Basics of Design I

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Design For Assembly

Integrated Baffle, Oil Pick-Up Tube and Scrapers

Mains

Existing baffle oil pick-up tube w/gasket and fasteners

11 parts Integrated Into one

Integrated baffle is captured and located by lower skirt and cranks mains eliminating the need for fasteners Lower Skirt Oil Pan

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Snap-Fit Opportunities
Integrated Snap Fits
No extra part Simple & reliable

Design freedom

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Snap-Fit Design
Q
Alpha

F h h/2 L

h b L f Alpha Q F

Height Width Deflection length Deflection undercut Angle Deflection force Engagement force POM High Viscosity POM Med. Viscosity Nylon 6.6 DAM Nylon 6.6 Cond. GR Nylon DAM GR Nylon Cond 8 5 2-3 4-6 0.5-1.2 0.9-2.0

mm mm mm mm degree Newton Newton PBT GR PBT GR PET TPC-ET 3-4 0.7-1.5 0.5-0.8 15-20

Es = Secant Modulus

Es =

ss es

[MPa]

General case Approx. values for

[%]

f =

e 1.09

2 [mm]

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Undercut Design

Undercuts rounded to avoid tearing of part & stress concentration. Ejectors should be large to avoid penetrating the part. Cycle time (specially hold pressure time) should be optimum to avoid excessive shrinkage.

POM Undercut = ((B-A)/B) 5%

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Influence of notches on
Impact Strength

V
(r = 0.023 mm)

U
(r = 3.2 mm)

U V 26 : 1 40 : 1

Nylon Dry as moulded Nylon Cond. 2.5 % RH

28 34

740 1340

POM

36

310

9:1

Break energy in J/m (Izod impact strength)

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Sharp Corners
Stress Concerntration Factor 3.0 2.5 2.0 1.5 1.0 0 0.2 0.4 0.6 0.8 R/T
7

P = Applied Load R = Fillet Radius T = Thickness

1.0

1.2

1.4

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Wall Section Design

Non-uniform wall thickness

Wall Thickness Design

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Deflection Beam Case

Tensile E-modulus for some materials
Steel
Aluminium 55% GR PET 30% GR PET 30% GR PBT 30% GR Nylon 6.6 (DAM) 30% GR Nylon 6.6 (Cond.) Nylon 6.6 (DAM) POM Med. Viscosity POM High Viscosity Nylon 6.6 (Cond.)
Force
x x

210.000
70.000 19.500 11.000 10.000 10.000 7.500 3.300 3.200 3.100 1.600
L

B I = x-x 12

F d =

Ix-x

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Profile Stiffness
6.0

A
140 4.0

Moment of Inertia for A, B and C 3 2520 mm

B
2.8 2.0 28

9.2

Compared to A material savings up to 22.9 % 11.2

Compared to A material savings up to 57.4 %

1.8

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10

Deformations with a Constant Load

Force
No deformation Profile 1, deformation 1 Profile 2, deformation 2

W H t H, W, t = constant

1.00

0.62

0.48

0.44

0.57

0.46

1.12

0.33

Reference

Relative deformation value versus the reference profile

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11

Relative Torsion Stiffness

Reference
1.0 1.5 13.5 14 27.3 30 28 10.5

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12

Rib Designs

Rib & Sink Marks

Alternative to ribs

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13

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14

Ten rules for designers

Aim for uniform wall thickness. Design wall thickness as thin as possible and only as thick as necessary. Use ribbing instead of greater wall thickness. Provide radiusing. Provide demoulding tapers. Avoid undercuts. Do not design to greater precision than required. Design multi-functional components. Use economic assembly techniques. Gate moulding on the thickest wall.
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A Polymer for Every Application

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