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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'
8/10/2019 CAD and Development 2 - Part 2
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
8/10/2019 CAD and Development 2 - Part 2
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.
8/10/2019 CAD and Development 2 - Part 2
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
8/10/2019 CAD and Development 2 - Part 2
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
8/10/2019 CAD and Development 2 - Part 2
6/70
x
x
I
x
+
I
Fr
qu*e
lrlCr-erSg
sv"*"y'^s^"t-SL
8/10/2019 CAD and Development 2 - Part 2
7/70
8/10/2019 CAD and Development 2 - Part 2
8/70
x
Frrr'uR"E
G
?A{{a}rg
oltir
8/10/2019 CAD and Development 2 - Part 2
9/70
-l-
r
I
Frq.ree
Mrrr
8/10/2019 CAD and Development 2 - Part 2
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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
8/10/2019 CAD and Development 2 - Part 2
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
$ls1 if
thir
rcrc
tq . cd iuldc ont? Bcvcrrcd?
Upridc dora?
e
Whatif it
rcrc
lergcr?
Eighcr?
lao3cr?
Yidcr?
friclar?
.
Soppore
t
rctr
lctt
out?
r
Eor
cea
hic
bc
aadc
uorc coaplc(l
.
T6al{rh|r gbttcrr;mnctricdgrgyoncdcal?
.
C.n caElc rld
clfect
bc
rcvcrscd?
r D,cDoosFatror dcscrlbc bt rhlt tt bo"t
.
Coqlda
vcndor
supply thir f6s tlsg
r
Eos cocld
this
bc cbaaged or
quicler
esscnbly?
.
W'hstotAcrDetdalr
rould
do
thirfub?
r
Should
t llidc Lastead f rotatc?
r
Whatb riuilar to this but eosts Les? Wby?
r
Fh*ilit rcrc Eadc tighter or
fastcr?
.
W'hat otion or
power
s
wastcd?
r
Could
bepackagc
bc uscd or soncthing aftcrsard?
o
Eor
do
oocoupctitoa solvr
problcnr
tilrilsr to this?
r
Caa eaothcr
part pcrforn
the
firactioo?
.
Caa
his
part
or fuactioa
bc
coobiacd
wit'b
aaother?
.
Wtrt
U
hc
prcsent
dcsignof nctbod
rcrc
prohibitcd?
.
Eor
caa recondaryopcratioas
bc rvoidcd?
r
Caa t bc st.igbt iastrrd of
curvcd?
. Eorcanitbeadaptrdtoahighspecducthod?
r
Eor
could this
bc
aadc
casier o [sc?
o
Caa t bc nadc safer?
r
Could
aaterials
be salvagedor rrclriued?
.
Wbat
othr operation equcncc
could be tsed?
.
Wbrt
ceusc
could
produec
thc
snc
cffcct?
.
What
othcr 6elds have r
i.
kind
of
problcu?
.
Wty bsJr't 8nyonedooe
t
beforc?
i-
r
cn
,tai
lo
8/10/2019 CAD and Development 2 - Part 2
12/70
H
-
rr.ltlct.d
.G.1"
\
^t.';t,i,
"F*
(+)
scFE
: nol .art ta dlgl
-
ttrid.ti
lt.'91|i9
to'l
(:)
rrctrrrrr
-
-l
.att
lc
rllgl
-
...ar lrol.tl|il a.ur
/6)
aexct
xurs
-,/'
lrgcarlrlttign
,LtG,/
o
-
r.{sl?.r
tti.t'rr
'b+,
tatt
(.|I -.rr.,n ly)
(t)
xererutt
-
n .dr lrolCla a.ti
-
6ol
...t
t.
allln
fz)
s.
. rc ,Ys
' .r.ttgpprx
-
ltst
.r3y
tq
.lign
-
raru'lcltd
rcclr'
I
t
a
Frqoee
rl
TEIr|
OCi
(C"ttiont
h
tnlltl
tl'?
I
I
I
, t
o
' r
f
r a t
::L-'----'
-2.-,
i
'
:r:..
'IJSE
8/10/2019 CAD and Development 2 - Part 2
13/70
ASSTBLY
EQUI}ICE
rL0cl(
PIRTS
IST
lin o.dar f aJradlyl
lli0.
i - - i
---t
?ARI
1AIIE
I
CliiElrTS
i I i t{Atl$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
8/10/2019 CAD and Development 2 - Part 2
35/70
8/10/2019 CAD and Development 2 - Part 2
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L Miscelloneousluniniunondzinc
coljtines
Covatand hscio castings
L Electrcnichostis
< Btdckets,evets
nd hondtes
L
Castingsat optrldt
equiptnenl
Y Bross,
unnetol,
phosphor
ronze
ond oluniniun bronzacostings
8/10/2019 CAD and Development 2 - Part 2
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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.
8/10/2019 CAD and Development 2 - Part 2
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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
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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
|
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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
8/10/2019 CAD and Development 2 - Part 2
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
8/10/2019 CAD and Development 2 - Part 2
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
-
8/10/2019 CAD and Development 2 - Part 2
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 .
8/10/2019 CAD and Development 2 - Part 2
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
8/10/2019 CAD and Development 2 - Part 2
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
8/10/2019 CAD and Development 2 - Part 2
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 $m ones
can
be supported
by
bultssss.
Thr *
Extenal
tcrea&
sre
easity
as
padicr|tarty
f they
ar ocats
8/10/2019 CAD and Development 2 - Part 2
47/70
Material
roperties
i*
V_.9-ti1"l
]IP rllel
c-9q 9
a;adiu;
nn
3.4-4.3
3.a-4.3
0,03-0.06
o.75-1.25
0.03-0.06
0.10 0.10
0,006
0.005
0.005
0.@5
0,oo2
0,002
Trbl.
2: Comp.ntlr.
ch.n ol n t.rl.t
Drlrrrt..
srorsrh mooLtuB
6.ono. ro. rs.stalc.
9;"ty
N/mhr
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l
tBs272
Method 02c.Slress
181N/mm
.
This esihelhod
s
no i
normally
sed
or metals nddalalor
2 nc
alloysa.nc
udedlorcomparison
Alumn,-ma,roy
1.
Ztalo-
23rto+
4.21
Ni l
as149oM 4
di6
.sr) ohm-lm/mn'
MidGiijh
alby s2eib
is
1.sx1o-
ajxlc
-a24s-
.
Faprd;
MAGT(dlca69
ohm_'/m/mm,
finety
dia$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
8/10/2019 CAD and Development 2 - Part 2
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.
8/10/2019 CAD and Development 2 - Part 2
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
8/10/2019 CAD and Development 2 - Part 2
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
8/10/2019 CAD and Development 2 - Part 2
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
8/10/2019 CAD and Development 2 - Part 2
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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
$i rEllon'tlio bch6vlour'
6
h.ldng ia impo.tfit
bu it mult
alwrYi
b6
mh6mb.rld
that.th con.
I
ditioni.Lindir lrhich cEollng k.t phc. lr :
hry
bs nO lal
crtticrl, alplchlv wian
-
;
:
8/10/2019 CAD and Development 2 - Part 2
53/70
, l t t
t
' -
'
,t,
.t
r*
:
f t |bdiq, {mlqhidedon
b ifMrd 6y
rav
d6hn d
pro
kno$/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-
8/10/2019 CAD and Development 2 - Part 2
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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
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,
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.
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i
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qoha
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k
wiir.nowbo rpproci*cdttrat.
qr:iti
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-
. 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.$ickn6t of scrion3 of.
8/10/2019 CAD and Development 2 - Part 2
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". '
::
bsr
n
'
Plaslica p8nd
on
heali.g
considerabty
more rhan do hst.ls.
wood
.nd sro.e.
Fig
8
giv
soms crmplr.tivo
figures,
Thi
propony
crete
probtms
spsciatty
wh.n
plr3tic
lro usd n
.$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_
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ise
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potished
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on ln. .t,bJcL
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ot
r numb.r
ol
Dllsrics nd roma
motal
ol|ltlcr . n ,omltims find ittlo
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for
using
hom
puraly
on tho
r of nw fi t.ri l , h i oflsn tho
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d6dgning
n
planlca.
Th
flst
ot $e8e
i
lh.
volumacon
(con pr
unlt
voluhe)
obtalnod y mulliplying ha cosi
p.r
unn
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idto
ccqunr
ou
tim and::
I
:
Cholng
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m rbl ch.rrcterinic
i outlids
rho
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anicle3.xc.pt in3obr
13
thla ohdructoristic
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plsatics
sl.t6d
to servicB ondliioirs o
thst, with tho
,id
ot
3
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or
6ncvclold6dir
he
conect choiceol
dratrial
8n
be made.
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compildon th
niddrn ao.t lrving whicharo
dos
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f.c
thrt docoration
s
wtght by th. danliry. Tho
seco.d is the
uMsc6tl1ry
or ihat
bonu
qullity
8 ch
co
pr
unir of ltiffnals obtrined
by
ar nigh .l.ctrical rudnanca n lo d-
dlvtding h. co
p6r
unit votwnoby th
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ldditionll olsclrhllinlulation. Tlss6, 6nd
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cosi
sr6 norma
y
expressed
mrny othr clorr, mult b taksn nto
ir
p6nc6pr
cubic ncn or
pnceper
account whon .lr3srinE rhr viabiliry ot
cubic centimotr nd Btitfnoss osB in
any
proj.t
in
pl8ltica.
porca pr poond
orco .ch$
or
pencF
pr
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pound
orc nch . T6ble
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Eiv
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Pric.r
ot
phstic
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modllus
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proce$lng
i in $ rung. 100-t15m
20'C.
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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.
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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
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lmprovi.
Iq
9aafotrnlnca
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is no
-
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lor
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at
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mry
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' of
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tiata
lra tha bonrr|
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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 ,
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it
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h
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n
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orry.b6
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ln
rom
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otndrt
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rn
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or nrndfino,
THERMAL
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cov.rt
tuch.fi.cr
ot rlnlhion
-
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high
or tow
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ri .
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ura wh.r.r
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I muclr
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tr
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