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Index
Over View of Plastic Product Design Polymer Fundamentals Plastic Product Design Steps Plastic Material Selection Process Plastic Product Design Guidelines Plastic Manufacturing Process Basics of Injection Mold
Select the material( Expected End Use Requirement, Material Data Sheets)
Modify Design as per the calculations results and desired function a) Specific property balance of selected grade b) Processing Limitation c) Assembly Method d) Cost of Modification
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Polymer Fundamentals
Polymer Fundamentals
Polymer Fundamentals
INTRODUCTION
CLASSIFICATION :
MATERIALS
Metals (as Ores) High-Molecular (Makromolecular) materails
Thermoplastics
Thermosets
Elastomers
Thermoplastic elastomers
PLASTICS
Thermoplastics :
They are thread-like molecules (Linear & Branched) They are always Deformable Fusible Soluble. As degree of polymerisation (molecule length) increases strength & toughness increases, but flowability decreases.
They are further classified as Amorphous thermoplastics & Crystalline (Partially crystalline) thermoplastics
Amorphous Thermoplastics:
Bulky thread-like molecules, with unarranged interconnected macromolecular structures, similar to that of staples in a cotton pad.
Examples: Polycarbonate (PC) , Polyvinylchloride (PVC), Acrylonitrile Butadiene Styrene Copolymer (ABS), etc.
Structure : amorphous
Properties : High rigidity & toughness also at low temperature to 40 C, High Scratch resistance, High impact resistance, High suspectability to stress cracking Temperature limits: Short-Term ~ 100C, Long Term ~ 85C Surface Quality : High gloss surface can be achieved. Natural colour: opaque, non-transperant Manufacturing related properties : Low shrinkage & low tendency to wrap, Good Paintability & electroplatability. Applications : Automotive panels - (Interior & Exterior parts), etc.
Polycarbonate (PC) :
Structure : amorphous Density : 1,20 1,24 g/cm Elastic-Modulus : ~ 2200 N/mm
Properties : High strength & Hardness, Toughness at low temperature. High impact resistance, High suspectability to stress cracking Temperature limits: Short-Term ~ 135C, Long Term ~ 100C Surface Quality : High gloss surface can be achieved. Natural colour: Transperant Manufacturing related properties : Low shrinkage & low tendency to wrap, Good Paintability & electroplatability. Applications : Automotive panels - (Interior & Exterior parts), Headlights, Helmets, etc.
Polyvinylchloride (PVC) :
Structure : amorphous Density : 1,38 1,55 g/cm Elastic-Modulus : ~ 3000 N/mm
Properties : High hardness & stiffness. High impact resistance at low temperature till -5C, below this brittleness increases. High suspectability to notch failure. Temperature limits: Short-Term ~ 70C, Long Term ~ 60C
Surface Quality : High gloss surface can be achieved. Natural colour: Transperant till Opaque
Manufacturing related properties : Low shrinkage High chemical resistance Applications : Ducts, Ventilation Channels, tubes, etc.
Crystalline Thermoplastics:
Bulky thread-like slim molecules, which are alligned or with each other.
Examples: Polyethylene (PE), Polypropylene (PP), Polyamide (PA), Polyacetal (POM) etc.
Polyethylene (PE) :
Structure : Semi crystalline N/mm Density : 0.91 0.96 g/cm Elastic-Modulus : ~ 1200
Properties : High stiffness & Hardness. Good elastic properties. Practically unbreakable, ductile till -60C Temperature limits: Short-Term ~ 135C, Long Term ~ 80C
Surface Quality : High gloss surface can be achieved. Natural colour: milky white
Manufacturing related properties : No water absorption, High Shrinkage & tendency to warpage High chemical resistance Applications : HR inserts, Ducts, Channels, etc.
Polypropylene (PP) :
Structure : Semi crystalline N/mm Density : 0.90 0.92 g/cm Elastic-Modulus : ~ 1450
Properties : High stiffness & Hardness. Stability higher than PE. High flexural fatigue strength. Low impact strength at low temperature. Temperature limits: Short-Term ~ 140C, Long Term ~ 100C
Surface Quality : High gloss surface can be achieved. Natural colour: Colourless shining through
Manufacturing related properties : No water absorption, High Shrinkage & tendency to warpage High chemical resistance Applications : Car Coverparts (Interior & Exteriors), etc.
Polyamide (PA) :
Structure : Semi crystalline 2800 N/mm Density : 1.02 1.15 g/cm Elastic-Modulus : ~ 1300 -
Properties : High stiffness & impact strength. Good friction & wear resistance Temperature limits: Short-Term ~ 170C, Long Term ~ 110C
Surface Quality : High gloss surface can be achieved. Natural colour: Translucent white-yellow
Manufacturing related properties : Good flow properties & chemical resistance, Not so good shrinkage. Tendency to warpage. Applications : Car (Inner, Outer), Bearings, Gear wheels, etc.
Thermosets :
They are closely crosslinked, that is the reason they are non thermoplastic. They are always Non - deformable Infusible Insoluble.
Elastomeres:
They are loosely crosslinked, highly elastic & show very low plastic deformation.
Design Guidelines
REQUIREMENT
MATERIAL SELECTION
( From customer)
(Die-Draw direction, Minimum silders and aesthetic requirement ) (Packaging data, strength requirement)
DECIDING STRENGTHING RIBS,LOCATIONS & GEOMETRY DRAFT ANGLES,RIBS WALL THICKNESS RATIO
Design Guidelines
TOOLING FEASIBILITY
( Minimum core thickness, Slider ejection space, Sharp corners etc.)
( Tolerance issues)
Design Guidelines
Material Selection:
The wide variety of injection moldable thermoplastics often makes material selection a difficult task. Factors governing material selection Cost Functionality Assembly (Typically when bonded) Temperature Strength Government Regulations. Surface finish/aesthetic etc.
Design Guidelines
Wall thickness/ Base thickness:
Proper wall thickness determines success or demise of a product. Like metals injection molded plastics also have normal working ranges of wall thickness. This can be taken into consideration while deciding wall thickness. Factors to be considered while deciding wall thickness. Structural strength of the part to be designed plays important role in deciding wall thickness. Normal working ranges of wall from chart for particular material selected. As a thumb rule 2.5mm. Prior experience or bench mark parts can also be referred while deciding on wall thickness.
Design Guidelines
Wall thickness/ Base thickness:
Once nominal wall thickness is decided, following are some design rules which should be followed.
Maintain uniform wall thickness wherever possible which helps in material flow in mold, reduces risk of sink marks, Induced stresses & consideration of different shrinkage
For non-uniform wall thickness change in thickness should not exceed 15% of nominal thickness & should transition gradually. At corner areas minimum fillet at inner side should be 50% of wall thickness.
Design Guidelines
Core-Cavity-Slider directions & Parting lines :
It is always recommended first to decide upon the core-cavity direction. Generally core-cavity direction & parting line depends upon following parameters
The shape & function of the component. Shape in turn is governed by ASurface, packaging/environment data.
Core-cavity & slider directions should be considered such that they do not appear on A-Surfaces, unless otherwise specified & accepted by the customer.
Design Guidelines
Draft Angles (On component walls):
Draft is necessary for ejection of part from the mold & are always Tooling (Die-Draw) & Slider direction. Recommended draft angle is minimum 1deg. Factors governing draft angle. Surface finish Highly polished mold requires less draft than an unpolished mold. Surface Texture (Graining) Draft increases with texture depth,normally 1 deg draft for every 0.025mm depth recommended. Draw depth To keep the draft angle to minimum as thumb rule draft angle draw depth charts are followed & often design engineer should discuss with tool maker.
Design Guidelines
Ribs :
Ribs should be used when needed for stiffness & strength or to assist in filling difficult areas. For structural parts where sink marks are no concerns -Rib base thickness can be 75%-80% of adjoining wall thickness For appearance parts where sink marks are objectionable: With texture (Graining) - Rib base thickness should not exceed 50% of adjoining wall thickness for part. Without texture (Graining) - Rib base thickness should not exceed 30% of adjoining wall thickness.
Design Guidelines
Bosses :
Usually designed to accept inserts, self tapping screws, drive pins etc for use in assembling or mounting parts. Some important points to consider while Boss design: The O.D of the boss should be ideally 2.5 times of screw diameter for self tapping screw applications. If O.D exceeds 50% of adjoining wall thickness, thinner wall boss of O.D 2 times or less of screw diameter can be considered with supported by ribs. Bosses should be attached to walls with ribs. Thickness at base of rib should not exceed 50% of adjoining wall thickness.
Boss inside & outside diameters should have 0.5 deg draft per side.
Design Guidelines
Bosses :
Design Guidelines
Coring :
Coring in injection molding terms to addition of steel to mold for the purpose of removing plastic material in that area Coring is necessary to create Pocket or, Opening in the part or to reduce heavily walled section.
Design Guidelines
Openings :
Openings are desired in a part to eliminate sliders, cams, pullers, etc. to accommodate features like snaps. As general thumb rule 5deg angle in the area of mating of core & cavity is required.
Design Guidelines
Assemblies :
Types of assemblies : Molded-in assembly Chemical bonding assembly Thermal welding assembly Assembly with fasteners.
Design Guidelines
Snap fit assembly :
Design Guidelines
Snap fit assembly :
Deflection required to assemble the part should always be less than maximum deflection(strain) for safe design.
Snaps increase possibility of sliders wherever possible try to eliminate sliders by providing slot below snap or moving snap to outer edge of the part, if design permits.
Design Guidelines
Press fit assembly :
Press fit design is more critical in plastics (Thermoplastics as they creep (Stress or Relax). Good design should minimize stress on the plastic,by considering assembly tolerance between assembled parts & clamping force due to creep relaxation.
Design Guidelines
Adhesive joints assembly :
Two similar or dissimilar plastics can be assembled in a strong leak-tight bond by using adhesives. The choice of adhesive depends upon the application & the environment to which the part would be subjected. Some of adhesives are Polyurethanes, Epoxies, Cyanoacrylates, Silicones etc.
Design Guidelines
Certain precaution must be taken while designing to reduce excessive compressive stress on the plastic. Larger head screw or larger washer is preferred as that contact area increases & stress reduces.
Design Guidelines
Molded in threads :
Coarse threads are preferred due to higher strength & torque limits. Generally 0.8 0.9 mm relief should be provided to prevent high stress at the end of the threads. To reduce the stress concentration minimum 0.25mm radius should be applied to the threads roots. External threads should be as far as possible located on parting lines to avoid need of unscrewing mechanism. Internal threads are usually formed by an unscrewing or collapse core.
Design Guidelines
Self Tapping Screws :
Further classified in 2 types Thread cutting & Thread forming Thread cutting screw is most used on brittle plastics such as thermosets & filled (50%) thermoplastics. They should not be reinstalled Thread forming screws is mostly used on thermoplastics. They can be reinstalled for 3 to 5 times.
5.
Molded Part
Horn Pin
Undercut
Slide
Pulled Undercut
Locking Block
Undercut
Spring
Slide core
Undercut
Angled pin
Molded part
Undercut
Horn pin
Lose core
Hydraulic Cylinder
FORCED EJECTION :
FORCED EJECTION :
FORCED EJECTION :
FORCED EJECTION :
FORCED EJECTION :
MULTIPLE UNDERCUTS
Hydraulic Cylinder
MULTIPLE UNDERCUTS
MULTIPLE UNDERCUTS
MULTIPLE UNDERCUTS
MULTIPLE SLIDERS:
Locking Block
Core Pin
Undercut
Spring
Slide
MULTIPLE SLIDERS:
MULTIPLE SLIDERS:
REFERENCES: Honeywell Injection Moulding Processing Guide (2002). Honeywell Design Soultions (2002).
THANK YOU
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Plastic Processing
Plastic Processing
Plastic Processing-IMD
Injection Mold
Injection Mold
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Design Major Messages 1. Maintain a Plastic uniform wall section - 2.0mm is typical. 2. Utilize the appropriate radii where applicable: 3. Strive to use snap fit and thread forming screws whenever possible to eliminate hardware, maximize design for assembly (DFA), and achieve the lowest cost.
4. Draft is mandatory. 1.5 degrees per side, plus 1 degree per 0.001 depth of texture.
5. Eliminate side draws (slides) and undercuts (lifters) whenever possible. Use through wall openings. 6. Use the general tolerance box - tight tolerances drive up part and tooling cost. 7. Do not put datum on flexible walls or points in space.
Draft Angles
Draft is needed to facilitate release of part from mold. The draft to use, unless otherwise specified, is 1.5 degrees per side. Indicate if draft is to be added or subtracted from nominal dimension. Show draft on part whenever possible to avoid confusion as to direction. The "No Draft Allowed" is not to be used. Even on critical areas allow 0.5 degrees.
Limits of Undercuts
Eliminate undercuts by alternative redesign. A minimum of 5 degree shut-off is required for all areas around a through opening. A 7 degree angle is even better. See "Bad" steel conditions for steel limitations
Slide Core
Molded Part
Horn Pin
Undercut
Slide
Slide Core
Slide Core
Slide Core
Pulled Undercut
Slide Core
Pulled Undercut
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Excessive travel
Slide Core
Slide Core
Cover tool
Locking Block
Undercut
Spring
Slide core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Locking Block Core pin
Undercut
Spring
Slide core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Accelerated Lifter
Lifter
Undercut
Angled pin
Accelerated Lifter
Accelerated Lifter
Accelerated Lifter
Accelerated Lifter
Accelerated Lifter
Accelerated Lifter
Accelerated Lifter
Crash condition
Hydraulic cylinder
Core pin
Undercut
Hydraulic Cylinder
Hydraulic cylinder
Hydraulic pin
Hydraulic Cylinder
Slide Core
Forced Ejection
Forced Ejection
Forced Ejection
Forced Ejection
Forced Ejection
Multiple Undercut
Molded Part Slide
Hydraulic Cylinder
Die Opening
Die Opening
Lifter Ejection
Part Ejection
Lifter Return
Slide Return
Die Closing
Undercut
Spring
Slide
Multiple Undercuts
Under
Spring
Slide
Angled Lifter
Lifter Molded part
Undercut
Horn pin
Lose core
Angled Lifter
Ejection
Ejection
Ejection
Ejection
Die closing
Die closing
Die closing
B
Impossible lifter condition B
Thanks