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P roperty
New
Graph stage
Min Max
Density 2
Modulus 200
Limit stage
Strength 100
1
T-conduction 10
CES Edupack
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Cambridge
University
Version MFA 05
Primeros pasos con CES EduPack
Estos ejercicios proporcionan una manera fácil e intuitiva para adentrarse en el uso del software Cambridge Engineering
Selector (CES) EduPack. Los completos archivos de HELP (Ayuda) y de CES InDepth instalados dentro del software,
brindan una guía más detallada.
El software CES EduPack cuenta con tres niveles de DATABASE (bases de datos):
• LEVEL 1(Nivel 1) 64 materiales y 75 procesos..
• LEVEL 2(Nivel 2) 91 materiales y 104 procesos, con un contenido más amplio
• LEVEL 3(Nivel 3) El nivel “profesional”: adecuado para estudiantes de 3ero – 4to año, Maestrías e Investigadores.
Datos técnicos para más de 2900 materiales y 200 procesos.
En cada nivel hay un número de DATA TABLES (tabla de datos). Las más importantes son:
• MATERIALS(Materiales) Imágenes, texto y datos para materiales.
• SHAPING PROCESSES (Prcesos de formado) Imágenes y atributos para procesos de formado.
• JOINING PROCESSES (Procesos de union) Imágenes y atributos para procesos que permiten la unión de
materiales.
• SURFACE TREATMENT(Tratamientos Superficiales ) Imágenes y atributos para procesos que permiten modificar la
superficie de los materiales.
El software CES EduPack hace mucho más que esto! Pero esto es más que suficiente para empezar.
Comience el software. Seleccione LEVEL 1 (Nivel 1). La DATA-TABLE (tabla de datos) por defecto es la de MATERIAL UNIVERSE (Universo de Materiales)
Ejercicio 1. BROWSE (ojear) materiales Toolbar Browse Select Search Print Search web
Injection molding
Polypropylene (PP) (CH2-CH(CH3))n
No other process has changed product design more than injection molding.
Polypropylene, PP, first produced commercially in 1958, is the Injection molded products appear in every sector of product design:
younger brother of polyethylene - a very similar molecule with consumer products, business, industrial, computers, communication,
similar price, processing methods and application. Like PE it medical and research products, toys, cosmetic packaging and sports
is produced in very large quantities (more than 30 million tons equipment. The most common equipment for molding thermoplastics is the
per year in 2000), growing at nearly 10% per year, and like PE reciprocating screw machine, shown schematically in the figure. Polymer
its molecule-lengths and side-branches can be tailored by granules are fed into a spiral press where they mix and soften to a dough-
clever catalysis, giving precise control of impact strength, and like consistency that can be forced through one or more channels ('sprues')
of the properties that influence molding and drawing. In its into the die. The polymer solidifies under pressure and the component is
pure form polypropylene is flammable and degrades in then ejected.
sunlight. Fire retardants make it slow to burn and stabilizers Thermoplastics, thermosets and elastomers can all be injection molded. Co-
give it extreme stability, both to UV radiation and to fresh and injection allows molding of components with different materials, colors and
salt water and most aqueous solutions. features. Injection foam molding allows economical production of large
molded components by using inert gas or chemical blowing agents to make
components that have a solid skin and a cellular inner structure.
General properties Thermal properties
Density 0.89 - 0.91 Mg/m 3 Thermal conductor or insulator? Good insulator Physical Attributes
Price Thermal Conductivity 0.113 - 0.167 W/m.K Mass range 0.01 - 25 kg Shape
1.102 - 1.61 USD/kg Thermal Expansion 122.4 - 180 µstrain/K Range of section thickness 0.4 - 6.3 mm Circular Prismatic True
Mechanical properties Specific Heat 1870 - 1956 J/kg.K Tolerance 0.2 - 1 mm Non-circular Prismatic True
Young's Modulus 0.896 - 1.55 GPa Melting Point 149.9 - 174.9 °C Solid 3-D True
Roughness 0.2 - 1.6 µm
Shear Modulus 0.31 - 0.54 GPa Glass Temperature -25.15 - -15.15 °C Hollow 3-D True
Surface roughness (A=v. smooth) A
Bulk modulus 2.5 - 2.6 GPa Maximum Service Temperature 82.85 - 106.9 °C
Poisson's Ratio 0.40 - 0.42 Minimum Service Temperature -123.2 - -73.15 °C
Economic Attributes
Hardness - Vickers 6.2 - 11.2 HV
Economic batch size (units) 1e4 - 1e6
Elastic Limit 20.7 - 37.2 MPa Electrical properties
Relative tooling cost very high
Tensile Str ength 27.6 - 41.4 MPa Electrical conductor or insulator? Good insulator
Relative equipment cost high
Compressive Strength 25.1 - 55.2 MPa Resistivity 3.3e22 - 3e23 µohm.cm
Elongation 100 - 600 %
Labor intensity low
Dielectric Constant 2.2 - 2.3
Endurance Limit 11.0 - 16.5 MPa Power Factor 5e-4 - 7e-4
Fracture Toughness 3 - 4.5 MPa.m1/2 Breakdown Potential 22.7 - 24.6 1000000*V /m Design guidelines
Loss Coefficient 0.025 - 0.044 Injection molding is the best way to mass-produce small, precise, polymer components with complex shapes. The
surface finish is good; texture and pattern can be easily altered in the tool, and fine detail reproduces well.
_ Decorative labels can be molded onto the surface of the component (see In-mould Decoration). The only finishing
operation is the removal of the sprue.
Design guidelines
Standard grade PP is inexpensive, light and ductile but it has low strength. It is more rigid than PE Technical notes
and can be used at higher temperatures. The properties of PP are similar to those of HDPE but it Re
Most thermoplastics can be injection molded, although those with high melting temperatures (e.g. PTFE) are
is stiffer and melts at a higher temperature (165 - 170 C). Stiffness and strength can be improved difficult. Thermoplastic based composites (short fiber and particulate filled) can be processed providing the filler-
further by reinforcing with glass, chalk or talc.When drawn to fiber PP has exceptional strength and
loading is not too large. Large changes in section area are not recommended. Small re-entrant angles and complex
resilience; this, together with its resistance to water, makes it attractive for ropes and fabric. It is
shapes are possible, though some features (e.g. undercuts, screw threads, inserts) may result in increased tooling
more easily molded than PE, has good transparency and can accept a wider, more vivid range of
costs. The process may also be used with thermosets and elastomers. The most common equipment for molding
colors. PP is commonly produced as sheet, moldings fibers or it can be foamed. Advances in catalysis promise
thermoplastics is the reciprocating screw machine, shown schematically in the figure. Polymer granules are fed
new co-polymers of PP with more attractive combinations of toughness, stability and ease of processing. Mono-
into a spiral press where they mix and soften to a dough-like consistency that can be forced through one or more
filaments fibers have high abrasion resistance and are almost twice as strong as PE fibers. Multi-filament yarn or
channels ('sprues') into the die. The polymer solidifies under pressure and the component is then ejected.
rope does not absorb water, will float on water and dyes easily.
Technical notes
Typical uses
The many different grades of polypropylene fall into three basic groups: homopolymers (polypropylene, with a Extremely varied. Housings, containers, covers, knobs, tool handles, plumbing fittings, lenses, etc.
range of molecular weights and thus properties), co-polymers (made by co-Polymerization of propylene with other
olefines such as ethylene, butylene or styrene) and composites (polypropylene reinforced with mica, talc, glass The economics
powder or fibers) that are stiffer and better able to resist heat than simple polypropylenes. Capital cost are medium to high, tooling costs are usually high - making injection molding economic only for large
batch sizes. Production rate can be high particularly for small moldings. Multi-cavity moulds are often used.
Typical uses Prototype moldings can be made using single cavity moulds of cheaper materials.
Ropes, general polymer engineering, automobile air ducting, parcel shelving and air-cleaners, garden furniture,
washing machine tank, wet-cell battery cases, pipes and pipe fittings, beer bottle crates, chair shells, capacitor
dielectrics, cable insulation, kitchen kettles, car bumpers, shatter proof glasses, crates, suitcases, artificial turf.
• Cree una BUBBLE CHART (diagrama de burbujas) del YOUNG´S MODULUS New
(E) (Módulo de Young (E)) en función de la DENSITY (ρ) (densidad (ρ))
(Seleccione los valores para el eje x (densidad) y para el eje y (módulo de Young)i; por Graph stage Choose x, y axes
defecto, las escalas en ambos ejes son logarítmicas) Limit stage
(Los nombres de los materiales se pueden poner de la misma manera que antes –
seleccione la etiqueta con el nombre de un material y sin soltar el botón, arrástrelo Tree stage
para ponerlo en otro lugar; use la tecla DEL (borrar) para borrar la etiqueta)
ELIMINE EL STAGE (ETAPA) (Haga Click con el botón derecho sobre el STAGE
(etapa) y seleccione DELETE (borrar))
Density 3
kg/m
Price 3 $/kg Results
All stages 3 of 67 pass
Mechanical properties
High carbon steel
Young’s modulus 200 GPa
Low alloy steel
Elastic limit 1000 MPa
Stainless steel
Tensile strength MPa
Hardness – Vickers HV
CFRP
Titanium alloys Ti alloys Steels
Al alloys
1000 Cast irons 1000
Aluminium alloys
CFRP
Mg alloys
GFRP Soda-Lime glass
PEEK Nylon
100 High-C steel PS
100
Line,
Polyethylene Polypropylene
Nickel alloys
slope 1
Cu alloys
Rigid foam
Flexible foam
0.01 0.01
0.1 1 10
Density (Mg/m^3)
Graph stage
(Resultado: aleaciones de Al, aleaciones de Cu, aleaciones de Pb, aleaciones de Mg
y aleaciones de Zn) Limit stage
ELIMINE LA ETAPA (STAGE) Select from materials
Tree stage
or process tree
(Resultado: una lista de 10 procesos de unión que pueden ser usados para unir
termoplásticos )
ELIMINE LA ETAPA (STAGE)
Tree stage: materials that can be extruded Tree stage: processes that can join thermoplastics
Usted verá:
Casting Ceramics
Ejercicio 11. Guardar las etapas de selección como un proyecto (PROJECT) File Edit View …..
Save project
Print …….
Change database
(Los records (archivos) que se muestran en la página 3 y las gráficas de selección que Delete
se muestran en las páginas 4 y 6 se hicieron de esta manera)
(Advertencia: Existe un problema con Word 2000: las imágenes en el record (archivo)
no se transfieren junto con el texto al momento de copiarlo a Word. Se le puede dar la
vuelta al problema copiando la imagen y pegándola en un documento diferente de
Word como DEVICE INDEPENDENT BITMAP).
• Agregue un LIMIT STAGE (etapa de limites) para eliminar a materiales con FRACTURE TOUGHNESS < 20
Mpa.m1/2 (resistencia a la fractura < 20 Mpa.m1/2)
• Buscar entre los materiales remanentes aquellos con los valores mas altos de E/ρ y σy/ρ
(Regrese a Graph Stage, y haga click en el icono “Intersect Stages” (intersectar etapas))
1 1 0 0 1 0 0 0 0 1 e + 0 0 6 1 e + 0 0 8
Overhead rate C oh = ….
- LOAD FACTOR = 0.5 B a tc h S iz e
Batch size
M a te ri al C o s t=2 G B P /k g , C o m p on e n t
• Haga click en el icono GRAPH (gráfica) para ver RELATIVE COST INDEX
en función de BATCH SIZE.
• Repita para COMPRESSION MOLDING (moldeo por compresión), y compare el coste de hacer el componente usando
estos dos procesos, tanto para grandes producciones como para pequeñas cantidades (alto o bajo BATCH SIZE).
(Resultado: Compression Molding (moldeo por compresión) es más económico para bajas producciones (low
BATCH SIZE), Injection Molding (moldeo por inyección es más conveniente para grandes producciones, altos
BATCH SIZE)
• Como alternativa, represente RELATIVE COST INDEX para todos los procesos (para un determinado BATCH
SIZE), e identifique estos dos procesos para comparar su coste.
(Utilice un GRAPH STAGE para crear un diagrama de barra con el atributo: Economic Attributes – Relative Cost
Index, en el eje de las ordenadas
(Utilice un TREE STAGE: ProcessUniverse – Shaping – Molding, , seleccione e inserte “Compression Molding”
e “Injection Molding” respectivamente.. Haga click en “Intersect Stages” en el diagrama de barras, y ponga el
nombre en los dos procesos)
• Modifique el BATCH SIZE (tamaño del lote de producción), para explorar el coste relativo de los procesos.
(El nombre del eje da el valor actual del parámetro – haga doble-click en el eje para
abrir la ventana de propiedades de la etapa (STAGE PROPERTIES) – “Edit”(editar)
– inserte el valor requerido)