DuPont Engineering Polymers: General Design Principles – Module I.pdf

This handbook is to be used in conjunction with the product data for specific DuPont Engineering Thermoplastic resins – DELRIN acetal resins, ZYTEL nylon resins including glass reinforced, MINLON engineering thermoplastic resins and CRASTIN (PBT) and RYNITE (PET) thermoplastic polyester resins. Designers new to plastics design must consider carefully the aspects of plastic properties which differ from those of metals: specifically, the effect of environment on properties, and the effect of long term loading.

Table of contents:

* 1 General [ Defining the End-Use Requirements ~ Design Check List ~ Prototyping the Design ~ Computer Simulations ~ Testing the Design ~ Writing Meaningful Specifications ]
* 2 Injection Moulding [ The Process and Equipment ~ Trouble Shooting Guide for Moulding Problems ]
* 3 Moulding Considerations [ Uniform Walls ~ Configurations ~ Draft and Knock-Out Pins ~ Fillets and Radii ~ Bosses ~ Ribbing ~ Holes and Coring ~ Threads ~ Undercuts ~ Moulded-in Inserts ~ Tolerances ~ Shrinkage and Warpage ]
* 4 Structural Design Formulae [ Short Term Loads ~ Modulus for Isotropic Materials ~ Orthotropic Material ~ Other Loads ~ Long Term Loads ~ Ribs and Strengthening Members ~ Structural Design Formulae ]
* 5 Design Examples [ Redesigning the Wheel ~ Chair Seats Reevaluated ~ Wheelbarrow Frame – a Potential Design ]
* 6 Springs and Living Hinges [ Design of Living Hinges ]
* 7 Bearings [ Shaft Hardness and Finish ~ Bearing Surface ~ Accuracy ~ Bearing Clearance ~ Lubrication ~ Protection Against Dirt Penetration ~ Thermal Conditions ~ Calculation of Bearings ~ Design Examples ~ Testing Guidelines ]
* 8 Gears [ Gears Design ~ Designing for Stall Torque ~ Gear Proportions ~ Accuracy and Tolerance Limits ~ Backlash and Centre Distances ~ Mating Material ~ Lubrication ~ Testing Machined Prototypes ~ Prototype Testing ~ Helical Gear Design ~ Worm Gear Design ~ Mating Material ~ Bevel Gear Design ~ Fillet Radius ~ Methods of Fastening ~ Combined Functions – Design Examples ~ When to Use DELRIN or ZYTEL ]
* 9 Assembly Techniques – Category I [ Mechanical Fasteners ~ Plastic Threads ~ Press Fittings ~ Snap-Fits ~ Hub Joints ]
* 10 Assembly Techniques - Category II [ SPIN WELDING ~ Practical Methods ~ Pivot Welding ~ Inertia Welding ~ Machines for Inertia Welding ~ Jigs (Holding Devices) ~ Joint Profiles ~ Calculations for Tools and Machines ~ Graphical Determination of Parameters ~ Quality Control of Welded Parts ~ Welding Double Joints ~ Welding Reinforced and Dissimilar Plastics ~ Spin Welding Soft Plastics and Elastomers ~ ULTRASONIC WELDING ~ Ultrasonic Welding Process ~ Welding Equipment ~ Part Design Considerations ~ Ultrasonic Welding Variables ~ Guide to Equipment Operation ~ Welding Performance ~ Other Ultrasonic Joining Techniques ~ Safety ~ VIBRATION WELDING ~ Basic Principles ~ Definition of Motion Centre ~ Arrangements for Producing Vibrations ~ Welding Conditions ~ Joint Design ~ Test Results on Angular Welded Butt Joints ~ Joint Strength versus Welded Surface ~ Joint Strength versus Specific Welded Pressure ~ Design Examples ~ Comparison with other Welding Techniques ~ Design for Vibration Welded Parts ~ HOT PLATE WELDING ~ TRANSMISSION LASER WELDING ~ RIVETING ]
* 11 Machining, Cutting, Finishing [ Safety Precautions ~ Machining HYTREL ~ Machining and Cutting of DELRIN ~ Finishing of DELRIN ~ Annealing of DELRIN ~ Machining and Cutting of ZYTEL ~ Finishing of ZYTEL ~ Annealing of ZYTEL]

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