Professional Documents
Culture Documents
Designing Rubber
Components
Undercuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Circularity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Deflashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Copyrights 2003 Minnesota Rubber and QMR Plastics. All rights reserved.
2-1
Designing Rubber
Components
Working Together
2-2
Engineering Design
Part design begins with answers to some basic questions
about how the part will be used and the environment in
which it must operate.
Transmit a fluid?
Transmit energy?
Absorb energy?
Oxygen or ozone?
Sunlight?
Wet/dry situation?
Properties in Balance
An improvement in
Usually improves
But sacrifices
Abrasion resistance
Hardness/Elongation
Resilience
Impact resistance
Elongation
Modulus
Creep resistance
Resilience
Flex resistance
Oil resistance
Tear resistance
Resilience
Creep resistance
Tear resistance
Tensile strength
Modulus
Elongation
Vibration damping
Impact resistance
Structural integrity
2-3
Application Type
60 - 80
Flow Controllers
50 - 70
50 - 60
Where to Start
Here are a few suggestions for beginning the process of
material selection:
Correct
Incorrect
Preferred
Least Preferred
Undercuts
An undercut feature of a part is one which projects back into
the main body of the part. As the undercut becomes deeper,
it results in a part that is difficult, or perhaps impossible, to
remove from the mold. An extreme
case of an undercut part is illustrated
below with the cross-section of a part
in a mold. The mold, composed of
three sections, opens vertically. In
this example, it would not be
possible to remove the part from
the vertically opening mold.
Sharp Edges
The height of the hole should not be more than twice its
diameter.
FEATHER
EDGE
.010 FLAT
(.254mm)
Holes
When designing a hole in a rubber part, there are a few
design requirements to consider. The hole in the part is
created by inserting a pin in the mold cavity. Since during
molding cavity pressures can be quite high (in excess of
7000 psi (500 Bar)), substantial forces can be exerted on the
FEATHER
EDGE
FEATHER
EDGE
Preferred
Alternate
Least Preferred
FEATHER
EDGE
.010 FLAT
(.254mm)
.010 FLAT
(.254mm)
.010 FLAT
(.254mm)
2-5
2-6
Circularity
Rubber Over-Molding
RUBBER
PTFE
PTFE .016
(.406mm)
MIN. THICKNESS
PTFE
RUBBER
CRYOGENIC CLEANING
WILL BURNISH PTFE SURFACE
Incorrect
Correct
12
+
34
5
6
.306
(7.77mm)
.294
(7.47mm)
21
43
5
6
12
.300
(7.62mm)
21
43
5
6
+
34
5
6
INSERT
.300
(7.62mm)
+.006 (.15mm) is defined
as .012 (.3mm) TIR
21
43
5
6
12
+
34
5
6
.015 MIN
(.381mm)
Correct
Incorrect
Special adhesives can be applied to the insert prior to molding to create a strong chemical bond.
2-7
.015 MIN
(.381mm)
INSERT
Correct
INSERT
Incorrect
.015 MIN
(.381mm)
INSERT
Correct
Incorrect
Mechanical Bond
Chemical Bond
Recommended Tolerances
Dimension
(in)
(mm)
.001 - .250
.0254 - 6.350
.004
.102
.005
.127
.251 - .500
6.375 - 12.700
.004
.102
.005
.127
.501 - .625
12.725 - 15.875
.005
.127
.006
.152
.626 - .750
15.900 - 19.050
.006
.152
.008
.203
.751 - 1.000
19.075 - 25.400
.006
.152
.008
.203
1.001 - 1.500
25.425 - 38.100
.008
.203
.010
.254
1.501 - 2.000
38.125 - 50.800
.010
.254
.013
.330
2.001 - 2.500
50.825 - 63.500
.010
.254
.013
.330
2.501 - 3.000
63.525 - 76.200
.014
.355
.015
.381
3.001 - 3.500
76.225 - 88.900
.017
.432
.018
.457
3.501 - 4.000
88.925 - 101.600
.020
.508
.020
.508
4.001 - 5.000
101.625 - 127.000
.025
.635
.025
.635
5.001 - 7.000
127.025 - 177.800
.035
.890
.035
.890
7.001 - 8.000
177.825 - 203.200
.040
1.016
.040
1.016
8.001 - 9.000
203.225 - 228.600
.045
1.143
.045
1.143
9.001 - 10.000
228.625 - 254.000
.050
1.270
.050
1.270
10.001 - 11.000
254.025 - 279.400
.055
1.397
.055
1.397
11.001 - 13.000
279.425 - 330.200
.065
1.651
.065
1.651
13.001 - 14.000
330.225 - 355.600
.075
1.905
.075
1.905
14.001 - 15.000
355.625 - 381.000
.090
2.286
.090
2.286
2-9
Molding Processes
2-10
Compression Molding
The compression molding process is not unlike making a
waffle. A surplus of material must be placed in the cavity to
ensure total cavity fill. Heat and pressure are applied, causing the compound to flow, filling the cavity and spilling out
into overflow grooves.
Compression molding is often chosen for medium
hardness compounds in high volume production,
or applications requiring
particularly expensive
materials.
The overflow, or flash,
created by larger diameter
parts is of particular
concern when using the
more expensive
compounds. Compression
molding helps to minimize
the amount of overflow.
The pre-load however,
can be difficult to insert
in a compression mold
of more complex design,
and the compression
molding process does not
lend itself to the material
flow requirement of harder
rubber compounds.
OVERFLOW
OR 'FLASH'
TO BE REMOVED
IN SECONDARY
OPERATION
Transfer Molding
Transfer molding differs from compression molding in that
the material is placed in a pot, located between the top plate
and plunger. The
material is
POT
squeezed from
GATES
the pot into the
cavity through one
or more orifices
called gates, or sprues.
Injection Molding
Injection molding is normally the most automated of the
molding processes. The material is heated to a flowing state
and injected under pressure from the heating chamber
through a series of runners or sprues into the mold. Injection
molding is ideal for the high volume production of molded
rubber parts of relatively simple configuration.
Deflashing
Feed Examples
Gates
Transfer and injection molds typically feature multiple gates
to ensure even flow of the material into the cavity. These
gates range in diameter from .010 - .150 (.254 3.81mm),
placed at intervals along the circumference of the cavity.
Gate diameter and location is determined by our Engineering
Department in conjunction with the customer so as not to
hinder part function.
Body Feed
Edge Feed
Compression
GATE
GATE
MARK
less than 50
50 or more
2-11
Building a Prototype
2-12
Unigraphics
ProEngineer
AutoCAD LT
SolidWorks
3-D IGES
VRML
STEP
DXF
HPGL
VDA
STL
DWG
Contact:
Date:
Company name:
Phone:
Fax:
Address:
2-13
e-mail:
Part name:
Part number/Rev.
Hardness/Durometer
(B)
Media to be sealed:
Specification
Concentration
Viscosity
Aniline point
(B) Dynamic
(B) Low
Continuous
Intermittent
Maximum
PSI
PSI
Minimum
Constant pressure
Pulsating pressure
Unidirectional
Bidirectional
Intermittent
PSI
Rotating
Reciprocating
Oscillating
RPM/FPM
Stroke length
Degree
Material
Hardness
total
Minimum
total
Running
continued on reverse
External
Leakage tolerance
None
Visual/Functional Attributes:
2-14
Critical dimensions
Engraving of part
Quality Related:
Anticipated AQL
Special packaging
FDA
Cleanliness factor
Lot control
UL
SPC requirements
NSF
Medical
Date needed by
Date needed by
Target price
Piston Seal
Rod Seal
Face Seal
Additional comments or sketch: Make a sketch or attach a print showing the seal area, clamp area, etc., or any of the above which may be easier to illustrate than to describe.
Copyrights 2003 Minnesota Rubber and QMR Plastics. All rights reserved.