CAD and Development 2 - Part 2

8/10/2019 CAD and Development 2 - Part 2

1/70

I.IHAT S

ASSE}ItsLY?

Assedb.Ly akes on various meanings f lod.conpany.to conPany'-We si l l

"""" iJ."

."""tury

to be

lhe

process

of

joiDing

logelher

conponent

p"rts

fo

foro

a conposife

l ten'

The

cor0Posi le

Palt

need

no

be

t l re

end

i i"J". i ,

la

courd

be

a

sub-assedblv

ln

a toachioe

or

a aachine

1n a

plant.

Sini lar l 'y

a conPonen

par ;eed

no

be an

indlvldual

i leD'

i l

I." iJ o"

. suu-assenuly

o a

oachlne'

see

Fi8ure

2'

Asseobly

has

TI{REE

isrlncr

Pnases'

*

HANDLIIiG

6lorlng,

EransPor lng, PosiEionlnS,

orientatlng

etc'

*

COI.IPoSINC

lhe

loj.nlng

Process.

*

CHECKING

eosullng

ne

asseEbly

9

satlsfeclory'

PRINCIPLES

F

DFA

The

fol lol ' int

l ist

of

I 'rules"

16

lntended

o

idcrease

lhe

deslSner'B

alrareness

of

asseEbly

lelsted

ProbleEs'

The

solulIons

are

no

beyono

;;;-;;;;4"

of

reasonabl 'e

hlnklng;

sone

anggesiLons

are

given

to

Ptodoi.g.

ldelas

.

."'N

d_,

,

_

u::

*

evota'

ranii

ing/nestln8

-

See

Fl8ure

3'

. r""irit.tl*i"ntation by Beking Parls oore sy,ure ricar or 1f

not

possible 1ncre69e

ltyoDetry'

_

See

igure

4'

*

M1nlD15e/eliEinate

ixlng

ha'dware

1'e'

screrB'

washers'

c11p9'

*

Use saap

flxlngs.

DeveJ,op

elf

Locarlnt/geJ.f

f ixlng

feetures'

Provlde

adequale

gulde

surfece6

4nd

chaEfers

e c'

* El lhhat e lnleErate part6 - See Fl8ure 5

Design

good bases.

Choose

siDple

Dovlng

palterns

-

See

Flgur

6'

V"

It

llake insertion

unanbYgrious

-

See

F1gure

7

Avold

lolelance

deEaods

-

See

Figure

8

Trv

o

Eee

Ehe

lequirenenls

of

lhe

sleel

col lar

I 'Jolker'

EveD

if

"" ' . . t . . i "- ."" . t t iy

is

noc

used

Eanua'L

assemoly

benerics'

See

Figure 9.

*

siEpl i iy

lhe

desiSn

using

idea

generalorst

see

Flgure

I0'


2/70

DFA

principles

can

be inpleEenled

Eanuatly

:t

*"::

q"i" l :-::::

corlDuler assislance. 8oollroyd aod Dewhur;t s soft\"are lefelred to

:;i ;;;^

1:";;;;.r i .".

i".r ' ' i ' i " i '

suldes

rhe

user.

throush

an,asserxblv

;;;; i ;;

;;

. ' r. i

""r

wav.

conside ,

for

exanPre'

the

conPorent-

shoen

in

f i rr""

l l .

Tie softrare

is

used

by

fi rsE

conside 1n8-the-1lem

to be

an

asJenb.Led

or0poslle

Part'

l {ex ,

each

cooPonenl

ln

lurn

rs.

i l ;;;;;;; l t

ieno,,ea

rroo

lhe

assedblv

and

lnforoal ion

rel 'atins

o

tt

. is fed

l l l to

the colnPuler.

Fot

exanple

PUTT]i.iC

THEORY

NTO

PRACTICE

Coropuler

a6ks

Neire of palt ?

ls

1t

necesSarY?

llow Eany?

Are lwo

necessarY?

U6er

rePl les

Nu

Ye6

2

Yes

Se.lect

oelhod

of

jolnlng

I scres

I

2

Press

f i l

3 cIaEP

Hotd

oany oPelallons

for ort intat lon?

I

The

questlott6 conl lnue

untLl

el l

lhe

lnforidarlon

for

the

psrt 13

led

lnlo

lhe

cot0pute .

Each

colrPonen

1s

lreated

ln

a 3io11aE

ney

and

at

lhe

end

of

t i le

exerclse

e

Prlnlou

for

the asselbLy

15

tlven',Fee

FLgure

12. As

the user

answers

lhe

questlons-end

afEer

lhe-Pl lniout

t i b"en

st lrat"d,

BiapLe

desitn

chenges

should

becooe

apParen

'e'

*

use sPeale

cooneclors

lnsleed

of

let-Dlnal '

screws'

* ose r ibbon sl le instead of 6ePsrale leads

-

;;" ; ; ; ; ; -- . i ; - ;arrep

la

te

with

ihe

base

bv Doul 'dl

rgl

s aepins

etc'

The

use

now repeats

lhe

exerclse

wlth

the

deslgn

changes

loPledertted

and

observes

the ef iect.

occasLonal ly

lhe

lesu1Es

ale

dranatlc

see

Figure

13.

Note that lhe

ideas

corle

lroo

rhe

deslgl ler

and

oo

fron

lhe

software'

WTiEN

SHOULD

DFA

BE

APPLIED?

*

1 is

never

too

earLy.

* I t is best aPpl ied lrhen everyrhing can be changecl '

PAGE 3


3/70

*

DFA

is a reviewiog

process

and should

be Eai l laioed lhroughout rhe

i erat j .ve

deslgn

cycle.

IIIL\T

BEIiIIITS

CAN DFA BRI IiG?

*

Reouction

in nanufacturing

cost

n

A be er qual i y

produc ,

*

A

producr

rhlch

is oore easlfy

Eaintahed.


4/70

oo

\J

ocC

4 Congoncnt

U*r

Aob-

c/'6,1hi^os

---l--t

r--1

tr , l

aaaen4vlies

I

r f I

M4onbr5

aalenbl5

e9l

er*b\

gl

a'.1

('yra_

4*s":\

A

ea"rhl.1


5/70

KI

N

u

N

N

N

N

il

N

N

N

s/

@

X

6

\stl

x

x

ttrs-T'le.

"1

*^rqu'*

:coeee

3

Avo

'5


6/70

x

x

I

x

+

I

Fr

qu*e

lrlCr-erSg

sv"*"y'^s^"t-SL


7/70


8/70

x

Frrr'uR"E

G

?A{{a}rg

oltir


9/70

-l-

r

I

Frq.ree

Mrrr


10/70

srEEL

q9 I,48

ASSEMBLER

dL6t-

a--.

E

ASSI

YBE

r8Y

ffisrqo3lwlqunur4oolrv

:WE&ii{i-ial-dii.o tEI}lIg

i

Usiffi

nivlrtlu ;f

nirtr

re

n

l:'-

9

tqu

zt


11/70

,ty*

sl}{PlrtrcArroN

IEA.

qnBAlggg

o lYbydocsthavc tblr rhapc?

o

Eor

rosld

I

dcslga t

ilI

had

to

bdH lt la uy hodd iortrhop

1

$ls1 if

thir

rcrc

tq . cd iuldc ont? Bcvcrrcd?

Upridc dora?

e

Whatif it

rcrc

lergcr?

Eighcr?

lao3cr?

Yidcr?

friclar?

.

Soppore

t

rctr

lctt

out?

r

Eor

cea

hic

bc

aadc

uorc coaplc(l

.

T6al{rh|r gbttcrr;mnctricdgrgyoncdcal?

.

C.n caElc rld

clfect

bc

rcvcrscd?

r D,cDoosFatror dcscrlbc bt rhlt tt bo"t

.

Coqlda

vcndor

supply thir f6s tlsg

r

Eos cocld

this

bc cbaaged or

quicler

esscnbly?

.

W'hstotAcrDetdalr

rould

do

thirfub?

r

Should

t llidc Lastead f rotatc?

r

Whatb riuilar to this but eosts Les? Wby?

r

Fh*ilit rcrc Eadc tighter or

fastcr?

.

W'hat otion or

power

s

wastcd?

r

Could

bepackagc

bc uscd or soncthing aftcrsard?

o

Eor

do

oocoupctitoa solvr

problcnr

tilrilsr to this?

r

Caa eaothcr

part pcrforn

the

firactioo?

.

Caa

his

part

or fuactioa

bc

coobiacd

wit'b

aaother?

.

Wtrt

U

hc

prcsent

dcsignof nctbod

rcrc

prohibitcd?

.

Eor

caa recondaryopcratioas

bc rvoidcd?

r

Caa t bc st.igbt iastrrd of

curvcd?

. Eorcanitbeadaptrdtoahighspecducthod?

r

Eor

could this

bc

aadc

casier o [sc?

o

Caa t bc nadc safer?

r

Could

aaterials

be salvagedor rrclriued?

.

Wbat

othr operation equcncc

could be tsed?

.

Wbrt

ceusc

could

produec

thc

snc

cffcct?

.

What

othcr 6elds have r

i.

kind

of

problcu?

.

Wty bsJr't 8nyonedooe

t

beforc?

i-

r

cn

,tai

lo


12/70

H

-

rr.ltlct.d

.G.1"

\

^t.';t,i,

"F*

(+)

scFE

: nol .art ta dlgl

-

ttrid.ti

lt.'91|i9

to'l

(:)

rrctrrrrr

-

-l

.att

lc

rllgl

-

...ar lrol.tl|il a.ur

/6)

aexct

xurs

-,/'

lrgcarlrlttign

,LtG,/

o

-

r.{sl?.r

tti.t'rr

'b+,

tatt

(.|I -.rr.,n ly)

(t)

xererutt

-

n .dr lrolCla a.ti

-

6ol

...t

t.

allln

fz)

s.

. rc ,Ys

' .r.ttgpprx

-

ltst

.r3y

tq

.lign

-

raru'lcltd

rcclr'

I

t

a

Frqoee

rl

TEIr|

OCi

(C"ttiont

h

tnlltl

tl'?

I

I

I

, t

o

' r

f

r a t

::L-'----'

-2.-,

i

'

:r:..

'IJSE


13/70

ASSTBLY

EQUI}ICE

rL0cl(

PIRTS

IST

lin o.dar f aJradlyl

lli0.

i - - i

---t

?ARI

1AIIE

I

CliiElrTS

i I i t{Atl$L I Pert r Flr( ld ito ro.l+ittur . I

'

---

I

--------.-------_--

i

i 2 i SCREI

I Pl.tr

.r .dr.d by

gtREl

I FASIENiX6.

(2

conrrcutiYa

parationa)

JINECT

i

Prrt ir tloTStC 88.rdirt.lY

I

i on

nsrrtioi.

r 1 | SCnEt

Put

rr. t .otrd

by SEREI

FTSTENIIIS.

l2 conrarutiYf

patrti n5,

l -- i - - - i

I I IFUSE

P t ir 5.Eur.d

y . PRE35

r

IIITERIERENCE

IT.

t t l

i --- i

------i

8l

LEAD

Prtr rr.

toTSEEURO.. dirt.lY

n

inrarti n.

(2

cooircltil

o0 rrtion )

IASHER

Pirtt .r

I0T SECURm.&di.trly

on

iEaatiol.

(2

Eoorratdit

g .tti

ontl

Pwt .rr rrEur.dt SCnEI

FASTETI116.

(2

conlacltir

Plrations)

F UIST

Oo

r ?o-t

b

rS

Lrr/

tle-e,.n'.r,tL

Fa

r l

-

oF

R'=uLts

Buoc f

Si't

a.

'r"r

t Ccstin$ otnilitory chictes


35/70


36/70

L Miscelloneousluniniunondzinc

coljtines

Covatand hscio castings

L Electrcnichostis

< Btdckets,evets

nd hondtes

L

Castingsat optrldt

equiptnenl

Y Bross,

unnetol,

phosphor

ronze

ond oluniniun bronzacostings


37/70

FROM

ASTINGS

O

FINISHED

OMPONEN

As uslomersncreosetheirdemondsorconrpletelyf

nished

componenhhich re eodyb rs

n

ieir

ossemblyi ies,

P.l .Cosl ings

oveespondedo l is equirernent.

inisl ing

operofionsn cosi ingson be underioken,uchos

mochining,lochloming,

iliing

f

hreoded

nseris,

oiniing,

polishing

ndsub-ossernbly.

L Aluniniutr' elac|,a.plical

bax.s, fin|h nochined,

dnodissd ond

point^d

lo

cuslan.B tp.cificolio .

L High stranglh

totnbss steal

conponentsi nish

nochinad

tor oircraft

door lockins

Knotterhook ossanblies

u

use

n

canbinehavettaft. he

.ostings

orenochined,hordened, olished,

.l.ctr'rpldtad

ond subassenbled

t0

Prototyp. bt pilslr diecosting

RAPID

ROTOTYPING

AND TEREOI.ITHOG

f

you

equireprolgtypm610lcomponenlsinodvoncof

roducfion

equirements

ih6n

P.l.Costingsonhelp

you n voriolswoys.

STEREOLITHOGRAPHY

Severolechniquesre ovoiloble o

enoble

our

designsto e okehrom omputerised-D olidmodelsnd urned irecllynlo

o

plostic,

ylon

or wox modeJ, ithinc molier f doys,withoul

he need or

tooiing. hewox

model on ien be used monufoctLre

n nveslmentosting

usi lg

ur bndord

PICAST"

'ocess

nslgel,loi. less,

rumiriur,roly 0$6r

moteriol hownn ourbrochrre.

leose sk or

ourseoorofeeb;led edflel.

PROTO

PES OR RESSURE

IECASTING

Invesimenlosling

ies

remony

times heoperion iools

or pressure

ie costifgondcon

be

produced ore

quickly.

he

motor or oilpon osling

shown

n ihephotogroph)

nobled ur

cusiomer

o fully eslcomponenh, oke esign honges

nd revoluoiehe

poris,

before

roducing xpensiyeie coslingools.

CADDESIGNS

To

meettheemondsfdesigners

nd

production

ngineers,

P.l. Cosiings ove nstolled 2-D ond 3-D design ociliry,os pod of o

sophisticotedolidificotion

odelling

opobility. esignson

be honslerred

from $e cusiomer y disc or

tope,

o enobleour technicol

tr:ff

o

study

componentsnd

give dvice t he

orl iesi

ossible

foge l design.hisoci l i f) '

can dlsobe used or

heproductionf

iooling.


38/70

DESIGN

ORNVESTMENTASTINGS

r-veslnerr

cosl i .q

q

.es

o wider reedon

ofde,iqn

Lo-

rrosr

-her e-ol

ro

rnirg rechr'ques,ro rhe

o

owi^9gL

de.

es"*,

e.oble

-e

oprirur

odvaltoges

o

be

90:

ed ho-

-his

.ocess

bul

p

eose o

o

.r

eipe's n ol

f ie

eorl iest

oxible

esiqn laoe o hotwe

qnwork

oqeiher

nd

advise f

how the de ign optionsmoy olect techniques

nd eco-nomics.

TOI.ERANCES

Slouldo-iy

besp"c.

o- cr ico' ond nc-io-o,

.ren.ro"s.

UnnecessoA

or over


39/70

INVESTMENT

ASTING

AN

ALTERNATIVE

OUTE OR

THE

MANUFACTURE

F

PRECISION

COMPONENTS

lnvestment astingolten

referfed o as the

"Lost

Wax Process"

may be definedas

the

production

f

precision

ast

components,til ising

n expendable

attern,

nd has he

distinctionfbeing

otonly heoldest asting

rocess

nown

o

man, utalso ne

of hemost

advancedechnologies

n the sphere f metalorming

chniques,

he nvesimentasting

Processs

unique

n tsabilityo convert

moltenmetal

n one

process

peration

o a inished r

virtuallyinished,

recision

ngineeringomponent.he

production

f a

"cast

o size"

component

ffectively

educes

production

osts,

eliminates nnscssary

achinlng nd

scrap, ndcan esult

n

considerable

avings n ools

ndoquipment.

THEPROCESS

Thsre re woalternative

rocesses

n use oday or h6

production

f

nvestmentastings nd,

althoughhe

"ceramic

hell"

rocess

n used

prEdominantly

hroughout

he ndustry,

block

mould"echniquesrealso mployed

o

give

evenmore

ersatility

n he ange l alloys ast

and,

n

many ases,

more

recise

omponent,

FINISHING

Diaqramtic Cctcn of

se.Mic StEll

Proc6

In both cases

the manufacturing ycle commenceswith the

production

of an expendable

pattern,

usuallywax,

rom

a

pattern

die. The

patterns

re mountad ntoa

wax runner ystem o

forman assembly,

hich s i n turn

invested"

ith

a finecoating f

refractory.n the ceramic

shell

process

he

pattern

ontinues

o be investedwith ayefsol refractory lurryand

stuccoed

with reiractory

particles,

nd

successive oats of refractory re applieduntila complete

hell

hasbeen

ormed roundheassembly.

ith he

blockmould echnique,

hebulkof he

moulds

produced n one operationby pouringa reiractory lurryaround he assembly ontained y a

metal lask , o

produce

solid

mould. n

eachcase, he mould s hendewaxed

nd hen

ired

to induce strength.

Molten

metal s

poured

nto

he

hot

mouldand,

afier cooling,

he refractory

mouldmaterial

s removed. he castingsare hen cut from he runner ystem

and

processedn

accordance

ith

he

customer's

equirements.

PATTEAN

ASITEMBLY

CASTING

INVESTIN9

|


40/70

ADVANTAGES

The manufacturing

echniques

mployed

n

the

productjon

f investment

astingsgve

advantages

verother asting

echniques,

hichgive

he

engineer

he opportunity

o achieve

ihe optimumequirements

or

hisdesign.

he

util lsation

f a one

piece

mould nd

heabsence

of

a

joint

ine.are

ust

wo

eatures

hich

g-ive

irtually

nlimited

eedom

of design. he

high

degreeol

dimensionalccuracy

nd

surface

inish

allow

cos

y

fjnishing

perations

o

5e

reduced

o anabsolute inimum

nd hus

acilitates

avings

n rawmateriais,

aoour

osts

ndexpenditure n capitalequipment. he use of ceramidmouldsaltows lexibil ityn

mouid

temperature,

hich ids he

production

f hin

walled

omponents,

ndallows

hesolidification

rate

o be

controlled

o improve

asting ntegrjty

nd

ulti;ate

perlormance.

Ili

pjg-"."-:.:_ilL"y:

_" lgl

d-"q 9"

f

.f

exibitity..with

egard

o

production

uantities,

ansins

rromprorolypes

nd

sma batches

j.e.

50

off) o

several

undredhousand

omponentsl

manufactured

y the atest

ostelfective

utomatedroduction

echniques.

neot ne

mosi

rmportant

eatures

f investment

astrngs

re

he

excellent

imensional

olerances

hich,

n

many

ases

iiminalehe necessily

or

inal

machining.

n

general,

linear

olerance

i t

u lJmm

per

z5mm

sachieved,

utcloser

olerances

n selected

imensions

ith

possible

improvements

l 1 0.08mm

er

25mm,.

owever,

mprovements

f this

naturemay

equire

additional

perations

nd controls.

ubject

o the

dlsign

of

thecomponent

nd with

due

considerationo thesize, reaandselectionf alloy,h; typicalmini;umwall hicknesss1.5mm,lthough

hinnerections

f 1mm

re

possib16.

heai-cast

inish

fan nvestment

ast

component

s

superior

o otherorms

l casting,

nd

s nfluenced

o somCegree

y

neattoy

type

ut, s

a

general

uide,

heCLA atue

ili

e

n he

ange

f

1

.5_3.2 icrometrei

OO_t

S

microinches),

lthough

gainmprovements

re

possible.

: .

Solechh ol

AeloiD.e ComtDcnts

PRODUCT

UALITY

The

quality

i

an investment

astcomponent

s nherent

n

he

process,

utrnorder

o

ensure

compliance

with

customer

Speciiications,

pproved quajity

and nspecron

proceoures

predominatehroughouthe ndustry nadditiono maintainingtandards, emoeroufor

es

-ave

access

o non-destr,ct

e testt.g

ano aoorato.y,ac.lit.es

-c

Ldi'1g

ye

pele.rarl

a^o

magnet part

cle

crack

detection, -Ray

chemrcat

nalysis

nd mechan;al

esting.

owever

ul isation

f al l

the facitit ies

il

dependupon

he

clas;li lca|on

l the

part

(i.e.

commerciat,

aerospace

lc) as

specfied

by the customer.

n

addition

o ndividual

usromer

pprovajs,

manv

ot the

member

oundries

old elevant

AA

N,4OD

ATLAS

nd BSI

aoorovals


41/70

CoDEaFL5 for

Et.ctronc AoDti6tiG

PROCESS UTOMATION

The ntroduction

f fobots t th moulding

tage

of the

process

s

oneof the mostsigniticant

developmentsn

the industry or many

years,

and has

dramaticallyncreased

hs capabilities

f

the

process.

Careful

programming

f the robot

o mimic manual

echniques

ives

the

repeatability

nd

conslstencyemanded l

a

precision

asting

rocess,

utmore

ignifjcants

the

capability f the robot o

manipulate eavier

moulds.

Weight,hsrsfores no longer

imilation

nd,as

a

result,

teel nvestment

astings

ver25okg renow

being

roducd

nd

castings

ithin 600mm

600mm 600mm

nvelope

re

now

ommonolac.he

oroduction

of

rarge.

and

heaver

"cast

to

srze"

nvestment

astings as

allowed

ew markets

o

be

explored, s well

as beinga serious

ontendero orged,wrought ndsand astcomponentswhere

inalmachinings

often

equired.

hisweight

apability

f he obotmay, lternatively,

e

used o

good

eilect or

moulding number

of smaller

multj-componenl

ssembliesn

one

operation. or

example,

ne assembly f 16

components

ouldbe moulded y

one man,

whereas he robot

may dip four

assemblies nd,

therefore,

4 comoonentsn a

similar

operatjon. his

combination llows

he

process

o be more

comDetii ive ith othermass

producrion

rocesses, ith

savings

n

both

costand ime.

Althoughhisaspect

of automationashad

a

significantmpact

n the

ndustry,

number f

othefdevelopments

re already

ndeMay

and many

are already eingutil ised. he

useof

steel, luminium,esin

and

rubber

orwax

pattern

ieshasseen iti le

hange n

recent

ears

blt

the useof modern

designand manufacturing

echniques,

uchas

CAD/CAM,

s

on the

horizon. lthoughnany

iesare

singie

mpression

ormanual

peration,ully utomated, ulti-

impressioniesarenowcommonplace here argequantjtiesre equired. heuseot "fi l led"

waxes or

he

product

n of

patterns

s not new

but mprovements

n hestrength ndsurlace

finish

and lower volumetric

hrinkages

ongoing

and vital o

the

manufacturef larger

rnvestmenl

astinos


42/70

PFTOCESSEVELUtsMEI\

Theuseof Directionalolidification

DS)

and

S

ngje

Crystal

SC)

casting

echnjques

or

the

production

f aero engine

gas

turbine

blades

rs Indrcative

i the continuous

rocess

deveiopment

ecessary

o

meet

the

performance

equirements

emanded f aero-enoine

components.

he

creepductii ity f lurbine

blades

has, n

the

past

been

a

limiting

acto;

as

aero-engineurbineswere

progressively

prated,

nd voids ni tiated

t transverse

rain

boundarlesavenowbeen

eliminaied y the

production

f

preieren|a

yonentated

olu;nar

crystals, sing el ined irectionalolidification

echniques.

he

prod c|on

of turbine

lades

withonlyone

grain

s

a

logical

xtensronnd

he ntroduction

f s ngte rystal

echnology

ith

modified lloy hemistry il l allowhigheroperatrngemperaturesc be reachedo meet he

optimum

erformance

equirements

f the

aerospace

ndustry.

Non

metallicnclusions,

articularly

and or

relractory

rains,

an be a

problem

with

any

casting

echnique ut,

size

or

slze, an be more

etrimental

s ar as nvestment

astinos

re

concerned,

ue o the

predominantly

hinner

ections.

he

useof ceramicilters,

heref6re.s

another

ecent nnovation

hichhas mproved

he

cleanliness,

nd hus

he ntegrity,

f both

ferrous

nd non-ferrous

nvestment

astings.

Oneof the

mo-st ignificant

nd recent

processes

o

complimentnvestment

asting s

hatof

Hot.lsostatic

ressing

HlPping).

he

process

nvojves

ublectinghe

casting o-very

high

levels

f temperature

nd

pressure

nder

controlled

onditlonsb eliminate

ny remiiniig

traces

of sealed

porosity,

ith

resultingmprovements

n casting ntegrity

nd mechanica-l

proprites,_nparticularlongation,mpact nd atigue trength, Ppingmaybecarried uton

a

varietyof

alloys,and its introduction

8s

added

yet

anothir

dimsnsion o'th

capabllities

f

investment

astings,

coNcLUstoNs

The

afo-rementioned

evelopments

epresent

major

tep orward

n rmoving

ome

of h

so

ca|eo

rmrranons

l investment

astings,

nd

he

process

s

nowbecoming

real

ompetitive

option

o forged,

rought nd

sand ast

components

here,or

many fplications,

he

nett

shape

an

onlybe

derived fter

ubsequent

achining,

onsultation

ith lhe

tounder

t he

earliest

pportunity,

referably

t th

design

tage,

wiil ensur

hat he

optjmum

roOuct

i

achievsd,

hereby

akingull

advantage

f

hecaaabilities

f the

process.

lnvestmentastings-a rowthechnotogynd s, ndeed, ntering new ra.Designersnd

engineers

like,

hErelore,

hould

ake

note

i hemany eatures

f oday

s

rnvestmn-i

astings

which

ncludei

* Virtuaily

nlimited

reedomn

design

*

Freedom

n

the

choice

of alloy

* Sizesanging

rom

a few

millimetres

p

to

goomm3

* Weights

anging

rom

a few

grams

o

over25okg Ferrous)

* Typical

olefances

l t

0.13mm

er

25mm ith

mprovements

p o

+ O.Ogmm

er

25mm

* Typical

inimum

all hickness

Smm

ith hinner

ectjonsf 1mm

possible

* Typicalurlaceinshot1.5-3.2micrometresith mprovements

p o

O.gmicrometres

nd

betler

i Variable

uantities

ateringor

prototypes

nd

mass

roduction

equirements.

BICTA

s fortunate

n

hat-it

njoys ctive

member

articipation

n

ts

affairs,hus

nsuflng

he

ongoing

evelopment

f the

process,

hlst

maintainrng

he integrity

f investment-cast

conponents.

o t'e

benefil .

user ndustries.

l^T: TEn.iy?

gu

de to

the

_capabitities

nd

speciatities

f UK member

oundriesFutl

MemDers)

availablerom

heBritish

nvestment

astingrade

Association,

oyton ouse,

George

oad,

dgbaston,

irmingham,

1S

NU.

et

NoiOZf

+SS_g-g7Z

-


43/70

Mai

Eilal or di6 ceeling

Table

showsa few

ol the

p.incipat

roperties

fzincdie

castjno

alloys onoaredwrlh

hose

ofo:"e, n-aLeriats

n

ddditjon

o

l're

properties,

here

are olher consjderat ions

h

ch

derermine

wheiherzinc

or anoiher

materialis he

most economicat

or

anv

pa4'cLlar

opl icar ion.Factors

hich 'ave

o

be ahennl o

consideration

re

speedof casting,castjng

emperature

wirh ts

consequent

ffects

on fuelcostsand

wear and ear

on the die

dirnensional

olerances

nd djmensional

tabiiity,

ompaijbitiiy

wi ' io lhe.mate. iats

Jo,arng

ro

trahg

apab.t i t |es,and

ne

possibilities

i applying

lectroplaled

r other

nisneswnere

Zincdie

castingscan

fien be

produced

more

qu

ckty o finer

tolerances

ndwith

betlerfinish han

die castings

n other merats

In addition incdie castings ave noreDossibititiesorjnteqral

fixi_g,ar

o willaccepl

eaoilya w'de

rd.ge

ot appt|edinishes

Severalkinds

l alloys an be

oressure

ie

casi.The ssential

principies

i

pressure

le caslingwere

irst usedmorelhan

10Oyearc go n

casling

printers'tyD

n ead jn

alloys,butihe

exlensionofthis

technique o the commerciat

foductjon

f

engInee ng

cor.

ponents

was

delayedbecause o suitable

trong

al loywasavai lablefordiecast ing.Therewasnorealchangeunti l

lhe developmentin he

1930's f the wo

principalzinc

ie casting

alloys

which

emajn

essentiallyhe sameafter

over

d0 years.

'Ihey

a.e specified

n BS1OO4,hichwas irsi

ssued n

1942.and

hasbeen evised

nd

updateci

everal ims.

Since he zinc

die castirg alloyswere developed,there

asbeen

considerable

rogress

n he echniques fdie

casting luminium

alloys,ma9nesjumlJoys,copper

l oys and even

errous

alloys

(stainlessteeD, ui ofthese only aluminium ie casting ttoys ave

come o equalin mportancethe

olderestabiished inc

arloys.

l'ro.e ecently,developrnenls

n

plastic

esinsand n he technoJogy

ofplasticsnroulding

rocesses

aveallowedih

oroduction

f

a wjde range

ofmoulded componeniswhich

can sometimes

competewithzincdie

castings n hoseapoljcations

Where heir

lowerslrength

an be

shown10be adequate.

qec{ros&d

4rsoiMo

oed

7tnc.

.1..,.

}'-'t

(' ii

:_

. , f i .


44/70

Osigning dle

cas

Section hickness

Sectiorls

houtdbe

ofa minimum

hickness

onsislentwith

ase

oI castj-g

a.d

adequale

trerglh

and

stiftness.t

|s

minrmrses

he

werghl

or rnetarrequ,red

nd

speeds

up sotidificaton

n he

dre

10

ncresse

roduction

ates_

hjn

sections

re

stronoer

n

proporiion

to heir

hrckness

han

are he

rhrcker

nts

bcause

ihe,strongerfine

raind,skjn

ormed

during

he

nitiat

cooting

maKes

p a targer

ortion

ofthe

lotat hickness.section

hickrss

should

beab

nearlyeven

s

possibte

nd

where

vanalons

are

necessarylransilion

rom

hjn o -ick

snoutdbe

gmdudtraiher

rnanaorupt.

Therearevery ew shapeshatcarnot be ciiecast. ndercuts

orolheriealures

requiring

moving

oarts

cores)

n

he die

ncrease

cosrs3fd

stow

down

productof.

Comer6,f

llts

and

blends

Sharp

corners

hould

be avojded

as ar

as

possible.

ternat

adii

areessenliarand

rsdius

s

generafly

esirabre

n Dorh nremal

and

exter-i

c osed

corners,The

aorus iven

o

corners

neeonor

oe.rarge.A

adius

of0,4mm

hasan

apprec,abte

treflgthentng

efieclyer

sbare'y

noticeabte

ven

on

outsrdeedges

arger;adil

are

proporliondtely

ore

effectrve

nd.parrrcutarty

n nsir,e

eogesj

renol

apDarent.

Thre recrtain

eneratdesign

oinlswhich

ave o

befolowed

to

gel

hebesl

possibte

dvantages

rom

diecasling_None

fihe

points

jsted

low

arehard

nd asi utes,but

sed

with

udqmni

theywillhelD

ovotve

tog;cat.emcie,rt

ndeconomicaj-toiasr

design.Many

iecaslers

ave weatlh

f

practicat

xperiencen

clie aslngwhich

an

enabtehem o

suggestpossibtyuite

minor

desjgn

hanges hich

an

grealty

tfect

he

efnciencyand

e@nomy

ithwhich particutar

omponent

an

be

Droduced.

ll svery

usetultherefore

o consutta ie

casting

xp;riat

anearty

slage no

oerore very

eature

ta desrsn

asbeen

inatised.

T}|e

nc Development

ssocration

itt

ffe. mparriai

dvice

n

thesuitability

f any

particutar

signor

cti asting

nzinc loy

o. he

useolz'nc

dje

castings nderanygiven

onditions_

Although

xtremelyine

oteranes

anbe

produced

nzioc

ie

-castings,the

inerthe

oterance

he

grealerthe

ost,because

f

tlnencreased

rec|sron

equned

ndie ras

ng.

nachrne

.adjustment

nd

diemaintenance.Desiqners

houtd sl or

lobrances

o

closer han

renecessary

uidetineolerances

of

most

coromicat

roductron

re

gj e,1In

ngineering

rdndards

]oii9sdFsigz(Ab]De


45/70

Section

hickness

Spcl ionssnoJro

eof

amtnimun

hickness

ons,stenr

rthease

or

caslng

ndadequate

trenglh

nd

trfiness.This

inrmrses

he

weighl

meral

equired

nd

peeds p

sotidificatjon

n he

die

ro

ncrease

roduction

ates.Thin

ecttons

re

sboooer

n

proportion

o hekthictness

han te

he

hrc\er

n;

bcause

lhestrongerfinerained

skjn'formed

during

he

niiial

ooting

makes

pa rargerportion

ith6 otal

hickness.

ection

hick;ess

should

e

asnearlyeven

s

possibte

nd

where

a.iatons

re

necessarylransition

rom

hin o

hjckshoutd

e

graduatrather

Undercuts

There

re

very ew

shapes

hat

annot e

die

castundercuts

o.other earuresequ,ring oving arts cores)n hedie ncrease

costs

nd

low own

prcductjon.

Comers,

itlets

and

blends

Sharp

omers

hould

eavoided

s ar

as

possibte.tntemaj

adii

areessenlial

nda radius

s

genera

deskabte

n

both ntemal

and

exlerralclosed

orne,s,lhe

aoius iven

o

curners eeo

or

De arqe.A

adius

f0.4mm

as

nsppreciabte

treoglhening

e'Iect

el,s

bare

noiiceaftb

ven n

ou6ide

edges,Larger

adii

are

proponionatety

ore

ffective

nd,

articutariy

n nside

eoges,

re

nolapparent.

Ribs

Ribs nbeused

o aid he

lowot metatioro

hin ections

nd

o

stffen

hem.]l)e

hickness

f he ibshoutd

otexceedthatof

adjacenlectionso avoid

ausing

shadow

n heback.

Bossesbould

metthe

eqoirementsforeven

al hickness

ancl limones

cn be

supported

by buttresses.

Sudacee

Large

plajn

lat wall

surtaces

houldbe

avoicted

s ar as

Dossible.

andwhere broad

urtace

's

necessaryslighr

urvrng r

enuring

heFs1o

void

nsiqhtlv

uperficiat

temishes.

Thr6ads

Extemal

hreads

areeasily

casl

particutarly

l they are

ocated n

lhe

partng

ineof he

die.Internd

hreads

anbecast utare

genrally

roducd

nore

conomicatty

vmachinrng

ter

cas

,ng.

Farrarhreads

aybe

adequateormary

purposes

nd

an

be

produced

ery

salisfaclorily

using lutetess

apswhich

create

a stong rolledhread

n a

cored ole.Atternativety,threadroljng

lJ

-9b

+'

l ]

:

. . : i :3c-:.

'

il

1e*"1i

at

-.

. .-. ' l

':

t,

r-

,tr8

,.-,,=.1


46/70

I

Elbs

cn be

u5d

o aid h

low

ot

ro6tst

nto

hin

sctions

ard to

stffen

lhrn

Th6

hidaEc

ot the rib sholtd

not

6xcd

hat of

adjacflt

seclicns

o sr'oi{t

causing

shadow

on h back

8q6.6

.

Bossa liould

met

he

requiremnts

or

6ven

walt hickEss

ano $m ones

can

be supported

by

bultssss.

Thr *

Extenal

tcrea&

sre

easity

as

padicr|tarty

f they

ar ocats


47/70

Material

roperties

i*

V_.9-ti1"l

]IP rllel

c-9q 9

a;adiu;

nn

3.4-4.3

3.a-4.3

0,03-0.06

o.75-1.25

0.03-0.06

0.10 0.10

0,006

0.005

0.005

0.@5

0,oo2

0,002

Trbl.

2: Comp.ntlr.

ch.n ol n t.rl.t

Drlrrrt..

srorsrh mooLtuB

6.ono. ro. rs.stalc.

9;"ty

N/mhr

N/mm.

?. J

l.mp

t6mp

i6mp

rdsiiCrvtoiiiuito

37--sd

.--1400-i7io

-E:if-- -o-7

''-so-120R

i

o--i,

lc-tat ionooorc4 66 :soo-3400 ta-?E

*0.9-r.6

t2oi

c-6iyirroc

yroi6r6

-

6-r+o i2ooi27oo

6o-3ijo

-

o.o-rr

166-,,6- ,,;

trorlca|bdab-

_

s4.6_1-

-

226__-..-0-100

_

t--

-i16R.-

--.r,j''

edivi'i6pv]lirJ

2e::3i-

-

l-1oo-isdi

20-o--7oo

o.a:i

---

sb--l1oR

ot-

Foltit-'.. (hiohl'ripacij-

i-5t 1,ibo-30b6

.2-4.5

--

o-- .s

.iio-i2oF-

1.oE

Zf|cAl;t65dtdoyA

i;t--i-d6---roooijo'.-'iE-E

-s8'.'--

b6a3i- B"j

zi;caii;tBslooa.raiB

0r-$5

Aruminiuft;ioiBli,ied

io

220-24A

2b64iii

100000

8-14

f4-724

6.7

2,8

60

60

400

M;tn;alum lloyBs2eTo-

Br;s;Bs1,iooaBl

Sii;rBS97o(hotroE.d)

Ata.?852872C2122

(ho1to.g.d)

ii,i;ilal.dsc.rptlon

Ads

;;ltroniiir,

44doo-

2-t

lbsooo

ia-4o

206000 _ idllio

105000

aa

'-.

o-ibt

B.g

(mrnrmufi)

34

60-1008

3.4

--r i -

55-678

18

9dip

? nm/ryn

Selt

2BOB

1.e

8,1

E,6nc.t

+tr6'iar

r,near

Spicrrc xcar.

prop.rrr.s

conducUvfty&amlon

h.ar

d.i.c on

w/m/rc

co.ftctgnt

l6mp.fglur6

p6rrc

rct

ior'

Lgrio-'

5.sx104

0.3-0.

dd-oo

buladinBBryr. f6)

ohm/m/mh:-3.4xlO_,

-1 lx1O-

Aiitari troi i idpotvmeo

-a.5tlba'2.a;loi

sri lrr

-o.as

-

6

ohm/m/mmz

Foryfiiae

tldn

/ icd"

'' z aro--Foi

io-a

a.t'

$lfflllt

ohfi/h/mmr

ioryca;bonaG

-

iotr-- i.6xior

-

6.6iidr

ohmh/hh,

Polypropylne

'0

12110-

St irCr ote

(hohopolym,

ohm/nhm,

-io.2x1o-u

Polyslyrr.

h

gF

rp.ctr

roa

r '2 i i t l

-

3 xO' .

032-0.s7

o.mh/trF,

-r2.6x10

,

-7x.0-

zin i ; ' ratBaloo&r

oy t5.7

1.13110r

2i 10.

OO3

4 ' lqll'r.

130

rcallovBS1OO4

0.093

Nl

Nt l

oyB 15.3

r.ogx1cr 2.7x1O-6

ohh

'/mhm?

'Thesealroyq

anbe usedund6r

hoderalestre$artemporaluros

plo

aboui200pC

pndino

n h6irheal

lleatmenl,

lc.Advic6

hould 6 60ught

on hlqh amperatuf

applicalions

l

tBs272

Method 02c.Slress

181N/mm

.

This esihelhod

s

no i

normally

sed

or metals nddalalor

2 nc

alloysa.nc

udedlorcomparison

Alumn,-ma,roy

1.

Ztalo-

23rto+

4.21

Ni l

as149oM 4

di6

.sr) ohm-lm/mn'

MidGiijh

alby s2eib

is

1.sx1o-

ajxlc

-a24s-

.

Faprd;

MAGT(dlca69

ohm_'/m/mm,

finety

dia$bslaoopaBl

it

osxib, rrx1o.-

o.oe2

.

fl;leqJgrJ"

(diecast) ohm ,/m/mm,

Si;ei6ss7a

sl

o.sx1f

lzax1o-

oios

(holrorg6d)

ohm- /m/mm,

d:ra$B{tdiacz

2

.5.1

'o5r:0.

2.o, io-

(holtorsed)

ohm

,/mhm:

Ni

Ni i

.092


48/70

Avaitabiti ty

MERCHANT

AR

Regular

rades

ave

a minimum

rder

equirement

r 6 tonnes

er

tem

ndnon-regu

r

grades

eneraly

he

pro-

duct

of a heator.

s[ibject o negotiation,

arl

hereot.

Table

4, Merchant

Bar

Regular

nd Non-regular

Grades

Product

Fegular

Grades

Non-regular

Grades

BHP/AISnd AS 1442crades

tvi i ld

teel

Si oo6j 1035

Bods

nly)1o5gt

cs10201030

1040

R1ol

s10061 008

10101015

1020

Rods

nty)

lo3ot 1oso.f

o7o+

082

10211025

10401045

1058*

R1008

Kl016

10221030f

10401045

1050+

1055

1070t

cs1100

K1i37+

1146

s12114

xsl

112

sl214

xK1115i

xK13201335+

340

13451

BHP/AIS

nd AS 1444

Ghdes

xK51sot

51s5

5160+

xK9050+

xK9255+

261

AS 1442,

S |

204

AS

1442lS1

3 55

56

AS 1442lK5

6 KS

AS

12O4:250

50i

BHP|AIS

ndAS 1447

crades

K10705+

xK5150St 155S 160St

XK9258S

Flats

nly)XK9261S

Shipbuilding

Gedes

Lloyd's

Grade

A

BHP.AIS

nd AS 1442

cisdes

Mild

Steel

csl020 1030

1040

sl010 10251040

1045

s1214

Kl022

1040

1045

AS

1442lK5

BHP|AISnd AS 1442ctades

N,lild

teel ully-killed

K1022

0401045

AS1442lK3

5

BHP/AIS

nd AS 1442

crcdes

xRl110

xs1115

xK11t5+

1152

K1137+

xK1315

1335

345t

Rounds

Squares

Flexagons

Etals

,ds'

Rd45

xK51sot

51601

xK9050t

xK92551

AlsTen

1

AS1442,/54

AS1442lK3

K4

AS 1204:3501

K1070Sl

10825xK5150St

160Si

t

I

Bounds

Sq ares

F1exagons

Flst8

Bods'

I

t

t .

*io"'^ts

Flounds

110

o170

mm

I

I

Large

Rounds

180

o 215mm

Lloyd's

Bivet

XK9050

Kwinana

nly)

AusTen

AS1204:

50

(Kwinana

onty)

I

l

Lioht

I

I

N.,titd

teel

cs1020

10301040

s10251040

1045

BHP.AIS

nd AS

1444

G?des

Angles XK905o

AS 1204

AS 1204: 50350

Shipbuilding

cedes

Lloyd's

crade

A

' Rods n

coil lorm

are

avartabten

rnany

ot the

grades

isted

above

nda{so

n steet

eintorcing

ar

grade

AS 1302:230R.

t

Kembla

nly.


49/70

l , foeK

- l

.n

t-z{ta

UNIVERSAL

SECTIONS

Table

8. Dime|rrlons

and Properti

ot Univercal

Beams

noi,-/oi,c

panrs

+"

...J--,

ii.J"

y\," e.1,,p,""-

DEA

mnz/mm

to6mm. 1o3mm3

o3mm3nm

I O6mm4

O3hm31O3mm3

mn

T

50 7

646

547

25 0

37.3

266

o

zse

f

164

q.

66,

?

o

" . .

rar i


50/70

. : :

2. Tim.

to conducl om

cilort.

tlorF.atura dif,ar.nc.

of 1oc.

1qm0

1@,0@ {Seconosl

of h..t

6rou9h

a crnim6rf.

cub.

of

nEr.rllt

wtrh

.

Plastics

6re suitablg

or

mass

production

mtfiods

By definirion. t.stics

catr

b shap.d

under rh6 innuenc.ol hearrnd prejluro.

At

ordinary

empsraiures

hEyhav

a

high

degrot torn

srabitiry

and by

the

use or

propgr

desisn

procEduros

h6

corect

th6pE

snd sizo

of E

camponont

cEn

be dl6rnined,

Bcaus6 tssrica

dre

ol lowr

densiry

hEnmosr

meEts-

dnd

Bven

ot tomo

orher nat.iat

of

consr cr io.- lhs

weighi

ot 6n

aft icta

may

be

rduced

onsiderably

y ls ing

prasr ics

omponenrs

fd ot 6n,

oo,

tr cost may

b0 low6r

In

g.nerat

h6

srrngrh.nd

igidty

ot

plast ica

.6

.ow6r

rhan

thoss

ot herats

6.d

this

tnds o read

o undeFdesign

rh6t

tn6n o

ovecdet isn,

hich

3

otren hE

cas6. ln ppl icar ionsl th6 ch6eo.

t

tlvhn

(lt

661

Fl

Nylooclars-fdled}

@F/C

E ,b6tos

{ bpe.)

+l

, t l

-zitEl

-SrFl

.^l

I

Erass

Atrninium

i

E

E

a

.n

,shapi ig

by h6r in9

nd

rcssi ig

ro

a

pr6d6t6rmin6d

ould

shapehss

many

lrtrrctions ior

rho m.nutsctur6r,

h

ruducos he

d.9r6.

of opor rot.skiil

r.q ired

8nd it

c3. vinu6ly

tihinara

rh

gr.ar

buqbar

ol th ,noratmachjni.O

procosFrho

g6.6rrtion

ot scrap.

In

l.ct, dhy

lcrap

prcduco.t

during

rh

proc.rshg

ot

phltics

c6n

ohon

bo

. cov6r6d

.nd

6-wort.d

wi$in

th6

l.crory. Tl.o

i3

g6n.r.

y

.o

n.c.t3itv

fo

it

to bo rtumod

o r

mrnutacruor

or l.ctof

.s occu?

wirh

m.t.t,

.Funh.rmoru.

r.producibithy

d p.nd

not on ihr lkill of rh. op66tof hr t

on thc

lccuracy

of

th. orjgtnll

mould-nrk..

fld

on th. wly in

which

.th.

mould

t oD

In rh m chjn..

Mlny

'engin..dno

firms

now .. in

tr llica

proc6ssing

or

.oh6rhing which

'

b

hight

complic.r.d

.nd byond

h.

ordin.ry

.ngin..r'r

.kilt bur r'har

ln


51/70

.,

.Ooc

old ozo'c

d

NYdr66

ii;

zut

"oor"ato

o"

Fbv(rurh/ rnltu(.yrate)

18ooc ooteo

o

2ooc

{

t95oc oec to 2ooc

5. Vo|.ulnocontriction

on coolt|g.

. Enthalpy ol

platic.

l|rd m.b e

(r6latv6

ro

20'C)

a

proRsir|g

cstrs l:rlCtCcr

':-.

':i.Ii..:.;--

ii-:t

u


52/70

l"*f*ly****f"i$"'Ii:.:Lr;jffi;;r|'jffi

lr':.r.'"#jj:l

'qeryo

rne

cnemtcar

caat'on_...

tn|r

ploc8lsing

tsmpraDrr63

ivino.

krng

ro Ult

p.opniea

sllch

_:r:.

off abho{ious jms.

6nd

nyt6n;

u-d

_

tsrb, l i ty

l ld.v i3cos' ty. 16.

.

.

.cryt ic

end o dpotymr:a

t.

. . .

vrrying

durrng

Proc6esln ,.

;

-..

ramporsrLroE'.

ew

degreshiqh.r

tb;n

:.

::.

.l

.

..

l.i ;',

.': oos

'166d

in proc6ssing.

Tls vot6tjt4

city

and thetrnal

:

:

.,:,:.j:.'..: lgucr

,wlrlcn

c.sutr

lusa rho

wsla

i,.-:,,.

rnarl

.:

;

:.: ;: :^':'-.1:;J.,:: ::'i .:;-"::i::'-::-:

'

'

;q;;;G

"l"dr;;,;

_&Fi

'|6y

ao;sisr

t;

-:-----,.rt:-..:1.

:'-'-_r;

nos

,r66d

n proc6ssing-

Itvot6tjta

rhrough h

dis along

wih

the marrisl

3nd

gilon

a

prsric

coaring,

Ptasiics

;;-;i;* ;;d;d; ; ;;i'v;;l;;

-.;.:i

Heat

GFacity

and 6errnat

:

:

. :...

.:.'. producE

wntcn

c.surr

lusa rho

wsr|

tm$'tui-txi;"ii'lTiq]ilf"'iff""JY,"-;*;; ;" ;,;r:t, il";1",".1",Tffi:lr:'eta:l"n'Jkh

msr.tlarden..Dylv,ooradon t in. r:

..:c,.Pscrry

0r enfilrpy

ot lomo

typtcEll

. r.

|n

gonrrr,prastic

aholtd

bs

procassod

.ot#iL.tns ta$sr

;st6ftst.,oiin clttd

.'$.rooPlasrcr

6t

tnir

p.ocsslng._r:-.

-:il

r 6

low63t

po33ibl6

srnpraturr

on,

, 6.ir.si.nid

will

n.rden bv funh6

.

.

.j:::

tmp9tEturst

comp.red

wir

rho

'

i. .,3t6nr

wlh obrijning.

cathfactory

*,ir:fHtTiff"tuT:,..::,:.:;;..;;"]effi"?1"?:;J.i^,.,"H,,i,I.,".".;,"

iil,"f:JT;flT,iJT#gff"::*,

qr.9*ss.(.

1d1

riisgcs":

.

'

'

.

:

:

.r

.'

li#i,'j:'# ,",XH"fi';

,#J',j:"

*"':l'

dourd

-

$'i tt

po ibr'

For u,r ejcdpdon

t

u lnltd

-

(dnporaturcs

"re

,sriiiwry

.;i;;

"

visc;siry

and

compresififty

"

proc s *

for

planica

mt.rrco

outd

ro',i

near n

u.

pranics

i very

*",_ elllili

_*,, n.ve

vry

h,shvircolido,

9t-dlj-_llJ ::ll-

"I;19-Il:

'9to:

.,rhi

hishhoot aplciry

acc;;parrd

;;;;;i""r

""61"

ora i,c.1.r, ..

s,.r1.".Tr* -'.4':-.1;Iii4fi,

ii:-,J.''i,illi',iiji'^:lli,

p',T.i:3ifr:

:3,'HT:"":trJ,8,:f".":"1"?,

.ors z Ino,caror

ne haitr

rMsss6e Ery.tow

rhlrn.t

conductivity

of

;;'r;;"

_"y

.s

do mtar .nd.manv

End intt

th.m with

$. rorm r

Dr"stic

.d

tn6k eh v-6ry

oor Jii"i-l"irs

;1,rci,.ii

ii-i;;;;;:il,

which_m6te

alE aro.vailabl..

iEsisrance o trear Fig

2 iohparue

ttre

ii u

-on"n

p,"",,""

.xcssdr

lbout ,o.

8y tuf.tb6.

most.

mpon.nr

prcc3r

th6rm t_

onductivrti6s

t

ptasrica

nd

pois6

nomat

procs3s.s

,uch s6xtru3ioo n which soridsr*urar o. m.bre in rarms0r te renirtrot time lrt-sion a"u Inlscrion

mourding

ar6

-vd'rsd

arerier

3 red.

o

'n

roqlir.d

o condld

"

*ii . ,iii-

"Jilp"i.rur"i"j

.p""r"i

tiir,ilqlJ,i-

ror.tinp

in

a

h6at.d

rhrough.a

unit ihicknoss

l darsriat

such';s

pressur6

rnrcring

5v6

o ba

:il:.i.l".i: iI 11::ll _soJtned

or

wirh

unit

lemporarur.

rr".mtiur.

r,o

,""J. r'"

ris : tho

mk

vi3cosirio6

r

iti':

i::e

l -ry i

ff ;"il"i:

"

:;TH_11i:,

;"""tr;$'::"".""?"

:J"JiJ,,:,jtr:

l,,::[,;:f:":l

*:T",

hap6 slch as

'od,

rube,

sh6et

frm o.

rivitv

ro.

prEsric_s

-sbouii^(e

$ar cm;e;;ur6

(rin6a.).

rt *rrr

i), i"iiiii.i,

orofil6.

8y a

posr

lomrng

op6ration

ho

ol copper snd 1/5@

thar oi stest. ;n

ttre mar

rns v,scos,ry

at t\

hrghst

exrrudedsction

d3y

b. hooifisd

ro

Tabt6

:

siv.r

rh6 houtdhs

reDp6m-

,;;p;,",,,"

,,

cros ro

1o

po,6.

L"ii"ii,l""T,jliili;

lXl,ljij,::,

ru,6s

ora nuhbor

'

prlsiics

na

rso witi ri

exceprion

rny,oi

h;t

can be mourdod

o shap6

by heati.q

and

prdEing

balwen mttling

hootd

sections or

by inj6cting

h6

solr.n6d

m.r.ri l inrc E closodmould.Shs6t3

m6y

b6 shapd

by first helt.3ottonino

..d

th.n

prrsing

.to

rh6 form .6qutrad

by 8ar, acuum or

mschanicsl

ms n3,

Solid .n6y

b.

Dlchin.d

by .|o|m6t

.ngin..ring

m.thod

lnd

riauids

.nd

powdors

may b6 .otlrionally

moutrt6d.

hollow

cri

or

dapolk.d on ro

surlac

.4d

tr]bsrrltsr. Soft.n.|

pl.stic

may

o|3 6d

b.rw.n

h.dad .ollsrs

to

I

.ucc

c6landlrod ,h.ai.

h all-tiai. hbiicltioo

plocrs .t

ttc.i

plGdcr

rru.t ba hdt.d. 6h p.d lnd

j:i:

coolad

-For

$i rEllon'tlio bch6vlour'

6

h.ldng ia impo.tfit

bu it mult

alwrYi

b6

mh6mb.rld

that.th con.

I

ditioni.Lindir lrhich cEollng k.t phc. lr :

hry

bs nO lal

crtticrl, alplchlv wian

-

;

:


53/70

, l t t

t

' -

'

,t,

.t

r*

:

f t |bdiq, {mlqhidedon

b ifMrd 6y

rav

d6hn d

pro

kno$/ing,

or

sxrrnplo, hs

vo'uh6nic

fiilino

r.16 or:

mould t ir

po lbl.

ro

calcullt.

iio

pr.3 uro

roquitad tor

mould

lillins il

dt

dimsn3iotr

(l6nsth

.d

di.hellr)

of tho v.riou ctut.el8

aro

known.

AliernEtivly,f th6

maxi-

mum

pr.s3 ru sv.il6blo known il i3

oossible

o c.lc

atB th dimnsion3ot

ffow channk

and mould

s6t63.

Plastics

mlls ars

eksric and .t tn

pD3sures

us.d

in extrusionand

injecrlon

mouldingare comp163sib16.

The

compressibility

f ths

melr varis

wirh

rh6 rype 01

m5t3ri1. hus tho

crysral inE

lst ics polyBthy en6

nd

nyloi) can

be compressed

Y ? or 8%

al

.

presslre

ol

10.000 bflin' whilst

rh6

amorphoos

ldstica

soch

as

poly-

styr6.a

6 comp.esssd

Y obout

5

o.

6%,

Thischaractsr ist ic

s m.de uso ol

in mouding ince

t becom.s

possibl

Mouldinss .d docoftpdltion tsmpoatur.s of common hrmopltstica

c

. l

-

-A-


54/70

i6i

; f;:l*;:.#*#;i

;

"*;

'ii;'*

'ii

;',:i'.

otuceistno

arc

'

..

.

pof,rtrod

op.

thor. Eo*la-"liiii"d

,i'"v-

:r

Ii

-;rr

noiv

o lpprEcist in'r'qohi

'

--:.;-, -h;-^^

.^d .rtu. ldrmdunrrbla dimculli3 it roai lrdd

coillld6rttroot or n1Aten6l

i+:.-.

. : ' i : r : ' . '

:::.

ir,L...

:;..,.u,,

-.,,

1,:j:-.i:'

.

,'

rT

t:,-.''

. r ' l

l r . .1: . '1-: , , i t ' , i i :

.

*. : . : , - ia

.

;

: . .1;

i i '

. : .

,

1i , . - j . . '

.

: r r : : : ; - - l ' : '

dess

-,_:

i

-r'.

'

pprEc'afrd

ha,

qoha

;;';;ii;;,",;;;; 't;;;;:

'

;;;;;;

i;;.-ih;

donri-eraions

av-.'

k

wiir.nowbo rpproci*cdttrat.

qr:iti

i.-'ii;;;;;;;;;;;,';it;'/t

-

. io3' atmosinll,mouotabroifficultis

r''

lpad{rcf,d

co

rdorrtjoo'

or

'rateri6li}.ii

iii":ini

suii k nra

i

:l-iotv

one

rocess

to b' considrodnd co.r . hr.$ickn6t of scrion3 of.


55/70

". '

::

bsr

n

'

Plaslica p8nd

on

heali.g

considerabty

more rhan do hst.ls.

wood

.nd sro.e.

Fig

8

giv

soms crmplr.tivo

figures,

Thi

propony

crete

probtms

spsciatty

wh.n

plr3tic

lro usd n

.$ocidtion

whh

6Etals

5 in

light

e.gin..ring

appticrrions.

Dini.nrions cln also

bs ffBctad wkh

so|na hrlerirls, .otably nyloN, .crylics

.nd

c.llulolica by lhs lbsorDrion

ot

w.ir. T.bl

5

giv.s

fgurr lor

th

lqlllibdum moiltu co.tonr lor

6 nunb.r

ot

warer-.bsorbertm.l.rials

lnd Fis

9

illustr.lBs

h6 chlnge

.

dim.nsionswnich

t.k.

pl6c6

n nylon

66 . wn6r is

lbsorbrd. Nylon I

behve n sjnil.r

mann6r nd it hly

b6 .lrJmd thrt

oth..

mdodll which Ebslrb

moistur. wiu

'

h v. in

rh6 mo way ahhough

hrb

-,'rr.rs

to b. linl.

poblishod

ntorhlrion

vribbl..

,

Oliviordy,'cnln 93 in dimrnsiom

ol

ihit

na$rttt dd c r crE

t6

probloms

fot

tlra.&lJgrDr irfld

prsGtgror

lliLo end if

'

v .y.da.6 tol6rmc.r rrl |rid down ir h

not

alw'ys. ry to

irrta

tha

prop.r

dlolidnc.r

|tl.

a y,

hould

d3Jcn,

'

.1.-

E

hct

d:siiE

raiiirs

o. 'rrtctr.'

"d

*l

.1n a,1r';.'

o.,;sti-r'; ";"

i

","

od",.r b i..r:t

..;i..*:in

;";

'ii;,,r;

,,;;l;l;;a*

ntEpidly

cr

nd-.:..

For

p

dcticat ajons

(q

b6cds6

t rho

rby

incored plocssing_irsjng

m6 wrong

lqal: T r"gl:

. amntudof condruct,onr 6-mourd) . -- reopenrures,ressr:reinr ,""o raer_

oldingiho mblsorla: . . mnhodof condruct,oni 6.moutd) .:-- r"i"pe,srr,e., rasir,;: il i;;;.1;;.

6ly.tgvdnbnom3liry:)shlrptyrnotedcorner m-syb-o_noc;$ri .- . .orbirh6wr""-ei l , ;" ; .rr*rd; i ih;

tq

ia lor;.iry houd.

j

-;.nd.

r

dard .rl;6r,

sharp

orneamay

cgn occlEionajti

ccur

becrus6

r

L

or

24

o

4A.tours ill

i

.

..b

dlirsd or

r.r$Eric or.pt:clt

rar3o; .]

conrrd6r6d

esirabr;

;

csEa hioh-,h,,.r

ls l lmlt .dbyrh. inhsrEr.hgenr | , .cohp/omils6uctssqtvino.

ooOena t r r , , . . in*i"*

" i l "- . j j - '

rcnn3rr6| l8( t l lonErrmlt .dbvrh. inhsrEr i .hgenr l t , .cohp/omils6uctssgtvins.

gooe

rna i t

i t

Las

r i f la now

orDion;"

.dtrnr't

('r

i

pl srl"'-

t .ou'".,

ho r rrdiulln

com6'ot Ot6O

n

(l+;mi..

ir,r" ,"

,t

"irri

d"iii

ii;;;-#il;;

fild.st

&hounr

of.'rhrlntagg't k6

pb.'

wi

.produc.

rn lcclptabra

gnd w;nh.'

r

firing

h mourd

producsr

rrEs

in

ri ,

wrdrln

ur

6rn

fas.horfr

but

l

can

: :

.witt.

tmprovo.ncnrn

implct

prrfo.rnsnco.

floutdino.

r nav

thBrEfore 66. r$.,,

rll.

|mprovo.ncnln

mplct

prrfo.rnsnco,

flouldino,

r nay

thBrEfora

on6

bor

contino or

-..

ditnlnrshing

.aro ror

mlrt

:

.

prDcessing

clr

produ&

*ress otren tr'ii",o*.r*"o

ord, bh..nv

dorC.

rrDrs

4 rftrcr|'.

th' tftor.mootdino

by rh. tomai'on

ot void,

or by

$s

proc6llsd

siv;,

r,idt", ;ripi-a

r,rrong6

lllll:_s:- -'-:oT-oEry:.9..liq*

rnEration

r.h'zn-h trEss..

he ir,"n

nen,s,,.,-r{.i

s,ea"

oaory

f9"1._L-"1T

.lf

l:.s

&o

3h'inklss to'm.'

c.n ohen

obvi.t6d

y h6oso

proce 'ad.

. rad

t i'-ofron

o;;d

dlrt

oEilmng-rn. n0

otr c$on of

9r6rr.n

ot

prop.iy

controfled

ooting

sft"'

dorignor

prccssing

rv6

, mucr,

f not

rh6.r,

Difi.r.rlill

lhdnkass

whiclr

can orocesling

nd by

proceesind

r the .",;"t"{;;

il;;i;;;;;;;;#;;

occur, or.rEnpts,

in

a contrs-ted

comd

temp@rrre

(genr.ti,s

ro o,nerenr

hsrsnlr.

houldinq

or

in

,n onrudod

s.ction

ot reclmmended

y the;w

mat ,i t

non_unirom.hictn*s, calsss wsDing o( supprier). r srourd be omphasizedere Minimizing processing taurts

bowins. arrhoush

mainronance

f unironn

rhat.rrho h

a void

nnoi bo

seer and

ii ri,e *.i",s

i.**i"qir"ur";s ar"

icknes horps

o redlc

bowing

and

rhereforo hs

codponont

may 5pp r

o tulit'u.derstood

by

ihs'd;sisnor

nany or

/aai.s,

tho

problm

s

sssntislrv

be

saristadoryir

ca.

cause 'npiit

taiturs.

do'subseqlont

rslts which

ise

can be

p.ocoseng

on 8nd can

onlv bo ovscone

on th6 orhs h5 .d

a sink

m.t

c6n be

Finifrked

or .vef avoided.

For

ex.npt6.

.

by

proper p.oc.ssi.g

methods.

3oenand hoogh

t may

cause he

stnkma.ts wi atwsys

show

uo on

a nai.

cohpon

ro bs rEjecied

n accoLrnt

f

potished

udace. n

tacr targe.

potished

Thornal oxpansion

End water sppeaEncs

t

is

nor likgly

ro calse s irar

areas re

test avoiaea n'

ptisrtjs

?bsg.ptioo

brcakdown

n sryica.

tlsr

ds rhey

arc

n

paint

work. tf

s

p fiirdfily nolcJr-$|l.ttrY *n, ao t .t-

trnprovrr

l lfirrcr

t rd4

Ddrb.

:1

t

,

,

.

..,

_,,,...,.

,.

''

i;,.,,:::

.

i,.;-;ri1


56/70

i;*,ffi

,il**;;f1;*;;;

;,,.;;;';1',.,.i,

' , .

' ,"

i .:.-,

J..,:

;,,,_..;

Iffi$ilf#t${{,",tr",9',ffi1";;ffi

l'*'=-*ft

;#W,i'#

#ffi**ffiimff

H-gffim$t'ffi#

fli:::::''tl{ir:"#;*}{":"$n-gtnt$:q,qr**+1*r'*:''

'ffiffi

r;'r':'"::*sE'[',"ri'i"*,,

l,affiffi{lffi,.

[, i.l'*1i-ffi-'".f1,1.@,** r;., I


57/70

l:..

-

,r,;,i"n"'

'l'"

;;dl-t"

i:s;"

r;,

l

ulur .16 tquied 6d

des: nus :

od

erc-

-

.ttr$

116

Dlrronhg

8nd rpacirl

matgriala

::

| t.

illto

rccount

botil

tino and

j

-

;-,i;i;r n j.;i;e1;;;;;;;;;;;;;-;i;,;;;a. .. ii'pu',t,i". rre rg',iei givenn it'r'l

r I t t t lct . r : : ; j : f ,1500pr. tonndbutpolyolsfr igs.PVcatc' t lb lo.rs6roushlr rdoloadfda3si4rr

#na.'-.:'

vi6

iii,iii'Ji"'r-'p-ityi"i{;"iii'pi,"

"tcl,

ub6 .rs 6

roish

eiido

i attttmss

r'..'

uso;t-

;::.

n oe;e'"llv .v.ilsbri

h th.

fanoe

ClOo.

::-|nd rholld

bE usd onrv in

de.ldinq'

.'

PvC.:-::i,-*to

fi5o

paiionn ,

Fncodot6iti 6rs,+1-L':

"ii'wi $sr

proisct

s tuasiblo

nd woii

-

::

'g;odt .PvC.r . : r : ,. : ' : tof25opai ionn . t r r icodot6i t i6rs. j . . : . .whsthsr t t ro igct isf .ssbl6 n. twof i t

:

,outlng not

_.rnt

::-

Dublishd

rorfl ms

lo

1fi6

n

tI6

ws6kly

-.

:

r|/nn6r

nuoy

l

nsy

.rso

36rv6 l

.

1 4 0

:::1j1":*li,:i-:"1,i., T-d_modhly

prel

rnd

rabr6

7

indi6ro ..'.

t'br6''n norpins.to

1618 [r't cnlica

ot

nor

pii"tt"cJFGldii,

.i...

rr'oi'

qr"i.1llo

apiit

..

.,

'n.rs.ar.

:

. . . :- ..

ti6ra

rnry ba;_ '-... In ftlking con comptdaoclt

riti ttl.ral

,

I du$ ba ft

prlsr:sd

tt6t

lor

de5irin8

ro

|rflnc.- lq :r:

:i..'r0Jr- y 1f-' j9l,l

Th. d.rigrlr loot{n lor colt $vingr In

lor

compnl$n.

mry' tdiul e:,non luppon,

Pllltlci mry airuct cnrngc

roftmrillto

plaltic

i.

co.ndirlons uttbs tsten into-sccounl

nd

Th6y

g.trllllti

l6at

::

pr

oth6r.n r6ri b th.

tdwdlnside3 ol

fot

p6ttormanc6

n

pll'uc

tlo comtlttr

i.tle

pvc

gutl6rtng

l dcr

rnult b ttln

{nto ccounl ll

a

ran-. t mt ilB

pro96ruet

n.l

5dlco

lJ'crpin:lvi, a'ttrrrii nw

mmrirtr * b.tns

nrd;witno r-d. |g;ins, fi.

llfsro1c. shouldba m d.

to tne manv

rr

tuiift.d

goo.ts

o rhc

marlrilt .nd w.igit rlvhq .nd

nsnc colr .vlng cln

.niclo lnd o$or

Psbliction

v ihbl6

,ro; ..

.conondca

mun

bs

tslan

inlo

b| .ignifc n1.

T b|.8

giv.

ti6 dnsiti ,

on ln. .t,bJcL

.cco0ril

ot

r numb.r

ol

Dllsrics nd roma

motal

ol|ltlcr . n ,omltims find ittlo

rulrifdltior

for

using

hom

puraly

on tho

r of nw fi t.ri l , h i oflsn tho

Two oth.r conrprrilon r usslolwhen

d6dgning

n

planlca.

Th

flst

ot $e8e

i

lh.

volumacon

(con pr

unlt

voluhe)

obtalnod y mulliplying ha cosi

p.r

unn

: : '&t.

idto

ccqunr

ou

tim and::

I

:

Cholng

lh6 raw rnatlrlal

Th. p.lvilion of d6tail6d nfo.mfiion on

m rbl ch.rrcterinic

i outlids

rho

lcoDaof th8s6

anicle3.xc.pt in3obr

13

thla ohdructoristic

nf ulnce

prccessi.g

llowv.r ir i.

possibl

o compil

limplg

chsck ilt ol lh. m.in cn.lEcisrilticsof

plsatics

sl.t6d

to servicB ondliioirs o

thst, with tho

,id

ot

3

propnis uido

or

6ncvclold6dir

he

conect choiceol

dratrial

8n

be made.

Ths cisck

lirr is

compildon th

niddrn ao.t lrving whicharo

dos

imporilni-tha

f.c

thrt docoration

s

wtght by th. danliry. Tho

seco.d is the

uMsc6tl1ry

or ihat

bonu

qullity

8 ch

co

pr

unir of ltiffnals obtrined

by

ar nigh .l.ctrical rudnanca n lo d-

dlvtding h. co

p6r

unit votwnoby th

b6dngmsmborobvi6ta ha n.d fo.

modutLr3 f olrlticiry.

ldditionll olsclrhllinlulation. Tlss6, 6nd

Voturn

cosi

sr6 norma

y

expressed

mrny othr clorr, mult b taksn nto

ir

p6nc6pr

cubic ncn or

pnceper

account whon .lr3srinE rhr viabiliry ot

cubic centimotr nd Btitfnoss osB in

any

proj.t

in

pl8ltica.

porca pr poond

orco .ch$

or

pencF

pr

1m,000

pound

orc nch . T6ble

Raw tnatldal costs

Eiv

som6 complEtiv. figurB sing

Pric.r

ot

phstic

m6t6rhl Jor tunhsf tha

.v.oE

3hon.torh

modllus

.t about

proce$lng

i in $ rung. 100-t15m

20'C.

Obviously,

r workins

out derig.

TABI.E7

ABS

(moulding

CELLULOSE

CETATE

brri3 th6 thsro nay bo 3omovsr

riding charrcterislica

irher

ol n6tsrial

or sorvicewhich narrow th6 choice

bslorccomin to tho fi.61dcision n

te.ms

ol srre.gth, stilfn6ls or

othel

m6ch6nicrl

roprny.

Th. llst can b6 made

und6f36vsn 6.dings o which h6

mnomonic

F

AM E ET is ppl ld.

SAFETY: h. fi|lr considsrations

whoihrtlr. mlrldrl c.n br $lsly used

lor$6

sp.clfic

pplic.tion. ll tho mqt6ri6l

Ir toric or conulns .ddirivs ot a toxic

nltur. th rc

t obvioE liditltionr.

Sinlhrly,

if ri3 co.3q .r.cs

ol

krlkdown

could ba. h.2.d

ro

hllrh

o.

lif.

th.r.

b 6n ov.riding linitation

ol

choica,.

ECONOMICS:t th u$ of Dllnici

lncn e th6 cosl of m lrticl. wlthout

lmprovi.

Iq

9aafotrnlnca

thlr

is no

-

o.r.

lor

aiploylng

rh m iarl |.

Howavar,

at

h6

aholdy b6a .t:t.d,

riar.

mry

b.

hidd.n co3i a v{n whld m*..tha uta

' of

pl 3iic

.conomildly

potrlblc.

Amorg

tiata

lra tha bonrr|

plltrnbt

ol

ptlnic.

aldr |. bull .in colcur Cactlaal r .bunca

.nd ..ia ol

proc .sing.

AESTHmCS: Th. choic. ol tnnsr runl

pldjcr

ir

lim,tad

ro a

r.hwtly sttld

nonb.r o{ |hdadslr-{crylic ,

calluloJcd

polyc.ftonrt ,

pvq

tltl

,.d

Polyrtyon.

.|. $i

hrin on.r-.rd wnan

funh*

clunctari.tic

|Uc

..

w.lttar G 'rl nc

it

dd.d

th choic. i.

v.ry lhltld

Ind..4

Som. m.t ri6b

cm ont b eDpli.d

h

dlrt colour

rlthotigh mort

of thsn Jr

' v.il-h

lr widr n'lor

ot

anr&tiv.

colotlrr Trr .t'bc

hqdnaar

ot

pbltica

=

'r: ' .,

'

- strirS dtrr tronrArtit rlumirriirn': :;i .-

(Gtyli.

$..r) lo

vrry

|'n

.nd_wrrl

j

I

-

:

(br|{ |rtv pdrdhybi.t

bf

ftflitlro^:

'

r : :11 ' - f_\ -

.r

5

s,

jr "

v.i, : ,-\ , : i ; : ' .

iJ

.-,;aii;-?:.iI,

-,

: ' . .1


58/70

-:":': n

:--:--.

j---

lyrqlqoon'crroil,

;p;$$Iirtiqr-+5i:.'.,,.'.''-:-:.-.'$'.,;;,'';r;y,:fiii;:li::i-'l.

-i

?::.i) :::i

t-i-;

:"r;11j

F:j=li,'-r:-:,

i..

.

r'ii;5ig:il;.-:;?.';

:;l_,4;.':j".

''

_''ii1i:.,1:;1 1

1,

,;

.

;Er . . t . rof f .c tonco; 'o; ; ; i;v ] r ; ; ' incrs 3 'ngr. t . 'ce."nt ty ' l .;wn:rg i " i - ;

,i h":*"11*l:i''d.l["-i't::i. ii

s:xr"ll:r**il$'."1i':;i-"'

;'T::i#'":i';:,:*':'[",::f;::"

;";;i..;;i,ilt*

i'.o,"rl

'r

ffi*,*"mxni#6:.-*YJtH*ir"nF**'":ig,:il#*,-j:#j

ffiffi'ffiTffi;'FF*',#,.um";rrr*,t

';

u{$p6';1fr""6

n$qrr,.1116odutu,nd 'p c j-. , lcryricrJ"t"r"iE;.. ' i i i ii i i i*;a.i ' . 'f i : ' j : j : ;s"ib"." l 'rnfl l . .9: ' ' : :

iHg#*:5ffi,'#:1,*i.:t'''ii#ii, i,G'r"1itli'v'llii3ji""i,'

i".1'"li::g.f:",."1";f"*:,

ffiFE:?4&1*i,ilr"iif*i,,-,'

iif.ii'il'diG? ?jil"e., i ,ifui,ri',

;6f.,mlil,*x"i";i;:i^j,

bE.tot

6.rcout;orgd

coodirioii

| ,

.

,

r

co-^trt&r,

tr.dr.

l.rup

rhould

b

pdckld

:,hlgh9d

rn ta

rcce_ptea.

o*svii,

wirr,

.

ht$r 6itha

b.

drorrnhtbv prrcrtcii

'i

tnro

porv.uvEns

ctt

..d

.. l.d

ror

"c r6

m*i,'ffi +',il'"-$*4*:rt*,i,.;lf'tr1','#j

*'mi:

;._fii;il;;ffilfjft.h"#,T:"

'I.-::."J'n.a.rJ.iiij-rirliJrlii*:,

:iiffi;"'i,:,i;;iiilPilf"T:i.,19i'

r

t6..r6cl

ot

w. rho..

rraiatoo

nJ_

_

mo|lrurrconrant

.6dd

o..ffctani-.

*.ffi* *$tT"l;$iff'''$:r-

"$F#,,;#'.ililii1i.,,-

ffi6s'$Ef

I

.nvirctmontll

conditioG

but

evnru.Iv

.

clraful

wltch

dould

bo kept

lor

n .

i :HT;#[:,I1,:,#::":liliT,:1','i,T'

ii""'1*:ffTT::11*';.il:,,

"..

chorca

'

p.ocs,,ns

snod

'nto

.oroo.nr

m t$j t

lnd

tiu-otia *u"r ,"r,r

""lrry-"rr-ii

i'"

a|ftousnvtrv oft6n$ proc6s o b.

:

:t':*#i:i*i,j:ff^ilfur:11,

:m""*::.*s:;1",il1.h:"".i,.::::

ilill"ffi::"Xi;lffi,T:,:'l'":'"

i tsy .

ot

orrdi:.d

m na;

";';;

;;;;;

docompo'l.or.

ou"iousty,

orcooporoa "r cd '

cuuE

o

u 'd

ro ofodu..

r

mri;ii*kir*',r.m,",.

:*"*i:l*"*"*:*li.""",

:[iitj'i1"i.""'ilij?;,ir

?

[j.;,.;i

ni;il; il;;;ffi;ir,i

",

il.il:.:9.,,.ir1,:-i..1"."t[i:"1;

*],liii;i:""iffiit;lf.#ii""

ll:,T;lfftl,il'3:i:1i::,#lrt1"j'*

"T:2.'$?fflii"*5:i:'::

,r"

".

,-l-s.-ry.:."."ruu"..

il

sr6

po:r

coldudors

or

r.crricrry

nd

our ,d.

shlduniirrins

canb

round dr ,.p"; ;lJ

,r,i

ii,.,Jjn1:ii"s.,i'".",""

"

. l .n nyh6v. |owp6rmilvkis$;hid;r .gr jndingit 'n .D tn | isth3nt kEn

orearoown

ortrscs.

rr.;;;;;;;i'

inIo

tre rrrtivory

nrrn

ni iumiJ

-

srnerrrrv

no

nJrnb6r5

uouirod

h'

r",,10

"

u. tJi'i,Tiio;H,iil;i;h

.,.",pr'".

"r

tri" ,iiii.v

""l

iijiluy

"'achm'rv

'prrd

md

unnins

osts

nd

raistivhy

cln b.

nui nc..

ri; ds

tis

TABLE

8

compononr

o

build up

n

.llctr$trtic

ch.rg6whidl c.n lttruc dust6nd d|n.

Although

ii

c.n b6

ovrcoma

nd hrv

orry.b6

.nuir.nc

ln

rom

lppric.rionj

In

otndrt

t

can conltifirto

dlng.r hh r

rn

uat

or nrndfino,

THERMAL

RoPEiTtEs:

Tfi.

fnll h6..IIn6

cov.rt

tuch.fi.cr

ot rlnlhion

-

poht

lnd

b.h.viour

high

or tow

rlmparlturl ,

Agrin,

th6

.isrt rhlv

nor

'

quit

.ndghdorwlrd

b.c.rr

ot

ri .

.rr

t*an

torhart

to

pan.v i

fir 3

ot

prlrticr

nll..l |,

Thur

cohponrnr

-firy

rf,tu

d rhon

t.rina

t

r.t.tiv.ty

nrgn

.mp.r

ura wh.r.r

long.l

P.r'od

.l

I muclr

lowar

r.mo..ituro

could

cru{

brutdown.

tr

.ddilion, I

cohpon.nt which cortC.r nridu.t lslt

-(.J

Dy

b.lng

jitcoot.d)

i

|'|or tit.ty

ro

u{

on

n.rlDg

rhrn

I

rEar.-h. mouldidg.

ri:


59/70

:.

Colt/Unlt

atltnaa

p/im.mhIin

ACEfAL

HOMOPOLYMEB

166

ACITAL

COPOLYMES

153

t31

ACFYLIC

o76

46

ot7

o52

3n

o17

o78

25

CEILULOSE

CETATE

PP0

(modifed)

36

NYroN 6E

(drv)

o(B

15

125

otz

NVroN 66

(olass

ir led-3oz,

dry)

1.07

40

0,21

NVroN I {drv)

145

100

o1/t5

Nvr.lN S ldl.

fll6d--252,

drv)

1.16

o34

DrlIV'AigONATE

o21

005

POLYSTYRENE

genersl

PUrFo3)

o^r YFTHYIENE

low

densi ty)

0-32

o2

16

o33

10

o33

POt-VgtXVtel.te

high d6n it,

o38

1.6

o24

o50

35 016

PVC

.isid)

erlelOUC

'tOUtOtttC

OWOtn

o

80

uaen

OnvnOeXvot

'outa"o)

q53

11.0

oo54

obt intd,

wh.r. rh. two

lin.

cro3l

rn '

'*r*$"g*:**1,+'sr::

[*h";il:'1,"i.*:i

ffii,m:r''

*t*:[$:*'''nl"

i*1f,i#+u'ft:',"t*'fl"-

ffi#fi$ffi

.

10.

A dtnpla

rpp.olch

to

cotdng

lo'

ffi

ffiffiw,il'ffi#

o24

t

hs

: l

i.

i

T

i

*Hffimmffi*r


60/70

tr:$;*+tt'i*.1,l;ll''lt,

I

_,,r"r*

",

,"",iii'ii,i,i,';

ii.:i,

-

lii*;'i,tgll-it

i[4:x,:"'m:

_

uri.r

proc s63

such

3

she6r

rabncr[on

nd

vrcuum

orhin,

havs

o-urput

.lss

lthjtarty

d6Fenda;t

upon

d

l

r t6

of h6 r

ran3rd;nd

; ; ; ; i ; ; : ; ;

" ' .

|

.r"rf*f' L

_ .H6ving

ut

n..t

inro

th6

ptastic

|

#irlt;',

j:rl1""*{i{trjr

@

filniJ*i;",i,'""*#_''l*E:'"

n.n

proc..ling

th.hoi.nino

in

h .;oud

'r

r

.l\ro[

dBlrtL

lo firltch

6.

'qqow

clp.ciry

ot

r m.crtn.

wirrr

_

rrry ,u, q

I sr .xtruci .. FIGURE ftl_

'

: ; .

_.

.

. - j

_ . . ,

1: ia_- : ' : r; -:

i : i -


61/70

tr

'-:

l

;i;;;t

";to;_

l

rrgl,r;er..dne b,ittreps.ticlo teviscous.llr9"-"I",1:-

thl: L-:..:l:ll9j :-r1[1.1-.,.-9:_":'tv

:

I

comlonenr-

rtrouetr

iny o.ponenr"

widetempr.rur.r 'ns.othrshave?..9Jl l" j l1l d;"d-111:r::I1.1 1q *

:

I

tor di r"tnlE;ng

t;dusny;m

mado y ,h.rp |nchin

point

nd changehir

trtt mal ll lhs ditere.ccbtwente

I oir'".in"tioa"

*itt

s xirusion,bw:

over

v'y w desruo3l tmpoatur..

tucces

or railur.ol I

pojecr

nd ir

is

' I ;i;;;;t-# diicu'sio. n rt r, rt's nouta. owover.a hrs or.eadvean : :r n..ds ro b. .nonis.d over mid:nufi1l

t

_

:

|

'nor,

acrr:ir r'a

.nes.

ho

rocr'

'

..

poinrd

ur

n.sn, ier

Tt L1,ll?.'l1l

_:

1..

093,:1d_lis-":_ry-d: -is:-:l_.9:19

-.

,

I inJ il;l;:;-il:i;li

ii,

,"*'i

"i

po'nraa

utinan

cra,er n'cro. onan

-

ro@ doutdins3.h.

d.lisnorrnourd'

.: I.hhfiion

,fl;ddiis

w,ll a considorEd

n

prasric

do

nor

b.hlvo in

sIrlishltodlrd

It rltEly 3impl..nd

rn.

m.nn .

h wh'ch

/

::.

Ibi.rr

dEr.ir,;pdtiurlrty

tr etariono m'nn6r.som6or$encha'e.i iomlorid..: l fL ,91.t_r'9.1". r9 i9^t?.'y:

i*,#l,,'ff

f.fl

TJ=';f

;;utdiir rc_

whe

considrabto

Arr

sr6

rtlecrd

n llow by

rh rats r tor rhi

reason

hat

rh .risin.r

.l bnio9

nu|nb.r3ol alicls

aro

rqutr.d,mado

o

which thoy rc h..red

6nd bentvt as

pltstict

component6

wltich

.rt to ba

I tiilh dd..

of lccurEcy

nd conlainr.s

non'Ndwlonian,

soldo'plastic

fuids

nado

bv

injectotr molldins t iflll

fin -d.rrii iniection

mould'.o

i tne

Tho

proces3

. c8pitai

ntenlivo. adviled to

.r dv lho

Proctt3

in

&m.

orlf rcd ollcess.

Mach,ne cost kod 3000

or

t on

oonca detail.

'

tnj.cno;

douldins

3

bas'crtly

a s,mple iulrt..lromdlic

prsss

o

4250.000 nd

ln

this

aniclg

the

prin.ipls3

ol rl.

process

arc ou iid, brlic moutd

d6is.

I

lf

warpr coohno I

parosrrs

16 oniidsrad ror|9 w'$

| ;;;;;"i. ' I stdns and coo,ingsy3rens ro 6void

I

t ie

Ua,

t- r i ; -

- -

|

mourdins

rcb[ef ts

dtn.se. 'e

I \ l . ,

. t

l l

- . - .^ . . , ,_

_,^.1

concrud.s i rh Di ,ef orrenr

on

rh-

I J2*+H7l

He.ter

bands

Ih ,

mak,nsol

p.otorrpe

noqlds.

| |

tn;uoton

moutding: ho

Foce.s

I V l

#j#,",r# #:r.ft

I ll

.::

t.reV:::a

I F


62/70


63/70

. ; i "

,B:

,i,

ii:'

:i,

JE

EI\jEI

n$:fliou#',i 'TJ":ii l i.i l ' i-Jin""'

siceptionoirerrr*rochrs.prc

::1:::

CAD and Development 2 - Part 2

Documents