产品设计之经典系列-part and mold design guide-bayer.pdf
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1、Part and Mold DesignBayer CorporationTHERMOPLASTICS A Design Guide Part and Mold Design Engineering Polymers THERMOPLASTICS KU-GE028Copyright 2000, Bayer CorporationPrinted in U.S.A. 570 (25M) 04/00 Printed on recycled paper Bayer Corporation 100 Bayer Road Pittsburgh, PA 15205-9741 1-800-622-6004 h
2、ttp:/ Sales Offices: California:9 Corporate Park Drive, Suite 240, Irvine, CA 92506-5113 1-949-833-2351 Fax: 1-949-752-1306 Michigan:2401 Walton Boulevard, Auburn Hills, MI 48325-1957 1-248-475-7700 Fax: 1-248-475-7701 New Jersey:1000 Route 9 North, Suite 103, Woodbridge, NJ 07095-1200 1-732-726-898
3、8 Fax: 1-732-726-1672 Illinois:9801 W. Higgins Road, Suite 420, Rosemont, IL 60018-4704 1-847-692-5560 Fax: 1-847-692-7408 Canadian Affiliate: Ontario:Bayer Inc. 77 Belfield Road, Etobicoke, Ontario M9W 1G6 1-416-248-0771 Fax: 1-416-248-6762 Quebec:Bayer Inc. 7600 Trans Canada Highway, Pointe Claire
4、, Quebec H9R 1C8 1-514-697-5550 Fax: 1-514-697-5334 Note:The information contained in this bulletin is current as of April 2000. Please contact Bayer Corporation to determine whether this publication has been revised. INTRODUCTION The manual focuses primarily on plastic part and mold design, but als
5、o includes chapters on the design process; designing for assembly; machining and finishing; and painting, plating, and decorating. For the most part, it excludes information covered in the following Bayer companion publications: Material Selection: Thermoplastics and Polyurethanes: A comprehensive l
6、ook at material testing and the issues to consider when selecting a plastic material. Joining Techniques: Includes infor- mation and guidelines on the methods for joining plastics including mechanical fasteners, welding techniques, inserts, snap fits, and solvent and adhesive bonding. Snap-Fit Joint
7、s for Plastics: Contains the engineering formulas and worked examples showing how to design snap- fit joints for Bayer thermoplastic resins. A product of the Bayer Design Engineering Services Group, this manual is primarily intended as a reference source for part designers and molding engineers work
8、ing with Bayer thermo- plastic resins. The table of contents and index were carefully constructed to guide you quickly to the information you need either by topic or by keyword. The content was also organized to allow the manual to function as an educational text for anyone just entering the field o
9、f plastic-part manufacturing. Concepts and terminology are introduced pro- gressively for logical cover-to-cover reading. Contact your Bayer sales representative for copies of these publications. This publication was written specifically to assist our customers in the design and manufacture of produ
10、cts made from the Bayer line of thermoplastic engineering resins. These resins include: MakrolonPolycarbonate ApecHigh-Heat Polycarbonate BayblendPolycarbonate/ ABS Blend MakroblendPolycarbonate Blend TriaxPolyamide/ABS Blend Lustranand NovodurABS LustranSAN CadonSMA CentrexASA, AES and ASA/AES Weat
11、herable Polymers DurethanPolyamide 6 and 66, and Amorphous Polyamide Texinand Desmopan Thermoplastic Polyurethane PocanPBT Polyester 1 Bayer CAMPUS: Software containing single and multi-point data that was generated according to uniform standards. Allows you to search grades of Bayer resins that mee
12、t a particular set of performance requirements. Bayer Web site containing product information on-line. This manual provides general information and guidelines. Because each product application is different, always conduct a thorough engineering analysis of your design, and prototype test new design
13、s under actual in-use conditions. Apply appropriate safety factors, especially in applications in which failure could cause harm or injury. Most of the design principles covered in this manual apply to all of these resins. When discussing guidelines or issues for a specific resin family, we referenc
14、e these materials either by their Bayer trade names or by their generic polymer type. The material data scattered throughout the chapters is included by way of example only and may not reflect the most current testing. In addition, much of the data is generic and may differ from the properties of sp
15、ecific resin grades. For up-to-date performance data for specific Bayer resins, contact your Bayer sales representative or refer to the following information sources: Bayer Engineering Polymers Properties Guide: Contains common single-point properties by resin family and grade. Bayer Plastics Produc
16、t Information Bulletin: Lists information and properties for a specific material grade. In addition to design manuals, Bayer Corporation provides design assistance in other forms such as seminars and technical publications. Bayer also offers a range of design engineering services to its qualified cu
17、stomers. Contact your Bayer sales representative for more information on these other services. 2 Chapter 1 PART DESIGN PROCESS: CONCEPT TO FINISHED PART 7Design Process 8Defining Plastic Part Requirements 8Mechanical Loading 8Temperature 8Chemical Exposure 8Electrical Performance 8Weather Resistance
18、 8Radiation 8Appearance 9Agency Approvals 9Life Expectancy 9Dimensional Tolerances 9Processing 9Production Quantities 9Cost Constraints 10Assembly 10Thermoplastic Processing Methods 10Injection Molding 11Extrusion 12Thermoforming 12Blow Molding 13Rotomolding 13Optimizing Product Function 14Consolida
19、tion 14Hardware 14Finish 15Markings and Logos 15Miscellaneous 15Reducing Manufacturing Costs 15Materials 16Overhead 17Labor 17Scrap and Rework 17Prototype Testing Chapter 2 GENERAL DESIGN 19Wall Thickness 22Flow Leaders and Restrictors 24Ribs 24Rib Design 24Rib Thickness 26Rib Size 27Rib Location an
20、d Numbers 27Bosses 30Gussets 30Sharp Corners 32Draft 33Holes and Cores 34Undercuts 34Slides and Cores 36Louvers and Vents 37Molded-In Threads 40Lettering 40Tolerances 42Bearings and Gears TABLE OF CONTENTS 3 4 Chapter 4 DESIGN FOR ASSEMBLY 83Part Consolidation 84Mechanical Fasteners 85Snap-Fit Joint
21、s 88Welding and Bonding 89Ultrasonic Welding 90Vibration and Hot-Plate Welding 91Spin Welding 91Solvent and Adhesive Bonding 92Retention Features 92Alignment Features 94Orientation 94Expansion Differences 94Tolerances Chapter 5 MACHINING AND FINISHING 97Drilling and Reaming 99Tapping 99Sawing 100 Pu
22、nching, Blanking, and Die Cutting 101 Milling 101 Turning and Boring 102 Laser Machining 103 Filing 103 Sanding 103 Polishing and Buffing 104 Trimming, Finishing, and Flash Removal Chapter 3 STRUCTURAL DESIGN 45Structural Considerations In Plastics 46Stiffness 46Viscoelasticity 48Stress-Strain Behav
23、ior 50Molding Factors 51Short-Term Mechanical Properties 51Tensile Properties 52Tensile Modulus 52Tensile Stress at Yield 52Tensile Stress at Break 53Ultimate Strength 53Poissons Ratio 53Compressive Properties 53Flexural Modulus 53Coefficient of Friction 54Long-Term Mechanical Properties 54Creep Pro
24、perties 56Stress Relaxation 56Fatigue Properties 58Structural Design Formulas 58Use of Moduli 59Stress and Strain Limits 60Uniaxial Tensile and Compressive Stress 61Bending and Flexural Stress 65Shear Stress 66Torsion 67Designing for Stiffness 67Part Shape 70Wall Thickness 71Ribs 73Long-Term Loading
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