Volkswagen Quality Requirements

Supplier Information for Graining

Produkttechnik Aufbau/Ausstattung Graining Team

GQE-K/ 3 Version 1/2011
 Volkswagen Requirements for Graining
 Graining realisation only by Volkswagen approved and for each part identified grain source.
 Enough draft angle for 100% graining depth  see graining specifications
 In case of core shrinkage x 3
 Critical areas to be identified and discussed with VW
 Tool offsets for graining metal removal to be considered due to tight gap conditions
 Accessibility of all grain areas
 No grain free areas allowed on parting lines inside graining area
 Core side areas to be prepared with inserts
 Inserts and sliders to be fixed and grained in position
 Eliminate mold mismatch and flash prior to graining
 Same certified steel quality for etching in all grained tool components
e.g. 1.2738 / P20
 Achieve polish requirements on steel surfaces prior to graining
 Weld only according to recommended procedures
 Achieve defined gloss level on part.
 Read and understand the „Supplier Information“ and forward to toolmaker

Produkttechnik Aufbau/Ausstattung Graining Team

GQE-K/ 3 Version 1/2011
Graining Specifications
Total material Consider
Graining removal Draft angle grain Tool offset
VW - No. depth in mm in mm in ° Design- Character direction required

K2G 0,100 0,16 6 Multilayer Yes Yes

K2K 0,130 0,18 7 Multilayer Yes Yes

K3A 0,120 0,20-0,25 6 Multilayer Yes Yes

K3D 0,110 0,14 6 Print/ Expose Yes Yes

K8A 0,110 0,15-0,20 7 Multilayer Yes Yes

K9A 0,100 0,15 6 Multilayer Yes Yes

K11 0,050 0,05 3 Single Yes No

K24 0,045 - min. 3,5 EDM No -

K26 0,110 - min. 6,5 EDM No -

The metal removal increases the wall thickness of
the plastic part (see sketch). K29 0,010 0,025 1 Stipple No No

To achieve dimensional accuracy the supplier has K31 0,027 0,06 2 Stipple No No
to consider a tool offset accordingly. K36 0,160 0,25 8 Multilayer Yes Yes

K41 0,050 0,1 3 Multiple No Yes

Please note:
The standard draft angle specification does not K50 0,030 0,05 3 Single No No

include variations in molding parameters and shrink K56 0,300 0,3 13 Print/ Expose Yes Yes
on conditions. K63 0,100 0,1 6 Multiple Yes Yes

K64 0,130 0,25 7 Multilayer Yes Yes

In conditions of shrinkage onto the grained surface
K77 0,050 0,07 3 Single No No
(for example: upstands in steel) the necessary draft
angle can increase by a factor of three! K85 0,085 0,15 4,5 Multiple No Yes

K97 0,260 0,3 13 Print/ Expose Yes Yes

K98 0,140 0,18 7 Print/ Expose Yes Yes

Produkttechnik Aufbau/Ausstattung Graining Team

GQE-K/ 3 Version 1/2011
EDM References

K29/K31
Certain parts may need a spark erosion finish instead of chemical etching,
e.g. due to feasibility or accessibility reasons

The references are defined as following:

K29  VDI 3400 Ref. 24

K31  VDI 3400 Ref. 33

EDM or spark erosion finished surfaces in visible areas are only allowed in
certain cases and have to be confirmed by VW Design prior to processing.

Gloss level on part see spec.

Produkttechnik Aufbau/Ausstattung Graining Team

GQE-K/ 3 Version 1/2011
Polish Requirements

• The surface must be polished 320-400 grit finish (no scratches).

• EDM spark scale, machine lines, etc. must be removed by polishing

prior to etching.

• Molding issues like mismatch, flash etc. must be solved prior to etching.

• Take care of feature lines and design contours while polishing.

• Prepare a polished reference area (see next page).

Produkttechnik Aufbau/Ausstattung Graining Team

GQE-K/ 3 Version 1/2011
Reference Area:

The reference area will be grained in parallel with the cavity surface to be able
to measure graining depth and gloss level during the process without touching
and damaging the cavity surface.
The reference area has to be prepared and polished prior to delivery of the
tool.

Position should be on tool insert, outside parting line,

on a flat and easily accessible surface.

Size min. 50 x 50 mm
polished in parallel with the cavity surface

Produkttechnik Aufbau/Ausstattung Graining Team

GQE-K/ 3 Version 1/2011
Parting Line Conditions for Graining without witness lines:

• Inserts should be prepared by the toolmaker to enable printing and etching

in molding position. The shut off surfaces will be protected by acid
resist to prevent from damage due to acid ingress.

• The perfect matching of the parting line pre etch (no flash, no mismatch
etc.) is a basic requirement for a good post etch result.

• All cavity areas to be grained have to be visible and accessible even after
fixing of the inserts to enable printing, retouch and etching.

• Avoid knife edged parting line conditions to prevent damage from metal
removal during the etching process.

• Location of all parting and split lines must be pre-approved by VW

Produkttechnik Aufbau/Ausstattung Graining Team

GQE-K/ 3 Version 1/2011
The possibility of printing and etching in position:
Parting lines within graining areas

Core

Insert

Cavity

Produkttechnik Aufbau/Ausstattung Graining Team

GQE-K/ 3 Version 1/2011
Welds:

• Where necessary, welds must be undertaken by a professional, who

understands the requirements for chemical etching e.g. welding rod
specification, heat treatment etc.
Contact texture source for specific requirements.

• All welds must be pre- approved by VW tooling engineer.

• Areas being welded must be marked-up on the official pre grain sample.

Produkttechnik Aufbau/Ausstattung Graining Team

GQE-K/ 3 Version 1/2011
Cavity shut offs:

• All cavity shut offs must be scribed prior to delivery to the texture source.

• Scribes must be done either with CNC or in a spotting press.

DO NOT USE PARTS!!!

• Parting lines adjacent to limited draft surfaces may require a larger ungrained
area, to avoid undercut condition created by metal removal.
If necessary, to allow ejection without scuffing the ungrained area may
need to be polished by the toolmaker to reduce the sharpness.

• Details to be specified by VW tooling engineer.

Produkttechnik Aufbau/Ausstattung Graining Team

GQE-K/ 3 Version 1/2011
Grain Depth Graduation

• Only Volkswagen determines the graining depth to be realised in the tool.

• Graduation of grain depth will be marked up on the last off samples by

VW Graining Team.

• It is not possible to predict the feasibility of ejection due to many variable

factors e.g. moulding parameters, shrinkage, critical draft angles…

• Despite decreasing grain depth, problems of ejection and scuffing may still
occur, requiring additional rework by tool shop and/or grainer.

Produkttechnik Aufbau/Ausstattung Graining Team

GQE-K/ 3 Version 1/2011
Mating Parts

• Matching of neighbouring parts will be determined by VW on the official marked-

up samples.

• Ideally tools for mating parts should be grained at the same time and in the
same graining facility considering economic aspects and target dates.

• This enables optimum matching of the tools in terms of gloss level, graining
appearance and grain direction.

• If package delivery of tools for corresponding parts is not possible, discuss this
issue with VW Graining Team.

Produkttechnik Aufbau/Ausstattung Graining Team

GQE-K/ 3 Version 1/2011
Required informations for the mark-up meeting :

Last- off samples:

Project No.:
Part No.:
Part Description:
Contact: name, phone, email:
Type of part and position in vehicle:
Plastic material:
Process: (e.g. injection molding, foaming, IMG, slush…)
Painted? yes/ no
Type of grain:
Mating parts:
Pictures: Position in assembly, general view, details, sections
(Area visibility: primary, secondary, grey)
Draft analysis:

Produkttechnik Aufbau/Ausstattung Graining Team

GQE-K/ 3 Version 1/2011
Documentation

Tools can only be released to the grain source after pre-grain approval by VW
Quality Dept.
Please include the following documents on delivery:

Sample part officially marked-up by VW Graining Team accompanied by

“Teilebegleitblatt” (official VW grain description document)

Tool release document from VW Quality Management (to be developed)

Volkswagen Quality requires the grainer to notify Volkswagen, the Tier 1 and Toolmaker
of any and all non conformity regarding tool condition and timing.

Welded areas and inserts must be marked on the last off component.
Limited areas of draft and potential shrink-on conditions must be shown
(e.g. 3°) on the marked-up sample.

Grainers “Texturing Guidelines and Checklist”

Steel certificates for grained tool components

Last off part samples

Produkttechnik Aufbau/Ausstattung Graining Team
GQE-K/ 3 Version 1/2011
Contact:
Other relevant details may arise during the mark-up meeting and upon arrival of the marked-up samples
and tools at the grain source.
Please do not hesitate to contact us, if you have any further questions!
Meetings according to prior agreement.

Graining Team:

Supervision: (focus on coordination and supervision)

Michael Otto Phone +49-5361-9-20074 michael.otto@volkswagen.de

Styling: (focus on creative process)

Oliver Franke Phone +49-5361-9-129859 oliver.franke@volkswagen.de
Andreas- Silvester Herbst Phone +49-5361-9-75954 andreas-silvester.herbst@volkswagen.de
Timo Petras Phone +49-5361-9-196248 timo.petras@volkswagen.de

Technical development (focus on part development / engineering process)

Claudia Rühmann Phone +49-5361-9-79701 claudia.ruehmann@volkswagen.de

Purchasing: (focus on buying process)

Ingo Janssen Tel.: +49-5361-9-17782 ingo2.janssen@volkswagen.de

Quality Assurance: (focus on realisation process)

Lutz Lampe Phone +49-5361-9-43142 lutz.lampe@volkswagen.de
Manuela Philipp Phone +49-5361-9-42290 manuela.philipp@volkswagen.de
Ingo Beinker Tel.: +49-5361-9-16589 extern.ingo.beinker@volkswagen.de

www.volkswagen.de
Produkttechnik Aufbau/Ausstattung Graining Team
GQE-K/ 3 Version 1/2011
Volkswagen Requirements for Graining

VW Project ______________________________

Group of Components: ______________________________

Supplier: ______________________________

Responsible representative: ______________________________

I herewith confirm, that I read and fully understood the VW requirements for graining. I will
forward these informations incl. the „Supplier information for graining“ to all involved parties,
such as tool makers etc.

Supplier Signature _______________ Date ____________________

Produkttechnik Aufbau/Ausstattung Graining Team

GQE-K/ 3 Version 1/2011