Uses Helicoil
Tips for Machined Plastic Component Design
The following guidelines for good machined plastic component design. These are not hard rules, but to obtain suggestions reasonable pricing. Exceeding the guidelines will generally lead to higher costs and the cost of the component.
Each part configuration and application is unique. For special design support, contact Connecticut Plastics Engineering at 203-265-3299 or visit Connecticut Plastics.com
- Flatness: From the extrusion and cooling, have plastic stress gradient through its cross section, not by post from the manufacturer relieved. Plastic flatness stability is much lower than metals. Consider the following to improve.
- Balanced design. Dish shaped plastic machined components are known to be difficult to avoid warping.
- 0.003 "per 4" square, unrestrained, is typical. Tighter tolerances require better fixturing and Processing.
- Consider specifying parallelism take flatness. If the plastic part is attached to another (especially a metal), unrestrained flatness is not important. The plastic part will follow the contour.
- Consider flatness reserved. Even when connected to another component, the plastic part will correspond to the contour.
- Choose a stable material: Low performance materials are easily forgiven. For tight flatness requirements, harder plastics are better. Try Ultem, PPS, PEEK and acrylic
- Hire a plastic processing company. Flatness can change over time, while sitting on a shelf in storage room. Advanced editing really works for flat-critical components.
- Inserts: For once Assembly with threaded inserts are not necessary as the correct torque levels can be used. Adds not add significant additional holding force. Applications that disassembly (usually cleaning) does not benefit to avoid repeated stretching to topic. Heat staked bets are a better solution than Helicoils by higher Withdrawal power. Helicoils convey heavy loads into a threaded hole in which hairline cracks at the thread root of sensitive materials. Helicoils are acceptable in materials that do not do goes well and have good heat resistance, such as UHMW.
- Polishing: Usually applies to plastics such as acrylic, polycarbonate, Polysulfone and Ultem clear, but is important for the improvement of opaque materials. Polishing methods are direct machine polishing, vapor polishing, flame polishing and Polishing. The professional-looking surfaces are made by machining and polishing with a provider. Polishing only services are available, but the goal is usually not so good. Heavy polishing can never catch up and overcome bad editing. Melted surfaces in the machining process inevitably result in stress cracks after the Polishing.
- Versions: There is a continuous demand for better surfaces to improve product performance. Given the possibilities of modern CNC machines, surface not accept more than 63 micro inches of a chipper.
- A 32 to 40 inch displayed is a standard view processed plastic finish for a + / – 0.005 tolerance components and should produce no additional cost.
- Models under 32 are reasonable and are expected to rely on close tolerance parts (+ / – 0.0005).
- Versions of 10-20 micro inches are typical for a polished plastic component particularly as a turned part.
- finished inside the pocket milled always have a higher / lower end. The effect of the nose of the end mill does not facilitate clean cut and chip removal.
- Exterior flat ground surfaces can be a very good surface quality
- In a 3D profiling good surface requires a large number of runs of a ball-end mill. Be carefully set the maximum allowable Done to excess To avoid machine time.
- Statements under 10 are difficult to reach and may require lapping or the like with limited application of part geometry.
- Some plastics such as Teflon can not be less than 20 surface finish of any procedure because of the porosity of the material.
- Tolerances: Dimensional tolerance has a lot of configuration and material used. But are not some general rules. + / – .005 "Is an easy-to tolerance for all; but reach very large dimensions of unstable material. For parts with a volume of 1 "cubes and down + / – 0.003 is easily held for small components, in soft materials such as Teflon, + / -. 0.001 reasonable + / -. .0005 "And + / – .0002" are of small dimensions in stable materials produced the corresponding Surface must be improved, such as tolerances are tightened to prevent the repeatability of measurements error ..
- Material Selection: There are many good references for plastic selection by the major manufacturers of both resin and semi-finished products. Choose carefully the materials such as plastics able to change the long term. Field defects do not occur when a plastic part has been in service with a chemical approved long after the part for use by inspection responding. Note that decisions are not limited to plastics made on unfilled materials. fillers such as glass fibers can improve specific properties.
- Dimensional stability: How do top flatness processed plastics do not have near the same stability as an identical metal component. Plastic parts are in the long run affected by many factors
- Thermal change: Plastics CTFE is higher than most metals. Some plastics have a measurable change simply by contact with body heat.
- Moisture absorption: Nylon can soak up to 9% of its weight when saturated with a dramatic Influence on dimensional change. Try Noryl for hot water pipes.
- Creep: Materials such as Teflon and UHMW when placed under high pressure to change their shape and extrude from the joint.
- Off-gassing: Many plastics processed gas in response to the extrusion and machining process. Remarkably, shrink Delrin components over time of the action.
- Stress relaxation: both the extrusion and machining processes mediate stress in a machined plastic part. Postprocessing help , but determined in part configuration, the direction of the plastic relax and size change.
- UV / aging: age and become brittle plastics in particular by UV or chemicals.
For more information, see the title = "Plastic Part Design Guide of Connecticut Plastics."> Plastic Part Design Guide on our website. Or to learn about the history of plastics, and it is our chemical characteristics title = "Connecticut Plastics On Line Learning Center"> On Line Learning Center. A good reference for information on Plastics, engineering and chemistry.
About the Author
Tom Rohlfs, Engineer and President
1264 Old Colony Road
Wallingford CT 06492
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August 15th, 2005 in
Tools
