Assembly techniques
¡ Welding techniques
¡ Adhesive bonding
¡ Solvent bonding
Cheil Industries Inc. R&D, Application Development Center 2 Last Updated SEP 15 1999
Design Guide For Assembly of Injection Molded Plastic Parts
hub
shaft
Cheil Industries Inc. R&D, Application Development Center 3 Last Updated SEP 15 1999
Design Guide For Assembly of Injection Molded Plastic Parts
Cheil Industries Inc. R&D, Application Development Center 4 Last Updated SEP 15 1999
Design Guide For Assembly of Injection Molded Plastic Parts
0.008
Interference limits for nylon 66 hub I = [(σD•Ø s)/W]•[[(W + νh)/Eh] +[(1- ν s)/Es]]
Room temp.
0.006 where: I = diametrical interference (inch)
50 % RH
Interference Nylon 66 shaft
σD = design stress level (lbs/inch 2)
limit - I Ø o = hub outside diameter (inch)
m/m of shaft Ø 0.004 Ø s = shaft diameter (inch)
Eh = hub modulus (lbs/inch2)
Steel shaft
Es = shaft modulus (lbs/inch2)
0.002 νh = Poisson’s ratio for hub material
νs = Poisson’s ratio for shaft material
W = [1 + (Ø s / Ø o)2]/[1-(Ø s / Ø o)2]
0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Ratio of (Shaft diameter/Hub outside diameter)
Ø s/Ø o
The amount of interference for a press fit can be determined using design equations, or
graphs, indicating the maximum recommended interference for a particular material.
Cheil Industries Inc. R&D, Application Development Center 5 Last Updated SEP 15 1999
Design Guide For Assembly of Injection Molded Plastic Parts
Ø i < Ø s2 < Ø s1
Ø s1 I = Ø s2 - Ø i
Ø s2
Øi
Hub reaches
final axial location
Hub is pushed over high spot (long term)
on shaft during assembly
(short time only)
Cheil Industries Inc. R&D, Application Development Center 6 Last Updated SEP 15 1999
Design Guide For Assembly of Injection Molded Plastic Parts
Press fit
smooth shaft
Time
Press fit
knurled or splined shaft
Time
Cheil Industries Inc. R&D, Application Development Center 7 Last Updated SEP 15 1999
Design Guide For Assembly of Injection Molded Plastic Parts
Lead-in
angle (α)
Insertion
R
∆R
Elastic recovery
Deflection
Cheil Industries Inc. R&D, Application Development Center 8 Last Updated SEP 15 1999
Design Guide For Assembly of Injection Molded Plastic Parts
y = 0.67 ε L2/d
y
d d/2
y = 1.1 ε L2/d
Cheil Industries Inc. R&D, Application Development Center 9 Last Updated SEP 15 1999
Design Guide For Assembly of Injection Molded Plastic Parts
3.5
Applied Load
Neutral
Deflection
axis
2.0
-σ
1.5
1.0
0 0.2 0.4 0.6 0.8 1.0 1.2 1.4
Stress concentration factors show that larger radius values tend to reduce the stress concentration
and mold filling orientation related problems, however, excessive radii can lead to complications
due to sinks, voids, shrinkage stress.
Cheil Industries Inc. R&D, Application Development Center 10 Last Updated SEP 15 1999
Design Guide For Assembly of Injection Molded Plastic Parts
Cheil Industries Inc. R&D, Application Development Center 11 Last Updated SEP 15 1999
Design Guide For Assembly of Injection Molded Plastic Parts
Machine screw and bolt Machine screw and insert Self threading screw and plastic boss
£Esthetic interruption on both top and £One smooth surface obtained £One smooth surface obtained
bottom surfaces £Fewer parts required for assembly £Minimum number of parts required for
£Many parts required for assembly £Internally threaded insert must be assembly
£Access to both top and bottom of the inserted into boss during or after £Mating plastic threads formed during
part is required during assembly molding assembly
£Need locking hardware to avoid £Requires special equipment/tooling for £Minimum fastener and equipment cost
vibration loosening insert £Limited durability (mating thread is
£Durable assembly £Good overall durability plastic)
£Suitable for repeated assembly £Repeated assembly possible but limited
Cheil Industries Inc. R&D, Application Development Center 12 Last Updated SEP 15 1999
Design Guide For Assembly of Injection Molded Plastic Parts
Radial
Mechanical Fastening Techniques clearance
Through
clearance
boss Minor screw Φ
Pilot hole Φ
The screw type, size, and the design of the boss system are dependent upon
Cheil Industries Inc. R&D, Application Development Center 13 Last Updated SEP 15 1999
Design Guide For Assembly of Injection Molded Plastic Parts
Failure
(destruction)
Recommended Yield torque:
tightening stripping...
torque
Prestress
Torque (clamping) Maximum
torque drive torque
(clamping starts)
Start
Drive
torque
Typical torque vs. turns of engagement behavior for a self threading screw
being driven into a plastic boss
Cheil Industries Inc. R&D, Application Development Center 14 Last Updated SEP 15 1999
Design Guide For Assembly of Injection Molded Plastic Parts
Shrinkage voids
Sink mark
Blind boss
Lb Lb
Through
boss Self
threading
screw
The core pins that are used to form the holes in blind bosses should
be extended as much as possible to core out excessive material.
Cheil Industries Inc. R&D, Application Development Center 15 Last Updated SEP 15 1999
Design Guide For Assembly of Injection Molded Plastic Parts
Lb
Lb
Lt
Lt
Lb =length of hole in the blind boss Lt= length of hole in the through boss
The blind boss core pin length is reduced to minimize the molding problems
associated with long, cantilever core pins
Cheil Industries Inc. R&D, Application Development Center 16 Last Updated SEP 15 1999
Design Guide For Assembly of Injection Molded Plastic Parts
Torque-turn curve for a self threading screw showing poor strip/drive torque ratio (left)
and high strip/drive torque ratio (right).
Cheil Industries Inc. R&D, Application Development Center 17 Last Updated SEP 15 1999
Design Guide For Assembly of Injection Molded Plastic Parts
High strip / drive ratio High strip / drive ratio High strip torque
and but but
high strip torque low strip torque low strip / drive ratio
Torque
Turns of engagement
The boss pilot hole diameter has a significant influence on both maximum drive torque and strip / drive
torque ratio. Low drive torque and high strip /drive torque ratios are most desirable as this limits the
potential for failure during the initial or subsequent assembly procedures.
Cheil Industries Inc. R&D, Application Development Center 18 Last Updated SEP 15 1999
Design Guide For Assembly of Injection Molded Plastic Parts
0
0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14
Boss wall thickness (inches)
Tensile screw pull out results for a type BT screw and a polypropylene boss.
Cheil Industries Inc. R&D, Application Development Center 19 Last Updated SEP 15 1999
Design Guide For Assembly of Injection Molded Plastic Parts
Welding Techniques
Molecular diffusion and entanglement
Upper part
Weld
interface
Lower part
Welded thermoplastic parts Entangled polymer chains at the
weld interface
Molecular diffusion and entanglement must occur during welding. The molecular mobility
can be the result of solvent swelling or thermal energy
Cheil Industries Inc. R&D, Application Development Center 20 Last Updated SEP 15 1999
Design Guide For Assembly of Injection Molded Plastic Parts
Welding Techniques
Ultrasonic Welding Air pressure
Pneumatic
cylinder High frequency Low frequency
electrical out Electrical electrical in
power
Ultrasonic welding process is commonly supply
used for the assembly of small to medium
size thermoplastic parts Converter
high frequency electrical signal in -
weld process variables include: high frequency (ultrasonic) mechanical
weld time vibration out
horn position
weld pressure Amplitude transformer
(booster horn)
Cheil Industries Inc. R&D, Application Development Center 21 Last Updated SEP 15 1999
Design Guide For Assembly of Injection Molded Plastic Parts
Welding Techniques
Ultrasonic Welding
Cheil Industries Inc. R&D, Application Development Center 22 Last Updated SEP 15 1999
Design Guide For Assembly of Injection Molded Plastic Parts
Welding Techniques
Ultrasonic Welding
Cheil Industries Inc. R&D, Application Development Center 23 Last Updated SEP 15 1999
Design Guide For Assembly of Injection Molded Plastic Parts
Welding Techniques
Ultrasonic Welding
Plastic part Insufficient spreading Excessive Optimum
before welding of energy director flow of melt weld
Energy
director
Surface textures opposite the energy
director can improve weld quality for
joint such as the butt joint
Textured
surface
Cheil Industries Inc. R&D, Application Development Center 24 Last Updated SEP 15 1999
Design Guide For Assembly of Injection Molded Plastic Parts
Welding Techniques
Ultrasonic Welding
Cheil Industries Inc. R&D, Application Development Center 25 Last Updated SEP 15 1999
Design Guide For Assembly of Injection Molded Plastic Parts
Welding Techniques
Ultrasonic Welding
General Guidelines on the Compatibility of Various Thermoplastics for Ultrasonic Assembly
Material Notation Complete compatibility Partial compatibility
ABS A A,B,D T
PC/ABS alloy B A,B,K D
Acetal C C ---
Acrylic D A,D B,E,J,K,T
Acrylic Multipolymer E E A,D,Q,T
Cellulosics F F ---
Fluoropolymer G G ---
Nylon H H ---
Polyphenylene oxide I I,Q D,K,T
Polyamide-imide J J ---
PC K B,K D,I,R
Polyester L L ---
Polyethylene M M ---
Polymethylpentane N N ---
Polyphenylene sulfide O O ---
PP P P ---
PS Q I,Q E,T
Polysulfone R R K
PVC S S ---
SAN T T A,D,E,I,Q
Cheil Industries Inc. R&D, Application Development Center 26 Last Updated SEP 15 1999
Design Guide For Assembly of Injection Molded Plastic Parts
Welding Techniques
Vibration Welding
Grooves
for welding
tools Relative
horizontal
motion Joint with
Welding flash traps
Frequency: 120 to 240 Hz.
Amplitude: 0.030 - 0.160 inch flash
Single (0.8 - 4.0 mm)
plane
parting line
Pressure
Cheil Industries Inc. R&D, Application Development Center 27 Last Updated SEP 15 1999
Design Guide For Assembly of Injection Molded Plastic Parts
Welding Techniques
Spin(rotational) Welding
Variable
speed
Clutch drive
and and brake
flywheel
Pneumatic
cylinder
Controls:
Ÿpressure
Drive head Ÿspeed
Ÿweld time
Ÿhold time
Driven
plastic part
Holding
fixture
Fixed
plastic part
Cheil Industries Inc. R&D, Application Development Center 28 Last Updated SEP 15 1999
Design Guide For Assembly of Injection Molded Plastic Parts
Welding Techniques
Spin(rotational) Welding
Butt joint
Welding Techniques
Spin(rotational) Welding
Temperature Displacement
Axial force
Temperature
Axial
displacement
Rotating
Softening part
temperature
Ambient
temperature Fixed
part
Time
Start
Phase 1 Phase 2 Phase 3 Phase 4
abrasion and initial melt steady state end rotation
external friction layer formed shearing and cooling
Typical temperature and axial displacement over the course of the spin welding cycle
Cheil Industries Inc. R&D, Application Development Center 30 Last Updated SEP 15 1999
Design Guide For Assembly of Injection Molded Plastic Parts
Welding Techniques
Induction welding
Welding Techniques
Hot tool welding
Step1. Parts placed in upper Step2. Electrically heated
Upper holding fixture (moving) and lower(fixed) welding platen is inserted
holding /alignment fixtures between parts
Plastic part
Plastic part
Cheil Industries Inc. R&D, Application Development Center 32 Last Updated SEP 15 1999
Design Guide For Assembly of Injection Molded Plastic Parts
Welding Techniques
Hot gas welding
Hot dry, clean
air or inert gas
Welding
Force tool
Plastic welding
rod(same material)
Beveled
groove
Force
Travel
direction
Finished
weld
Plastic parts
to be welded
Cheil Industries Inc. R&D, Application Development Center 33 Last Updated SEP 15 1999
Design Guide For Assembly of Injection Molded Plastic Parts
Adhesive Bonding
Advantages
Cheil Industries Inc. R&D, Application Development Center 34 Last Updated SEP 15 1999
Design Guide For Assembly of Injection Molded Plastic Parts
Adhesive Bonding
Adhesive theory
Water
droplet Time Time
Cheil Industries Inc. R&D, Application Development Center 35 Last Updated SEP 15 1999