 1,6 ± 2,5 >50-100 ± 1,3 ± 1,4 ± 1,7 ± 2,2 ± 3,1

>100-150 ± 2,0 ± 2,1 ± 2,3 ± 2,9 ± 3,8 >150-200 ± 2,7 ± 2,7 ± 3,0 ± 3,6 ± 4,5

1

>200-250 - - ± 3,7 ± 4,2 ± 5,2

W 2405 Sheet 2

General Tolerances

for flame-cut parts

similar DIN V 32540


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8.

B. Plasma-cut parts Plasma cutting was originally used for the thermal cutting of material that could not be flame-cut, like high-alloy steel, aluminum and copper. Today it is increasingly used for cutting thin-walled work pieces from non-alloy or low-alloy steel. Nowadays the main field of application is stainless steel. For the cutting process, the work piece is incorporated in the electric circuit and the variant of the transferred electric arc is used. Work pieces up to 50 mm can be cut. Depending on the burner type, different plasma gases are used.

C. Laser-cut parts The classic and the most exact procedure is laser cutting. The laser beam is focussed on the work piece that is to be cut by means of a lense. Depending on the strength of the laser beam, the material is melted, burnt or evaporated. A coaxially guided gas current removes the material from the cutting seam. When using inert process gases, the cutting technique is called laser fusion cutting. Cutting with oxygen is called laser flame cutting. All materials which sufficiently absorb the laser radiation can be cut. The laser beam Ø is 0.25 mm. Maximum tool piece thicknesses are 25 mm for steel, 20 mm for stainless steel and 15 mm for aluminum.

1. Tolerances for length dimensions

2. Tolerances for rectangularity and inclination Starting at 15 mm work piece thicknesses, slight bevel cuts appear. If work pieces are less thick, negligible bevel cuts appear.

3. Surface property at cutting edge If the work piece thickness is small, the surface of the cutting edge is better than Rz 200. If the work piece thickness is great, the surface can be worse. The following mean value applies:

Tool piece thickness

up to 8

over 8 - 15

over 15 - 25

Tolerances ± 0.1 ± 0.2 ± 0.3

W 2405 Sheet 3

General Tolerances

For welded parts



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8.

The value in mm/m corresponds to the tangent value of the tolerances ∆α. It must be multiplied with the length in meters of the shorter leg.

This standard serves for the simplification of drawings. It contains the following general tolerances for welded parts (also made of sheet-metal plate).

General tolerances apply to measurements which do not contain any special indications on the required dimensional accuracy. If smaller tolerances are required or larger tolerances are admissible and more economical, these tolerances must be indicated on the drawing. Tighter tolerances than the general tolerances mentioned here must only be applied in special cases as they increase production costs. The following tables contain tolerance values which can be achieved without any extra work but which have to be met by all means.

1. Tolerances for length dimensions

Length ranges up to 400

over 400 - 1000

over 1000- 2000

over 2000 - 4000

Tolerances ± 1.0 ± 2.0 ± 3.0 ± 4.0 2. Tolerances for angle dimensions

The length of the shorter angle leg must be used for determining the tolerance. Moreover, an agreement can be made to extent the leg length up to a certain point. In this case, the reference point must be indicated on the drawing.

3. Tolerances for straightness, planeness and parallelism tolerances

For welded parts which are made up of flame-cut parts, the flame-cut part tolerance W 2405 Sheet 4 must be applied and added (besides the tolerances mentioned here).

Length ranges of the shorter leg up to 10 over 10 - 50

over 50 - 120

over 120 - 400

starting at 400

Tolerances ∆α (in degree and min.) ± 1° ± 0°30’ ± 0°20’ ± 0°10’ ± 0°5’

Tolerances t (in mm/m) ± 0.2 ± 0.4 ± 0.7 ± 1.1 ± 1.1


over 400- 1000

over 1000 - 2000

over 2000 - 4000

over 4000 - 8000

Tolerances 0.5 1.0 1.5 2.0 3.0 4.0

Reference point

Reference pointReference point

Reference point

Reference point

W 2405 Sheet 4

General Tolerances

For sheet-metal parts (thinner than 4mm)


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This standard serves for the simplification of drawings. It contains general tolerances for sheet-metal parts that are thinner than 4mm.

General tolerances apply to measurements which do not contain any special indications on the required dimensional accuracy. If smaller tolerances are required or larger tolerances are admissible and more economical, these tolerances must be indicated on the drawing. Tighter tolerances than the general tolerances mentioned here must only be applied in special cases as they increase production costs.

The tolerances mentioned here are increased due to partly strongly varying raw material tolerances. The following values apply: A. Flat sheet-metal parts 1. Tolerances for length dimensions

Length ranges 0,5 - 6.0

over 6.0 - 30

over 30 - 120

over 120 - 400

over 400 - 1000

over 1000- 2000

over 2000- 4000

Tolerances ± 0. ± 0.2 ± 0.3 ± 0.5 ± 0.8 ± 1.2 ± 2.0 2. Tolerances for angle dimensions

3. Tolerances for beveled edges 4. Tolerances for straightness and planeness


over 400 - 1000

over 1000- 2000

over 2000 - 4000

over 4000- 8000

Tolerances 0.5 1.0 1.5 2.0 3.0 4.0

Length ranges of the shorter leg up to 10 over 6,0 - 30

over 30 - 120

over 120 - 400

over 400 - 1000

Tolerances ± 1° ± 0°30´ ± 0°20´ ± 0°10´ ± 0°5´

Length ranges up to 0.4 0.5 - 4

Tolerances + 0.2 ± 0.2

W 2405 Sheet 4

General Tolerances

For sheet-metal parts (thinner than 4mm)


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B. Bent sheet-metal parts (up to 15mm thickness) 1. Tolerances for length dimensions

2. Tolerances for angle dimensions

3. Tolerances for beveled edges

Length ranges up to 0.4 von 0.5 bis 4

Tolerances +0.2 ±0.2 4. Tolerances for straightness and planeness


over 400 - 1000

over 1000- 2000

over 2000 - 4000

over 4000- 8000

Tolerances 0.5 1.0 1.5 2.0 3.0 4.0


over 1000- 2000

over 2000- 4000

Tolerances ± 1 ± 2 ± 3 ± 4

Length ranges of the shorter leg up to 400 over 400

- 1000 up to 6mm sheet-metal

thickness ± 0°30´ ± 1°

8 - 15mm thickness ± 1° ± 2°

W 2405 Sheet 5

General Tolerances

For rough castings

similar DIN 1680 and 1683


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This standard informs about tolerances of rough castings (sandcasting). It states tolerances for unmachined dimensions which can be achieved in castings witout any extra work. No general angle tolerances are determined for rough castings as there are no empirical values available. They are only entered, if certain accuracies have to be met. Length tolerances are entered, if they need to be checked.

1. Tolerances for length measures

for castings (corresponding to CT9 in accordance with DIN EN 8062 Bl. 3)

Length ranges

up to 10

> 10 - 16

> 16 - 25

> 25 - 40

> 40 - 63

> 63 - 100

> 100 - 160

> 160 - 250

> 250 - 400

> 400 - 630

> 630 - 1000

> 1000 - 1600

> 1600 - 2500

Tolerances 1,5 1,6 1,7 1,8 2 2,2 2,5 2,8 3,2 3,6 4 4,6 5,4

for steel castings (corresponding to CT11 in accordance with DIN EN 8062 Bl. 3)

Length ranges

up to 10

> 10 - 16

> 16 - 25

> 25 - 40

> 40 - 63

> 63 - 100

> 100 - 160

> 160 - 250

> 250 - 400

> 400 - 630

> 630 - 1000

> 1000 - 1600

> 1600 - 2500

Tolerances 2,8 3 3,2 3,6 4 4,4 5 5,6 6,2 7 8 9 10

2. Drafts of the mold (DR) Drafts are alterations of the shape that are required by the casting process in order to separate the rough casting from the mold. They do not exceed the tolerance. The materials management department indicates drafts on the order. Usually, the following indications are made:

Protective hoods DR – Large bodies DR ± Normal parts DR –

If surfaces have to be machined, drafts have to be arranged in such a way at the casting that the required production dimensions can be met.

3. Machining allowances Machining allowances must be agreed on with the supplier. The following table shall serve as a reference.

Largest nominal dimension of rough casting

up to 50

over 50 - 120

over - 250

over - 400

over - 500

over - 800

over 800

- 1000

over 1000

- 1600

over 1600- 2500

Machining allowance 2 3 4 5 6 7 8 9 10

DR -DR +

W 2405 Sheet 6

General Tolerances

For metric ISO thread

according to DIN 13-20

signed: Gminder rev.: UG consists of 1 Seite

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Typical of a screw connection is the thread that connects the screw with the nut. The following depends on the thread dimensions and the profile accuracy: • Whether the parts that are to be connected

can be screwed together without problems and without rework

• Whether the thread can transfer the forces for which the components have been designed

• Whether a protective layer can be applied to the thread flank

Example: External thread M10- 6g ( 6g- tolerance class for flank Ø and outer Ø) Internal thread M10- 6H (6H- tolerance class for flank Ø and core Ø) Wafios has determined the following tolerance classes for standard and fine threads:

Thread Tolerance field

Tolerance class

Nut thread 6H medium Bolt thread gen. purchased parts, screws 6g medium Standard

Adjusting threads with small play 4h fine with indication on drawings

For square-head screws DIN 479 up to M16 tolerance class 4h applies Limit sizes for bolts and nuts with standard threads For limit sizes for bolts and nuts with fine threads see DIN 13 Sheet 21

Bolt thread Nut thread Tolerance field 6g Tolerance field 4h Tolerance field 6H

Nom

inal

th

read

Ø

Pitc

h P

Flank Ø d2

Core Ø d3

Flank Ø d2

Core Ø d3

Flank Ø D2

Core Ø D1

Core hole drill

M 3 0.5 2.66 –0.08 2.37 –0.09 2.68 –0.05 2.39 –0.07 2.68 +0.10 2.46 +0.14 2.5 M 4 0.7 3.52 –0.09 3.12 –0.12 3.55 –0.06 3.14 –0.08 3.55 +0.12 3.24 +0.18 3.3 M 5 0.8 4.46 –0.10 4.00 –0.13 4.48 –0.06 4.02 –0.09 4.48 +0.13 4.13 +0.20 4.2 M 6 1.0 5.32 –0.11 4.75 –0.15 5.35 –0.07 4.77 –0.11 5.35 +0.15 4.92 +0.24 5 M 8 1.2 7.16 –0.12 6.44 –0.17 7.19 –0.08 6.47 –0.12 7.19 +0.16 6.65 +0.27 6.8 M10 1.5 8.99 –0.13 8.13 –0.19 9.03 –0.09 8.16 –0.14 9.03 +0.18 8.38 +0.30 8.5 M12 1.7 10.83 –0.15 9.82 –0.22 10.86 –0.10 9.85 –0.16 10.86 +0.20 10.11 +0.34 10.25M16 2.0 14.66 –0.16 13.51 –0.24 14.70 –0.10 13.55 –0.18 14.70 +0.21 13.84 +0.38 14 M20 2.5 18.33 –0.17 16.89 –0.27 18.38 –0.11 16.93 –0.20 18.38 +0.22 17.29 +0.45 17.5 M24 3.0 22.00 –0.20 20.27 –0.32 22.05 –0.13 20.32 –0.24 22.05 +0.27 20.75 +0.50 21 M30 3.5 27.67 –0.21 25.65 –0.35 27.73 –0.13 25.71 –0.28 27.73 +0.28 26.21 +0.56 26.5 M36 4.0 33.34 –0.22 31.03 –0.38 33.40 –0.14 31.09 –0.29 33.40 +0.30 31.67 +0.60 32

D N

omin

al th

read

siz

e

D1 C

ore

diam

eter

D O

uter

dia

met

er

D2 F

lank

dia

met

er

Nut

Bolt

d2 F

lank

dia

met

er

d O

uter

dia

met

er

P Pitch

Nut Bolt

WAFIOS AGSilberburgstrasse 572764 Reutlingen, GermanyTel. +49 (7121) 146-0Fax +49 (7121) 49 12 [email protected]

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