The route sheet (Figure 1.21) is designed to suit the requirements of the individual plant and, therefore, the information route sheets contain will vary. However, the following elements are usually included:
1.The heading. This is located at the top of the sheet and contains information such as:
•Part name
•Part number
•Drawing number
•Number of parts required
•Name of product engineer
•Date
In addition, the product name and model number may be included.
2.The number of each operation required to make and inspect the part. Numbers are most frequently listed in increments of 5, such as 5, 10, 15, 20, etc., to provide numbers in sequence for additional operations which may be found necessary in manufacture or when changes are made in the design of the product.
3.The name of each operation.
4.The name and number of the machine on which the operation is to be performed.
5.Estimates of the number of parts that will be completed per hour for every operation. These estimates are altered after production rates have been measured accurately by the time study department. Route sheets are supplied to the following departments:
•Tool design department
•Production department
•Inspection department
Of course, any machine or product will contain many components, which have been standardized and which can be purchased from outside suppliers or vendors. Such items would include screws and dowels, bearings, clutches, motors, and many others. The purchasing department would be supplied with a bill of material, and purchase orders would be issued for all parts to be bought.
Figure 1.21 A typical route sheet.
Figure 1.22 A typical tool operation sheet.
b) Tool Operation Sheet
The tool operation sheet (Figure 1.22) is prepared from the route sheet and it usually lists the following:
•Number of each operation
•Name of each operation
•Machine data
•List of all standard and special tools required for the job
•Names and numbers of all special tools that are to be designed and built. These numbers are marked on tool drawings and later stamped or marked on the actual tools for identification.
Tool operations sheets are helpful in planning and developing a tooling program. Copies go to the tool designers and to the tool purchasing department. Before proceeding further, study carefully the tool operation sheet illustrated.
c) Design Order
The design order (Figure 1.23) authorizes work on an actual design. An order is prepared for each die or special tool required and the information is taken from the route sheet. In addition, the design order may give instructions regarding the type of die preferred. The following lists the information usually given on a design order:
Figure 1.23 A typical design order.
•Department name
•Tool name
•Date
•Tool number
•Part name
•Part number
•Operation
•Machine in which tool is to be used.
1.3.3 Designing the Die
Before designers begin to draw, they must seriously consider a number of things. It is now possible for them to list all the items that will be required so they can begin designing intelligently. These items are:
•The part print
•The tool operation sheet, or route sheet
•The design order
•A press data sheet.
In addition, designers may have either a reference drawing of a die similar to the one they are designing or a sketch of the proposed design prepared by the chief tool designer or group leader suggesting a possible approach to solving the problem. Let us consider further the information required:
Part print. The part drawing gives all necessary dimensions and notes. Any missing dimension must be obtained from the product design department before work can proceed.
Operation sheet. The operation sheet or route sheet must be studied to determine exactly what operations were previously performed upon the workpiece. This item is very important. When the views of the stamping are laid out, any cuts that were applied in a previous operation must be shown.
Design order. This item must be studied very carefully because it specifies the type of die to be designed. Consider particularly the operation to be performed, the press in which the die is to be installed, and the number of parts expected to be stamped by the die. The latter will establish the class of die to be designed.
Press (machine) data sheet. The die to be designed must fit into a particular press and it is important to know what space is available to receive it and what interferences may be present.
In time you will come to realize the importance of careful and repeated study of the part print, operation sheet, and design order because there can be no deviation from the specifications given.
a) Die Drawing
If the information on a drawing is complete, concise, and presented in the simplest possible manner, the die maker can work to best advantage. The first step in originating plans for a new die is to prepare a sketch or sketches of significant features of the proposed die. These are a guide for beginning the actual drawing of the full-size layout. However, it is a mistake to spend too much time in this phase of the work or to try to develop the entire design in sketch form because doing so can result in arbitrary and inflexible decisions.
Always keep your mind open to possible improvements as you develop the design in layout form. You will often find that the first or second idea sketched out can be considerably improved by alteration as work progresses. Often the first idea
