Plastic Parts Design_Autodesk

PlasticPartsDesignPlasticPartsDesignKevinSchneider,AutodeskMA32-2.Plastics“Polymers”Plastics-PolymersPoly(many)Mer(parts):AlargemoleculemadeupofoneormoreAlargemoleculemadeupofoneormorerepeatingunits(mers)linkedtogetherbycovalentchemicalbondsExample:covalentchemicalbonds.Example:polyethyleneorpoly(ethylene)n=numberofmonomersreacting12EffectofMolecularWeightonthePropertiesofPolyethylene3OutlineOutlineFundamentalsConceptModelsandLayoutsConceptModelsandLayoutsSplittingTechnicalModelingTheAssemblyProcessTheAssemblyProcess4DesignExampleDesignExampleFilenamingWallthicknessFillets,DraftandRibsDesignForManufacturingFUNDAMENTALS5AutodeskConfidential©2006TheDesignTheDesign6AutodeskConfidential©2006FilenamingFilenaming•DefineasimplelogicalnamingschemeDefineasimplelogicalnamingscheme•Stickwithit•Namesfor1.Skeletons(sklXXXX.ipt)1.Skeletons(skl_XXXX.ipt)2.Keepouts(ko_XXXX.ipt)3.Tooling(tooling_XXXX.ipt/iam)4Intermediatefileslikederivesorwrapperassemblies(naXXXXipt/iam)4.Intermediatefileslikederivesorwrapperassemblies(na_XXXX.ipt/iam)5.Toplevelassemblies(_XXXX.iam)7AutodeskConfidential©2006WallthicknessWallthickness•Unevenwallthicknesspresentchallengestotheplasticmoldermanufacturer.Designingyourpartwithuniformwallsandcrosssectionwillsimplify•Designingyourpartwithuniformwallsandcrosssectionwillsimplifymanufacturingandcosting.•Atwallintersectionorteessinkingwilloccur.•Thickwallscoolslowerandgreatershrinkingwilloccur.•Thinwallscoolfasterasthus,lessshrinkage.•Waystodealwiththisshrikage“a)Unwantedsinkb)Disguise(texture)c)Coreouttopd)Coreoutbottome)Foamingagent(structfoam)8AutodeskConfidential©2006f)Gasassistmoldingg)SpreadsinkovermoreareaFillets,DraftandRibsFillets,DraftandRibs•Yourrulesmaybedifferent…Yourrulesmaybedifferent…•Filletsshouldbemin¼XWallthickness•Filletsshouldbemin¼XWallthickness•Highstressparts,¾xWallthickness•Draftminof1degFinishaffectsdraft•Draftminof1deg.Finishaffectsdraft•Ribsshouldbe1/2to2/3ofthenominalwallthicknessandlessthan3timesthicknessinheightthicknessandlessthan3timesthicknessinheight.Taperof1deg.istypical.Note:excessthicknesspromotesshrinkageExcessribheightcombinedpromotesshrinkage.Excessribheightcombinedwithtaperwillproducethinsectionsrequiringextrafilltimeatthemold.9AutodeskConfidential©2006teatteodDesigningforManufacturingDesigningforManufacturing•Isyourideamanufacturable?Isyourideamanufacturable?•Whatisyourbudget?•Complexparts=complextooling=$$$$•Doyouneedtomodel:Partingline/SurfacesƒPartingline/SurfacesƒShrinkageƒDraftDraftƒEjectorpinlocations/pads•Whatdoyouneedtodeliver2Dor3D?10AutodeskConfidential©2006Whatdoyouneedtodeliver2Dor3D?DesigningforManufacturingDesigningforManufacturingThisClassassumes:ThisClassassumes:•Yourideaismanufacturable-YES•YoulikeKISSprinciples•YoulikeKISSprinciples•Youdoneedtomodel:ƒPartingline/SurfacesƒPartingline/SurfacesƒShrinkageƒDraftƒEjectorpinlocations/padsƒYouarebuildingthetoolin-house11AutodeskConfidential©2006BasicParametersWorkingwithinternalcomponentsLayoutsTheworkingModelCONCEPTMODELSANDOSLAYOUTS12AutodeskConfidential©2006MakeaplasticsTemplateMakeaplasticsTemplate•Make5UserParametersMake5UserParameters1.Wallthickness2.InsideRadius3.OutsideRadius4.Rib5.Draft•Addmaterials13AutodeskConfidential©2006MaterialsMaterialsCommonMaterials.xlsPlastic Properties Matieral Young's Modulus, psi Poisson's Ratio Shear Modulus, psi Mass Density, lb/in3 Thermal Exp Coef, 1in/in/F Ultimate Tensile, psi Ultimate Compressive, psi Ultimate Shear, psi Thermal Conductivity, Btuin/hrft2F Specific Heat, Btu/lb/F Cycolac DH 3800000.35140000.037883.90E‐0513000NA NA NA NA Cycolac GSM 3200000.35120000.03752NA 10700NA NA 1.22NA Cycolac KJB 3200000.35120000.044015.50E‐0510000NA NA NA NA Delrin 100/500/900 4100000.35NA 0.051234.20E‐0514100520095001.60.35Lexan 101/201 340000NA 1140000.043293.75E‐051420012500100001.350.3/Lexan 121/221 340000NA 1140000.043293.75E‐051400012500100001.350.3Lexan 141/241 340000NA 1140000.043293.75E‐051400012500100001.350.3Lexan 141L/241L 340000NA 1140000.043293.75E‐051400012500100001.350.3Lexan 150 340000NA 1140000.043293.75E‐051350012500100001.350.3Lexan 161/261 340000NA 1140000.043293.75E‐051420012500100001.350.3Lexan181/281340000NA1140000.043293.75E‐051420012500100001.350.3Lexan 181/281 340000NA 1140000.043293.75E051420012500100001.350.3Lexan 3412(20%GF) 800000NA 2030000.048781.49E‐051900016000100001.470.28Lexan 3413(30%GF) 1100000NA 2600000.051811.21E‐052300018000105001.50.27Lexan 3414(40%GF) 1400000NA 3190000.054959.30E‐062700021000110001.530.25Lexan 500/503 500000NA 1470000.045051.79E‐05150001400085001.410.29Lexan 920/940/950 325000NA 1140000.043293.80E‐051320012500100001.350.3Lexan PPC4501 294000NA NA 0.043295.10E‐0513800NA 98001.460.3Lexan PPC4701 338000NA NA 0.043294.50E‐0514100NA 106001.430.314AutodeskConfidential©2006WorkingwithinternalcomponentsWorkingwithinternalcomponents•DefinelogicalworkinggroupsforInternalsDefinelogicalworkinggroupsforInternals15AutodeskConfidential©2006LayoutProcessLayoutProcessCreateLayoutAblAssemblyCreateLayoutPartDefinecharacterc