www.distrupol.com basics of design i. 2 design for assembly integrated baffle, oil pick-up tube and...
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Basics of Design I
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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 IntegratedInto one
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Snap-Fit Opportunities
Integrated Snap Fits
No extra part
•Simple & reliable
•Design freedom
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L
h/2
h
f
Q
F
Alpha
f = 1.09 • s • L
h
2
[mm]
Es = [MPa]s
s
Es = 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 8POM Med. Viscosity 5Nylon 6.6 DAM 2-3Nylon 6.6 Cond. 4-6GR Nylon DAM 0.5-1.2GR Nylon Cond 0.9-2.0
PBTGR PBTGR PETTPC-ET
3-40.7-1.50.5-0.815-20
General case
Approx. valuesfor
[%]
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• 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
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Break energy in J/m (Izod impact strength)
V(r = 0.023 mm)
U(r = 3.2 mm)
UV
Nylon Dry as moulded
28 740 26 : 1
Nylon Cond. 2.5 % RH
34 1340 40 : 1
POM 36 310 9 : 1
Influence of notches on…Impact Strength
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Stress Concerntration Factor
3.0 2.5 2.0 1.5 1.0
0 0.2 0.4 0.6 0.8 1.0 1.2 1.4
R/T
P = Applied Load R = Fillet Radius T = Thickness
Sharp Corners
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Wall Thickness Design
Non-uniform wall thickness
Wall Section Design
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Steel
Aluminium
55% GR PET30% GR PET30% GR PBT30% GR Nylon 6.6 (DAM)30% GR Nylon 6.6 (Cond.)Nylon 6.6 (DAM)POM Med. ViscosityPOM High ViscosityNylon 6.6 (Cond.)
210.000 70.000
19.50011.00010.00010.0007.5003.3003.2003.1001.600
Tensile E-modulus for some materials
F L
3 E I
3
x-x
d =
I = B H
12x-x
3
X
Force
x
x
L
B
H
Deflection Beam Case
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140
2.8
1.8
4.0
2.0
6.0
9.2
11.2
28
Moment ofInertia forA, B and C
2520 mm3
Compared to Amaterial savings
up to 22.9 %
Compared to Amaterial savings
up to 57.4 %
A
B
C
Profile Stiffness
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1.00 0.62 0.48 0.44 0.57 0.46 1.12 0.33
Force
W
H
t H, W, t = constant
Profile 1, deformation 1Profile 2, deformation 2
No deformation
Reference Relative deformation value versus the reference profile
Deformations with a Constant Load
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1.0 1.5 13.5 14 27.3 30 28 10.5
Reference
Relative Torsion Stiffness
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Rib Designs
Rib & Sink Marks Alternative to ribs
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Aim for Aim for uniformuniform wall thickness. wall thickness.Design wall thickness Design wall thickness as thinas thin as possible and only as possible and only as thickas thick as as necessary.necessary.Use Use ribbingribbing instead of greater wall thickness. instead of greater wall thickness.Provide Provide radiusing.radiusing.Provide demoulding Provide demoulding tapers.tapers.Avoid undercuts.Avoid undercuts.Do notDo not design to design to greater precision than required.greater precision than required.Design Design multi-functionalmulti-functional components. components.Use Use economic assembly economic assembly techniques.techniques.GateGate moulding on the moulding on the thickest wall.thickest wall.
Ten rules for designers
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A Polymer for Every Application