General Design Principles for DuPont Engineering Polymers - Module

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Figure 3.22 Correct termination of threads Figure 3.23 Suggested end clearance on threads Threads—Effect of Creep When designing threaded assemblies of metal to plastic, it is preferable to have the metal part external to the plastic. In other words, the male thread should be on the plastic part. However, in a metal/plastic assembly, the large difference in the coefficient of linear thermal expansion between the metal and plastic must be carefully considered. Thermal stresses created because of this difference will result in creep or stress relaxation of the plastic part after an extended period of time if the assembly is subject to temperature fluctuations or if the end use temperature is elevated. If the plastic part must be external to the metal, a metal backup sleeve may be needed as shown in Figure 3.24. Figure 3.24 0.8 mm (1/32″) GOOD POOR 0.8 mm (1/32″) 0.8 mm (1/32″) 0.8 mm (1/32″) 0.8 mm (1/32″) 12 Undercuts Undercuts are formed by using split cavity molds or collapsible cores. Internal undercuts can be molded by using two separate core pins, as shown in Figure 3.25 B. This is a very practical method, but flash must be controlled where the two core pins meet. Figure 3.25 A shows another method using access to the undercut through an adjoining wall. Offset pins may be used for internal side wall undercuts or holes (see Figure 3.25 C). The above methods eliminate the need for stripping and the concomitant limitation on the depth of the undercut. Figure 3.25 Punch Plastic part Plastic part A Cavity Molded part Cavity Ejector wedge C Offset ejector pin Knockout plate Undercut B Core pins separate here Molded part ejected Ejector pin movement Undercuts can also be formed by stripping the part from the mold. The mold must be designed to permit the necessary deflection of the part when it is stripped from the undercut. Guidelines for stripped undercuts for specific resins are: • Delrin ® acetal resin—It is possible to strip the parts from the cavities if undercuts are less than 5% of the diameter and are beveled. Usually only a circular shape is suitable for undercut holes. Other shapes, like rectangles, have high stress concentrations in the corners which prevent successful stripping. A collapsible core or other methods described previously should be used to obtain a satisfactory part for undercuts greater than 5%.
• Zytel ® nylon resin—Parts of Zytel ® with a 6–10% undercut usually can be stripped from a mold. To calculate the allowable undercut see Figure 3.26. The allowable undercut will vary with thickness and diameter. The undercut should be beveled to ease the removal from the mold and to prevent overstressing of the part. • Reinforced resins—While a collapsible core or split cavity undercut is recommended for glassreinforced resins to minimize high stress conditions, carefully designed undercuts may be stripped. The undercut should be rounded and limited to 1% if stripping from a 38°C (100°F) mold; or 2% from a 93°C (200°F) mold. Figure 3.26 Allowable undercuts for Zytel ® % Undercut = (A – B) · 100 B % Undercut = (A – B) · 100 B B A C B A Inside of molded part Outside of molded part Molded-in Inserts Adding ribs, bosses or molded-in inserts to various part designs can solve some problems but may create others. Ribs may provide the desired stiffness, but they can produce warpage. Bosses may serve as a suitable fastening device for a self-tapping screw, but they can cause sink marks on a surface. Molded-in inserts may enable the part to be assembled and disassembled many times without loss of threads. Considering these possible problems, the appropriate question is, when should molded-in inserts be used? The answer is the same for ribs and bosses as well. Inserts should be used when there is a functional need for them and when the additional cost is justified by improved product performance. There are four principal reasons for using metal inserts: • To provide threads that will be serviceable under continuous stress or to permit frequent part disassembly. • To meet close tolerances on female threads. B A C B A 13 • To afford a permanent means of attaching two highly loaded bearing parts, such as a gear to a shaft. • To provide electrical conductance. Once the need for inserts has been established, alternate means of installing them should be evaluated. Rather than insert molding, press or snap-fitting or ultrasonic insertion should be considered. The final choice is usually influenced by the total production cost. However, possible disadvantages of using molded-in inserts other than those mentioned previously should be considered: • Inserts can “float,” or become dislocated, causing damage to the mold. • Inserts are often difficult to load, which can prolong the molding cycle. • Inserts may require preheating. • Inserts in rejected parts are costly to salvage. The most common complaint associated with insert molding is delayed cracking of the surrounding plastic because of molded-in hoop stress. The extent of the stress can be determined by checking a stress/strain diagram for the specific material. To estimate hoop stress, assume that the strain in the material surrounding the insert is equivalent to the mold shrinkage. Multiply the mold shrinkage by the flexural modulus of the material (shrinkage times modulus equals stress). A quick comparison of the shrinkage rates for nylon and acetal homopolymer, however, puts things in better perspective. Nylon, which has a nominal mold shrinkage rate of 0.015 mm/mm* (in/in) has a clear advantage over acetal homopolymer, with a nominal mold shrinkage rate of 0.020 mm/mm* (in/in). Cracking has not been a problem where molded-in inserts are used in parts of Zytel ® nylon resins. The higher rate of shrinkage for acetal homopolymer yields a stress of approximate 52 MPa (7600 psi), which is about 75% of the ultimate strength of the material. The thickness of the boss material surrounding an insert must be adequate to withstand this stress. As thickness is increased, so is mold shrinkage. If the useful life of the part is 100,000 hours, the 52 MPa (7600 psi) stress will be reduced to approximately 15 MPa (2150 psi). While this normally would not appear to be critical, long-term data on creep (derived from data on plastic pipe) suggest the possibility that a constant stress of 18 MPa (2600 psi) for 100,000 hours will lead to failure of the acetal homopolymer part. If the part is exposed to elevated temperatures, additional stress, stress risers or an adverse environment, it could easily fracture. * 1 ⁄ 8″ thickness—Recommended molding conditions
Page 1 and 2: dDuPont Engineering Polymers Genera
Page 3 and 4: 8—Gears . . . . . . . . . . . . .
Page 5 and 6: 1—General Introduction This secti
Page 7 and 8: Prototyping the Design In order to
Page 9 and 10: 2—Injection Molding The Process a
Page 11 and 12: As a general rule, use the minimum
Page 13 and 14: Figure 3.11 Cored holes Figure 3.12
Page 15: Figure 3.19 Mold-ejection of rounde
Page 19 and 20: 4—Structural Design Short Term Lo
Page 21 and 22: Form of section Area A d d R R 1 1
Page 23 and 24: Table 4.03. Formulas for Stresses a
Page 25 and 26: Form of bar; manner of loading and
Page 27 and 28: Figure 4.01 Creep Stress (S), MPa (
Page 29 and 30: Figure 4.05 Creep in flexure of Zyt
Page 31 and 32: Example 1 It there are no restricti
Page 33 and 34: Determine the moment of inertia and
Page 35 and 36: Figure 4.11 Stress curves The compu
Page 37 and 38: Rim Design Rim design requirements
Page 39 and 40: Figure 5.08 Chair Seat Zytel ® 71
Page 41 and 42: Cantilever Springs Tests were condu
Page 43 and 44: 7—Bearings Bearings and bushings
Page 45 and 46: debris is moved around continuously
Page 47 and 48: Table 7.01 Coefficient of Friction*
Page 49 and 50: Figure 7.15: Connecting rod spheric
Page 51 and 52: 8—Gears Introduction Delrin ® ac
Page 53 and 54: 9—Gear Design Allowable Tooth Ben
Page 55 and 56: Delrin ® 500. See the section on D
Page 57 and 58: Figure 9.06 Sizes of gear teeth of
Page 59 and 60: The following additional examples i
Page 61 and 62: In practice, the most commonly used
Page 63 and 64: Driving Gear Meshing Gear Table 9.0
Page 65 and 66: A full-throated worm gear is shown
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Worm Material Gear Material Possibl
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10—Assembly Techniques Introducti
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For these materials, the finer thre
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Table 10.01 Self-Threading Screw Pe
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Figures 10.07 and 10.08 show calcul
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Undercut Snap-Fits In order to obta
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Cantilever Lug Snap-Fits The second
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11—Assembly Techniques, Category
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Figure 11.03 Drill spindle position
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Inertia Welding By far the simplest
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Machines for Inertia Welding The pr
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This is not always easy, because ap
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The holder a, will have equal and o
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Calculations for Inertia Welding To
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If, for example, the angles of the
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Welding Double Joints The simultane
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Figure 11.37 Commercial bench-type
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Heat is generated throughout the pa
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Figure 11.45 Tapered or stepped hor
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Weld strength is therefore determin
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) General Part Design The influence
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eticule in the eye piece is suitabl
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For this reason, if the strength of
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Figure 11.64A shows a variation whi
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3. Vibrations, generated either by
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If one part is only vibrated at twi
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Another joint design, with flash tr
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Figure 11.82. A linear welded motor
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B) Commercial linear and angular we
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Hot Plate Welding of Zytel ® One o
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Figure 11.94 Applications of riveti
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Tolerances may be difficult to hold
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are used in either hand- or power-o
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ather than scrape, these drills wil
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The polishing operation is performe
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General Design Principles for DuPont Engineering Polymers - Module

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