Basics_of_Design_I.ppt

Basics of Design I A Polymer for Every Application Design For Assembly Integrated Baffle, Oil Pick-Up Tube and Scrapers Mains Lower Skirt Integrated baffle is captured and located by lower skirt and cranks mains eliminating the need for fasteners Oil Pan Existing baffle oil pick-up tube w/gasket and fasteners 11 parts Integrated Into one Snap-Fit Opportunities Integrated Snap Fits No extra part Simple reliable Design freedom L h/2 h f Q F Alpha f = 1.09 ? e s ? L h 2 [mm] E s = [MPa] s s e s E s = Secant Modulus Snap-Fit Design Height Width Deflection length Deflection undercut Angle Deflection force Engagement force mm mm mm mm degree Newton Newton h b L f Alpha Q F POM High Viscosity 8 POM Med. Viscosity 5 Nylon 6.6 DAM 2-3 Nylon 6.6 Cond. 4-6 GR Nylon DAM 0.5-1.2 GR Nylon Cond 0.9-2.0 PBT GR PBT GR PET TPC-ET 3-4 0.7-1.5 0.5-0.8 15-20 General case Approx. values for e [%] Undercuts rounded to avoid tearing of part stress concentration. Ejectors should be large to avoid penetrating the part. Cycle time (specially hold pressure time) should be optimum to avoid excessive shrinkage. POM Undercut = ((B-A)/B) ￡ 5% Undercut Design Break energy in J/m (Izod impact strength) 9 : 1 310 36 POM 40 : 1 1340 34 Nylon Cond. 2.5 % RH 26 : 1 740 28 Nylon Dry as moulded U V U (r = 3.2 mm) V (r = 0.023 mm) Influence of notches on… Impact Strength Sharp Corners Wall Thickness Design Non-uniform wall thickness Wall Section Design Steel Aluminium 55% GR PET 30% GR PET 30% GR PBT 30% GR Nylon 6.6 (DAM) 30% GR Nylon 6.6 (Cond.) Nylon 6.6 (DAM) POM Med. Viscosity POM High Viscosity Nylon 6.6 (Cond.) 210.000 70.000 19.500 11.000 10.000 10.000 7.500 3.300 3.200 3.100 1.600 Tensile E-modulus for some materials F L 3 E I 3 x-x d = I = B H 12 x-x 3 X Force x x L B H Deflection Beam Case 140 2.8 1.8 4.0 2.0 6.0 9.2 11.2 28 Moment of Inertia for A, B and C 2520 mm 3 Compared to A material savings up to 22.9 % Compared