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Plastics Mould and Product Design Tech.
Chapter 1
PART DESIGN PROCESS: CONCEPT TO FINISHED PART
7 Design Process
8 Defining Plastic Part Requirements
8 Mechanical Loading
8 Temperature
8 Chemical Exposure
8 Electrical Performance
8 Weather Resistance
8 Radiation
8 Appearance
9 Agency Approvals
9 Life Expectancy
9 Dimensional Tolerances
9 Processing
9 Production Quantities
9 Cost Constraints
9 Assembly
10 Thermoplastic Processing Methods
10 Injection Molding
11 Extrusion
12 Thermoforming
12 Blow Molding
13 Rotomolding
14 Optimizing Product Function
14 Consolidation
14 Hardware
14 Finish
15 Markings and Logos
15 Miscellaneous
15 Reducing Manufacturing Costs
15 Materials
16 Overhead
16 Labor
16 Scrap and Rework
16 Prototype Testing
Chapter 2
GENERAL DESIGN
17 Wall Thickness
20 Flow Leaders and Restrictors
22 Ribs
22 Rib Design
22 Rib Thickness
23 Rib Size
24 Rib Location and Numbers
25 Bosses
28 Gussets
28 Sharp Corners
30 Draft
31 Holes and Cores
32 Undercuts
32 Slides and Cores
34 Louvers and Vents
35 Molded-In Threads
38 Lettering
39 Tolerances
41 Bearings and Gears
Chapter 3
STRUCTURAL DESIGN
43 Structural Considerations In Plastics
44 Stiffness
44 Viscoelasticity
46 Stress-Strain Behavior
47 Molding Factors
48 Short-Term Mechanical Properties
49 Tensile Properties
49 Tensile Modulus
49 Tensile Stress at Yield
49 Tensile Stress at Break
49 Ultimate Strength
49 Poisson’s Ratio
50 Compressive Properties
50 Flexural Modulus
50 Coefficient of Friction
51 Long-Term Mechanical Properties
51 Creep Properties
53 Stress Relaxation
54 Fatigue Properties
55 Structural Design Formulas
55 Use of Moduli
56 Stress and Strain Limits
57 Uniaxial Tensile and Compressive Stress
58 Bending and Flexural Stress
62 Shear Stress
63 Torsion
64 Designing for Stiffness
64 Part Shape
67 Wall Thickness
68 Ribs
70 Long-Term Loading
73 Designing for Impact
75 Fatigue Applications
77 Thermal Loading
Chapter 4
DESIGN FOR ASSEMBLY
79 Part Consolidation
80 Mechanical Fasteners
82 Snap-Fit Joints
85 Welding and Bonding
86 Ultrasonic Welding
86 Vibration and Hot-Plate Welding
87 Spin Welding
87 Solvent and Adhesive Bonding
88 Retention Features
88 Alignment Features
90 Orientation
90 Expansion Differences
91 Tolerances
Chapter 5
MACHINING AND FINISHING
93 Drilling and Reaming
95 Tapping
95 Sawing
96 Punching, Blanking, and Die Cutting
97 Milling
98 Turning and Boring
99 Laser Machining
99 Filing
100 Sanding
100 Polishing and Buffing
101 Trimming, Finishing, and Flash Removal
Chapter 6
PAINTING, PLATING, AND DECORATING
103 Painting
103 Types of Paints
104 Paint Curing
104 Paint-Selection Considerations
105 Spray Painting
106 Other Painting Methods
106 Masking
107 Other Design Considerations for Painting
107 In-Mold Decorating
108 Film-Insert Molding
109 Metallic Coatings
109 Electroplating
110 Design Considerations for Electroplating
111 Molding Considerations for Electroplating
112 Vacuum Metallization
112 Design Considerations for Vacuum Metallization
113 EMI/RFI Shielding
113 Design Considerations for EMI/RFI Shielding
114 Printing
116 Labels and Decals
116 Texture
Chapter 7
MOLD DESIGN
119 Mold Basics
119 Types of Molds
122 Mold Bases and Cavities
123 Molding Undercuts
126 Part Ejection
128 Mold Venting
128 Parting-Line Vents
129 Vent Placement
131 Sprues, Runners, and Gates
131 Sprues
133 Runners
135 Runners for Multi-cavity Molds
138 Gates
142 Other Gate Designs
144 Gate Optimization
145 Gate Position
146 Hot-Runner Systems
146 Hot-Runner Designs
147 Hot-Runner Gates
148 Valve Gates
149 Thermal Expansion and Isolation
150 Flow Channel Size
151 Mold Cooling
151 Mold-Cooling Considerations
153 Cooling-Channel Placement
156 Cooling-Line Configuration
157 Coolant Flow Rate
158 Mold Shrinkage
160 Mold Metals
161 Surface Treatments
162 Mold Cost and Quality
APPENDICES
163 Index
166 Part Design Checklist