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Polymer Families
Polymer Families
Thermoplastics
Plastics capable of softening and flowing when heated, hardening when cooled, and softening when reheated
Thermosets
Plastics which become permanently rigid when heated, chemically reacted or irradiated
Thermoplastics
Examples:
Refrigerator Liner Tails for handles Some Coatings (Paint) PE Tubing
Thermosets
Examples:
Refrigeration Foam BMC for handles Some Coatings (Paint) Crosslinked PE Tubing
ADVANTAGES:
Recyclability Faster Processing Time Toughness Assembly Options
ADVANTAGES:
High Temperature Arc Resistance Mechanical Rigidity Creep Resistance Chemical Resistance
DISADVANTAGES:
Creep Thermal Stability Chemical Resistance
DISADVANTAGES:
Brittle Limited Post-Mold Assembly Options Not Recyclable
40
35
30 Mostly Linear to Yield Point 25 20 Non-linear 15 10
Annealed Steel Polycarbonate (PC) Polybutylene terephthalate(PBT) Modified polyphenylene ether(M-PPE) Polytherimide(PEI) PC-PBT blend
5 0 0 1 2 3 4 5 6
LEXAN 141
Mechanical
Tensile Strength Tensile Strain Tensile Modulus Impact Strength
What do you use as a material stress limit in design? Not on the Data Sheet
Thermal
HDT Vicat Softening Temp. RTI
Electrical
Vol Res
LEXAN 141
Mechanical
Tensile Strength Tensile Strain Tensile Modulus Impact Strength
Thermal
HDT Vicat Softening Temp. RTI
Electrical
Vol Res
ULTEM 1000
Data sheet Tensile Strength = 15,200 PSI Allowable Working Stress Steady load, 730 F = 3,800 PSI Intermittent Load, 730 F = 6,300 PSI Momentary Load, 730 F = 8,400 PSI
Selection Criteria
Define criteria
Necessary Desirable
Rank criteria
Definite value Weighted opinion
Typical Criteria
Cost Strength / Toughness Dimensional stability Operating Temperature Chemical Environment Flammability Production Method Shrinkage Assembly Techniques Aesthetics Post Processing
Dimensional Stability: <..% Distortion Tolerance @. , C.. Rel Humidity ENVIRONMENTAL Chemical exposure (Incidental) (Continuous). Weatherability (Outdoor) (Indoor). Duration. Hrs AGENCY Flammability: V-0 V-1 V-2 5V HB @mil Others:
Will the part need to be disassembled? Frequently. Occasionally. Never.. How: Heat Staking Ultrasonic Welding Screws Adhesives Snap Fits
COMPRESSIBLE
Injection Flow
Injection Flow
Injection Flow
Injection Flow
Injection Flow
Plastic Flow :
Plastic will only flow so far
What is Freeze-off?
Plastic Flow :
Does not like to change direction
Uniform wall thickness promotes better flow
Sink Marks
Voids
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Plastic Flow :
will flow around holes and cut-outs to form weld lines
Flow Direction
Flammability Limitations
UL Flammability Requirements: If a flammability rating is required for an application, the resins minimum thickness to pass the flammability test is the parts minimum wall thickness.
Example: A NORYL resin has a UL 94 V-0 rating at .060. An application requiring a V-0 rating will require a .060 minimum wall thickness.
Why Warpage?
Non uniform thickness builds stresses near the boundary of the thin section to thick section. The thin section does not yield because it is freeze-off, the thick section (which is still liquid) must yield. Often this leads to warping or twisting. If this is severe enough, the part could even crack.
Warpage
Factors Affecting Warp:
Uneven Wall Thickness
Unequal Cooling Rate Unequal Pressure
Anisotropy
(Uneven Shrinkage Causes Warp)
Wall Thickness
What if you cannot have uniform walls, (due to design limitations) ? When uniform walls are not possible, then the change in section should be as gradual as possible
Poor
h
Good
h
Best
3h
Alternatives
Molded-in Stress
Mold-in
Assembly
Application
High Performance
Mold-in
Assembly Application
Low Performance
Molded-in Stress
Causes:
Overpacking
More Material than Required in the Mold Cavity Results in Molded in Stresses
Shrinkage
Decreased spacing between polymer chains at cooler temperatures Must be accommodated in tooling design
Moldability Shrinkage
Post-Mold Dimensions of Plastic Parts Differ From Mold Cavity Dimensions Vpart Vmold
lpart
lmold
Sl =
Sv =
Moldability
Material Considerations
Part
Crystalline
Amorphous
Filled Amorphous
Some materials shrink differently than others and require different part & tool design considerations
Semi-crystalline
VALOX (PET/PBT) 5-25
Blends
XENOY (PBT/PC) NORYL GTX (PPO/Nylon) CYCOLOY (PC/ABS) 5-10
Sink Marks
Surface Yields to the Still Shrinking Interior Mass
Voids
Already Cooled Surface Will Not Yield to Shrinking Interior
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Reinforcement Structures
Ribbing
Gusset
Boss
Rigidity Balance
Two parts with equivalent RIGIDITY
E1X I1
= Modulus of Elasticity
E2X I2
= Moment of Inertia
I bh3
(E)
(I)
Equivalent Rigidity
12 x 24 Plate Solid Plastic 0.182 3.2 x 105 Steel Thickness (in.) E (psi) 0.040 3.0 x 107 Structural Foam 0.196 Ribbed* Solid 0.125
I (in.4)
Exl (Rigidity)
0.000064
1920 .065
0.006
1920
0.0075
1920
0.006
1920
.270
Equivalent Rigidity
12 x 24 Plate Solid Plastic 0.182 3.2 x 105 Steel Thickness (in.) E (psi) 0.040 3.0 x 107 Structural Foam 0.196 Ribbed* Solid 0.125
I (in.4)
Exl (Rigidity) Weight (lbs)
0.000064
1920 3.24
0.006
1920 1.881.78
0.0075
1920 1.60
0.006
1920 1.60
Rib Thickness
Ribs which are too thick: Cause sink marks cause voids increase cycle time Click
60% t
In structural parts where sink marks are of no concern, rib base thickness can be 85% of the wall thickness For High appearance parts, where sink marks are objectionable, rib base thickness should not exceed - 50% of the wall thickness if the outside surface is textured - 30% if not textured
Rib Height
Suggested Height = 3 to 5t
Limited By:
Thickness - Shrink and Warp Issue Draft - Ejection Issue
= 2xt min.
Avoid hot blade and cooling
Stiffener Orientation
No Increase in Stiffness
Increased Stiffness
Boss Design
2D
R = .25 T
H = 2 to 5T
Gussets
Gussets are often placed at points of attachment, support, or contact with other components.
Plastic Flow :
Does not like to change direction
The stress concentration factor is a multiplier factor, it increases the stress. Actual Stress = Stress Concentration Factor K x Stress Calculated The stress concentration factor is very high if r/t values are less.
Easier Ejection
No Draft Angle
Where minimum draft is desired due to design limitations, good polishing recommended and depth should not exceed 0.5 in.
More draft aids ejection but may generate a material mass on sections contained in one side of the mold.
The mold parting line can be relocated to split the draft in order to minimize it.
Without draft
P/L relocation
Parting line
Parting line consideration depends upon shape and the function of the part. Specify the mismatch on the parting line to meet the required function.
Drag at shutoff will wear over time and develop flash. When a stepped parting line required allow 70 draft for shutoff . Minimum shutoff angle is 50.
Direction of Pull
Direction of Pull
Mold
Part
Mold
How to Stiffen Areas Not Parallel to the Parting Plane of the Tool: Thicken the wall and do not use ribs Use ribs created with slides and cams in the tool (Costly)
Often best molded as two separate ribbed parts and then assembled
Click
Click
Click
NO SLIDE REQUIRED
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