Automotive Platic Part Design

Venue: University of Michigan

Location: Dearborn, Michigan, United States

Event Date/Time: Jul 17, 2008
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Description

Seminar Outline
Plastics Materials and Automotive Technologies
North American Automotive Plastics Usage by Segment
Interiors: Infotaiment, Instrument Panel
Exterior: Mega Front End Module
Underhood: Upper Engine Module, Brake-by-Wire, Steer-by-Wire, Active Suspension
Powertrain/Chassis: Hybrid, Run-Flat-Tire, Fuel Cells
Understanding and Selecting Plastic Materials
Resins: Thermoplastics & Thermosets
Structures: Crystalline, Amorphous & Liquid Crystal Polymers
Inherently Conductive Polymers (ICP)
BioPolymers: Poly Lactic Acid (PLA Polymers)
Light Emitting Polymers
Electro-optic Polymers
Carbon Nanotubes
Reinforcements: Glass Fibers, Aramid, Fibers, Carbon Fibers
Fillers: Talc, Mica, Calcium Carbonate, Wollastonite
Additives, Effect of Additives, Physical Properties
Elasticity, Toughness, Plasticity, Notch Sensitivities, Mechanical Properties
Moisture Sensitivities, Processing Shrinkage and Post-Processing Shrinkages
Thermal Expansion and Contraction, Creep, Stress Relaxation
Automotive Thermal Characteristics
Automotive Chemical Characteristics
Material Initial Selection & Screening
Thermal Behavior, Automotive Chemicals
Dimensional Tolerance & Burning
Impact, Specific Gravity & Cost
Engineering Properties, Snap Fits & Hiving Hinges
Assembly Methods
Understanding Safety Factors
What is a Safety Factor?
Using Safety Factors in Automotive Design
Design Safety Factors: Static, Dynamic, Time Related
Processing Safety Factors
Reliable Automotive Brands
Operating Condition Safety Factors: Legal Aspects of Automotive Business
Rules for Proper Automotive Plastic Part Design
Boss Design for Different Type of Polymers
Boss Design Layout, Ribbing: Dimensions, Junctions
Automotive Case History: Mercedes Benz E-Class Seat Trim
Wall Thickness, Fillets, Part Stiffness, Undercuts
Draft Angles: Core Vs. Cavity, Texturing
Strength of Materials for Plastics
Stresses: Tensile, Compressive, Shear, Torsion, Elongations (Strains)
True Stress and Strain Versus Engineering Stress and Strain
Poisson's Ratio, Modulus of Elasticity-Which One to Use, and How to Use It
Non-Linear Considerations
Material: Linear and Non-Linear Polymer Models
Geometry: Linear and Non-Linear Models
Finite Element Analysis (FEA) and How to Use It
Design Optimization Tools: BMX, ISight, TRIZ
Theory of Solving Problems Inventively, Conclusions
Ultrasonic Welding
Equipment, Type of Vibrations, Ultrasonic Cycle, Troubleshooting
Design: Shear Joint, Energy Director Joint (Tongue & Groove)
Fixture Design
Ultrasonic Stake Designs: Flash, Hollow, Spherical, Knurl
Ultrasonic Spot Welding, Swaging, Stud
Heat Staking
Post Design: Round Solid, Round Hollow, Cross, Angled
Hot Plate Welding
Process, Equipment, Joint Design
Advantages & Disadvantages
Joint Area Strength Capability
Automotive Case History: Mercedes-Benz M-Class Windshield Washer Bottle
Vibration Welding
Equipment, Process, Phases, Cross-thickness
Joint Design
Welding Glass Reinforced Polymer
Fixture Design
Laser Welding
Equipment, Surface Heating, Through Transmission Infrared Welding, Staking
Joint Design, Single Movement Mode, Continuous Illumination, Mask Welding
Automotive Case History: Ignition & Trunk Keys
Electromagnetic Welding
Equipment, Induction Coil Materials, Bonding Agent
Joint Design
Automotive Case History: Mitsubishi Motors - Power Steering Fluid Reservoir
Bonding
Failure Theories: Adhesive, Cohesive
Substrate Wettability Tests
Drafting Symbols for Bonding
What is Surface Energy and How to Improve It
Surface Treatments: Corona, Plasma, Flame
Bonding Stresses: Tensile, Compressive, Shear, Peel, Cleverage
Joint Designs
Automotive Case History: DaimlerChrysler CCV Vehicle
Stress Cracking, Adhesives, Solvents
Automotive Painting
Adhesive Promoters, Primers, Base Coat, Top Coat
Painting Considerations, Painting Work Flow
Power Wash Parameters
Automotive Case History: Mercedes-Benz E-Class Wheel Hub
Press-Fits
Material Properties, Geometric Definitions, Safety Factors, Creep, Loads
Press-Fit Theory
Design Algorithm Methodology
Case History: Cassette Deck
Solution and Discussion: Case A, B, C, and D
Automotive Case History: DaimlerChrysler 300M - High Output 3.5l V-6 Engine
Fusible Core Injection Molding, Upper Intake Manifold Background
Design Requirements, CAMPUS Database
Material Properties, Summary: Geometry/Material Properties
Algorithm, Conclusion
Case History: Examples of Successful Press-Fit Designs
Living Hinges
Design for PP, PE, Common Living Hinge Design
Design for Engineering Plastics, Living Hinge Design Analysis
Elastic, Elastic/Plastic, Plastic Hinge Designs
Automotive Case History: GM World-Class Electrical Connector
Step-by-Step Design Analysis
Automotive Case History: Delphi Ignition Cable Bracket for V-6 Engines
Molding Hinges, Processing Issues, Coined Hinges
Class Exercise: Design, Material Selection & Processing, Tooling
Oil-Can Terminology & Concepts, Oil-Can Designs Incorporating Living Hinges
Software Demo for Designing Living Hinges
Snap Fits
Material Considerations, Design Considerations
Assembly Positioning, Assembly Motions, Yield Criteria Safety Factors
Cantilever Snap-Fits
Snap-Fits: Instantaneous Moment of Inertia, Angle of Deflection, Self-Locking Angle
Automotive Case History: One-Way Continuous Beam with Rectangular Cross Section
Finite Element Analysis Example
Case History: Hewlett-Packard Omnibook
Annular Snap-Fits: Shallow Groove, Deep Groove
Case History: Pen & Cap
Torsional Snap-Fits: Round, Round Hollow, Square, Triangular
Automotive Case History: GM World Class Electrical Connector
Deformable Rib Design, Springiness Rate, Automotive Recyclability Symbols for Plastics
Assembly-Disassembly Assists, Over-deflection Prevention
Tooling for Snap-Fits, Issues with Snap Fitting
Case History: Injection Blow Molded Bottle Assembly
Serviceability, Conclusions
Software Demos for Snap-Fits
Automotive Integral Seal Design
Design Issues: Integral Seal - Design A, Integral Seal - Design B
Structural Analysis: Step 1 through 7, Material Model
Engineering Stress-Strain Curve
True Stress-Strain Curve - Plastic Region
Analysis Results: Total Displacement, Von Mises Stress Detail
Simulating Leak Through Seal 1, Simulating Leak Through Seal 2
Processing Issues, Drying, Melt Temperature, Injection Pressure
Injection Rate, Screw Forward Time, Mold Temperature, Cooling Time, Screw Retraction
Tool Design: Mold Closed - Part Filling
Mold Opening Phase 1 - Gate Breaks, Mold Opening Phase 2 - Slide Moves
Part Ejection, Sprue & Runners, Gates: Tunnel (Submarine) Gate Features, Pinpoint Gate
Venting
Troubleshooting
Air Traps, Black Specks, Burn Marks, Dark stripes
Flashing, Flow Marks, Hesitation, Jetting, Parts Not Releasing from Tool
Peeling, Sink Marks, Shrinkage, Splay, Sprue Sticking, Unfilled Parts (Short Shots)
Unmelt, Warpage, Weld lines
Over-molding
Reasons for Multi-Material
Part Design & Material Selection
Indexing (Rotating Platen) Tool
Mold with Core Retraction
ABS, ASA, CA, EVA, PA, PC, PE, PMMA
Fasteners
Self-Threading
Recessed Driving Heads, Tread Forming
Clamp Load Vs. Time, Torque Vs. Penetration Depth
Type AB (Standard Thread), Type B (Standard Thread), Type C (Standard Thread)
Hi-Lo, PT (Plastic Thread), Free Body Diagram
Pullout Load Vs. Engagement Area
Assembly Stress, Plastic Boss Design for PT Fasteners
RS Plast, Delta PT , Polyfast, and Plastite Thread Designs
Automotive Case History: Threaded Assembly Calculation
Weld and Meld Line Present into a Plastic Part
Weld Lines in Parts made of Reinforced polymers
Thread Cutting: Type BF, T, Hi-Lo, RS Duroplast, and Duro PT
Pilot Hole Design detail
Tooling Considerations
Gate Design: Direct (Sprue), Edge (Standard), Film, Fan, Tunnel (Submarine), Pin (Point), Ring, Sprue, Spoke, Disk, Tab, Diaphragm, Valve, Hot Runner
Sprue Design: Reverse Taper Puller, Z Sprue Puller, Ring Sprue Puller, Sprue Design Formula
Runner Design: Runner Cross-Section
Runner Layout: Herring Bone, H-Type, Star
Processing Issues for Design Engineers
Melt Temperature Profile, Screw Design, Boost Stage
Fill Speed, Hold Stage, Tool Temperature & Back Pressure
Reducing Part Weight & Size, Increasing Part Weight & Size, Venting
Plastic Part Design on the World Wide Web

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