e-mug Teclnologies Pvt. Ltd, Aeiosuce Division - DEDC loi B/E Aeiosuce Inc.

,
VACUUM FORMING
PROCESS FOR
KYDEX PARTS
Prepared By
A.S.DESHMUKH
e-mug Teclnologies Pvt. Ltd, Aeiosuce Division - DEDC loi B/E Aeiosuce Inc.,
KYDEX
PROPERTIES
Formability :
Excellent forming properties, easy machining and
fabricating using conventional methods, further
expanding finished part possibilities.
For deep or hard to form parts or where good finished
detail is required. KYDEX is unsurpassed.
Rigidity:
KYDEX is more rigid than most other thermoplastics
resulting in parts that will deform less when loaded.
e-mug Teclnologies Pvt. Ltd, Aeiosuce Division - DEDC loi B/E Aeiosuce Inc.,
Breakage Resistance:
With a high Notched impact resistance, KYDEX offers
unsurpassed resistance to breakage.
Chemical Resistance:
KYDEX meets the highest standard for chemical
resistance for thermoplastic materials.
Fire Retardance:
KYDEX is recognized by Underwriter's Laboratories,
Inc. for Standard 94 V-0 and 5V and UL 746C in all
gauges and colors.
e-mug Teclnologies Pvt. Ltd, Aeiosuce Division - DEDC loi B/E Aeiosuce Inc.,
Applications
Aircraft interior
components
Mass Transit vehicle and
RV interiors
Equipment Housings
Medical Products
Certified As Per
FAR (Federal Aviation Regulation) 25.853 (a) 60s, 12s
e-mug Teclnologies Pvt. Ltd, Aeiosuce Division - DEDC loi B/E Aeiosuce Inc.,
KYDEX PART TO BE MANUFACTURE
e-mug Teclnologies Pvt. Ltd, Aeiosuce Division - DEDC loi B/E Aeiosuce Inc.,
Kydex Sheet Wooden Frame
Need to clamp Kydex sheet between wooden frame with
the help of clamps as shown in snap.
Clamp
e-mug Teclnologies Pvt. Ltd, Aeiosuce Division - DEDC loi B/E Aeiosuce Inc.,
Heaters are generally infra-red elements mounted within an aluminum reflector plate.
In order to obtain the best vacuum forming results, it is essential that the sheet is
heated uniformly over its entire surface area and throughout its thickness and reach
the Forming Temp or ( Plastic State). In order to achieve this it is necessary to have a
series of zones which are controlled by energy regulators.
Heating Temp.- Between 400 to 430F
Heating Time- 4 min
Heating of Kydex Sheet
e-mug Teclnologies Pvt. Ltd, Aeiosuce Division - DEDC loi B/E Aeiosuce Inc.,
FORMING TOOL MADE AS PER PART PROFILE
MATERIAL: MDF BOARD (Medium Density Fiber Board)
Forming
Tool
Vacuum
Chamber
e-mug Teclnologies Pvt. Ltd, Aeiosuce Division - DEDC loi B/E Aeiosuce Inc.,
Vent Holes for evacuating air to creating Vacuum
e-mug Teclnologies Pvt. Ltd, Aeiosuce Division - DEDC loi B/E Aeiosuce Inc.,
Forming Tool with Vacuum attachment
Forming Tool
Vacuum
Chamber
Vacuum
Attachment:
Which suck air
from vacuum
chamber through
PVC connecting
pipe
e-mug Teclnologies Pvt. Ltd, Aeiosuce Division - DEDC loi B/E Aeiosuce Inc.,
Another Example
Forming Tool Kydex Part
e-mug Teclnologies Pvt. Ltd, Aeiosuce Division - DEDC loi B/E Aeiosuce Inc.,
Forming Tool
Kydex Part
Another Example
e-mug Teclnologies Pvt. Ltd, Aeiosuce Division - DEDC loi B/E Aeiosuce Inc.,
Another Example
Forming Tool Forming Tool
e-mug Teclnologies Pvt. Ltd, Aeiosuce Division - DEDC loi B/E Aeiosuce Inc.,
Setup while Vacuum forming
For Ex.-
Kydex Heated sheet
Clamp
Forming
Tool
Vacuum
Chamber
Air Evacuated
to sucking
Kydex onto
Forming Tool
Air between
Kydex
sheet and
Tool
surface
e-mug Teclnologies Pvt. Ltd, Aeiosuce Division - DEDC loi B/E Aeiosuce Inc.,
After Vacuum Forming
For Ex.-
e-mug Teclnologies Pvt. Ltd, Aeiosuce Division - DEDC loi B/E Aeiosuce Inc.,
Hear we can see the part surface is not smooth, Excess material is formed on part surface, which is
called Webbing.
As in this part that portion will be cut in final trimming no need to bother about that.
But if we want to avoid Webbing then female part of forming tool is required and need to match with
male part while vacuum forming.
For Ex.-
Excess Material (Webbing)
Forming Tool (Male)
Forming Tool (Female)
e-mug Teclnologies Pvt. Ltd, Aeiosuce Division - DEDC loi B/E Aeiosuce Inc.,
For Ex.
Forming Tool (Male)
Forming Tool (Female)
e-mug Teclnologies Pvt. Ltd, Aeiosuce Division - DEDC loi B/E Aeiosuce Inc.,
COOLING
Once formed the Kydex must be allowed to cool before being released. If
released too soon then deformation of the moldings will result in a
reject part.
For speed up the cooling cycle air flow is required.
Air Gun
e-mug Teclnologies Pvt. Ltd, Aeiosuce Division - DEDC loi B/E Aeiosuce Inc.,
Formed Part Before Trimming
For Ex.-
e-mug Teclnologies Pvt. Ltd, Aeiosuce Division - DEDC loi B/E Aeiosuce Inc.,
Part After Rough Trimming
e-mug Teclnologies Pvt. Ltd, Aeiosuce Division - DEDC loi B/E Aeiosuce Inc.,
Finish trimming is required as per Drawing with the help
of jig & Fixture on Vertical or horizontal Saw M/c, CNC or
Hand Router.
Hand Router
For Ex.-
e-mug Teclnologies Pvt. Ltd, Aeiosuce Division - DEDC loi B/E Aeiosuce Inc.,