metaltoplastic upp v3[1]

8/2/2019 MetaltoPlastic UPP V3[1]

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SOLVAY ADVANCED POLYMERS

1 2007 Solvay Advanced Polymers, LLC

Designing with Ultra PolymersPractical Guidelines for Metal-to-Plastic Conversions

July 25, 2007

MORE PLASTICS WITH MORE PERFORMANCE


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Topics

Introduction to Solvay Advanced Polymers

Description of Ultra Polymers

Metals vs. Plastics

Simulation Technology

Case Study


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3



Solvay Advanced Polymers

Headquartered in Alpharetta, Georgia (US) with manufacturing,

R&D sites and affiliates in NA, Europe and Asia

Formed in 2001 when the Solvay Group acquired BP Amocos

high-performance plastics business

Dates back to 1974 and the inception of high-performanceplastics production at Amoco and Union Carbide

Recently acquired Mississippi Polymer Technologies and

Gharda Polymers in Panoli, India

14 distinct product families which include Sulfone Polymers,

Aromatic Polyamides and SolvaSpire Ultra Polymers

Solvay Offers More Plastics with More PerformanceThan Any Other Company in the World



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4



Plastics Performance Pyramid

PrimoSpire

self-reinforced polyphenylene

Ultra Polymers

Exceptional thermal properties

Excellent mechanical properties

Superior chemical resistance

Outstanding flame resistance

Un-matched wear resistance


5/60

5



Orthopedic Fixation Device

Fasteners

Applications - PrimoSpire SRP

Why PrimoSpire SRP?

Superior strength and stiffness

without reinforcements

Excellent chemical resistance

Superior surface hardness

Ease of machinability

Semiconductor Test Sockets Stock Shapes


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6



PrimoSpire SRP Comparison with Unfilled Plastics

PrimoSpire SRP is the Stiffest and StrongestUnreinforced Plastic in the World


Tensile Properties

Strength,M

Pa

Mo

dulus,GPa

0

2

6

8

10

4

0

50

100

150

200

250

PrimoSpire

PR-120

PrimoSpire

PR-250

PPS PI PEEK PEI

Strength

Modulus


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PrimoSpire SRP Comparison with Metal

PrimoSpire SRP has Properties Similar to Metals

On a Strength-to-Weight Basis



Specific Tensile Strength(MPa/g/cm3)

0

50

100

150

200

250

PrimoSpirePR-120 PrimoSpirePR-250 Aluminum,Heat

Treated Die

Casting,

296

Aluminum6061-T4 CarbonSteel,

C1018

MagnesiumAE42-F StainlessSteel, 301 Titanium 6-2-4-2


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Topics

Introduction to Solvay


Metals vs. Plastics


Case Study


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Metals vs. Plastics

STRESS

ELONGATION

FlowDirection

TransverseDirection

Fiber-Reinforced PolymersReinforcedPolymers

Metal

ELONGATION

STRES

S

UnfilledPolymers

PrimoSpire SRP

PrimoSpireSRP has Exceptional Strength andStiffness Without Reinforcements



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Material Strength in Molded Part

WELD LINE

GATE

GATE

ORIEN

TATIO

N

Several Factors Affect Strength

Fiber orientation

Weld line

Gate location

Processing


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Metals vs. PrimoSpire SRP

Tensile Youngs SpecificStrength Modulus Gravity(MPa) (GPa)

Metals

Aluminum 320 70 2.8

Die Cast Zinc 280 70 6.6

Magnesium 225 40 1.8

Self-Reinforced Polymers

PrimoSpire PR-120 207 8 1.2



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Equivalent Stiffness

For Same Deflection: Tensile Modulus (E) x Moment of Inertia (I)for metal and plastic should be the same

With Same Area: Moment of Inertia of plastic cross section is

approximately 12 times the Moment of Inertiaof metal cross section along the x-axis

Difference in Modulus Can Be Compensated ByGeometrical Stiffness Without Increasing the Volume


METAL PLASTIC

T

W

T/3

W

WW = 2T

x

xxx


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Stress vs. Strain

0

50

100

150

200

250

0 2 4 6 8

Strain (%)

Tensile

Stress,

MPa

23C

50C

70C

80C

100C

120C

130C

150C

180C

200C

Linear

Non-linear

Latch Assembly

Ultra Polymers Offer Higher Strain andStrength at Higher Temperature


30% GF Polymer


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Creep Is Deformation Under Constant Load

STRAIN

TIME

Elastic

Viscoelastic

Elastic

Relaxation

What is Creep?

1

2

3

TYPES OF INSERTS

1. Molded in

2. Ultrasonically assembled

3. Press fit


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What is Tolerance?

Tolerance is a Combined Effectof Variations in

Tool dimension

Shrinkage

Process parameters

Optimize Tolerance in Part Design

Design for plastics

Make Certain CPk is Achievable

Metal

Plastic

Interference Fit

Tight Tolerance Represents Poor Plastic DesignTight Tolerance Represents Poor Plastic Design

Plastic hasadvantage oflower modulus


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Topics



Metals vs. Plastics


Computer Aided Engineering (CAE)

Optimization

Case Study


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Flow Analysis

Flow balance

Pressure profile

Weld line

Fiber orientation

Stress Analysis FEA(Finite Element Analysis)

Stress distribution

Deflection

Optimization

CAE Insures Functionality and MoldabilityCAE Insures Functionality and Moldability


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Stress Analysis (FEA)

Design Requirements1 million thermal cycles at 210C

with 2 bar internal pressure

Edge clamped onaluminum body

Objective: Based on success of a smaller charged air cooler,conduct feasibility study to convert to larger size


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FEA Results Stress Distribution

Structural stiffnessincreased by adding rib

Maximum Stress Level Should Be Well Within

Design Limit of Plastic in a Given Environment




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Flow Analysis

Objective: Recommend gate location to minimize warpageand improve flatness for better sealing surface

Options

Edge gate

Center gate

Warpage affected by

Flow balance

Fiber OrientationUniform Cooling


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Center GateEdge Gate

Pressure Profile

Flow Balance Provides Minimum WarpageFlow Balance Provides Minimum Warpage


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Optimization

Design

Use only where needed

Processing

Insert molding

Machining stock shapes

New Approaches

Collaboration

CAE Integration

Stock Shapes

Insert Molding


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Collaboration - Team Approach

Material

PartDesign

Tooling&

Processing

MolderDesigner

ResinSupplier

Performance

Geometry Regulations

Cost

Processing

Tooling Moldability

Cycle Time

Material Characteristics Application Database

CAE Support

Secondary Operations

New Product Development


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CAE Integration

Material

Part

Design

Tooling&

Processing

FlowAnalysis

StressAnalysis

FinalDesign

Material

PartDesign

Tooling&

Processing

ORIENTATIONEFFECT

FinalDesign

FlowAnalysis

StressAnalysis

Design Team

CAE Integration(Accurate Prediction)

Traditional(Silo Effect)

Integration of Flow Analysis with Stress AnalysisGives More Accurate Prediction



25/60



Topics



Plastics vs. Metals


Case Study


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Case Study - Motor End Cap

Background

Metal cap with thermoset brush card

Five different parts

Machining and anodizing

Critical features

Creep and flatness

Chemical resistance

BenefitsCost reduction

Weight reduction

Parts consolidation


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Technical Support

Concept insert molding, crush ribs, improved flatness

Material Selection chemical resistance, strength, and

stiffness, plus improved creep requirements and flatness

Design Finite Element Analysis (FEA) for improved

performance and Flow Analysis for optimized gate location

Prototype Development tooling and molding

Testing process verification (viscosity and crystallinity)

Production

cycle optimization, fabrication, assembly,secondary operations

Solvay has Over 20 Years ExperienceSuccessfully Replacing Metal with Plastic



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Keys to Success

Apply team approach

Use flow analysis and stress analysisto validate functionality and moldability

MUST redesign and optimize the design

Select the right ultra polymer for the job

Well-Designed Part Made from the Right PlasticCan Outperform a Metal Part



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SolvaSpire Ultra Polymers

KetaSpire PEEK (polyetheretherketone)Broadest chemical resistance, highest strength

AvaSpire modified PEEKBest way to bridge price and performance gaps

PrimoSpire self-reinforced polyphenyleneWorlds stiffest and strongest unreinforced plastic

EpiSpire high-temperature sulfoneBest combination of exceptional creep resistance

at high temperatures with processing ease

Torlonpolyamide-imideBest wear-resistance and lowest friction properties

Solvay Offers More Plastics with More PerformanceSolvay Offers More Plastics with More Performance


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30BUSINESS CONFIDENTIAL 2007 Solvay Advanced Polymers, LLC


Want To Know More?

For additional information,

please e-mail us at

[email protected]
mailto:[email protected]:[email protected]


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1



Designing with Ultra PolymersPractical Guidelines for Metal-to-Plastic Conversions

July 25, 2007

MORE PLASTICS WITH MORE PERFORMANCE


32/60



Topics



Metals vs. Plastics


Case Study


33/60

3



Solvay Advanced Polymers

Headquartered in Alpharetta, Georgia (US) with manufacturing,

R&D sites and affiliates in NA, Europe and Asia

Formed in 2001 when the Solvay Group acquired BP Amocos

high-performance plastics business

Dates back to 1974 and the inception of high-performanceplastics production at Amoco and Union Carbide

Recently acquired Mississippi Polymer Technologies and

Gharda Polymers in Panoli, India

14 distinct product families which include Sulfone Polymers,

Aromatic Polyamides and SolvaSpire

Ultra Polymers




34/60

4



Plastics Performance Pyramid

PrimoSpire

self-reinforced polyphenylene

Ultra Polymers

Exceptional thermal properties

Excellent mechanical properties

Superior chemical resistance

Outstanding flame resistance

Un-matched wear resistance


35/60

5



Orthopedic Fixation Device

Fasteners

Applications - PrimoSpire SRP

Why PrimoSpire SRP?

Superior strength and stiffness

without reinforcements

Excellent chemical resistance

Superior surface hardness

Ease of machinability

Semiconductor Test Sockets Stock Shapes


36/60

6



PrimoSpire SRP Comparison with Unfilled Plastics



Tensile Properties

Strength,MPa

Modulus,GPa

0

2

6

8

10

4

0

50

100

150

200

250

PrimoSpirePR-120

PrimoSpirePR-250

PPS PI PEEK PEI

Strength

Modulus


37/60

7



PrimoSpire SRP Comparison with Metal





Specific Tensile Strength(MPa/g/cm3)

0

50

100

150

200

250

PrimoSpire

PR-120

PrimoSpire

PR-250

Aluminum,

HeatTreated Die

Casting,

296

Aluminum

6061-T4

Carbon

Steel,C1018

Magnesium

AE42-F

Stainless

Steel, 301

Titanium 6-

2-4-2


38/60



Topics



Metals vs. Plastics


Case Study


39/60

9



Metals vs. Plastics

STRES

S

ELONGATION

FlowDirection

TransverseDirection

Fiber-Reinforced PolymersReinforcedPolymers

Metal

ELONGATION

STRES

S

UnfilledPolymers

PrimoSpire SRP




40/60

10



Material Strength in Molded Part

WELD LINE

GATE

GATE

ORIEN

TATIO

N

Several Factors Affect Strength

Fiber orientation

Weld line

Gate location

Processing


41/60



Metals vs. PrimoSpire SRP

Tensile Youngs SpecificStrength Modulus Gravity(MPa) (GPa)

Metals

Aluminum 320 70 2.8

Die Cast Zinc 280 70 6.6

Magnesium 225 40 1.8

Self-Reinforced Polymers




42/60

12



Equivalent Stiffness

For Same Deflection: Tensile Modulus (E) x Moment of Inertia (I)for metal and plastic should be the same

With Same Area: Moment of Inertia of plastic cross section isapproximately 12 times the Moment of Inertiaof metal cross section along the x-axis



METAL PLASTIC

T

W

T/3

W

WW = 2T

x

xxx


43/60

13



Stress vs. Strain

0

50

100

150

200

250

0 2 4 6 8

Strain (%)

TensileStress,

MPa

23C

50C

70C

80C

100C

120C

130C

150C180C

200C

Linear

Non-linear

Latch Assembly



30% GF Polymer


44/60

14



Creep Is Deformation Under Constant Load

STRAIN

TIME

Elastic

Viscoelastic

Elastic

Relaxation

What is Creep?

1

2

3

TYPES OF INSERTS

1. Molded in

2. Ultrasonically assembled

3. Press fit


45/60

15



What is Tolerance?

Tolerance is a Combined Effectof Variations in

Tool dimension

Shrinkage

Process parameters

Optimize Tolerance in Part Design

Design for plastics

Make Certain CPk is Achievable

Metal

Plastic

Interference Fit

Tight Tolerance Represents Poor Plastic DesignTight Tolerance Represents Poor Plastic Design

Plastic hasadvantage oflower modulus


46/60



Topics



Metals vs. Plastics



Optimization

Case Study


47/60

17




Flow Analysis

Flow balance

Pressure profile

Weld line

Fiber orientation

Stress Analysis FEA(Finite Element Analysis)

Stress distribution

DeflectionOptimization

CAE Insures Functionality and MoldabilityCAE Insures Functionality and Moldability


48/60

18



Stress Analysis (FEA)

Design Requirements1 million thermal cycles at 210C

with 2 bar internal pressure

Edge clamped onaluminum body

Objective: Based on success of a smaller charged air cooler,conduct feasibility study to convert to larger size


49/60

19



FEA Results Stress Distribution

Structural stiffnessincreased by adding rib






50/60

20



Flow Analysis

Objective: Recommend gate location to minimize warpageand improve flatness for better sealing surface

Options

Edge gate

Center gate

Warpage affected by

Flow balance

Fiber Orientation

Uniform Cooling


51/60

21



Center GateEdge Gate

Pressure Profile

Flow Balance Provides Minimum WarpageFlow Balance Provides Minimum Warpage


52/60

22



Optimization

Design

Use only where needed

Processing

Insert molding

Machining stock shapes

New Approaches

Collaboration

CAE Integration

Stock Shapes

Insert Molding


53/60

23



Collaboration - Team Approach

Material

PartDesign

Tooling&

Processing

MolderDesigner

ResinSupplier

Performance

Geometry Regulations

Cost

Processing

Tooling Moldability

Cycle Time

Material Characteristics Application Database

CAE Support

Secondary Operations

New Product Development


54/60

24



CAE Integration

Material

Part

Design

Tooling&

Processing

FlowAnalysis

StressAnalysis

FinalDesign

Material

PartDesign

Tooling&

Processing

ORIENTATIONEFFECT

FinalDesign

FlowAnalysis

StressAnalysis

Design Team

CAE Integration(Accurate Prediction)

Traditional(Silo Effect)




55/60



Topics



Plastics vs. Metals


Case Study


56/60

26



Case Study - Motor End Cap

Background

Metal cap with thermoset brush card

Five different parts

Machining and anodizing

Critical features

Creep and flatness

Chemical resistance

Benefits

Cost reduction

Weight reduction

Parts consolidation


57/60

27



Technical Support

Concept insert molding, crush ribs, improved flatness

Material Selection chemical resistance, strength, and

stiffness, plus improved creep requirements and flatness

Design Finite Element Analysis (FEA) for improved

performance and Flow Analysis for optimized gate location

Prototype Development tooling and molding

Testing process verification (viscosity and crystallinity)

Production cycle optimization, fabrication, assembly,

secondary operations




58/60

28



Keys to Success

Apply team approach

Use flow analysis and stress analysisto validate functionality and moldability

MUST redesign and optimize the design

Select the right ultra polymer for the job



SO C O S


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29



SolvaSpire Ultra Polymers

KetaSpire PEEK (polyetheretherketone)Broadest chemical resistance, highest strength

AvaSpire modified PEEKBest way to bridge price and performance gaps

PrimoSpire

self-reinforced polyphenyleneWorlds stiffest and strongest unreinforced plastic

EpiSpire high-temperature sulfoneBest combination of exceptional creep resistance

at high temperatures with processing ease

Torlonpolyamide-imideBest wear-resistance and lowest friction properties

Solvay Offers More Plastics with More PerformanceSolvay Offers More Plastics with More Performance



60/60


Want To Know More?

For additional information,

please e-mail us at

[email protected]
mailto:[email protected]:[email protected]

metaltoplastic upp v3[1]

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