Procedures for constructing a preliminary EM24.01.250...

© RENAULT 2003 Origin: PEGI - Renault Page: 1 / 33

Procedures for constructing a preliminary project, a manufacturing sheet, a press tooling study

EM24.01.250 /F ________________________________________

Standard ________________________________________

Status Enforceable Importante Note : This document has been translated from the french. In the event of any dispute, only th french

version is referred to as the reference text and is binding on the parties. Object List the documents and give the information required for producing a preliminary range

and preliminary tooling project. Define the content and specify the documentation method to be included to the folios of a manufacturing sheet. Apply the range lengths authorised by existing press lines. Search the optimum process by comparing with the reference ranges. List the documents indispensable to producing a tooling study. Facilitate archiving in process files and study under GDG (Geometrical data management under CATIA).

Scope of application Renault group Issued by 65307 - Pressing Process Industrialisation Confidentiality Non confidential Approved by Function Signature Application date

D. COURATIN Head of department 65307 06/2003

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History of versions

Version Update Object of main modifications Author A 11/1999 Creation H. SIMON Dept 65302 F 06/2003 2 paragraph 5.2: replaced the term "assembly sheet" by

"assembly FOP" B. Nouhant Dept 65307

Supersedes same document as 02/200 Version E Availability Inside Renault, on the Intranet: http://gdxpegi.ava.tcr.renault.fr

Outside Renault, on the Internet: www.cnomo.com E.mail: [email protected]

Documents cited Regulations : International : European : French : CNOMO : Renault : EM24.01.200, EM24.01.340, EM24.01.375, EM24.02.030,

EM24.02.032, EM24.02.040, EM24.02.100, EM24.03.200, EM24.53.100, GE24-017R, GE24-050R.

Other internal doc : 01-50-000. Other external doc : Coding ICS: 25.120.10 Class E24 Key words emboutissage, outillage de presse, projet, fiche de fabrication, FOP, procédure,

manufacturing sheet, project, pressing, press tooling, procedure Language English

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Contents Page

Foreword ...................................................................................................................................4 1 General ......................................................................................................................................4 2 Confidentiality...........................................................................................................................4 3 Procedure for producing a preliminary project .....................................................................4 3.1 Content of the file for producing the preliminary project ( AVP )................................................................ 5 3.2 Preliminary range ....................................................................................................................................... 5 3.3 Modification of the reference file ................................................................................................................ 5 4 Procedure for producing a manufacturing sheet ..................................................................5 4.1 Writing a manufacturing sheet ................................................................................................................... 5 4.2 Rules of representation and plotting of originals for proper legibility ......................................................... 6 4.3 Administrative information (folio 1)............................................................................................................. 6 4.4 Description of title block (folio 1) ................................................................................................................ 8 4.5 Table of modifications (folio 1) ................................................................................................................... 9 4.6 Synoptic table of methods plan (folio 1) ................................................................................................... 10 4.7 Sheet #1 standard of manufacturing sheets describing the flow ............................................................. 11 4.8 Diagram with an example of synoptic sequence of operations (folio 1) .................................................. 12 4.9 Technical folios (folios 2, 3, 4... ).............................................................................................................. 15 4.10 Modification of the manufacturing sheet .................................................................................................. 21 4.11 Formatting the document ......................................................................................................................... 21 4.12 Data transmission..................................................................................................................................... 21 5 Procedure for producing a tooling study .............................................................................21 5.1 Allocation of studies ................................................................................................................................. 21 5.2 Contents of the study file.......................................................................................................................... 22 5.3 Contents of the study file valid for modelling............................................................................................ 22 5.4 Contents of the study file for consultation and construction .................................................................... 22 5.5 Formatting of tooling drawings ................................................................................................................. 23 5.6 Transmission of data and study files........................................................................................................ 23 6 List of documents cited .........................................................................................................23 Appendix 1: Preliminary range............................................................................................................24 Appendix 2: Reference process..........................................................................................................30

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Foreword On the date of issue of this document, there is no French, European or International standard covering the same purpose. The rules for writing documents defined in this standard allow reducing costs in:

anticipating on the deadline of delivery of foundries by distributing the “OK for modelling” preliminary studies,

unifying our requirement expressions in respect of our engineering offices in subcontracting, observing the procedure to apply for producing a preliminary project, formulating mandatory indications for full and accurate writing of a manufacturing sheet, listing the documents contained in the different files required for producing the studies.

1 General According to the computer resources or not used for drawing, the procedure and writing of documents must in no case contradict the present prescriptions. These prescriptions are identical for a complete contract. A Renault partner calling upon subcontracting is liable for taking any provision to ensure the subcontractor applies this standard.

2 Confidentiality During consultation, performed by Renault from the files: preliminary project, studies, as well as production of tooling, the supplier commits to ensure strict confidentiality of the information transmitted by Renault, more particularly, vehicle parts which must be hidden for non certified persons.

3 Procedure for producing a preliminary project Documents to be given to engineering offices for subcontracting studies for producing the formalised

preliminary range and preliminary projects at 1/10 scale in the A0 drawing format:

drawing of the part or parts, material, its protection, thickness, specification of the press.

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3.1 Content of the file for producing the preliminary project ( AVP ) The following information must be documented in the AVP:

number of blades and waste cutters, number and diameter of punches (in case of temporary part drawing these values can be

determined by experience), number and type of gas and air springs, material, treatment, and weight of cast or cut parts, definition of mechanical functions (suspended cam, back-ram, calibration zone, dropping,

rising, lifting, separators...), number and type of standard cam stations, parts passage tunnel upon loading and extraction.

3.2 Preliminary range An example of the preliminary range is supplied in appendix 1. Produced according to reference ranges (see appendix 2).

3.3 Modification of the reference file The reference file is made of the file for producing the preliminary project and consultation – production file. Any proposition of modification of the reference file upon the initiative:

of the supplier, must be notified in writing

and/or any other intervener,

Only modifications validated by the contract manager are taken into account by Renault. Any modification, likely to result in refitting the reference file, deadline, cost,... is subject to negotiation with Renault.

4 Procedure for producing a manufacturing sheet 4.1 Writing a manufacturing sheet 4.1.1 Administrative folio

folio #1, drawing format A0 This folio describes all operations performed on the panels in the production flow (i.e. transformation, handling,...) If A0 is not sufficient, a second A0 drawing must be inserted to finish the process description.

4.1.2 Technical folios drawing format A0, recommended for archiving needs. These folios describe the transformations undergone by the panel. The scale recommended is: 0.5 for MP (Medium Presses) and GP (Large Presses), 0.4 for TGP (Very Large Presses). Scale 1 can be used for parts including many details (example: door caisson medallion). If there are few details, use preferably magnifying glasses. The rule is: 1 folio per different balance (or more if the dimensions of the part are large). The manufacturing sheets must be written exclusively in the French language.

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4.2 Rules of representation and plotting of originals for proper legibility The line must be black colour. Shading is forbidden: frame technical information with a single or double outline or use hashing

(spacing will be 1 mm minimum). Prefer drawing lines in bold CAD. Added labels must be transparent. The texts must have a height of 2 mm minimum.

4.3 Administrative information (folio 1) The following information must be included in the title block. (see model page 8).

4.3.1 Title blocks Number of folios contained in the file. Metal shade and protection. Material thickness and its tolerance. Width of the reel according to standard with its tolerance. Step. Gross weight of the vehicle (density 7.85 for steel, and 2.7 for aluminium).

4.3.2 Manufacturing sheet numbers The folios representing the manufacturing sheets (FF) are identified by three mandatory identifiers:

The first two numeric characters are identical to part number 77 or 82. The third alphabetical character represents the plant The last 7 numeric characters are identical to the last 7 characters defining the part drawing:

Table 1: Plant codes according to EPM *

Manufacturing sheet # coding EPM code Manufacturing sheet # coding EPM code A: Cordoba 985 M Maubeuge 602 B: Bursa 966 N: NovoMesto 961 C: Curitiba 990 P: Palencia 760 D: Douai 190 R: Dacia 998 E: External 101 S: Sandouville 170 F: Flins 150 U: Luton 845 G: Gennevilliers 900 V: Valladolid 763 L: Le Mans 121

* Press and Material Commitment Example: For a reference part drawing: 7700123456 or 8200123456 The corresponding Manufacturing Sheets are identified as follows:

Flins 77F0123456 instead of 7700123456 82F0123456 instead of 8200123456

Valladolid 77V0123456 instead of 7700123456 82V0123456 instead of 8200123456

The number for Right and Left parts and the derivatives The FPA number (forecast automation sheet).

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4.3.3 Type of press

Abbreviations of presses to use: PROG Progressive

PT2M Transfer press, 2 movements

PT3M Transfer press, 3 movements

MP Medium press 250 t

GP Large press 400 t

GPR Large reinforced double effect press

GSE Large simple effect 1200 t

TGP Very large press 1000 t

TGPR Very large progressive

PTC Bodywork transfer press 5400 t

TGSE Very large simple effect 2000 t

PAL Long advance cutting press

PAC Short advance cutting press

PAVAR Front/back cutting press

4.3.4 Other zones Numeric folio number (3 characters). Numeric plant code (3 characters) to differentiate Process Tooling lining them. The length of the range and type (example: 1+4 TGP, 5 MP, 1+3 MP, 4 PTC, number 1 defined

in the double effect and number 4 the simple effect rework presses). Ratio (1G + 1D, 1 or 2). Designation of the unit belonging to the part (example: HOOD). Type of vehicle (example: BDL 64). Part name (example: HOOD PANEL). Part represented preferably in perspective. In the case of a son blank or daughter part, its name must be included in the title block. The bubbles are documented in each new mark.

4.3.5 Index evolution columns FF mark (modif index), numeric (3 characters).

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4.4 Description of title block (folio 1)

PLANT CODE Part represented:

Nr of blank(s)

PART (S):

VEHICLE:

UNIT:

PER LINE STROKE

TYPE OF PRESS

NUMBER OF PART(S)

RANGE:

Index:

Date of availability:

Partner:

Nr of part(s) manufactured

OBSERVATIONSDIVERSITY:

Cancelled marks:

List of cancelled folios:

Nr:NoYesPLANNED AUTOMATION SHEET

(plain text)APPROVALName of Process Pilot:

% ENGAGING (NON HOLED PARTS)

GROSS WEIGHT PER VEHICLE KG

NUMBER OF BLANK(S) IN A STROKE OF CUTTING PRESS

NUMBER OF PART(S) IN CUTTED BLANK

MARK

STEP

WIDTH

THICKNESSMATERIAL:

GRADE

PARTS:BLANKS:REELS:

Packaging code:Material code:

Comments:

Plant code

Plant code

Stamping tool linings

Cutting tool linings

This document is the property of RENAULT and may not be reproducedor disclosed to a third party without prior written authorisation.

MANUFACTURING SHEETDICAP _ Department 65307

PRESS AND TYPE OF CUTTING

Nr OF PARTS PER CUTTING:SPECIFY 1L + 1R OR 1 MOTHER PART + 1 DAUGHTER PARTETC.....

OPERATION OUT OF CUTTING

LIST TO SPECIFY WHETHER CANCELLATION OF FOLIOS

PROCESS PILOT

GROSS WEIGHT PER VEHICLE

WEIGHT OF PARTS ON VEHICLE

EXAMPLES:- PAL RECTANGLE- PAL TRAPEZOID

- PALISOCELES TRAPEZOID- PAL RECTANGLE TRAPEZOID- PAL PARALLELOGRAM- PAL RADIUS SHEAR

- PAL SPECIFIC EQUIPMENT- PAL SPECIFIC TOOL

- PAL POSITIVE EJECTION- ETC

USE THE CODING WRITTEN ON THE METAL SHEET REELS DELIVERED TO THE PLANT

WRITE THE NUMBERS OF MARKS ALLOCATING THE MATERIAL

UNIT NAME

EPM PLANT CODE

TOTAL NUMBER OF FOLIOS IN THE SHEET(INCLUDING CANCELLED FOLIOS WHICHMUST NOT BE DESTROYED)

MENTION THE SUCCESSIVE MARKS BY GREYING THE PREVIOUS

(index evolution column)

SHEET NUMBER = LEFT PART NUMBER IN WHICH THE 3rd CHARACTER IS REPLACED WITH THE LETTER REPRESENTING THE PLANT (see plant codes table according to EPM))

IN THE CASE OF 2 SYMMETRIC PARTS, THE PARTREPRESENTED IS USUALLY THE LEFT PARTIN ORDER TO PROCESS POSITIVE Y COORDINATES

SPECIFY THE NUMBER OF OTHERSHEETS TO BE CONSULTED IN THE OBSERVATIONS COLUMN

C) BUTT WELDED BLANKS, SPECIFY: NUMBERS OF BASIC BLANKS NUMBER OF BUTT WELDED BLANKS

B) BLANKS SUPPLIED TO MANUFACTURING

A) BLANKS RECEIVED FROM OTHER MANUFACTURING

FILL IN ONLY IN THE FOLLOWING CASES:

BY 2, THE INDEXES CAN BE DIFFERENT

IN CASE OF NON SYMMETRIC PARTS

IN THE OBSERVATION COLUMNINDICATE THE START-UPS FOR VEHICLE VERSIONSSPECIFIED IN THE SHEET (INCLUDING DAUGHTER PARTS),NUMBER OF PARTS PRODUCED USING THE TOOLS

OF THE DEFINITION FILE WITH: INDEX AND/OR DATENrOF PART DRAWING USED FOR PRODUCTION THE SHEET AND INDEX

DATE OF AVAILABILITYNAME OF THE PARTNER

TOTAL GROSS WEIGHT PER VEHICLE

OR MOTHER PART + DAUGHTER PART, ETC...Nr OF PARTS PER STROKE: SPECIFY 1L + 1R OR 2 IDENTICAL PARTS

E.G: 2 BLANKS /STROKE + COLLECTED BLANKNr BLANKS PER STROKE + SECONDARY BLANKS COLLECTED

IF BUTT WELDED BLANKS, CREARED COLUMNS

CORRESPONDING TO THE DIFFERENT BLANK ELEMENTS

NOMINAL WIDTH AND TOLERANCE

NOMINAL THICKNESS AND TOLERANCE

CONVEYOR ADVANCE STEP

RESERVED TO DIVD

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4.5 Table of modifications (folio 1) In the respective columns: operations, registrations, inventories are documented. The marks are alphabetical (numeric marks are incompatible with GDG archiving), do not use i,o,x to prevent confusion.

Des

ignation

Nam

eD

ate

Rea

son

Reg

istr

ation I

ND

EXES

Mark

sIN

VEN

TO

RY

REG

ISTRATIO

NS

OPERATIO

NS

MO

DIF

ICATIO

NS

Mark.

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4.6 Synoptic table of methods plan (folio 1) Use drawing 000018.dxf To fill in folio 1, consider the products at all stages of the production flows (see the example of synoptic sequencing of operations pages 12 and 13):

The sequence of operations is from bottom to top. The operations are described in the columns of the description with their functions. The representation of the part(s), according to the cases, must be included for each operation,

including idle stations. The plan view and cross-section are positioned according to the sequence of operations. The indication of the position of digitised products in respect of the facility’s axes:

(the blanks and parts must be digitised in CATIA or AUTOCAD ) blanks / axes of cutting presses, blanks / axes of the blanks stacking palette before and after butt welding, blanks / axes of the palette of blanks to boss, blanks / axes of the pressing press, blanks / axes of rework presses, parts / axes of last press, parts at entrance of containerising door in respect of conveyor or verticaliser, parts / axes of the container, parts / axes of path in panel work.

The flows converging to butt welding from conveyor setting (1 stroke / 1 blank, 1 stroke/several blanks) are mentioned in the description column.

The balance is indicated and dimensioned at each operation with its rotation point. The collectable son blanks or daughter parts are represented in the mother part. The press front is indicated according to the automation and containerising sections. In certain

cases (lateral flaps), specification is made of the reversion of the press front to avoid changing the automation (symmetrical parts).

The automation is symbolised at each operation according to table 2 (see page 11). Marking of traceability (ink or mechanical) is indicated opposite the operation chosen, and its

location is specified on the part. Packaging (palette, container, MTM, bin, etc.) must be mentioned opposite the operations

concerned. A palette can receive several stacks of identical blanks, the outgoing flows are indicated (parts by 2, daughter parts, etc.).

For specific palettes or containers, their capacities (number of parts) and storage direction is noted.

If one or several tools are added in the range of tooling after distributing the sheets, the latter(s) is (are) registered and coded 15, 25, 35, etc.

The date and # of the containerising sheet supplied by the logistics manager of department 65320 must be mentioned opposite the containerising operation.

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Table 2: Representation of symbols for automation

4.7 Sheet #1 standard of manufacturing sheets describing the flow To allow GDG archiving, the A0 format must be applied. In order to do this, the presentation is as follows:

Folio AO allowing to include to the same drawing the description of the process and history of modifications, completed, for example in the case of butt welded blanks, with a second folio describing the operations of the flow beyond 6 operations.

The holes for suspension conveyors are no longer necessary due to archiving under GDG. To have a .dxf file of these 2 A0, refer to the master drawings GE24-017R. The equivalent folios in the native CATIA format are being produced.

The following 3 pages presents an example of sheet produced under CATIA and an example produced under AUTOCAD.

NAVETTE EXTRACT-VENTOUSES CHARG-VENTOUSES ROBOT MAIN DE FER

EXTRACTION PAR PARALLELOGRAMME

EVACUATION PAR GRAVITE TAPIS

EXTRACTION COUP DE POING RETOURNEMENT

OP-MANUELLE HORIZONTALE

OP-MANUELLE VERTICALE

DESEMPILEUR CHARGEUR A VENTOUSES

DESEMPILEUR CHARGEUR A PINCES

DESEMPILEUR ROBOT

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4.8 Diagram with an example of synoptic sequence of operations (folio 1) (Flow start part)

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Diagram with an example of synoptic sequence of operations (folio 1 cont’d) (End of flow)

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Diagram with an example of synoptic sequence of operations (folio 1 cont’d) (End of flow)

Case of sheet formalised under AUTOCAD

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Edge dropping or edge return line

Outline sketch of a calibration zone

Edge flanging line

Cross-section of a punch

Cross-section of a trimming line

Outline sketch of a trimming or slotting line at op 30

Outline sketch of a trimming or slotting line at op 20

Die entrance line EM

4.9 Technical folios (folios 2, 3, 4... ) 4.9.1 General

It is always the left part which is represented, otherwise specify this in the title block of folio 1. The maximum format must be 840 mm wide. The representation of the part must be checked (part upside down). The plotting of the lines, different operations, is performed according to table 3 below.

Table 3: Distinctive signs of representation of different operations

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Operation numbering is performed according to table 4 below.

Table 4: Operation numbering

Operation numbering Designation of tools or operations 01, 02, 03 blank cutting

04 blank flipping 06 butt welding 08 blank reconditioning 10 pressing or forming

16, 17, 18 swivel or flipper 26, 27, 28, etc. idle station

20, 30, 40, 50, 60 rework tool 70, 71, 72 etc. storage in specific container 15, 25, 35, etc. additional rework tool 80, 85, 90, 95 crimping

The operations required upon fitting are indicated:

what is done is listed beside each operation, upon the pressing operation, the following is indicated:

whether there is digitising of the blank holder surface or full digitising, whether there is a series process test prototype tool, whether there is an "approached simulation" calculation, whether there is a "full simulation" calculation, whether there is a lancing.

The indication of strike indicators must be included for:

pressing operations, calibration operations, cam returns.

The indication of the load must be included for:

cutting and punching loads in cutting operations, pressing load under plunger (or punch) and under blank holder for Simple Effect, Double

Effect, and Stretch Draw tools. The following is indicated beside each operation:

tool registration numbers, type of press (start or backup press), workshop number for blank cutting, workshop number for rework.

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A conveyor start diagram is drawn upon operation 01 or (02, 03) by specifying:

the conveyor start step, the width of the reel with the tolerance, the displacement direction. the indications of the following operations concerning the folio are visible in the bottom right

corner after folding the drawing, all sections are represented in the previous operation, the scale between the views and cross-sections must match, a folio is produced on a small scale representing the full part with marking of the detailed folios, if the folio is drawn in scale 1, studies are provided with lines in reduced scale according to

their request (lines non included in the set), changes in balancing upon each operation must be avoided, blank and part centring is indicated in each operation, the diameters of the punches must be standardised (see Renault standard EM24.53.100), the bubbles in the folios, concerned by a modification, are documented.

4.9.2 Blank cutting Check whether:

the capacity is consistent with conveyor laying, the forward direction corresponding to the type of press (see Renault standard EM24.03.200), the recovery of the blank at outlet of the press is free, the position of the lateral blank matches automatic collection, the position of the secondary blank is correct (specific tool), search for single blanks is possible (rectangle, trapezoid, parallelogram, curve), the specific folios are avoided (use of the space available in the rework folios), for specific cuttings, the theoretical conveyor laying is dimensioned.

Indicate: the width of the standard conveyor with its tolerance, the step, the forward direction, the standard shear cutting (see Renault guide GE24-050R), the collection of secondary blanks, the special guidelines on cutting straightness in the case of butt welded blanks, the cutting press axes, the position of the blanks in respect of stacking palette axes.

4.9.3 Destacking The blanks must be digitised and dimensioned in respect of the axes of the OP.10 pressing press, as well as in respect of the blanks palette.

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4.9.4 Stamping On figurines representing the part, the following is requested:

sequence the different balances, mark the rotation axes or rotation point, dimension the balance angles (+ or -) and sequence of these balances, represent the part in the pressing balance, on symmetrical parts or similar indicate the same starts. mark the pressing horizontal, indicate the starts in drawing in respect of car coordinates for parts by 2, mention over curving to fit on the pressing punch in the case of certain parts with little curves.

4.9.5 Punch cladding Indicate:

the quotation of the punch radius(es), the quotation of die entrance radius(es), the draft angle of the die wall, the die entrance line (EM) highlighted (see page 15), the full die entrance line (with closing of the pressing for open pressing), the trimming lines according to the operation (see page 15), the distortions or folds to rework.

4.9.6 Definition of the blank holder surface The blank holder surface is defined systematically in CAD. Cross-sections must be produced every 100 mm, and folded in the drawing view. The main sections are fitted (part, cladding, blank holder). The blank is drawn before pressing, pushed on the blank holder surface as well as the

embedded blank. The blank holder span must be limited. The position of the strike marks is indicated on the finished part. The position of the reference holes ∅ 6 H7 must be defined. A coordinates table is created at each balance for reference holes. The pressing direction is indicated by an arrow. To facilitate reading the manufacturing sheet, the part lines are drawn (same marking as the

part drawing), as well as the balance lines. Note to be included for parts not requiring lateral retaining:

open pressing test to be performed upon tooling development. in the case of a local presser, indicate its location. indicate the retainers, pins, steps.

4.9.7 Trimming - Punching The part is drawn in the trimming balance. The rotation axis or rotation point is marked. Trimming horizontal is marked. Slots and punching must be hashed on the verso of the drawing.

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Mark: final trimming on the drawing verso, preliminary trimming on the drawing verso, trimmings (e.g. preliminary trimming OP 20 ), punching (e.g. punching 1 hole TO ∅ 8.2), part lines (same marking as in the part drawing).

Indicate: the position of holes ∅ 6 H7 or ∅ 8.2 reference, trimming direction with an arrow, position of scrap cutters, as approved with tooling studies.

The part is represented as it arrives from the previous operation to ensure scrap evacuation.

4.9.8 Calibration – Dropping - Rising The multifunction tools are privileged to reduce the length of ranges. The spring effect must be evaluated, compensated, and indicated on the folio. The part is drawn in the calibration balance. The rotation axis is marked. Calibration horizontal is marked. Zones to calibrate are defined. The position of the reference holes ∅ 8.2 or with flanges ∅ 12.2 must be indicated. The calibration direction is indicated by an arrow. The part lines are drawn (same marking as in the part drawing). The positions of the punching marks, mark for fraud, traceability, must be defined and indicated

on the part. Compensation for flange drop, crimped edges, must be sized (use a magnifying glass showing

this detail). The dropping balance agrees with that for crimping. The adhesive label to mark offset tolerances must be used.

4.9.9 Cam tool The part is drawn in the cam operation balance. The rotation axis is marked. The horizontal to the cam operation is marked. The references of each cam station are marked. The limit of cam rework is indicated and defined. The orientation in respect of the operation’s baseline must be indicated for:

the cam in plan view, the cam follower in plan view.

Slope in respect of horizontal of the operation must be dimensioned for: the cam, the cam follower.

The views are drawn according to the cam for the tooling studies (lines not included in the set). The vertical direction is indicated by an arrow. The parting lines are drawn (same marking as in the part drawing). The position of the strike marks is indicated (on the calibration cam).

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4.9.10 Position of products at end of press line Indicate the position in respect of conveyor axes or in respect of verticaliser axes.

4.9.11 Position of products in the containers To refer to the blank packaging sheet.

4.9.12 Position of products upon decanting in panel shop Correct if required the spring effect on the cam and cam follower. Compensation for flange drop, crimped edges, must be sized (use a magnifying glass showing

this detail). Cam trimming scraps are drawn with representation of the part at previous operation.

4.9.13 Crimping The crimping operations on the skin parts must be documented. The different crimping stages with dropping compensation are drawn in scale 5. The crimping operation balance must be specified. For a mono part, the balance must be identical to the balance for crimped edge. A specific folio with the different components in the crimped unit must be plotted. This folio

must contain: main sections, the value of the angle between the flanged edge and the surface part, whether fixed or

evolutive. Example: Evolutive angle 95° to 105° from point A to point B

The edge heights are dimensioned (see Renault standard EM24.02.100). Any over curving must be studied individually.

4.9.14 Progressive tool The title block specifies the step, number of parts in the step, gross weight of a part. The position of the fitted face is specified. The choice of press retained. The operating differences in conveyor laying are drawn and the loads upon each station are

documented. The start conveyor is indicated. The position of crimped nuts, when the part is fitted, must be included to conveyor laying. The location of traceability as well as the strike mark must be materialised. The direction for part evacuation as well as scrap are not specified. The conveyor advance checking position is marked. The conveyor scrolling kinematics is drawn.

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4.10 Modification of the manufacturing sheet General

The label of modifications is condensed at maximum in administrative folio 1, by indicating the operations concerned.

The modifications are grouped, whenever possible, under a same marker to restrict distributions.

The modification is marked with an alphabetical index. For part modifications (engineering office), index taking is marked with a letter of the alphabet

A, B, C, etc. The letters I, O are forbidden to prevent confusion with l in lower case and zero, as well as X, incompatible with archiving in GDG.

For tooling modifications which do not impact the product definition (Process, Development or tooling reliabilisation), index taking is marked with letters of the alphabet followed with the X in order to differentiate the modifications for products AX, BX, CX, etc. In archiving under GDG, the modifications for X are classified "MODIF-PROCESS". The letters IX, OX and XX are forbidden.

Indicate the following names in the title block: the pilot, subcontractor and firm, as well as the creation date.

Modification by the partner It is not necessary for partners to take indexes on the registrations of tooling before RO

(Réalisation d’Outillage). However, they can mark events before RO in order to memorise the history of tooling and mark them using digits.

Modification outside partner Several cases can occur:

when studies are not delivered, there is no taking of modification index on tooling inventories. however, it does mention Studies drawn compliant,

when the studies are delivered, but foundries are not launched, a modification index must be taken on tooling inventories. It indicates Studies to modify, tools produced compliant,

when tools are being manufactured (foundry, machining), a modification index must be applied to the inventories. It indicates Studies and tools to modify.

4.11 Formatting the document CATIA CAD computer files, to be taken in the Renault guide GE24-017R "manufacturing sheets" which contains:

Folio 1 start (modifications + 6 operations) Folio1 cont’d (operations according to 6th operation in flow) Technical folios

4.12 Data transmission For data transmission, see Renault standard EM24.01.375 Procedure for producing a tooling study.

5 Procedure for producing a tooling study 5.1 Allocation of studies

List of documents to be supplied to engineering offices by Dept 65307 for preparing their price quote:

manufacturing preliminary sheet or formalised preliminary range, the copy of the price quote to be completed by the supplier, the end study deadline.

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After signing it, the supplier gives his price quote mentioning the number of hours of the study (AMDEC included). Work initiation is officialised by co-signature, on the price quote, by the study manager and study piloting manager. One copy is then given to the supplier.

List of documents to be supplied to engineering offices by Dept 65307 before the initiating the study:

manufacturing preliminary sheet, part drawing, technical sheets for the presses concerned, drawings of loading and extraction arms in scale: 1/2 or 2/5, frame drawings and master drawings (if they exist).

List of documents to be supplied to engineering offices by Dept 65307 during the study: manufacturing sheet (except in case of a Manufacturing sheet + Studies contract).

5.2 Contents of the study file List of elements supplied by Dept 65307:

part drawing, manufacturing sheet.

List of supplier documents supplied to Dept 65307 during distribution at initial index "_ _ _":

tool drawings, in the A0 computer format (see Renault standard EM24.02.030), line of the kinematics for loading and extraction arms, assembly FOP (see Renault standard EM24.02.032), nomenclatures, study checking reports, AMDEC reports (see Renault standard EM24.01.340), process approval (see Renault standard EM24.01.200). automation forecast sheet (see Renault standard EM24.02.040), maintenance program (with frequencies), spare parts list, particular fitting – removal instructions of complex elements.

5.3 Contents of the study file valid for modelling (non archived in GDG)

Tooling plans with machining quotation. Nomenclatures of the foundry parts specifying the materials, treatment, and weight calculated. Index "_"

5.4 Contents of the study file for consultation and construction Non sized studies. Nomenclatures of foundry parts.

EM24.01.250 /F


5.5 Formatting of tooling drawings The studies are plotted in CAD. If modifications are made manually, they are included in A0 format tear-proof overlays (use the *. dxf model number E15900004). DRAWING-A0-TOOL-BLANK. Folio 1 "general information" (000017.dxf) is part of study drawings.

5.6 Transmission of data and study files For data transmission, see the Renault standard EM24.01.375.

6 List of documents cited NOTE: For non dated documents, use the latest applicable version. EM24.01.200 : Process approval for press tooling EM24.01.340 : Choice of subjects to address in "facility" AMDEC of pressing tools EM24.01.375 : Transmission of digital process data for pressing EM24.02.030 : Press tooling. Technical drawing, main presentation principles EM24.02.032 : Implementing pressing tools under presses EM24.02.040 : Press equipment. Automation study rules in pressing EM24.02.100 : Press tooling. Crimping. Choice of the process and edge geometry EM24.03.200 : Technical sheets. Cutting and feed presses EM24.53.100 : Press tooling – Punch holder – Punches – Strippers – Shapes and dimensions GE24-017R : Press tooling. Miscellaneous master drawings GE24-050R : Press tooling. Blank cutting tools 01-50-000 : Footprint required for fitting crimping nuts

EM24.01.250 /F Annexe 1 informative

© RENAULT 2003 Origin: PEGI -Renault Page: 24 / 33

Appendix 1: Preliminary range (example sheet)

Note: The doc file used to document the information related with this appendix is available in the standards management computer bases.

SHEET DEPARTMENT PRELIMINARY RANGE PRESSING METHODS 1 / 8

RENAULT «65307»

VEHICLE PART DESIGNATION #: Ind.: DATE NOM B-C-E-K-L INF. WORK. BAY LOW PART 8200009970 V1-3.

. 23/04/99 84 HEATING PARTITION 8200009974 V5-2

MATERIAL GRADE: G 10/10 XES Blank weight: 8.966 Kg Material engagement: THICKNESS (0.92) & (0.72) Part weight: 4.209 Kg 46,94 %

OP DESIGNATION OF THE OPERATION LOADS Type of tool

Manuf press

Cutting 1 + conveyor laying (folio 2) Grade: G 10/10 XES

STAND

01 1 str = 1 blank Thickness: 0,92 520 kN R-2500 PAL (WORK LOW.BAY) Dimensions: 1640 x 360

Cutting 1 + conveyor laying (folio 2) Grade: G 10/10 XES

02 1 str = 1 blank Thickness: 0,72 385 kN STAND PAL (CLOISON CHAUF.) Dimensions: 1460 x 570

Flipping blank stacks 04 Flipped blank =

Reconditioning blank stacks 08 Reconditioned blank =

Butt welding 06

Punch

10 S./E. PRESSING 2,107 kN GP GSE Blank

holder 12000 kN

Balance: 7° in Y, ref. point 200.0,700 (folio 3) 2,111 kN

20 TRIMMING - 10 PUNCHES TO BE INCLUDED CAM SLOTTING 1,738 kN GP GP (HEATING PARTITION) Balance: Vehicle position (WORK LOW.BAY) Balance: Position OP.10 (folio 4)

30 TRIMMING – CAM TRIMMING 930 kN GP GP

PUNCHING (10 PUNCHES TO BE INCLUDED) 4000 kN Balance: Position OP.20 (folio 5)

40 CONFORMANCE CALIBRATION 1,136 kN GP GP DROPPING - LIFTING 4000 kN CAM EDGE RETURN – CAM EDGE DROPPING Balance: Position OP.20 (folio 6)

AUXILIARY DOCUMENT: Product modification request (folio 7 and 8)

85 Crimping



1 OP.01 – Blank cutting

Constraints: (LOW.BAY.CROSS.) If R 2000 instead of 2500, material is gained, but a cutting tool must be built (PAL)

Scale 1:10STRIP WIDTH 1640

STR

IP A

XIS

STRIP WIDTH 1460

STEP

360

OP.01 BLANK CUTTING

STE

P 57

0

STR

IP A

XIS

LOW.BAY.CROSS.LOW.PART 8200009970

HEATING PANEL 8200009974

EM24.01.250 F Annexe 1 informative


2 Balance for OP.10

BALANCE FOR OP.10

PRESSING S./E.

This provision allows fitting in D./E. but by flipping the tool.

LOW.BAY.CROSS.LOW.PART 8200009970HEATING PANEL 8200009974

PRES

S AX

IS

CROSS-SECTION PRESS FRONT

Scale 1:10

Possibility material economyStep reduction with specific R



3 Balance for OP.20

Intersection x 200

Constraints: (Heating Panel)

Part balance: Drop by gravityLOW.BAY.CROSS.LOW.PART 8200009970

HEATING PANEL 8200009974Trimming

TrimmingTrimmingTOOL AND PRESS AXIS

Cam

Slot

Scale 1:10

CROSS-SECTION Y 0

FRONT OF PRESS

Trimming

BALANCE FOR OP.20

GENERAL TRIMMING – PUNCH. CAM SLOTTING

Pres

sax

is



4 Balance for OP.30



Trimming

Trimming

TOOL AND PRESS AXIS

Cam

2

Trim

min

g

Scale 1:10

CROSS-SECTION Y 500 FRONT OF PRESS BALANCE FOR OP.30

GENERAL TRIMMING – PUNCH. CAM SLOTTING

Trimming

Cam

2

Trim

min

g

Pres

sax

is



5 Balance for OP.40



Loads: (HEATING PANEL)

Direct flange dropping (no cam) if modif.acceptance (see folio 7 request)

CAMCou

nter

-cam Edge calibration

Edge rising Edge risingTOOL AND PRESS AXIS

PRES

S AX

IS

2 C

AM

Edge return

PRESS FRONTScale 1:10

CROSS-SECTION Y 690CAM

1-2

Edge rising Edge risingEdge dropping

Edge dropping

Intersection x 200

Edge calibration

Edge dropping

CA

M -2

edge

retu

rn

CAM

-1ed

gere

turn

GENERAL CALIBRATIONDROPPING – EDGE RISINGCAM EDGE RETURNCAM FLANGE DROPPING

BALANCE FOR OP.40


© RENAULT 2003 Origin: PEGI -Renault Page: 30 / 33

Appendix 2: Reference process

Pressing ranges technical policy

1 POI range length

TGSE PT 5400T

Technical policy: 4 OP MAX. If 5 OP are required, POI allocation if plant with a line with 5 presses or one PT 5400 T. Backup must be planned in POE or in another site. Restrict to a single range in 5 OP per project.

GP/GPR GSE

Technical policy: 4 OP MAX. Backup of the GSE in TGSE, if 5 OP are required, possibility of allocation in POI. For 6 OP, POI allocation, if the plant is fitted with a line including 6 presses. Backup must then be planned in another site or POE.

MP Technical policy: 4 OP MAX. If 5 or 6 OP, possibility of allocation in POI. Backup to be studied in GP.

Other TGPR, PT3M machines Compliance of the number of stations of the press.

2 Number of parts per stroke

All symmetrical parts except on the body side in TGSE or GP or GSE

Association of 1L+1R by loading a single blank: if material gain is demonstrated and if allowed by dimensions and tonnage of the press line. Please note that the production of L parts without R parts is not feasible, and leads to scrapping the excess in case of unbalanced requests. Loading 2 blanks in the same tool is forbidden if press lines are non fitted. In the application cases, compliance of characteristics of destackers (layout and min and max dimensions of the blanks on production press and backup press). Part production per unit, by cutting suction cup suction on one side to meet an unbalanced request, must be planned provided a false part is left in the tools to prevent unbalance. The production of different parts in TGSE in the same blank is too complex to master and must be excluded. The production of identical parts must be avoided as the 2 parts produced are never exactly identical and the working parts are launched in double. To be reserved in case of major material gain

Body side butt welded or not By 1 in TGSE

Insertion of a daughter part or son blank with same shade and thickness as he mother part in GP, GSE, TGSE

To be planned if: a) the consumption quantities for the daughter part or son blank are less or equal to

the mother part, to prevent restocking, b) Packaging of the mother parts is possible at end of line without disturbing

packaging of the mother part, c) The son blank can be stacked on the cutting line

TGPR 1, or 1L + 1R, according to blank nesting, while remaining compatible with the evacuation conveyors. 2 identical parts or 2L + 2R to be prevented unless very high material gain.



3 PROFIL crimped nuts Type RND M6 to M12 and PROFIL crimped screws Type SBF or EBF Removal with pre-punching and lubricating nuts with oil FINA 5746 or QUAKER 6130

Feasibility study on presses

Feasibility must be checked by department 65307 (see standard 01-50-000 "Footprint required for fitting nuts to be crimped upon pressing"). Fitting is performed with standard head. Removing the screws requires a particular study, notably the risk of damaging screws upon handling. Profitability of a specific tool performing only removal of screws or nuts must be proven.

The possibility of the capacity must be checked according to the type of press: See table below

MP/ GP / GPR / GSE/ PT 3M PROGRESSIVE TOOL / TGPR

Removal and crimping of screws and nuts possible

TGSE / PT 5400T No crimping of screws and nuts

(Economic risk) TGSE fitted for GSE backup only

Profitability of the investment (heads, sheaths, tooling, distributor, press modification) is studied in respect of the assembly implementation solution.

If the application is not feasible or not profitable on presses, removal is performed upon assembly (Hydraulic fitting, usually without valve: fitting nuts or screws manually upon assembly).

Fitting and starting applications Financing to be planned by the project:

1) Valves and sheaths: Orders, reception, start up by standardisation sector pressing department 65307.

2) Heads and implantation of heads and dies in the tooling: Order, implementation and adjustment by the partner (piloting by project).

3) Fitting of spare parts for head bodies, spare dies in first fitting: Order, implementation and delivery by the partner (piloting by project).

4) Additional equipment of the presses (modification of the software and connectors with valve): Orders from automation sector by standardisation sector pressing department 65307.



4 Main reference ranges for aspect parts and their lining

Source Nr parts

Type of press

DE SE By Nr tools Observations

Mono body side (laser butt welding multi thickness) son blank on cutting = FR damper cup skirt

B65 J64 BK 74 BC84 J84

2 TGSE 0 4 1 8 No fitting holes for double sealing with cam. Depth of roof link body side max. 16 mm

Lateral panel lining single part B or L B64 2 TGSE 0 4 1 8 Lateral panel lining single part D or C D64 X06 TGSE 0 4 2 Inside wheel housing RR B64 2 GP 1 3 2 4 Roof with built-in gutter B64 B84 1 GP, GSE 0 4 1 4 No OP30 moving cam follower Front fender without cheek (basic solution in plastic) F76 2 TGSE 0 5 2 5 If return to target panel 1+4 by 2 in GP FR foot lining B65 2 GP 1 3 2 4 Doors (semi-autoclave pressing frame) Doors (without frame)

B65 (AVAR)B74(AV)

B84

4

4

TGSE

GSE

0

0

4

3

2

2

8 6

Target 0+3 by cutting the panel in a single operation

L+R FR and RR door caisson Flap butt welding

F76 BC84

B74 and K25

4 TGSE 0

4 2 8 No cam punching for contamination gasket. Trimming and calibration at OP30. Depth 140 mm max. to reduce to 125

Hood Hood lining

F76 J84phase 2

1 1

TGSE 0 4 1 4 Monolithic tool

Boot (single part) B65 1 GSE 0 4 1 4 Boot lining (single part) B65 1 GPR 1 3 1 4 Central floor: Tunnel with stringers B74 1 GSE 0 3 1 3 Open blank pressing with central presser Lateral part of FR floor B74 2 GP 1 3 2 4 RR floor with spare wheel housing B65 1 TGSE 0 4 1 4 31 78

Number of tools per part (O/P) on perimeter above = 78 tools / 31 parts = 2.52

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