PlasticProductdesign 323

Design of Plastic Parts Part III
DESIGN OF PLASTIC PARTS
Figure 6.40. The classical living hinge is often used in conjunction with snap fits for clamshell type storage containers
DESIGN OF PLASTIC PARTS 2
Suggest Countermeasures to cope with the thermal expansion mismatch between plastic & metal mating parts
Figure I6.41. A variety of methods can be used to cope with the thermal expansion mismatch that occurs when plastic parts are fastened to parts produced from materials (e.g. other plastics, DESIGN OFother PLASTIC PARTS 4 metals, etc.),
Comment on the Goodness of Design
Can we suggest a countermeasure now please?
Internal Bosses touch each other. But is anything wrong still?

Figure 6.43. Conical head (flat head) screws should be avoided as high tensile stresses can develop.
Figure 6.44. The coefficient of thermal expansion for steel fasteners is lower than that of most plastic materials. The CTE mismatch leads to change in compressive preload when the ambient temperature changes.
Countermeasures?
Compare the following for clamping two plastic parts wrt Aesthetics,Number of Parts,Effectiveness against loosening on vibration, Durability & Cost
Machine screw & Nut Machine Screw & Insert Self threading-Screw & Plastic Boss
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1.Option of Assembly
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2.Option of Assembly
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3.Option of Assembly Choose the assembly type based on service requirements & cost
Sketch the bottom half part
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Figure 6.46. A self threading screw boss assembly typically includes the screw, a through clearance boss, and a blind pilot boss.
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Comment on dimensioning of the hole sizes in the two half parts
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Figure 6.48. The through bosses used with self threading screws have a radial clearance. The blind (or through) receiving bosses have a pilot hole diameter that determines the percent thread depth utilization for the screw.
Figure 6.49 Typical torque vs. turns of engagement behavior for a self threading screw being driven into a plastic boss.
Figure 6.50. Many of the ANSI standard thread cutting screws are commonly used with molded plastic parts. Thread cutting screws are most commonly used with rigid polymers.
Figure 6.52. Some of the ANSI standard thread forming screws are also used with molded plastic parts. The thread forming screws are typically used with softer, more ductile polymers.
Figure 6.53. The specialty HiLo @ screw is available in a variety of configurations including the thread cutting and thread forming versions shown.
Figure 6.54. The Plastite @ thread forming screw. The screw has a non-circular, trilobal cross section (exaggerated cross section shown).
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Figure6.55. Configuration of the PT@ thread forming screw.

Figure 6.56. Thread profile configuration of the Polyfast@ thread forming screw.
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Conventional screw head Flange screw head (integral washer) Conventional screw head and washer Serrations under the screw head Spring or wave washer under head
Figure 6.57. A variety of both head styles and washer types are used with self threading screws.
When to use which type?

1.Can induce high local stresses due to relatively small contact area between the plastic part and the screw head.
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2.Reduction in local stress due to an increase in the surface area of contact between the plastic part and the washer.
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3.Reduction in local stress due to an increase in the surface area of contact between the plastic part and the washer.
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4.Designed to increase stripping torque and reduce potential for vibration loosening.
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5.Designed to maintain clamp load and reduce the effects of material cold flow or creep.
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Comment on the design
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How can we improve 1.Torsional & Bending Stiffness? 2.Flow of material? 3. Improve venting during mold filling?
One answer to three questions
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How will you address the problems shown in picture?
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Hole in blind boss (pilot hole) is just long enough.Core pin producing the blind hole is extended enough to accept screw, resulting in thick in order core out the thick section (also creates wall section at the base of the boss, a chip cavity for thread cutting screws).
Comment on these designs
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Figure 6.61. Excessively thick or thin sections at the base of the blind boss should be avoided. The radii values used for the fillet must be large enough to minimize stress concentration, yet must be small enough to limit shrinkage related problems such as shrinkage 40 stress, sinks and voids. DESIGN OF PLASTIC PARTS
Unsupported core pin length may present a problem in molding; Any suggestion to improve the situation?
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Figure 6.62. The blind boss core pin length is reduced to minimize the molding problems associated with long, cantilever core pins.
What should be the ratio of Stripping Torque to Tightening Torque, for a reliable assembly? Please write your answer
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Figure 6.65. The boss pilot hole diameter has a significant influence on both maximum drive torque and strip / drive torque ratio. Low drive torque and high strip / drive torque ratios are most desirable as this limits the potential for failure during the initial or subsequent assembly procedures. DESIGN OF PLASTIC PARTS 45
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For one time assemblies
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Plastic part shrinks away from insert along the direction of Red arrows . Can we improve the bond strength of the assembly by design?
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Figure 6.81. Inserts should be designed so that the plastic shrinks around the insert, rather than pulling away from the insert.
How do they make two distinctly different colored tooth Brushes?
Add Photo
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Two totally different polymers can be used. Use of recycled material as the core filler possible!
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Shown is the condition after assembly Sketch the situation before assembly Explain the process of assembly
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A variety of methods can be used to install, and anchor the inserts within the hole. These secondary insertion processes include 1. 2. 3. 4. 5. Cold press fitting (interference) Hot pressing Ultrasonic insertion Expansion inserts Self tapping inserts
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Part designer has been told to maintain parallel hole for effective retention of a plain cylindrical metal insert. Explain what is the mistake committed by the part designer (Sketch the correct design) DESIGN OF PLASTIC PARTS 68
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Sketch the design for a metal insert which is to be installed into a molded plastic boss, assuring enough guarantee against pullout forces & also pullout torsion Sketch also the detail of the cored hole in the boss
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Is anything wrong with this design?
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.Ultrasonic welding .Vibration welding .Spin (rotational) welding .Hot tool welding .Induction welding .Resistance welding .Hot gas welding .Extrusion welding
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Comment on the design of the energy director especially at the corner area
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When to use which design?

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Figure 6.133. In theory, adhesive bonding is bonding by surface attachment. However, when polymeric adhesives are used to bond plastic parts, molecular diffusion can occur (i.e. welding). A number of situations are possible: (a) no diffusion of adhesive, (b) adhesive / substrate inter-diffusion, and (c) diffusion due purely to solvent welding (no adhesive).
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Thank You
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PlasticProductdesign 323

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PlasticProductdesign 323

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Design of Plastic Parts Part III

DESIGN OF PLASTIC PARTS

Comment on the Goodness of Design

DESIGN OF PLASTIC PARTS

Can we suggest a countermeasure now please?

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

Internal Bosses touch each other. But is anything wrong still?

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

Sketch the bottom half part

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

Comment on dimensioning of the hole sizes in the two half parts

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

Figure6.55. Configuration of the PT@ thread forming screw.

DESIGN OF PLASTIC PARTS

When to use which type?

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

Comment on the design

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

One answer to three questions

DESIGN OF PLASTIC PARTS

How will you address the problems shown in picture?

DESIGN OF PLASTIC PARTS

Comment on these designs

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

For one time assemblies

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

How do they make two distinctly different colored tooth Brushes?

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

DESIGN OF PLASTIC PARTS

Is anything wrong with this design?