I.IHAT IS ASSE}ItsLY?

conPany'-We sill
Assedb.Ly lakes on various meanings flod.conpany.to
to be lhe process of joiDing logelher conponent
."""tury
""""iJ."
The cor0Posile Palt need no! be tlre end
p"rts fo foro a conposife lten'
or a aachine 1n a
la courd be a sub-assedblv ln a toachioe
ii"J".i,
ileD' il
indlvldual
be
an
no!
a conPonen! par!;eed
plant. Sinilarl'y

I."iJ

2'
o" . suu-assenuly o! a oachlne' see Fi8ure

Asseobly has TI{REEdisrlncr

* HANDLIIiG
- 6lorlng,

Pnases'

EransPor!lng, PosiEionlnS, orientatlng

etc'

* COI.IPoSINC
- lhe loj.nlng Process.
* CHECKING
- eosullng !ne asseEbly !9 satlsfeclory'
OF DFA
PRINCIPLES
deslSner'B
list of I'rules" 16 lntended !o idcrease lhe
The follol'int
beyono
no!
are
alrareness of asseEbly lelsted ProbleEs' The solulIons
to
given
are
of reasonabl'e lhlnklng; sone anggesiLons
;;;-;;;;4"
Ptodoi.g.

ldelas .

."'N
d_, , _ u::!
* evota' ranii ing/nestln8 - See Fl8ure 3'

by Beking Parls oore sy,ure!ricar or 1f not

. r""irit.tl*i"ntation
possible 1ncre69ealtyoDetry' _ See ligure 4'
* M1nlD15e/eliEinatefixlng ha'dware 1'e' screrB' washers' c11p9'
* Use saap flxlngs.
DeveJ,op6elf Locarlnt/geJ.f fixlng

feetures'

Provlde adequale gulde surfece6 4nd chaEfers e!c'

* Ellhhat e / lnleErate part6 - See Fl8ure 5
Design good bases.
Choose siDple
llake insertion
Avold lolelance

Dovlng palterns - See Flgur

V" It
unanbYgrious - See F1gure 7
deEaods - See Figure

6'

if
of lhe sleel collar I'Jolker' EveD
Trv !o Eee! Ehe lequirenenls
See
is noc used Eanua'L assemoly benerics'
""'..t..i"-."".ttiy
Figure 9.
* siEpliiy

lhe desiSn using

idea generalorst

see Flgure

I0'

PUTT]i.iC THEORYINTO PRACTICE

*":: q"i"!l:-::::
DFA principles can be inpleEenled Eanuatly :tt
soft\"are lefelred to
s
corlDuler assislance. 8oollroyd aod Dewhur;t
i".r''i'i"i'
suldes rhe user. throush an,asserxblv
1:";;;;.ri.".
:;i;;;^
shoen
wav. conside!, for exanPre' the conPorent;; .' r.!i
;;;;i;;
to be
softrare is used b y f irs E c o n s id e ! 1 n 8 -t h e -1 le m
ll. T ie ""r
i n fir r ""
rs.
lurn
ln
an asJenb.Ledcor0poslle Part' l{ex!, each cooPonenl
rel'atins !o tt
ieno,,ea rroo lhe assedblv and lnforoalion
il;;;;;;;lt
.is fed lllto the colnPuler.
Fot exanple
Coropulera6ks

U6er rePlles

Neire of palt ?

Nu!

ls 1t necesSarY?

Ye6

llow Eany?

Yes

Are lwo necessarY?

Se.lect oelhod
of jolnlng
I scres
2 Press fil
3 cIaEP

Hotd oany oPelallons

for ortintatlon?

for the psrt 13 led

The questlott6 conllnue untLl ell lhe lnforidarlon
ln a 3io11aE ney and at
lnlo lhe cot0pute!. Each colrPonen! 1s lreated
the asselbLy 15 tlven',Fee
lhe end of tile exerclse e Prlnlou! for
afEer lhe-Pllniout
questlons-end
FLgure 12. As the user answers lhe
apParen! !'e'
becooe
should
ti!
b"en stlrat"d, BiapLe desitn chenges
* use sPeale cooneclors lnsleed of let-Dlnal' screws'
* ose ribbon slle instead of 6ePsrale leads
etc'
la te with ihe base bv Doul'dl rgl s taepins
;;";;;;;--.i;-;arrep
deslgn changes loPledertted
The use! now repeats lhe exerclse wlth the
see
occasLonally lhe lesu1Es ale dranatlc!
and observes the efiect.
Figure 13.
fron lhe software'
Note that lhe ideas corle lroo rhe deslgller and oo!
WTiENSHOULDDFA BE APPLIED?
* 1! is never too earLy.
* It

is

best aPplied lrhen everyrhing

PAGE3

can be changecl'

* DFA is a reviewiog process and should be Eaillaioed

i!eratj.ve
deslgn cycle.
IIIL\T BEIiIIITS
* Reouction

n A be!!er

CAN DFA BRIIiG?

in nanufacturing

quali!y

* A producr rhlch

cost

produc!,
is

oore easlfy

Eaintahed.

lhroughout

rhe

oo
oc C

\J

4 Congoncnt
U*r

M4onbr5
tr,l

---l--t

r--1

I
Ao b - aaaen4vlies
rfI

aalenbl5

c/'6,1hi^os

e9l er*b\

gla'.1

('yra_!

4*s":\

Area"rhl.1

KI

u
N
N

N
N

il
N

N
N

@ 6\stl

s/

(:coeee 3

Avo'5 {*^rqu'*

ttrs-T'
rle.
,"1

x
Frqu*e

lrlCr-erSg

sv"*"y'^s^"t-SL

a
x
l'lquR. 5

ELrMrnlATE/tNreqcarg

?aers

Frrr'uR"EG

Moltir

?A{{a}rg

-l-.r
I

x
Frq.ree

Mrrr<e

lNsEe'fro.r

tJNrflgrquorJS

5o.aT r ^r

FrqucE

-foueer"ncg

twtouss

B,r+N>s 6a

oF

VAAto j!

Ass6MBL./

ASSEMBLER
srEEL q9!I,48
a--.
dL6t-

EASSI

YBE

r8Y

ffisrqo3lwlqunur4oolrv

:WE&ii{i-ial-dii.o!tEI}lIg
Enivlrtlu!;frnirtrarern
i Usiffi

l:'-

F t qu z t

,ty*

sl}{PlrtrcArroNIIEA.qnBAlggg

o lYbydocslthavc tblr rhapc?

o Eor rosld I dcslgatt ilI had to bdH lt la uy hodd iortrhop
1 $ls1 if thir rcrc tq!.!cd iuldc ont? Bcvcrrcd? Upridc dora?

_
,

e
.
r
.
.
r
.
r
.
r
r
r
.
r
o
r
.
.
.
r
.
r
o
r
.
.
.
.

Whatif it rcrc lergcr? Eighcr? lao3cr? Yidcr? friclar?

Sopporelt rctr lctt out?
Eor ceathic bc aadc uorc coaplc(l
T6al{rh|r!gbttcrr;mnctricdgrgyoncdcal?
C.n caElc rld clfect bc rcvcrscd?
D,cDoosFatror dcscrlbc bt rhlt tt bo"t
Coqlda vcndorsupply thir f6s tlsg!
Eos cocld this bc cbaagedfor quicler esscnbly?
W'hstotAcrDetdalr rould do thirfub?
Shouldit llidc Lasteadof rotatc?
Whatb riuilar to this but eostsLes? Wby?
Fh*ilit rcrc Eadc tighter or fastcr?
W'hatnotion or power is wastcd?
Couldtbe packagcbc uscdfor soncthing aftcrsard?
Eor do loocoupctitoa solvr problcnr tilrilsr to this? .
Caa eaothcr part pcrforn the firactioo?
Caathis part or fuactioa bc coobiacd wit'b aaother?
Wtrt U thc prcsentdcsignof nctbod rcrc prohibitcd?
Eor caa recondaryopcratioasbc rvoidcd?
Caa it bc st.igbt iastrrd of curvcd?
Eorcanitbeadaptrdtoahighspecducthod?
Eor could this bc aadc casierto [sc?
Caait bc nadc safer?
Couldraaterialsbe salvagedor rrclriued?
Wbatothr operationrequcncccould be tsed?
Wbrt ceusccould produec thc snc cffcct?
Whatothcr 6elds havetr i. kind of problcu?
Wty bsJr't 8nyonedooeit beforc?

i- r cn.,tai

lo

/6) aexct xurs

(+) scFE

lrgcarlrlttign

: nol .art

ta dlgl

- ttrid.ti

lt.'91|i9

H
o

.G.1"

- rr.ltlct.d

-,/'

,LtG,/

to'l

^t.';t,i, "F*

I
I

- r.{sl?.r

tti.t'rr

(:) rrctrrrrr
-

.att

-l
- ...ar

lc rllgl
lrol.tl|il

a.ur

tatt
,t
f r

(.|I!-.rr.,n!ly)

'r
t

::L-'----'
a

(t) xererutt
.dr lrolCla! a.ti
- n
t. allln
...t
- 6ol

i
-2.-,
:r:..
'

'b+,a

'IJSE
- raru'lcltd

'.r.ttgpprx

.lign
- ltst .r3y tq

I
t

rcclr'

F r q o e e rl

fz)s.r. rc!,Ys

TEIr|

OCi

(C"ttiont

h tnlltl tl'?

ASSTBLY
SEQUI}ICE

rL0cl(
TIST
PIRTS
lin o.darof aJradlyl

lli0.i

CliiElrTS

?ARII1AIIE

---t

i- - i

i I i t{Atl$L

I Pertir Flr(ld iito ro.l+ittur!.

' --- I ---------.-------_--

I Pl.tr .r! !.dr.d by gtREl

I FASIENiX6.
oparationa)
! (2 conrrcutiYa

i 2 i SCREI

i.rdirt.lY
i Prrt ir tloTStC!88!

!JINE CT

i on insrrtioi.
Put! rr. t!.otrd by SEREI
FTSTENIIIS.
opatrti!n5,
l2 conrarutiYf

r 1 | SCnEt
l--i-IIIFUS E

ttl

-i

or
P t ir 5.Eur.dby . PRE35
FIT.
IIITERIERENCE

i..!dirt.lY
Prtr rr. toTSEEURO
!n inrarti!n.

LEAD

(2 cooircltil! o0!rrtion!)

i.&di.trly
Pirtt .r! I0T SECURm
on iiEaatiol.
(2 Eoorratdit!og!.tti ontl

IASHER

i---i

------i

8 l F UIST

Fr4"'eg 12 g1

Pwt! .rr rrEur.dtt SCnEI

FASTETI116.
(2 conlacltir!nPlrations)

Oo r ?o-t b rS?Lrr/

ft<
ti!

tle-e,.n'.r,tL

Fa r l -

oF

R'=uLts

Buoc f Si't a. 'r"r

oao

MAtt*bl5

Aob - aaiae*b

,"7

auc,*bl5
a fi d l c h i n c S ' -'-

aste,*b\

914*k

('5oro_!

w_:\ Arsc'+h1,1

. t-

Econonic

Deslqn for

Production

fntroduction
the

econoElcally,

ploba.bly

reductlons

in Earufacturl,ng

and profltabllity

been resealcheal

productlon
design

and develoged

should be the

in realuclng

can ue Eanufactule
re-ilesigrr

X 60 that

dleslgn fo!

econ@ic

autoloation

ln loanufacture

at low cost

Danufactured
lnanufacturlng

facillties.

Eanufacturlng

let}loils

itesiqn

offlces

plocesses

ale

usually

and that

Frequentty

neaki

often

1s poor lJd

is

only possible

ln

engineerr s effectlveness

antt develolment,

&re costly

practice

to ove!-ilesigr.
and nanufactule
being

baterlal,

Ihe

that

Iabour

of a ner,r ploduct.

to be

account avallable

the "shoPs" over

between qtorkshoPs aJrd

costs

ls

of roarufactuling

often

lnaalequate.

etlth the Ddst uP to ilate bachLne

but

lhese ate of no use lf

Eigh glrile

ilesigrl

technlcal
directly

arld quality

t}le

!lo!k on the BhoP floor

Plays

assularce

affects

into

a vitally

Many cost
that

I3 AeterDined

knowledge ultinatefy

such cost eleroents as deslg!

assulance.

has a way of creePing

extra

into

coDDunlcations

Proceilures,

1n applying

speclflcation

padded to provldte

ileslgnE ale lntenileil

Is good.

ltself

Product

as Dole

have consul.ted

ltolkBhoP faclllties

1f the deslgn

1lrportajrt

Cleally,

lDpleEenteil.

hls

\dork satisfactolLly.

done hls

by cost conallseratlons.

ls

on Eanufactullng

to obealn econoDlc Eanufactullng

dleslgne! has not

roole econoElcally?"

knowledge about the cap6bilttles

Lnfolroatlon

A co@pany loay have the flnest

tool6

gowever,

and costs.

A coDPany

wllf

ta.ke fufly

he wlll

costs,

usually ask "Eor.r

They should ask I'gow can we

clal.E that

ileslgners

and

the deslgnels

sought.

ploductlvlty

and asselobly plocesss

vlII

D!11 has not

Datrufacturlng

ls becololng 1ncleasingly

lranufactule

desigrie!

ale

can t rnanufactuled

lt

fo!

to leduce

econorolcally?"

X !o!e

lool

leproveEents

and iDprovlng

costs

Product

Ploduct

engineering

area $he!e

flr6t

an effective

Although

slgnlficant

for

ln ploductlvLty,

and lncleases
into

nanufacturing

of a coEpany.

potentlal

1n any effolt

Cleally,

engineers,

ifiterested

the greatest

costs

so they Day be oanufactureal

as a Deatrs of reducing

has long been lecog:nlsed

is the area witl

t}lls

ltle

or proilucts,

to enhance the ccmpetltlveness

cosls

yet

parts,

Ltoportance of deslgning

ileslgn

efforts

l-Dportant

ttrivets
the palts

arise
will

is the tendency

rol.e iluling
through
fulflll

tne deslgn

the speclflcation
theli

function.

In such cases, adalilional

costly

processes,

net}lods pla$ers

dltlenslons

and operators

expectatj.ons

never be afrald

the use of special

quauty

ot ihcreased

achleve the speclfled

englneellngrs

operatlons,

checklng

and flnlshes.

equj.pEent or Eore

are usuall-y

requtred

Costs can escalate

also dectde to heilge a llttle

r,r1ll be achieved.

of questloning

to
furt]]e!

to lte sule

the designe!

should,

lf

that

thetefole,

the spectflcatlon.

Conceptual Desiqn
The concptual

deslgn

the speclflcatlon

lsr

6tage which seeks Eolutlons

I think,

the bost challenglng

Un]lke toat-\eDatlci.rns , deslgnels

elti
(

s@e unj.que solutlon.

Hh1ch p!e6ent6

have tle

ts lnvarl.bly

tf several ideas are folticord.ng

parts

rnd rewalallng

luxury

glven

of belng

of

of deslgn
problebs

roore than one pos61b1e desigm

probleE.

to t-lie stateil

Duling th conceptuaL stage tie

successful solutlon.

larely

ttlere

a solutlon

to beet the requiretoents

aiD 1s to produce as Eany ideas as posslble,

there ls a greate! poss1blllty

Often the flnal

result

of, flndlng

rday be a cotrblnatlon of a nuobe!

of the LileaE put fomard.

?hete 15 rn air
Even lf

whLch sullound

of urgency

no !1glil

target

date has been set for

PresEure to produce lesults

generally

llrthelDore,

alternatlves,

s@ething

on ludgeEent,

and th16 ls

Detall

long befole

plojects.

engineellng

a solution,

a6 posslble.

insteail

he slEply

all

thele

1s usually

Consequently,

the englnee!

he has had tfuoe to uncover

of an exhaustive

does not have tiDe

evaluatlon

fo!,

he bust

all

oi t}Ie
heaviLy

rely

a ilerdandlng aspect of a desLgmet,s day-to-day

ruork.

Deslqa

the pleparation
Any errors
affectl.Dg
It

as quickly

tlu6t lecoE@end a solutloa

t}le ilcsslbllltleg.

almost

of akawinqs

fiDdlng

t}Iel!

for

Darufactullng

date and the eventual

nust be real.izeal even ilown to the level

dtawlng

autholity

statlng

tnevltable

ln not

of the fiiished

Just

toLerances,

anal llrecovable
aitlcle.

ls

extlebely

way to the qrotkshops can have serious

both the del.Ivery

aletalleil

pulposes

an instructlon
tnaterlals

expenditure

proJect

of t}|e Junlor

consequences,

cost.
dllaughtsdajl

to roanufacture;

and constructlon

irportant.

tiat

of suhs of Doney that

Lt ls
will

that

a flnajlcial
ateroanalthe

add up to the cost

Thele aae roany areas which requlre

consldelatlon

Arcng

by the designer.

these are included:

a) natelial

selection

b) geonetric

shape chatactellstics

c) tolerance

and surface f.inlsh

d) avatlable

productlon

requllenents
anal processes

Eachlnes

the alestgne! needs to consider

points

follo$tnq

the

to Eeet the

lssuing

befole

iltawlnqs

fo!

manufactule I
-

capable,

1s t]re desigr

si-Eply

and easl]y,

of roeeting t}Ie tequlreEent

of the sPeclficatlon?
-

uslng

car the coEponents be rosnufactuleal

conventlonal

Ploductlon

ldetlods ?
-

reailily

are the loaterials

avatla.ble?

and

al]d can they b treated

Dachlneil as speclfieal?
asseEbly?

is any Dachlnlng

can the coDponentE be asseDbl-ed wlthout

wlth

or an asselobly fltter
.ny alignnent

ls t}|e product

can the asseEbled Bachine and any lalge

lt

is

possible?
toolst

sPecj.al eguiPEent?

safe?

ale

llfting

ajry sPectal

are t}|ele

Problens,

so,

the need of sPecial

requlrlng

ale there

If

eyes and arDs 2 loetres 1on9?

PeriscoPic

tlansporteal?

\_

after

requiled

available

Polnts
factors

EaviDg consltlered

the above points,

design,

regarallng

the costs

plovldes

a selles

coBPonents be hatldled a-nd

or needed?

to consiilelr

such.as

the desigine!

still

abbrevlated

of usefuL questlons:

Gne!a1
be used?

can a staJldaril Part

wo\rlal an altered

ca.n the desig!

can a less

can the nuDber of different

standalal part,

be loole econoaoical?

be changed to sinpflfy

exPensive r0aterlal

Lhe Pa!t?

be useil?
roaterials

be reduced?

Machj.ninq
-

are all

nachlneal sulfaces

lrill

does the desiqn pernLt

ale tolerances

can a fastemer

a coarser

finish

closel

necessarlt?

be ailequate?
the use of standard
tha!

they

cutting

shoulal be?

be useal to elinlnate

taPPing?

anil rolsuse?

neeals to question

The followlng

of nanufacture.

envlron$ent

tools?

the
llst

-4-

Assepbly
- can tlro or roore palts
'

can Palts

be comblned ln one?

be Dade s)rorDetrlcal?

_ are a rllnl-Bum nuiobe! of haralware slzes

- are stock cooponents
Speciflcation

called

- are all, threaals

- can strndard
- is Daterlal

whele possible?

andl Standalds

- car the speclflcatlon

ell.Elnate

for

used?

be changed to effect

a cost

leductlon?

stanilald?
too15 be used?

cutti,ng

wLth a tolerance

avatlable

and flni.sh

t}lat

lr1ll

oachLnlng?

qood Functlonal Deslgn t{ay Not b6 cood Productlon Deslqn

Deslgnlng .ny ploduct

Lnvolves consiilelatlon

cost and appeal to purchaser.

Eethod of Danufacture,
Ihe designett origllrgal
now lt

probably have eEblaced only purpose and functlon,

ldea lrlll

to econoolc ploduction

Eust be lelated

llhese tri,o groups of aspecta flequebtly

floo!.

Day not be easy.

Functlonal

efflclency

but t-he advj.ce of t}e ploductlon

and tl.e lequireroents of the frctory

confllct

anil thelr

Eust be the engineer's

His knowleilge of works plant,

leconclliation

fLrst

concern,

tlhe productlon

englnee! also is essential.

englnee! should be Lnvol,ved in any aleslgn. eitier

o:. as a consultant.

purpose, wolklng reliabilj.ty,

of lts

as a roetlbe! of the design ter.E

t}le cost of speciaLlst

productlo[

t|)l oulslde folDs and the avaih.biu.ty

and ptice of roaterlals Day
ena.ble hllo go suggst alteratlons
to tlle deslgm to achleve the Dost econoBlcal

/'

Eethods of Danufacture.
Alternatj.ves
ellDinated
tie

n111 neeil to be illscusseal,

by fabrlcatloni

desigEr to be.Eodlfied

a notr-standlafd

ale ll.kely

Ehoulil cast

coDlronent

relnfotce

ratler

than coDflict

wlth

Ought
o! can

opelatlons;

to plovj.ale

sotoe knowleilge of productlon

wolk be

by plesswolk?

be replaceil

t-he nuEbe! of loachlning

by a stanilaril

trossesses
to

fabllcatlon

to leduce

be replaceil

llhen the designer

Itleas

o! car

For exa.Bple,

intelch.ngeabtl-tty?

processes

his

o!191nal

of the productLon

those

englneer.
llhe vely
cdurot

heav]' buralen of responsibllity

be enphasizedl too eally.

rtrentloned

previously,

placed

on the

alesigner

The Clesigne! can only

he j.s faDiliar

with

production

ful-f1ll

betltotls

ls

a fact

that

thls

task

if,

as

anil ls

able

alul.ing

of the part

t}le deslgnlng
through to the

of basjc desj.gn.
a deslgn wlth
oanufacture
the patt
lt

durlng

a vlew to roal<ing it

but

call

that

o! rather

a wrong one,

It

every

in thelr

erlors

Dade ajril lssued

ileslgn

the b1afLk rj.ght

of tiloe,
fact

that

that

fact

desj.gned.

materLals,

{ork.

For this

theo as "Hints

can generally

deslgners

for

be avoiiled

alone,

condillon

filEs

all,

fixtures?

as posslble?

always fall

leason celtaln

to

And so indeeil,

econoDic reasons

this

to

after

that,

or xpensive

as cheaply

student

lines

$econoroical

the oblection

for

the

to roale corlectlons

and less

as orlglnally

of being Eanufactuled

is a 1on9 esta-blisheil

Deslgn errors

coopllcated

design which dos not satlsfy

elrors

floo

forro \4hich follows

the beginner

in tems

One oust al-ways be rolnalful of tie

tirerefore

basic

less

fron

folth

at what cost

design oust be capable

nachlning

deslgn exercises

have been Danufactu.eil

could

could,

fro& a sinplifted

Any attnpt

usualLy

lts

ploduct.

flnished

A design always starts

to vlsualj.ze

evely
It

follo{s

ls

a baal one,

lnto

the saloe

have catalogued

the

t}|e Deslgner".
polnts

Lf the folloping

are taken

lnto

account:
lll

(v) Avoldance of reduidant

u :^ h ln a } llll+ v

(vl) Accessibility

EconoDy

{tl)
(IIi)

(vii)

clanpabiltty

(iv)

Exlsting

Deslgnj.aq fo!

tool

Ease of asseDbly

equilDent

Machinabllltv

Itre neh'cme! to Clesigrdng very often

aroount of run-out
equally

llts

o! ove!-travel

to tur4ing,

planing,

forgets

tf

lt

that

ls to lDpart
grindlng,

ElUtng,

a cutting

tool

a clear

ialolng

needs a certallr
fhls

flnish.

and drllllng,

applies

as shobal

ln Flg.l.
By appropliate
operations.

design beasures t}Ie deslgrrer

fhoughlessness

loachined faces

Deslgning

fo!

so positioned

on all

that

or inAj-rectly
such Datters

aware of all
and nachiningr

that

sibpllfy

of the deslgner

nachlning

nay leaat to holes

they are inaccessible

to tie

cuttlng

anal

toof.

Econ@y

Itre cost question,

dilectly

on the part

caJI often

ls
afl

to say tle
design

econoinic aspect,

anil, of course,

can be nade onl,y afte!

the co&ponent forEing

arrd the quantities

proaluction,

calculation.

bet-hods, e.g.
requiled

influences,

lriU

castlng,
dictate

elthe?

a final

decision

lhe desig,ner ldust be

forglng,

fabr.lcatlng

which nethod of

-6-

Balufacture

should be used.

laaj<ing a cost
econ@LcaI

analysls

to design

{nto

the deslgner

h1s product

is

often

the necessaly

lble

$tthout

conilltlons

Danuf actqle.

Low cost Danufactule requlles

therefore

Fortubately,

tiat

Eachlntng work be kept to r EinLouE and

the cost can b lowereil by leduclng the alea of DachLnsClsurfacas.

for

InnovativedesQnrnaterial
Aluminiulr extrosions can offe!
designels a new'lateral thinking'
rp p loac h r o r he de i i g n o fma n y
producrs. !ays Howard Spencer'.
Dsign Gartr.r havina-bo-th practical
Iabncatlon mct.!rembty tunctioru or
*ith aesth.ric
(or both) ca' b
'tylins
built-in ro.n.xtruiion,
somrirner
with a resuhant cost lo*er than that
ofa solid cxtrurion ofcomparabte

For,: basrcundcaundin g of rht principl*

o n d c n g n .ro u r
hc!ors nccdconridd.tion:
tr ihc p.oduction proccssi
tr gcneralcheracrcrisrisr
O spcci6callov orooerdcsr:nd
! sn rP .r c er or " r \ .
Ptoducnon
p,occ* A r.tprczlsccr:onthrough
prcrsis illusrrrrcd rn Fic L
:
'nodcrn
C)'lind.icil
bill.r! ofcrsr or cxtr;dcd
produclionarc hc.rcd ro 550oCbcforc
bcing Ioadcdinro thccont:incr. Thc billcr
nthcnrqucczcd rlrough rhedic orificc bv
ralr p.cssurd!ofupro68CMPr. The die is
supportcdbv a scri:r of b+ck dicsrnd
b o h t.s s or hr r lhc m , -i nD rc $Io a d rs
transfcrrcdro the frc,Ltplarcn.
Thc cmersins scc;ionk cooled.nd
su rd .d, r lon;r ; oqns n i n -o u ! ra b rc .
ocrorcbcrnqcut lnto oroductronlensrhs
o fu p to . t 0; . I hc lc ; g rh i rre th .n g i ' controllcd.rr:tch Losrraightcn:nd :re "
ti:cn cut to finnhcd ordcr lengths.A final
prccjpiiationor'ageing rrearmcntis
givcn ro hcrt+e*ablc allorr tocomplcte
'nc Producr'onploccss.
J.n.tu l. lnruu.tisIki A|\'I'.inium allovsarc
corccdr dcscribcdrs hrung good
* re n g rht owc r ghr r au o sd: i 6 c rc n ta l l o r
formulrtions can havc a nr:rkcdcFccton
this end othcr charactcmtics.knowlcdee
ofwhich willbe ofimponance to rhe
dciigncr. Tablc l ietsou! v:lucs forthose
propcrri.s which.rc oore or lesconstant
forallaluminium allols. Thc factor
inlluenccdbraJlov wpes are considered
Withthc wide raneeofmatcrielsnow
avrilablc to dcsignersitis uscfulto have
sp.cific properly lcvlslor asnrnl' ryp.s
aspossiblcso thatrclarive perlormanccs
crn be worked out. Thcrc n. howcver.
difiicuhv in obtiinins informarion in a
forn that aliows easvcornparnonand,
sincemetric.tioh, in rhc correctSl unirs.
Table 1 ancmprsto presenrdru in sucha
simplifiedforn which should be useful
'HoNnd sp.ftr. (..hnrcn ![.
En! neer ng Seplembel

m]me{. Bnfl'h A L.nI

Cro$-!6ctionthrolghd mod6rnsxtuiionpr.!!

2.62 2099 580-650 24,0

785 8097 1900 126
8,93 9200 1083 r.5
565 29,0
.60 618
4.5
2,64 2620 1600
8.4

0.96
0.42
0,38
r,O2

1.ea 1442

1.40

95
r25

700
96.0

69
207
120
44

26

69-

2,a

Tabl61 M.r6ri,I pfo!,6ni.s

whcnconsidcring
m:rcri:l sclcchon,
cirhcronthcb:sisofcomprribilitvo
subsdcurion.
Fu.rhd comp.tisonis,of
coursc,n.ccsr.ryon rhoscch:leccristicj
irflu.nccdby Alloying.
Aluminiuna oy'Prrrc
isa sofr
^llrJniuEr
matcrirlbut by thc:ddition
oisn:I
anountsof othcrclcmcnrs
itspropcrrics
c:n b.l,aricdro improvcsrr;qrh,
durabilny,elcc!ri;l conducri;ry,
rnachinability
rnd rnenyothcrpreferrcd
charactedstics.
Therearcnow overone
hundrcddiffcrentaluminiumallovsinthe
intcmationalrcgisrcrandthsc rrc hrcd,
:ccoidinsro ihc mdor elloying
constituenr,
into ciehtdiffcr.ntcle$es

Gc r.bk 2).

Thercarc l5nainexliusion alloysin

the UK and fou. ofrhescneet rnostofthc
rcquirenenrsofrhe ogrneenng market
orberallovs avarl.blefor specialisr
applictions arc 1350and 6101Afor
c l e c tri c a l use
and2014Aw herevervhi gh

Mdor.llovina con{lts.nr
Aluninium199,00%hl.ihuhl
Copp.r
Mrneln.r.
Silicon
M.s...iun
M.on..ioh 5ndSilico^
Zn.
Orh...l.m..G

AIoV No, H N
rrr
.
2*
3!r
4s
5ru
.
6rt
.
7r*
As

Th.rrnftr'dis6inrh'rloynumb
ormodrrk.i
onfto6ih. br!. ercu,rlova.dn.o dr
i.dividur.lloy'.hrrnc.
iu6b.r Hd
rhnd.v.iop$.nrnnBh rh@ulh.h
TEb162 Alloy dosigns:ions

AsiD all indosrial processes,rlcrei.e

nuufacruring tinniand dcsirabte

producrionfaturcs bur they shouldnor be
allowcd to adversclyafect design
hnovaflon more rhans necersary.
kis
bencr that dcsignersconsidering
aluniniub sectionsshould be inttuen.ed
by rheend-usespecilic,tion. celrainlvin
th inn,al projectstage.De,ien
XI

informationend,*rence n rerdiiy
!vejl.ble from exffude6.en!blinsrle
jnirhl proposalro bcreined.R),rhis
approach
itn Do$iblroachicvctlcbest
blirnce bctwientargetspecifi
ca;on,
manuf.cruiingfecihy, c.seof frbrication

The scdion should,asfaras pos'ble. bc

dislributedequ.llv around rhc c.nffr of
theccDlllhough rhis doesnor meenthat
rhe seclionitselfhasro besvmmerrical.rn
anyextrusion.nctal flow isslower
towardsthcoursideedgeofthe die sothat
by placingtficker partsofthesction near
ShapeJed"bility'the pcrc cnugeof dicaree thc peripheryamorc evcn metalfiou,ir
rnarteevrlt:btcror cxtrunondcpend!
obt.incd. Scctionlhicknessis probabl!
uponth. lypc ofrccrion.Ir isusuallygivcn on. or memost hpo.tanr t.crors
b! rhccircunscribingc'rcled;am.rcr
g o v e rn ,n gc x !rudabi li tv eD di (muchmor(
{ccD)whicLis b:rcdon thc nccdto kccp complcx thanquoring a fr.cfi on of th.
anunbrokcnstructural
rins roundthcdic. scctionccD. It .Feds .xr.udabilitv both
The dcpthofthet ringc:n v:ry from
bv itsrctual and rclativc positionsonthe
20rnmon rn avcr.gcsizcsoliddic ro
dic. Aselrcdy mcnrionca,itis more
60 mm orrnorcondicsfor lrrge hollow
difiicult ro extrudc thin wcbsor fance.
sc*ions,Mosrsccrions
fit into e CCD
n c rr th c c d g cofthedrc rnd sectronbclow 155mD, wnh rmcdium ranqcof
strbility during cxrtusion crn bc helpcd
250mnand vcN largclc.rionsup ;o
by rhickcr wellsrcsuhingin lessdistonion
and dghrcrrol.rencc!. Extrurion speedis

t////zf

2. n6l.tlon
otccD
roblll.rdism!t..

NEW
95

OID
l9

6l

F.

Cu

0,40 0.7

5.0

Zn

8r0.20- 0.l 5
0,60
Pbo.2o0.60

0. 20 0, 35 o r0 0 .1 0 0,45 0,r0 0.to o,t0

0,6
0,9

6082

t3 0

0, 30 015 0 .1 0 0 .1 5
0.6 0.35
07
0. 50 0 1 0 0 4 0
1, 3
L00

0 ,6
0,9

0,6 0 .2 5 0 .2 0 0 ,10
1 .2

T D 255 310
T F 235 310

6 063

T8
TF

v=Vtyqsd

o r5

D wpc ofnt (eg- slidc.hinse,clip,

perm.nentfir. removeable
fi4:
O sernbly lengths(maximuna
minimumfor erchscction);
natcriAlspecifrcations:
and
surface
6nish.
Fig
rypeof lock,ng
- s shos5asimple
rctronthatironlyposibleafrcrbeine
fixeddownrnrhc;ormrlua\ bv bolrso!
screws.
Fig6sbowsa semi-permanent
6r
wLereextracrionis
posiblebut onlv with
access
to tLeinsideofrhescctionarthc
ends.Fig 7 showsr pe(nancntfirwherc
q!rerion isonlypo$ibleb,vpri!ingopcn

..*$""s"s
o'1"."1"-*$'$
^.o
"$se

2 011

6042

Thc nccdtoproduccmatings.crions
!o
v.r,vrighrtoicranccs
reduces
rhenofrh:l
rllowanccfordic wcrr. rhcrcbvrfccrinq
d:c hfc.k iscscndrl,thcrcforc.thrrrs nuch informrion *po$ihlc isavrilablc
arlhedjcd.sisnstrse.Thegencrrl

0 .0 5 0 .1 5 0 .10

Table3: Ch6mica
I conpdition

.
av

slotor deepchannclin
asection
n producedbv a spigoror
tongueon rhedic.Underrhe
v.ry hish prc$uresusedin
cxtrusionr! i5csscntialthat
rhcspigotissupporrcd
asf:r as
prrcdcablefor it nacringasac:ntitevcr
and,.ssuch.movc'nenrorbrerkaqcis
Iikclvifthe aspect
rarioisnot corrict.
Thcrearctwo ryp.tofdo!. nr1lshr
forwardchannclrwhcrcthcdeDrh/widtL
idcairilio n 3r1and.omphx!l;ts whcrc
svmmctryi!imporranrandwhcicrhe
arcr/grp:idcrl nrio $ 3:l GccFiq3).
k rsnow slandzrd
p'aclrceror;ord
hollowscrcwponsin favourofoocn
rcrc* groovc'.Theopcnpa.roftle
groovci!(Ooorrminimum
of1.75mln.
Althoughstanderd
dimcnrions
rrc
rvrileblcto suitmostsclAtapping
lcrcw5,
it is:lwrys bcttcrto iupph rhc.xrrudcr
with:n actu:lsamplc.
thuscnsurinqsood
Th.r. Lan incrcrsing
dcmandfor
kctionsthatm.t. wirh: lhcmsclvcsi
lnothcrdufiliniumsccrionis.vcral
:lurniniumscclions
ofothcr
i or sccrions

T]

6,0

ako iniuenced bl clickncs throueh rhe

shapefactor which n tbe r"r- ter;*"
secuonperiphervand crosFsectionalarca
The e6'ectofabrupr charge oftlickne$
en be mnhi s.d bl m.dpdari ng !
generous
rrorus.I
ri \o aP P tr es
ro
corncrsotunifbrnr rhickDess.
'.ftion

8
I

95
105

163
163

70 130
160 1a5

14
7

50
79

t9 ?
201

TB
TF

90 150
190 230

12
7

TB

120 190
G= Good

P=Pod

V GV
GV V

vGv
GVV

70
to o

172
144

N = Nor3uicbr.

propenies
Table4: Mechanical
andrypicalchracreristics

VGV

Rccentmarketreserrch
hasshownrhar
morederigiessc currcnrlvrhinkingoi
alumrnrum
cxtrusonsthanevcrbeiorcbutsdllthercis.bour4s{,ofrhc
industrlnotusingextrusrur.
cngineering
E ngineeang

Design6xsmples

flangs
ends,
calsedbyrapid
changejn
cross-section
wherdeformadoncould
Thefollowing
casehisrories
iltvstrate
rhe asilybeca!sedduringtheposrversatiliryot
alumini!mo{rrusions
handljng.
Byworkingclosety
for use e)(rusion
in gensra
I engineering.
wirhrh6dssignconsukanrs,
the
Containetfor electrcniceguipn.nt
retinments
we.emade,diescutand
Alarge141x 106mmchannetsoctionsecdons
fabdc6
tedandtestedwhhour
wsdrawnuPbya dsigncon3ult6nt
6nydeiayintheproiecr
programm6.
whhrhetollowingterg6tspsciftcation:
s ting ersectioh for matlne pontoon
A larg200 x 120mmsoliddoubls
cfunnslsec{orwasdrewnupby th
designdepartmenr
ofa loadlngmarina
manufaclur3rwiihthstollowing
3pc'flcaiion:
Mat.rhl - sluminium
a oy
Str.dgth - hlgh3ructlral
Mar.risl - 6lumlnlutn
prformsnce
slloy
Str.ngth - capabl
Dall.ction- nolsp6cifi6d
oftaklnga
100kgloed6t a 450 mm Ourlbillty - suitabllormsrin
l6vrdrm,eciingass
(6!tnot
6lmo3phsr6s
immers6dl
Doflacrlon- n0targetflgur6,
burto b6 Flnllh
- mill1.36xlrudd)
k6pra! lmall e! posliblo Tol.ranca!- toB tishStendard
excpr
Fini.h
to b6anodlsgd
toAA 15
tordidefitsto tik6
Tolarancaa-op6nJdw3
totak6.cryllc
taktlsd!,bollards,
rh6et
pontoonflngffhing@and
!6ctlonto fofin crucifoam,
lmpsctped3
tharofora
engular
- 3 Oen6r.l3lldln
fitfor
loltr8ncaof chann6llg!
ll8nlvsrlochnnel
lo b6b6lowgrld8h
!lctions
Standard
Fabricatlontolors
nc6
wrldabl
byl|c orME
4. op.n!cr.wgroov.5,!,7,nr.!!.chnlqu6.
Fabricltion- vdlcalllottotake
m6thods
u!.rl torlocklng.xtrud.dt.cdon.
Dur8bllhy
3llinlalrsl61
ts$ werccariodoutst
16lf.
pro6p0ctlv6
!vrral
16ppan9
pl6
lcrw,
!it6sin theUKsnd
{3afi
Ihc objcctivcofrhcrlurninium
provid.d)
ovoruaa3,
U3lnglhwirt
onboltmethod.
cxtrulionindus$vn ro rriscrhc
mElsrial
to b6sultablofor Thrcluh!conllrm6d
penemtionlevelofexrrusions
thtAlcanB6t STF
in qeneral
drillingIarg6hol63jn
matrial
confomlnglo 6082TF
(o 80a bv thc endofihc
cns:neering
com.r
!p6c'tlction
bo3!93
wouldb6acc6ptabb,
wlthout
dccadc.wirh allrhcrdvrntrsesthrt
Som
secdon
wb3w6l6
diltortlon
thlcft
andtoimprov;soction
aluminium:nd cy!rusions
ofEr. couDhd
tranlvruo
onturionbE16nc6
3lotwithin
andradllwrsnlargad
with thc rvcalthoftcchnicalexpcrtix
rhlckn.lsof bottom
wh6ramEtlng
withothsrsections
av:ihbleqithin thc:luminiunindu3r.,
would
flangErc tekflxing3plste notb6impaired.
for hdpingdcsigncrs.
thn ambitioull
Theinitl6lde!jgnws! dlscus!6d
with
targctrhouldbc achicvablc.
thcon3ultan$
andth6tnivrs6slot
wasremoved
rndr6placd
bya bohslot
torakeanM5 square
nut.Rsdlia hs
pointw.re 16lared
bosg4eg
transhion
wh16po3sibl6.
By3lightmodificstjonof
thessclion,
6sshown,extrusion
w63
possible
withjnlhestands;d
requirsd,
usingAlcanE50STF
whichconslponds
tothe BS60634specificatlon.
This
mediumstlengthalloyme6ts
allfie
requiremsnts
ofthestructural
psrfornancs,machinability,
in
Hollowsec{onswereevaluated
durability
but
industdalenvironm
entsandis suitable
thebestall-.ou
M sohition
wascloseio
for anodising.
th6odginalproposal
na prformance
of
Theonlyreal!roblem
one)drusion
thesclionin service
hasconflllned
atl
waslhenabilhyoflherelativetyrhin
thedesigndecisions
m6de.
E ngnee ringSep temb er

An ;ntroduction to powder metal.-rgy

5 u b tr o.cX'w-

Add"t '-

3\,^p<.
c|...ry/\/6,r rrerf
fr cc"a'>

sr,.r_

Basic production process

SPECIALEXPERTISE
AT
RIGBYMETALCOMPONENTS

Wg

60

.=.
J2- _ffie #
r--! tr-{ltr
tr{n]= =_l!l_rf-

gg^
DESIGNINGFOB POWDER
METALLURGY

I-T

---l

Be-entantlalerallearur.sshourdbeavoided
a sl h e yw r l l p r a ve n r e r e cr i o n l r o m r h d te

OlivettiProcess
Flsbyt\4eral
Componen6aB rhesolel_1.(
cence.lo.theOliveniSptitDieorocess.
and
componcnisimpossiblero
hanufacrureusinq
convenlonalrooting.anbe manufact!@d

c'o o v Xh r sr b e m a ch i n e d

7::z2f?m

frJ}:z-a'
r,ro

N_

E_

$=J $5

"o C

$4"

vrs

Normarundercurscannotbe
incorcorared
b!rt
oneisrequtedlo. ocarionpurposes
n musl

yES

D i a m o .d kn usa r e i m n o ssi b l e i o p ,o d L ce
dte.ily, bur straehrknurtscanbercadrty

ves

C h a h l e 6 th a r b l e n d p e cl tvw i r h i n r e m a l o r
exlernrldiahetercshould
beavoided.A005
tl a l i sd e sta b l e a n d th e a n q l e sh onuol d
i
e xce d 4 5 '

YC 5

Sharpconersslrould beavorded on duts de

p@i,lesa.dalchanqes ir se.rion

+,sFfel
TT ffi.
L:J Ll "
HelicalGears

Multipiec Construction

Thea b i l i l y l o p r o d u c q he lica lq e a Bin ' o n e sh o i'

c.n Frovidevervsubslarlialcosi savinosand
R. M C h a v e a r r h e n d i s p o sa lan u m b e f;t
todlinstechniq!esfo.hanulacru. nq heiical

n.M.C.havesuccesstullv
dev.looeda b6zino
iechniquewhichenabtesseveratcomotx
c om po n p n l s rboj o i n e d r o s e r hdeur n n q t h e

IITI-

,
l--

w-

ill'

Lens th (L) ro D i arE rc r (o)rrtos hou d nor

Mi n w a l hi c k nos si s 31mm( 032 l .
aramax ,num ens rhol r mnr (62s ).

'

ewl

l..-

I f :r*l':,t"fi
.1n"1?"1
r"* N\\N

Design
Considerations

i-

illl [ilifi#:'

-l f. I

f-i]
tl
rtJ

-r_
'i
f.
trl

rtj

-1."1

fL ri

ini;'*
i#*,:#ffl:ffit#!;:"#:rii'"*l::Jff

A
\t

/''i\

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NNS N'N

N] N N N
Nrf.) NN

NJIN L\IiN
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NiI ,

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'Hl-

' Lomp-onents
CoTp-gnents produced
produced by the powder

Batcheso15000componenlsppr annumcanbe producedon a

compeflnvebastslo conventional
methodsof manufacure.
Yourareaservicedby experienced
engineeringrepresentatives.

=l*l!i-ry^qP'91g111qredvi1s
establish_e4 methods of pr,oduction.

Thece well known intern--ational products

illustrated are manufas{qLred by Rigby
Dletal Components Ltd. Have v5u
Metal

Consullancvservice:-investigationsdnd consulatronsinto the ledsibilt!

oI produdng your components:with re designback up where roquirod.

An in'housefacilitylor the designandmanufactureoftooling.

considered
cons_ide_redyour
vour range
ran.re of components
r:orrinrtt
for the P M.Process.-

lirst piecesand/orsampleblanks,suppliedfree of charge.for your

developmenl
trialsand maleridlassessment.

(@,
C.nDond

td'stdkunl

4dpb.

AUTOMOTIVEENGINEAPPLICAIIONSFORCOMPONENTS
MANUFACTUREO
METALLUFGYPFOCESS

Further Operations
a blqe
'.nqe

or addirmnil

snrr]Ig.sr
,hc'qh,,,'hs

&^16l;".

! rndk,lDukr

D'orrriV rEr orDrarea

"-'*'

--o-eleptonJlvc|@'o|gIc6arc
's4qurcd

s.

.,-*"^"* _,__---=o

rhepii5.rc

*Br'n

Machining

F .ze o. Bu.r Remov.l

Barring,vib,arinqandread

Oneot rhe
dvanrdFs ot
'hhg6r
lhes'ntgingllasislhatlhe
arhF rin'.ard s mnsddabry

canbacamedo0r ahe, hardenLiq

Finishing Operations
s'n|eedoaismaybh@trcdtd

AUIOIVOIIVE TFANSMISSIONCOMPONENTS
MANUFACIUREOAY THE POWDER
METALIURGYPfiOCESS
nad"nins sinrsd mareiars rh
GxNPo'delMel@ddhe

Blboniridiqr

cvan'd harda,ns

biq talped drh,n rhe@rcus

6bon co@mb
a,e Gdunred
slhgs,nosh'p|yde'id*'s

@n!d6'nq hi'l dcnv s'nr6d

Haftq|hsi.laedFns'nsU@I

o
<Gr

khh4redc.r6sH'gh$ed

no--4

oE dd

bvdo|b|Trno.oi'deohan

ar 76 2_9t. m F nn

H''oh5Eedn*|ol,bi&noo.d

idlrt'rysnaled6'ha

trlg.ltt

im 5 - - lllllH*

ruix-lllllH,H*

silir"*

TECHNOI.OGY
TOR
CASTING
ENGINEERING
COMPONENTS
CANINVESTMENT
WHAT
CASTINGS
OFFER? QUAI,ITY
n every indusirywhere rnelo cornponenhore used,
nvesimenlcostjngs
coriofferodvonloges
- io thepfoduction
englnee.,
designer
or buyer,especiolywherecomplex
shopesore requred.
Invesimenlcoslings
coneliminoie
mostrough
mochining
oDero'io-s:give g eore.Ireedor of oesg-: p odJce
to mochine;providelighlef
shopesfhotore impossible
ond cJeonerlookingcoflrponenis;
relieveproducfion
probems by replocingossemblies
wiif "one piece"
coslings
embodied
in fi e widesl
- cll of theseodvonioges
choiceofmoieriols.

wosrhefirsilnv-^slmenlcosling
P.l.Cosiings
compony
io
io BS5750pari2 ondISO9002.
beregistered
byB.S.l.
isopproved
Thecompony
byfie CivilAviotion
Authoritu
ondby monyiniernoliono
orgonisoiions.
Furtherdeiaili
o'n e'olu'gcolo-douo"vcon-ollociliies
oreg usne.
poges12 ond I 3.

MATERIATS
lisiolmoteriols
Adetoiled
isgiven
onpogesl4 ond15,
mec\or:coorope.t:es
ndud19conposrlion,
ondc.oss.

DIMENSIONAT
TOLERANCES
These
depend
oncomponenlconfigurotion,
ly
butgenero
:0.125nn pe' 25mmlr0.O05'per;nch;Seede'oiled
tobesonpogeI L No cosiing
nodfofitoper.
iointlines,

SURTACE
FINISH
A finerquoliryfinishlhonmosioihercostingprocesses,
in fie orderof 125C.L.A.(3.2microns,
NB).

TOOTING
Lowiooingcosis,sinc6ollminiLrm
diescre usedio
producaoccu1016
wox potierns.
Liftleweoflokesploce,
so die lil6 is excellnt
ond modificotions
ore relotively
chonges
orerequired.
eosywhandesign

SIZEIANGE
Lowcnd higholloysieels- homlessthonsmmlong1o
Losnngstn row oroy o.o statnress
slee\ ntcKetord
morethon400mmdiomeler.
-, cabolt bosed alloys, and aol steeh
Aluminium
olloy costings.moximurn
dimensions
of
600mm.Wollthickness
downto l.smm.
Bross,
Bronze
ondZinc- dimensions
upfo tr00mm.

QUANTITY
Depending
on sizeond complxily,
bolchquontilies
os
low os 25 con be economicol,or high quontity
requiremenh
of severolihorsond
perweekore regulody

RAPID
PROTOTYPING
Uslng
Stereolithogrophyiechniques
orother
ropid
similor
profolypes
ioolingmethods,
ondsamples
conbequickly
supplied-see
pogel0 forfurther
detoils.

I e-*.t-",.

Aluniniun olloy cdstihss

PROCESS
THE
PICAST
ofo die fromwhichihewox poilefnsore proCuced.
The{irsisiepin iheP CASTprocessis the mcnufoclure
Diesore
toolmcikers
ond are usLroly
consirucled
in o uoriniLrm,
modeon siieor by speciolisi
sub-confrocl
whichenoblesdte
lntothed ie,underpressure
modificotions
io be modewithcomporoiive
eose.Wox is iniected
{Fig I ) to glveo replico
inloihedie io alow removoiol ihewox potiernin one piece.
cosiing.
Movingparisore incorporoied
of fheflnished
wox iniection
poiterns
oreproduced
by o fulyoutomotic
riochinelFig.2)A1terinspeciton
Forlorgevo umeproducflon,
on lo a wox runnersysiemio formon ossembly
(Fig.3J.
ond cleoning,o numberof pofierns
ore ossembled
The
cost
of
the
ccsting
is
greo
y
inf
En:-.---------uenced
the numberof
by
i
---poiiernson eoch oxemby. For smollitems,therernoybe
hundred
perossernbly
whlchcon be costin onepour,
severol
whereoslhe lorgesiilems,wiih dimensions
of up to 600mm,
will be modewith onlyone oer ossemblv.
Thecompleied
ossembyis dlpped(or "invested")
in o high
grodeceromicsluny(Flg.4)usingoneof thelorgesiroboisof
itstype ovoiloble.Therobol thenoliomoficollycootsthe wet
mouldsurfocewiih o loyef of fine rehociorypo icles.
Thlsoperotionformsfie mostimporionlmouldcootingos ii
loier comesinto direcicontociwlh lhe cosf metolond is
iherelore
crilicolin determining
ihe good definitlon
ond fine
finishoflhecosting.
surfoce
Afierhordefingofthecooling,the
ore repeoled
operoiions
severoliimes
usingcoorsergrod6s
o[
/Atlc,lt Woxpotan iniection

L FlG.2t Autonoticporem iniection

Lttc.3: wox assenbly

FlG,AtRobaticshellhajld

untila mouldis buih up hovingsulficient

refrocrory,
lo wiihsiond
iheforceoflhemoltenmetoldurlng
Jhickness
ihe po!ringoperofion.
Afierdrying,the moud is p oced in o sieomouioclove
{Fig.5)ond thewox is meledoui,henceihe nome,"losl
Themouldis thenfiredot overl0O0'C for severohours
to burn off ony rernoining
wox ond to sirengthen
the
mould(Fie.6).
Steelsond hlgh meltingpointoloys ore mehedin high
i'eouenc)ind.dion l-rloces {E9.71of 30k9.-00k9
ofd 250k9 copocities.
Aluminir:m
ond copperbosed
olloysoremelted
ir bole-oul
orcrucible
furnoces,
ondthe
rnetolis pouredwhilsilhe mouldsore stillhot,erobling
ihe metolto flow infoihinwoli seciions
ond givingfine
surfocedeloil.
Aftersolidificotion
ond cooling,Ae mouldmoteriolis
brokenowoyfromfie coslmelol(Fig.8)ondthecostifgs
ore cui owoy from lhe runnersystern.Alter shot blcsi
cleoning
ond iniiiolinspecllon,
ihecotingsore coref!ily
feltled
ond,wherenecesscry,
skoighfening
ondgouging

^^6r ^ti ^.(

^16.^( i 6;

l E^ol

Moslmoterios ore heolireoled

in our owf worksond the
cos:rgt ore r er ine blos-ed5e o e -o -specror "
occofdoncewilh
cuslorlrers'
requiremefh. Themosimodern
tesring
fociliiesore
ondoredescrjbed
in moredetoi
13, olong with o lisi of the vorious
on poges l2 ond 'rsed
opprovolshe d.

,AllG,6 Fningthenoulds

LllG.8:

LFlG.Tt Pouing steelinta

) rtc. e: Suriing
ondgo, girg costings

Ca'tins'oh.,,.navins shelnauld

INVESTMENT
OUAI.ITY
HIGH

Steels,
Staintess
Sieels,
CASTINGSin[o* Alloyond(srbon

L Pd s lot pneunoticondhydrculi.equiPnnt

Y Levarondseat canpanents

Stuct!rclcastings

Costingslor snoll orns

(oboltBused
Tool
Nkkelond
Alloys.
Steels,

Airhoneconponents

Guided nissilepdtts

> Ccstin$lotnilitoryrchictes

Aircrchengiheco'tinss

INVESTMENT
INTEGRITY
HIGH
Bross,
Bronze
ondZinc.
Alloys,
CASTINGSinAluminiurn

po withnodelshawi.gcanpiexity
Aerashucture

Eleclta.ichausings

D toree e/e*onic boxes

L Electrcnic
chostis

<

Miscelloneous
aluniniunondzinccoljtines

Covatand hscio castings

Btdckets,
tevetsond hondtes
L

Castingsfat optrldt equiptnenl

Bross,gunnetol,phosphorbronze
ond oluniniun bronzacostings

TO
CASTINGS
FROM
COMPONENT
FINISHED
Ascuslomers
increosetheirdemonds
forconrpletelyf
inished
componenh
whichorereodybLrs
onfieirossembly
liies,
hoveresponded
io tlis requirernent.
P.l.Coslings
Finisling
operofions
on cosiingscon be underioken,
suchos
filiingofihreoded
poiniing,
mochining,
dlochloming,
inseris,
polishingond sub-ossernbly.

Aluniniutr' elac|,a.plical
bax.s, fin|h nochined,
dnodissd ond point^d lo
cuslan.B tp.cificolio .

High stranglhttotnbss steal

conponentsfi nishnochinad
tor oircraft door lockins

Knotterhook ossanbliesfu usein

canbinehavettaft. fhe .ostings
orenochined,hordened,polished,
.l.ctr'rpldtad ond subassenbled

PROTOTYPING
RAPID
ANDSTEREOI.ITHOGR
producfion
lfyourequireprolgtypm610lcomponenlsinodvoncof
requirements
conhelpyou in voriolswoys.
ih6nP.l.Costings
Prototyp. bt pilslr diecosting

ore ovoilobleio enobleyour

STEREOLITHOGRAPHY
- Severollechniques
3-Dsolidmodels
designsto
betokehfromcomputerised
ondturneddirecllyinlo
withinc molierof doys,withoulthe needfor
o plostic,nylonor wox modeJ,
tooiing.Thewox modelconfien be usedb monufoctLre
on inveslment
costing
p'ocess
inslgel,
sloi.less,
orumiriur,
oroly 0$6r
usilgoursbndord"PICAST"
oskfor our seoorofe
moteriolshownin our brochrre.Pleose
deb;ledledflel.
DIECASTING
coslingdiesoremony
PROTO PESFORPRESSURE
- Invesimenl
timescheoperfion ioolsfor pressure
die costifgond con be producedmore
quickly.Themotorcor oilponcosling{shownin ihephotogroph)
enobledour
lo fullyleslcomponenh,
mokedesignchongesand revoluoie
cusiomer
lhe
poris,beforeproducingexpensiye
die coslinglools.
demonds
ofdesigners
CADDESIGNS
ondproduction
engineers,
-Tomeetthe
instolled
P.l. Cosiingshove
o 2-D ond 3-D design{ociliry,os pod of o
modellingcopobility.Designs
sophisticoted
solidificotion
con be honslerred
from $e cusiomerby disc or tope, io enobleour technicolstr:ffto study
possible
components
ondgivecdviceottheeorliesi
sfoge
ol design.
Thisfocilif)'
the
production
of
can dlsobe usedfor
iooling.

t0

FOR
INVESTMENT
CASTINGS
DESIGN
r-veslnerrcosli.qq .es o widerfreedonofde,iqn Lo- rrosro-herne-ol
ro rnirg rechr'ques,
oro rheIo lowi^9gL de. -es"*, I e.oble -e oprirur
odvaltoges-o be 90: ed ho- -hisp.ocessbulp eoseco I o .r eipe's n ol
poxibledesiqnslaoesothotwecqnworktoqeiher
fie eorliest
ondadviseof
how the de!ign optionsmoy olect techniquesond eco-nomics.

TOI.ERANCES
Slouldo-iy be sp"c.!e! o- crico' ond f nc-io-o,o.ren.ro"s.UnnecessoA
or over<ose'olero'lces
mov mokethe costno! lesseconomic.Consitenl
process
repeotobility
will be'ochieved,
evenoi' nontolefonced
dimensions.
Referto the ioblesfo. lineorond aeometrictoleronces,
which o.e fhe
reconne-dednrr qrn for functio-61
oe-olr T-eseoppy lo cosringsr
-fe d nersiorol occurocyo'
prod-c'o1q,or-.lie5wLenrocionir!1ue-cirg
the costingslove been fully developed.

TINEAR
TOTERANCES

GEOMETRIC
TOLERANCES

SOLUEtE
WAXCORES
These ore used ro form o. inlerno
shope n ihe wox ponerns,wh ch
would oiheeise be impossiblelo
wiihdrow lrom the die in o.e piece

TW

Lr '

Sdon

$or

4 Eur;

4.F

CER,AMIC
PRE.FORMED
CORES
ronrcrcd d.p.i! oi.slsuF

on, bd o6 ori.E I i

n'klo.s .I wll *ior

d, oi ctro g{qh thoi 25 q .f,
1.{ i )b ho! o n iih!6 b.roe. o{:.256h F010")

DATUM
PTANES
Theseore beslchosen
io sotisly
thefunciionol
requiremenis
of ihecomponenl.
Tlusdolur olo.esoc'oss'hecenyeof rhcosrinorofirfionotoneend.o-e
Lsuollyoreferob
e. Tooriloooinrsshowinowhe-rs
lie coslinowill be oicied
up foi nochini"g,will eriobre'ne ro." ioint' ,o be rsedIor dimensiono
checking.

Ceroniccoresore osedony when

inrernolshopesconnotbe soisfocioriy repfoduced
in lhemoulding
operotonevenrhoughi moybe
possibe io producethe shopen ihe

fl--I
f'rr'l
illl
.
l-, ----.-.1..'r.

I-:-_----_::l\:r,r

A ifouth qvid
!.\oF 6!li !. n!d.
h.n. d4
n . lbr uiioi t4td 5. b
Fo!]d ndriorb
b. od{sbt
lEtud

o o lu Fbh
h i b.tubh {r

HOtES

possible
Holasshould
bekeptosshodos
holes,
inreloiion
lodiomeler.
Squore
'D'.ondotherodd.lhooed
holes
oreoseosvtocostosrorndholes.
Blindholes
oremofedifficu
I fion ihrough
holes
youonwholconbecosl
- we willodvise
al theenquiry
sioge.

WATL
SECTIONS

u.rl ke die costinqsond p'os_cmourdinqs' is -ot necessory'o-ove o

ur fo.my thin secilor o I over. In loc', i :;fier helpl-l ro hove lome fiicle.
sections;oendblenelol
obeleo nto'hecosilqotlfo5epo nts.Gooddesiqn
w', enoblesou,rocos'nqslo be o-odJceoondmovenobleno-e costiraslo
oe,nodeo" eocnnould.res-hi;gin signirconlcoslsovrgs. Peoseosl ro.
IeCnntcot
oovrceon soecrirc
de!rons
Thinseciions
conbe cosrdownio 1mmi.010"),depending
on oiloy,surfoce
oreoand coslingcompe( l./.Mo'e rornol ft.1in,r -hicknesses
ore L5mn
lo 2.onn for o|"rriniumond zi-c o loysord 2 omr to 3.oTn for steelord
copperbosedoloys.Avoid shorpknifeedges- useo floror rodiuswhere AVOID
UNDERCUTS
lf possible,
ovoid undercuts
whichwill
not wifhdrow from ihe ioolino os ihese
INTERNAL
CORNERS
odd io the costol ioolino ontr cosiinos.
These
con be stress
roisers
will Where complex intern-olshopes o're
Exiernol
corners
- usefil et rodiiwhenDossible.
nolhovebtiffsor shorpedgesikemochined
corners
ondwhilslexternolrodii required,removobleinsertsin thetoolinq
cqn eosilybe costtheymoy increose
ihe ioolingcosi.
mcy be used,but if ihis is norpossibl;
then solublewox cores or cerom;c
FINISHED
MACHINED
AREAS
preformedcorescon be used,but these
-hereco- be [.p- o o nirin' n .^o-^s I L]erio
to e
itvo'oe'iqn heono..- will inevitably
odd io ihe cosunocosl.
o[rochi- rg o lo.orce w , dependor c s.omeyeq
but*e o.e Seeillustrotioioboveexploiningi.heuse
' 'errents,
readylo odvlseon thisol lhe desgn sioge

CASTING- AN
INVESTMENT
ROUTEFORTHE
ALTERNATIVE
OF PRECISION
MANUFACTURE
COMPONENTS
lnvestmentCastingolten referfedto as the "Lost Wax Process"may be definedas the
pattern,
production
utilisingan expendable
and hasthe
of precision
cast components,
process
known
distinction
of beingnotonlytheoldestcasting
to man,butalsooneofthemost
in the sphereof metalformingtchniques,
TheInvesiment
Casting
advanced
technologies
to a finishedor
Processis uniquein itsabilityto convertmoltenmetalin oneprocessoperation
ngineering
component.
The production
of a "cast to size"
virtuallyfinished,precision
production
costs,eliminatesunnscssary
machinlngand
componenteffectivelyreduces
savings
on toolsandoquipment.
scrap,and canresultin considerable
THEPROCESS
processes
in usetodayforth6production
castingsand,
Thsrearetwoalternative
of investment
"block
the industry,
although
the "ceramic
shell"processin usedprEdominantly
throughout
to giveevenmoreversatility
in therangeol alloyscast
mould"techniques
arealsoemployed
and,jn manycases,a moreprecisecomponent,

PATTEAN

ASITEMBLY

CASTING

INVESTIN9

|<NOCK-OUI

STUCCOING

FINISHING
Diaqramtic
Cctcn

DE.WAXING

INSPECTION
of se.Mic StEll Proc6

In both cases the manufacturingcycle commenceswith the productionof an expendable

pattern,usuallywax,from a patterndie. The patternsare mountadontoa wax runnersystemto
ln the ceramic
whichis in turn "invested"witha finecoatingof refractory.
form an assembly,
shellprocessthe patterncontinuesto be investedwith layefsol refractoryslurryand stuccoed
with reiractoryparticles,and successivecoats of refractoryare applieduntila completeshell
Withtheblockmouldtechnique,
thebulkof themouldis
hasbeenformedaroundtheassembly.
produced in one operationby pouringa reiractoryslurryaroundthe assemblycontainedby a
metalflask,to producea solidmould.In eachcase,the mouldis thendewaxedandthenfired
to induce strength.Moltenmetalis pouredintothe hot mouldand, afier cooling,the refractory
mouldmaterialis removed.The castingsare then cut fromthe runnersystemand processedin
requirements.
accordancewiththe customer's

ADVANTAGES
The manufacturing
techniquesemployedin the productjonof investmentcastingsgve
advantages
overothercastingtechniques,
whichgivethe engineerthe opportunity
to achieve
ihe optimumrequirements
for his design.Theutillsation
of a onepiecemouldandtheabsence
of a jointline.arejusttwo featureswhichg-ivevirtuallyunlimitedkeedomof design.The high
degreeol dimensional
accuracyand surfacefinishallowcos y fjnishingoperations
to 5e
reducedto an absolute
minimumandthustacilitates
savingson rawmateriais,
raoourcostsand
expenditureon capitalequipment.The use of ceramidmouldsaltowsflexibilityin mouid
temperature,
whichaidsthe production
of thinwalledcomponents,
andallowsthesolidification
rateto be controlled
to improvecastingintegrjtyand ulti;ate perlormance.

pjg-"."-:.:_ilL"y: d-"q!9"of texibitity..with

regardto production
quantities,
ransins
.f
Ili
_"sma
llgl batches(j.e.
rromprorolypes
and
50

off)to severalhundredthousand
componentsl
manufactured
by thelatestcostelfective
automated
production
techniques.
Oneot ine mosi
rmportant
features
of investment
castrngs
arethe excellent
dimensional
tolerances
which,in
manycaseseiiminale
the necessily
for finalmachining.
In general,
a lineartolerance
oi t
u lJmm per z5mmrsachieved,
but closertolerances
on selected
dimensions
withpossible
improvements
ol 1 0.08mmper 25mm,.
however,
improvements
of thisnaturemayrequire
additional
operations
and controls.
subjectto the dlsign of the component
and withdue
consideration
to the size,areaand selection
of alloy,th; typicalmini;umwallthickness
is
1.5mm,
although
thinner
sections
of 1mmarepossib16.
Theai-castfinishof anlnvestment
cast
component
is superior
to otherformsol casting,
andis influenced
to somCegree
Oytneattoy
typebut,asa general
guide,theCLAvatuewilibe intherangeof .1.5_3.2
micrometrei
ZS
1OO_t
microinches),
although
againimprovements
are possible.: .
Solechh

ol AeloiD.e

ComtDcnts

PRODUCTQUALITY
Thequalityoi an investment
cast component
is inherentin the process,but rnorderto ensure
compliancewith customerSpeciiications,
approved quajity and nspecron proceoures
predominate
rhroughout
the industryIn additionto maintaining
standards,
memoerroufores
-ave accessto non-destr,ct
ve testt.gano laoorato.y,ac.lit.es
t-c Ldi'1goye pele.rarl a^o
magnetc partcle crackdetection,
X-Raychemrcat
analysisand mechan;altesting.However
ul lisationof all the facitities
wil dependuponthe clas;lilca|onol the part (i.e.commerciat,
aerospaceelc) as specfied by the customer.ln additionto ndividualcusromerapprovajs,
manvot the memberfoundrieshold relevantCAA N,4OD
NATLASand BSIaoorovals

CoDEaFL5

for Et.ctronc

AoDti6tiG

PROCESS
AUTOMATION
Theintroduction
of fobotsat th mouldingstageof the processis one of the mostsigniticant
developments
in the industryfor manyyears,and has dramaticallylncreasedths capabilitiesof
the process.Carefulprogrammingof the robot to mimic manualtechniquesgives the
repeatability
and conslstency
demandedol a precision
castingprocess,butmoresignifjcant
is
the capabilityof the robot to manipulateheaviermoulds.Weight,thsrsforeis no longera
imilation
and,as a result,steelinvestment
castingsover25okgare nowbeingproducdand
castings
withina 600mmx 600mmx 600mmenvelopearenowcommonolac.
Theoroduction
of rarge.and heaver "cast to srze" investmentcastingshas allowednew marketsto be
explored,as wellas beinga seriouscontender
to forged,wroughtand sandcastcomponents
wherefinalmachining
is oftenrequired.
Thisweightcapability
of therobotmay,alternatively,
be
used to good eilect for mouldinga numberof smallermultj-componenl
assemblies
in one
operation.For example,one assemblyof 16 componentscould be mouldedby one man,
whereasthe robot may dip four assembliesand, therefore,64 comoonentsin a similar
operatjon.This combinationallowsthe processto be more comDetiiive
with other mass
producrion
orocesses,
withsavingsrn bothcost and time.
Althoughthisaspectof automation
has had a significant
impacton the industry,
a numberof
othefdevelopments
are alreadyundeMayand manyare alreadybeingutilised.The use of
steel,aluminium,
resinand rubberfor wax patterndies has seenlitilechangein recentyears
blt the use of moderndesignand manufacturing
techniques,
such as CAD/CAM,is on the
horizon.
Althoughrnanydiesaresingieimpression
for manualoperation,
fullyautomated,
multiimpression
diesare nowcommonplace
wherelargequantjties
Theuseot "filled"
are required.
waxesfor the producton of patternsis not new but improvements
in the strengthand surlace
finishand lower volumetricshrinkageis ongoingand vital to the manufacture
of larger
rnvestmenl
castinos

I
PFTOCESS
UEVELUtsMEI\
(DS)and S ngje Crystal(SC)castingtechnjques
The use of Directional
Solidification
for the
productionof aero engine gas turbine blades rs Indrcativeoi the continuousprocess
necessaryto meet the performance
deveiopment
requirements
demandedof aero-enoine
The creepductiiityof lurbinebladeshas, ln the past beena limitingfacto;as
components.
aero-engine
turbineswere progressively
uprated,and voids nitiatedat transverseorain
boundarles
havenowbeeneliminaiedby the production
of preieren|aly onentatedcolu;nar
crystals,usingrelineddirectional
solidification
techniques.
The prod!c|on of turbineblades
withonlyone grainis a logicalextensron
and theintroduction
of s ngtecrystaltechnology
with
modifiedalloychemistry
will allowhigheroperatrng
temperatures
ic be reachedto meetthe
optimumperformance
requirements
of the aerospaceindustry.
Non metallicinclusions,
particularly
sand or relractorygrains,can be a problemwith any
castingtechnique
but,sizefor slze,can be moredetrimental
as iar as investment
castinosare
concerned,
due to the predominantly
thinnersections.
The use of ceramicfilters,theref6re.
is
anotherrecentinnovation
whichhas improvedthe cleanliness,
and thusthe integrity,
of both
ferrousand non-ferrous
investment
castings.
Oneof the mo-stsignificant
and recentprocesses
to compliment
investment
castingis thatof
Hot.lsostatic
Pressing(HlPping).The processinvojvessublectingthe castingto-veryhigh
levelsof temperature
and pressureundercontrolledconditlonstb eliminateiny remiiniig
tracesof sealedporosity,with resultingimprovements
in castingintegrityand mechanica-l
proprites,_
in particular
elongation,
impactandfatiguestrength,HlPpingmaybe carriedouton
a varietyof alloys,and its introductionh8s added yet anothir dimsnsionto'th capabllitiesof
investment
castings,

coNcLUstoNs
Theafo-rementioned
fepresent
developments
a majorstepforwardin rmovingsomeof thso
ca|eorrmrranons
ol investment
castings,
andtheprocess
is nowbecoming
a realcompetitive
optionto forged,wroughtand sandcastcomponents
where,for manyafplications,
thenett
shapecanonlybe derivedaftersubsequent
machining,
Consultation
;ith lhe tounder
at the
preferablyat th designstage,wiil ensurthat the optjmumproOuctti
earliestopportunity,
achievsd,
thereby
takingfulladvantage
of ihe caaabilities
of the process.
lnvestment
Casting
is-agrowthtechnotogy
andis,indeed,entering
a newera.Designers
and
engineers
alike,thErelore,
shouldtakenoteoi themanyfeaturesofiodays rnvestmn-i
castings
whichincludei
* Virtuaily
unlimited
freedom
in design
* Freedomin the choiceof alloy
* Sizesranging
froma fewmillimetres
!p to goomm3
* Weightsranginglroma few gramsto over25okg(Ferrous)
* Typical
tolefances
per25mmwithimprovements
ol t 0.13mm
per25mm
up to + O.Ogmm
* Typicalminimum
wallthickness
1,Smmwiththinnersectjons
of 1mmpossible
* Typical
finsh ot 1.5-3.2micrometres
surlace
withimprovements
uptoO.gmicrometres
and
betler
quantities
i Variable
catering
for prototypes
andmassproduction
requirements.
BICTAis fortunate
in that-itenjoysactivemember
participation
in itsaffairs,
rhusensuflng
the
ongoingdevelopment
of the process,whlst maintainrng
the integrity
of investment-cast
conponents.
to t'e benefilo. userindustries.
gude to the
and speciatities
of UK memberfoundries
(Futl
l^T:!TEn.iy?
MemDers)
s available
fromthe_capabitities
Britishinvestment
Casting
lrade Association,
BoytonHouse,
GeorgeRoad,Edgbaston,
Birmingham,
B1S1NU.TetNoiOZf_+SS_g-g7Z

Mai Eilalior di6 ceeling

Table2 showsa few ol the p.incipatpropertiesofzincdie castjno

alloysconoaredwrlh lhose ofo:"e, n-aLeriats
In ddditjonro tl're
properties,
thereare olher consjderations
whjch derermine
wheiherzincor anoihermaterialisthe most economicatfor anv
p a 4 ' c L l aar o p l i c a ri o n .F a c to
wrhsi chi ' aveto be l aheni nl o
consideration
are speedof casting,castjng
temperaturewirh its
consequenteffectson fuelcostsand wear and iear on the die
dirnensional
tolerancesand djmensionalstabiiity,compaijbitiiy
w i ' i o l h e .m a te .i a tse J o ,a rnagr o trahgcapab.ti t| es,and
| ne
possibilitiesoi applyingelectroplaledor otherf inisneswnere

Severalkindsol alloyscan be oressuredie casi.Theessential

principiesoi pressuredle caslingwerefirst used morelhan
qec{ros&d
10Oyearcago in caslingprinters'tyDin lead tjn alloys,butihe
exlensionofthis techniqueto the commerciatpfoductjonof
engInee ng cor. ponentswas delayedbecauseno suitablestrong
al l oyw asavai lablef or diecast ing. Ther ewasnor ealchangeunt il
lhe developmentinthe 1930'sof the two principalzincdie casting
alloyswhich remajnessentiallythe sameafterover d0 years.
'Ihey a.e specifiedin BS1OO4,
whichwas rirsi issuedin 1942.and
has been revisedand updateciseveraltims.

Zincdie castingscanofien be producedmore quicktyto finer

tolerancesand with betlerfinishthan die castingsin other merats
In additionzinc die castingshavernoreDossibitities
forjnteqral
fixi_g,aro willaccepl reaoilya w'de rd.ge ot appt|ediinishes

Sincethe zinc die castirg alloyswere developed,therehas been

considerableprogressin the iechniquesofdie castingaluminium
alloys,ma9nesjum
alJoys,copper
al oys and evenferrousalloys
(stainlesssteeD,bui ofthese only aluminiumdie castingattoyshave
come to equalin importancetheolderestabiishedzinc arloys.

7tnc .

.1..,.( }'-'t

(' ii :_

l'ro.e recently,developrnenls
in plasticresinsand ln ihe technoJogy
ofplasticsnrouldingprocesseshaveallowedih oroductionof
a wjde rangeofmoulded componeniswhich can sometimes
competewithzincdie castingsin thoseapoljcationsWheretheir
lowerslrengthcan be shown 10be adequate.

. , f ; i.

4rsoiMo

oed

Osigning dle cas

Sectionthickness
Sectiorlsshoutdbe ofa minimumthicknessconsislentwithease
oI castj-g a.d adequalestrerglh and stiftness.th|sminrmrses
the
werghlor rnetarrequ,redand speedsup sotidificatonIn the dre
10Incresseproductionrates_
Thjnsectionsare stronoerin
proporiionto theirlhrcknessthanare the rhrcker
onts bcause
ihe,strongerfinegraind,skjnformed duringthe jnitiatcooting
maKesup a targerportionofthe lotatthickness.sectionthickrss
shouldbeab nearlyevenas possibteand wherevanalons are
necessarylransilion
trom thjn to i-ick snoutdbe gmdudtraiher
rn a n a o ru p t.
Thereare very few shapesthatcarnot be ciiecast.undercuts
orolheriealures requiringmovingoartstcores)rn the die Increase
cosrs3fd stowdown productof.
Comer6,filltsand blends
Sharpcornersshouldbe avojdedas far as possible.hternat radii
areessenliarandarsdius is generaflydesirabreon Dorhinremal
and exter-ic osed corners,Theraorusgivento cornersneeonor
oe.rarge.Aradiusof0,4mm has an apprec,abtestreflgthentng
efieclyer isbare'ynoticeabteevenon outsrdeedgesLarger;adil
are proporliondtelymore effectrveand.parrrcutarty
on insir,e
eogesjare nol apDarent.

Threarecrtaingeneratdesign
poinlswhich
haveto befolowed
to gelthebeslpossibte
advantages
iromdiecasling_None
ofihe
pointsljstedtlowarehardandfasirutes,but
usedwithiudqmni
theywillhelD
to votvea tog;cat.emcie,rt
andeconomicaj-toiasr
design.Many
diecaslershavea weatlhof practicat
experience
in
cliecaslngwhichcanenabtethemto suggestpossibty
quiteminor
desjgnchanges
whichcangrealtyatfectthe efnciencyand
e@nomywithwhicha particutar
component
canbe Droduced.
ll is veryusetultherefore
to consuttadiecastingexp;ri at anearty
slageanooeroreeveryfeatureota desrsnhasbeenfinatised.
T}|eZnc Development
Assocration
wittoffe.imparriai
adviceon
thesuitability
of anyparticutar
dsignforcticastingin zincaloy
o. theuseolz'ncdjecastingsunderanygiven
conditions_
Although
extremely
finetoteran
cescanbe producedin ziocdie
-castings,the
iinerthetoterance
thegrealerthecost,because
of
prec|sron
tlneincreased
requnedin dierrasing.,nachrne
.adjustment
anddiemaintenance.Desiqners
shoutdasl ior
lobrancesno closerthanarenecessary
c uidetine
tolerances
fof
mostecoromicatproductron
aregj!e,1InFngineering
Srdndards

]oii9sdFsigz(Ab]De

Sectionthickness
SpclionssnoJro
beofamtnimun
thickness
cons,stenr
wrthease
or caslngandadequate
strenglhandstrfiness.This
minrmrses
the
weighlof meralrequiredandspeedsupsotidificatjon
in thedie
roIncrease
production
rates.Thin
secttons
aresboooerin
proportion
lo thekthictnessrhanatethe(hrc\eron; bcause
lhestrongerfine
grained,skjn'formed
duringtheiniiialcooting
makesupa rargerportion
oith6 totalihickness.
Sectionthick;ess
shouldbeasnearlyeven
aspossibte
andwhereva.iatonsare
necessarylransition
fromthinto thjckshoutd
be graduatrather
Undercuts
Thereareverytewshapesthatcannotbe diecastundercuts
o.otherfearures
,equ,ring
movingoarts(cores)in thedieIncrease
costsandslowdownprcductjon.
Comers,fitlets andblends
Sharpcomersshouldbeavoidedasfaras possibte.tntemaj
radii
areessenlial
anda radiusis generay deskabte
on bothintemal
andexlerralclosed
corne,s,lheraoiusgivento curnersneeonor
Derarqe.A
radiusof0.4mmhasan sppreciabte
streoglhening
e'Iectyel,sbarey noiiceaftbevenon ou6ideedges,Larger
radii
areproponionatety
moreeffective
and,particutariy
on inside
eoges,
arenolapparent.

Ribs
Ribscnbe usedto aidtheflowot metatioro
thinsectionsandro
stffenihem.]l)elhickness
of theribshoutdnotexceedthatof
adjacenl
sectionsto avoidcausing
ashadowon theback.
Bossessbouldmetthereqoirementsforeven
wal thickness
anclslimonescnbe supportedby buttresses.
Sudacee
Largeplajnflat wallsurtacesshouldbe avoictedastar as Dossible.
andwherea broadsurtace necessaryslighr
curvrng
or tenuring
heFs1oavoidunsiqhtlv
's
superficiat
btemishes.
Thr6ads
Extemallhreadsareeasilycasl particutarlyil they are tocatedin
lhe partnglineof thedie.Internd
threadscanbe castbutare
genrally
producdrnoreeconomicatty
bv machinrng
ater casr,ng.
Farrarthreadsmaybe adequate
for marypurposes
andcanbe
producedvery salisfaclorilyusingflutetesstapswhichcreate
a stong rolledthreadin a coredhole.Atternativety,threadroljng

,tr8
,.-,,=.1

l]

: . . : i: 3c - : .

'

il

1e*"1i
at

. . - . 'l
':

-.
t, r-

lJ
-9b

+'

Elbscnbe u5dto aidrh flow ot ro6tstinto thinsctionsard to

stffen lhrn Th6thidaEc ot the rib sholtd not 6xcdthat of
adjacfltseclicnsto sr'oi{tcausinga shadowon lh back
8q6.6 .
BossaEliouldmetthe requiremntstor 6venwaltthickEss
ano$m onescanbe supportedby bultssss.

Thr!*
Extenal tcrea& sre easitycas! padicr|tartyif they ar tocats<tin
U|6prEngfne ot t|e die.Inremstthradscanb castbut de
generallyproducedfiors economicallyby macfilningaft6r casting,
parlar ureads |haybe adequatator rmrryptrrpor6and
canb
ploducedv6ry satsfactodv
flutehl tapswt ich crate
'r8ing
a suongrolhd threadin a cored
hote.Atsmatn/UO,readrp[ing
. sc'6*S mAyb6 used

Materialproperties

3.4-4.3

i*

V_.9-ti1"l

0,03-0.06

3.a-4.3
o.75-1.25
0.03-0.06

0.10

0.10

]IP!!rllel
c-9q!9!

0,006
0.005
0.005

a;adiu;

nn

0.@5
0,002

0,oo2

Trbl. 2: Comp.ntlr. ch.n ol n!t.rl.t

Drlrrrt..

srorsrh
N/mhr

mooLtuB
N/mm.

6.ono.!ro.
?.

l.mp

t6mp

i6mp

-.--1400-i7io -E:if-37--sd

rdsiiCrvtoiiiuito

rs.stalc.
J

9;"ty

-o-7 ''-so-120R

i o--i,
*0.9-r.6
lc-tattionoooyrc4
66
:soo-3400 ta-?E
t2oi
c-6iyirroc
-yroi6r6 _ 6-r+o - i2ooi27oo 6o-3ijo_- o.o-rr
166-,,6- ,,;
-i16R.- --.r,j''
trorlca|bdabs4.6_1- 226__-..-0-100
t-edivi'i6pv]lirJ
2e::3i--- l-1oo-isdi'20-o--7oo o.a:i --- sb--l1oR ot.iio-i2oFFoltit-'..!(hiohl'ripacijii-5t
1,ibo-30b6r.2-4.5--- o--!.s
1.oE
-s8'.'-Zf|cAl;t65dtdoyA i;t--i-d6---roooijo'.-'iE-E
b6a3iB"j

t:

zi;caii;tBslooa.raiB
i0r-$5

100000

8-14

f4-724

Aruminiuft;ioiBli,iediio

I
I

3.4

M;tn;alum!lloyBs2eTo220-24A

44doo-

Br;s;Bs1,ioo
iaBl

lbsooo

2b64iii

ia-4o

206000 idllio

aa-'-.

55-678

18

o-ibt

B.g

400

ii,i;ilal.dsc.rptlon

E,6nc.t +tr6'iar r,near

Spicrrc xcar.
prop.rrr.s conducUvfty
.&amlon h.ar
d.i.c!on

105000

co.ftctgnt

Ads(;;ltroniiir,

ior'
Lgrio-'
--a.5tlba'2.a;loi
Aiitaritroiiidpotvmeo
buladinBBr y r . f 6 )

Foryfiiae
ntldn
o/
ioryca;bonaG
Po lyp r o p yl n e

ohm/m/mh:-3.4xlO_,

ohm/m/mmz
ohfi/h/mmr
ohmh/hh,
'0!

(hohopolym,
ohm/nhm,
Poly s ly r r(.h gFr r p . c t r r o a
o.mh/trF,
z ini; ' r at Baloo&r o y I
t5.7

rcallovBS1OO4
E loyB
Alumn,-ma,roy

Ztalo-

as149o
LM24(di6c.sr) ohm-lm/mn'
MidGiijh albyds2eib is
1.sx1oMAGT(dlca69

ohm_'/m/mm,

dia$bslaoopaBl

it

osxib,

sl

o.sx1f

(diecast)

Si;ei6ss7a
(holrorg6d)
tBs272Method102c.Slress
r. Thistesihelhod s noi
1 81N/mm
d:ra$B{tdiacz
22
normallyusedtor metalsanddalalor
(holtorsed)
2 nc alloysa.inc udedlorcomparison

ohm ,/m/mm,

'o5r:0.
ohm ,/mhm:

! 9dip

?!nm/ryn

Selt

4!'!!lqll'r.

S ti rC r

Nl

2.7x1O-6

0.093

Ntl

23rto+

4.21

Nil

ajxlc

-a24s-

rrx1o.-

o.oe2

Faprd;
finety

fl;leqJgrJ"

lzax1o-

oios

Ni

2.o,io-

0.092

Nii

ohm- /m/mm,

.5.1

130

ote
60
-io.2x1o-u
r '2 i i t l 3 ! x O '.
0 3 2 - 0 . s 7 60
,
-7x.0-!
-r2.6x10
1.13110r 2i!10.
OO3

15.3
r.ogx1cr
ohh '/mhm?

1.

$lfflllt

i.6xior - 6.6iidr
12110-

8,1

l6mp.fglur6

p6rrc
rct
5.sx104 0.3-0. dd-oo
-1lx1O-!
-o.as - 6
srilrr

icd" '' zraro--Foi io-a a.t'

- iotr--

1.e

2BOB
(mrnrmufi)
34
60-1008

Ata.?852872C2122
(ho1to.g.d)

w/m/rc

canbe usedund6r
'Thesealroyq
hoderalestre$artemporaluros
uplo
aboui200pCdpndinoon th6irheal
lleatmenl,elc.Advic6shouldb6 60ught
on hlqhtamperatuf
e applicalions
ol

2,8

--ri-

2-t
_

Sii;rBS97o(hotroE.d)

'1

6.7

Avaitabitity

MERCHANT
BAR
Regulargradeshavea minimumorderrequirement
or 6 tonnesperitemand non-regu
ar gradesgeneralytheproduct of a heator. s[ibjectlo negotiation,
parl lhereot.
Table4, MerchantBar Regularand Non-regularGrades
Product

Rounds
Squares
Flexagons
Etals
,ds'

Rd45

tI

Bounds
Sq!ares
F1exagons
Flst8
Bods'

I
tt.

*io"'^ts

Flounds
1 10t o 1 7 0m m

Large
Rounds
180l o 2 15m m

- lI
LiohtAngles

II
'

Fegular
Grades

Non-regular
Grades

BHP/AISand AS 1442crades
tviildSteel
Si oo6j 1035(Bodsonly)1o5gt
cs102010301040
R1 o lo
s100611008101010 1 51 0 2 0(Ro d so n t y )K lo 3 o t 1 o s o . 1
f o 7 o +1 0 8 2
102110251040104 51 0 5 8 *
x Rl1 1 0
R1008
xs1115
K l016 10221030f 10 4 01 0 4 51 0 5 0 +
x K 1 1 t 5 +1 1 5 2
10551070t
K 11 3 7 +
cs1 100
x K 1 3 1 51 3 3 51 3 4 5 t
K 1i37+1146
s12114
xsl 112
sl214
xK 1115i
xK13201335+134013451
BHP/AISand AS 1444 Ghdes
xK 51sot51s55160+
x K 5 1 s o t5 1 6 0 1
xK9050+
xK9050t
xK9255+9261
xK92551
AlsTen 1
AS 1442,AS | 204
AS 1442lS1S3 55 56
AS 1442,/54
AS 1442lK5K6 KS
AS 1442lK3K4
AS 12O4:250
350i
AS 1204:3501
BHP|AISand AS 1447 crades
K10705+
K1070Sl10825
xK5150St5155S5160St
xK5150S5
t 160Si
XK9258S(Flatsonly)XK9261S
Shipbuilding Gedes
Lloyd's- GradeA

Lloyd's
- Bivet

BHP.AISand AS 1442 cisdes

MildSteel
csl020 10301040
sl010 10251040104 5
s1214
K l022 10401045
AS 1442lK5
BHP|AISand AS 1442ctades
N,lildSteelfully-killed
K 102210401045
AS 1442lK3K5
BHP/AISand AS 1442crcdes
N.,titd
Steel
cs1020 10301040
s102510401045
BHP.AISand AS 1444 G?des
XK905o

XK9050{Kwinana
only)
AusTen1

AS 1204
AS 1204:250 350
Shipbuilding cedes
Lloyd's- crade A

Rodsin coil lorm are avartabte

in rnanyot the gradestisted
aboveanda{sorn steetreintorcing
bar gradeAS 1302:230R.

AS 1204:350 (Kwinana
onty)

Kemblaonly.

l,foeK

.n

-l

t-z{ta

UNIVERSALSECTIONS
Table 8. Dime|rrlons and Properti ot Univercal Beams

noi,-/oi,c

panrs

+"

...J--,

ii.J" y\,"

e.1,,p,""-

DE A
T
mnz/mm to6mm. 1o3mm31o3mm3nm
646

250

I O6mm4rO3hm31O3mm3mn

37.3

547

50 7
266

164

q.

zse lf

66, ?

"..

ra ri
o

.::

t
Fl

tlvhn (lt! 661

Nyloo{clars-fdled}

@ F /C
E
I-SrF
l
-zitEl
.^ l
I
!

Erass
Atrninium

,b6tos { tbpe.)

+l
1qm0

,tl
1@,0@ {Seconosl

2. Tim. to conducl om cilort. of h..t 6rou9h a crnim6rf. cub. of nEr.rllt wtrh .

tlorF.atura dif,ar.nc. of 1oc.

E
a

.n

Plastics 6re suitablg for mass

productionmtfiods

By definirion.pt.stics catr b shap.d

under rh6 innuenc. ol hear rnd prejluro.
A t ordi naryi empsrai ures
thE y hav a
high degrot torn srabitiryand by the
use or propgr desisn procEdurosth6
corect th6pE snd sizo of E camponont
cEn be dl6rnined, Bcaus6gtssrica
dre ol l ow r densi ryrhE nmosr m eEt sdnd Bven ot tomo orher nat.iat! of
consr!cri o.-l hs w ei ghi ot 6n af t ict a
may be rducedconsi derablbyy lsing
prasri cs
componenrs
sfd ot!6n,!oo,
tr cost may b0 low6r In g.nerat th6
srrngrh.ndri gi dty ot pl asti caa. 6
.ow6r rhan thoss ot herats 6.d this
tnds ro readto undeFdesi g6r
n h6t
tn6nro ovecdeti sn,w hi ch i 3 otr enr hE
cas6.l nappl i cari ons
ol th6 ch6eo.
,shapi i g by h6ri n96nd ,rcssiig r o a
pr6d6t6rmin6dnould shape hss many
lrtrrctions ior rho m.nutsctur6r,h
ruducosihe d.9r6. of opor!rot.skiil
r.q!ired 8nd it c3. vinu6ly tihinara
rh gr.ar buqbarol th ,noratmachjni.O
procosFrho g6.6rrtion ot scrap. In
l.ct, dhy lcrap prcduco.t during rh ,
proc.rshg ot phltics c6n ohon bo
.!cov6r6d .nd 6-wort.d wi$in th6
l.crory. Tl.o i3 g6n.r. y .o n.c.t3itv
fo! it to bo rtumodro r mrnutacruor
or l.ctof .s occu?! wirh m.t.t,
.Funh.rmoru. r.producibithyd!p.nd!
not on ihr lkill of rh. op66tof hrt
on thc lccuracy of th. orjgtnll
mould-nrk.. !fld on th. wly in which
.th. mould i! !!t oD In rh! m!chjn..
Mlny 'engin..dno firms now !.. in
tr!llica proc6ssingnor .oh6rhing which
' b hight complic.r.d .nd byondth.
ordin.ry .ngin..r'r .kilt bur r'har ln

.,

.Ooc*oldrozo'c

NYdr66

ii;

Zo"
zut "oor"ato
Fbv(rurh/ rnltu(.yrate)
18ooccooteoto 2ooc

t95oc*oec to 2ooc
l. Enthalpy ol platic. l|rd m.b!e
(r6latv6 ro 20'C) a proRsir|g

5. Vo|.ulnocontriction on coolt|g.

cstrs

l:rlCtCcr

':i.Ii..:.;--

':-.

ii-:t u

rne cnemtcarrcaat'on_... tn|r ploc8lsing tsmpraDrr63oivino.

'qeryo
krng ro Ult p.opnieasllch _:r:. off abho{ious tjms. 6nd nyt6n; u-d _
'
:.: ;: :^':'-.1:;J.,::
.:;-"::i::'-::-:
tsrb,l i tyl::'i
l l d.vi
3cos' ty.!16. ' . . .cryti c! tendro dpotymr:ast .
...
vrrying durrngProc6esln!,. ; -.. ramporsrLroE'.lew degreshiqh.r tb;n
.': lnos
oos ,r66din proc6ssingproc6ssing.TItvot6tjta
Tls vot6tjt4
:. ::. .l . ..
l.i ;',:'-'-_r;
'166d
Heat GFacity
city and 6errnat
wntcnrc.surr
-:-----,.rt:-..:1.
thetrnal : : ..,:,:.j:.'..:
rc.sutrclusa rho wsr|
:... .:.'. producE
plgucr!
wsla

i,.-:,,.

rrnarl .: ;
;q;;;G
"l"dr;;,;
ao;sisr
ot;
_&Fi
'|6y
; ;;i'v;;l;;
-.;.:i

,lr':.r.'"#jj:lor:
l"*f*ly****f"i$"'Ii:.:Lr;jffi;;r|'jffi
'eta:l"n'Jkhs
;;"i;,;r:t,i il";1",".1",Tffi:l
;;-;i;*!;;d;d;

,wlrlcn

tm$'tui-txi;"ii'lTiq]ilf"'iff""JY,"-;*;;

msr.tlarden..Dylv,ooradonot in. r: ..:c,.Pscrry 0r enfilrpy ot lomo typtcEll . r. |n gonrrr,prastic! aholtd bs procassod

.ot#iL.tns ta$sr ;st6ftst.,oiin clttd .'$.rooPlasrcr 6t tnir p.ocsslng._r:-. -:il r!6 low63t po33ibl6tsrnpraturrcon,
, 6.ir.si.nid will n.rden bv funh6! . . .j::: tmp9tEturst (comp.red wir! rho
' i. .,3t6nr wlh obrijning. cathfactory

*,ir:fHtTiff"tuT:,..::,:.:;;..;;"]effi"?1"?:;J.i^,.,"H,,i,I.,".".;,"
iiil,"f:JT;flT,iJT#gff"::*,"

qr.9*ss.(.
.1d1nriisgcs":'.' ' . : : .r .' li#i,'j:'#
Fortu,rdejcdpdon!

,",XH"fi';i,#J',j:""
(dnporaturcs

*"':l'

dourdb.!!-$'i tt po!!ibr'

"
ot u lnltd
,sriiiwryi.;i;;
visc;siry and compresififty
proc!s!* for planicamt.rrcodoutd ro',i nearin u.
"repranicsii verys*",_
elllili _*,, n.ve vry h,shvircolido,
9t-dlj-_llJ
!::ll- "I;19-Il:.'9to: .,rhi! hishhootcaplciryi! acc;;parrd ;;;;;i""r
ora!i,c.1.r, ..
""61"
r.ors z Ino,carortne haitr rMsss6e
Ery.tow rhlrn.t conductivityof
;;'r;;"
_"y .s do mtar!.nd.manv
.ii-i;;;;;:il,
Endrintt th.m with $. rorm!ir
Dr"stic!!.d tn6k.eh v-6ry
;oor
Jii"i-l"irs ;1,rci,.ii

ip',T.i:3ifr:::3,'HT:"":trJ,8,:f".":"1"?,"
s,.r1.".Tr*!-'.4':-.1;Iii
!4fi, ii:-,J.''i,illi',iiji'^:lli,
which_m6tealE aro.vailabl..
8y tuf.tb6. most.impon.nr prcc3r
6xtru3iooin which sorid sr*urar o.

iEsisranceto trear Fig 2 iohparue ttre

th6rm!t_conductivrti6sot ptasricalnd
m.bre in rarms0r te renirtr ot time

p,"",,"" .xcssdr lbout ,o.

ii u
pois6 -on"n
nomat procs3s.s ,uch !s
lrt-sion a"u Inlscrion mourdingar6

narerieri3 red.to
-vd'rsd
'n a h6at.d
ror.tinp in
(or
:il:.i.l".i: iI 11::ll!_soJtned

roqlir.dro condld *ii . ,iii" ol darsriat

rhrough.aunit ihicknoss
wirh-unitlemporarur.
arr".mtiur.
ir,o

"Jilp"i.rur"i"j
pressur63rnrcringh5v6 !o ba
such';s

orofil6. 8y a posr lomrng op6rationtho

exrruded sction d3y b. hooifisd ro

ol copper snd 1/5@ thar oi stest.

Tabt6: siv.r rh6 houtdhs reDp6m-

;n ttre mar rns v,scos,ry at t\ hrghst

,;;p;,",,,"
,, cros ro 1o po,6.

.p""r"i tiir,ilqlJ,i-

,""J. r'" ris : thomkvi3cosirio6

or

ii::eas :irube,
jff!;"il"i:
, " :;TH_11i:,
";"""tr;$'::"".""?"
::J"JiJ,,:,jtr:
"*:T",
il,,::[,;:f:":l
iti':
shap6 slch l!-ry
sh6et frm o.
rivitv ro. prEsric_s
i!-sbouii^(e
$ar
cm;e;;ur6 (rin6a.). rt *rrr i), i"iiiii.i,
'od,

L"ii"ii,l""T,jliili; lXl,ljij,::,

rhroughrh dis along wih the marrisl

3nd gilon a prsric! coaring,Ptasiics
can be mourdodro shap6 by heati.q
and prdEing balwen mttlinghootd
sections or by inj6ctinglh6 solr.n6d
m.r.ri!l inrc E closod mould. Shs6t3
m6y b6 shapdby first helt.3ottonino
..d th.n prrsing i.to rh6 form .6qutrad
by 8ar,vacuum or mschanicslms!n3,
Solid! .n6y b. Dlchin.d by .|o|m6t
.ngin..ring m.thod! lnd riauids .nd
powdors may b6 .otlrionally moutrt6d.
hollow cri or dapolk.d on ro surlac!!
.4d tr]bsrrltsr. Soft.n.| pl.stic! may
o|3!!6d b.rw.n h.dad .ollsrs to
.ucc c6landlrod ,h.ai.
I
h all-tiai. hbiicltioo plocrs!.t ttc.i
plGdcr rru.t ba hdt.d. 6h!p.d lnd j:i:
coolad -For $i! rEllon'tlio bch6vlour'
6 h.ldng ia impo.tfit bu! it mult
alwrYi b6 mh6mb.rld that.th! con. I
ditioni.Lindir lrhich cEollngrk.t phc. lr :
hry bs nO lal! crtticrl, alplchlv wian - ; :

ru,6s
rora nuhbor
o' prlsiics
anaarso witi tri exceprion
or ny,oi;h;t

,ltt
t.t
' ,t, r*
kno$/ing,lor sxrrnplo, ths vo'uh6nic
fiilino r.16 lor: mould it ir po!!lbl.
ro calcullt. iio pr.3!uro roquitad tor
mould lillins il dt! dimsn3iotr! (l6nsth
!.d di.hellr) of tho v.riou ctut.el8
aro known. AliernEtivly,if th6 maximum pr.s3!ru sv.il6blo i! known il i3
oossible to c.lc! atB th dimnsion3ot
ffow channkand mould s6t63.
Plasticsmlls ars eksric and .t tn
pD3suresus.d in extrusion and
injecrlon mouldingare- comp163sib16.
The compressibilityof ths melr varis
wirh rh6 rype 01 m5t3ri1.Thus tho
crysralinEpls t ic s( po l y Bth y !e na6n d
n yl o i ) c an be c om pr e s s ebdY ? o r 8 %
al . presslre ol 10.000lbflin' whilst
rh6 amorphoospldsticasoch as polystyr6.a 6 comp.esssdbY obout 5 o.
i scm .d e u s o o l
6 % , This c har ac t s r is ti
i n mo udings inc eit b e c o m .sp o s s i b l

ft| bdi q,{m l qhi dedon

b ifMrd
6y rav d6hn

'-:

d pro

Mouldinssa.d docoftpdltion tsmpoatur.s of commonthrmopltstica

I-

.l

-A-

i6i

:::. ir,L...

i+:.-.

t.
t:,-.''
1,:j:-.i:'
:;..,.u,,
,' rT
a:. ;:; :..1;.ii' .:.
i. *.:.:,-i
i, 1i,.-j..': .
.r'l:lr..1:.'1-:,,it',ii:
-.,,
'
i
dess
.:' i:r :' .'

#; "*;;'ii;'*:'ii ;',:i'.
;f;:l*;:.#*#;i
: r r : : ! : ; - - l ':'

-r'. qr:iti
-,_:din'r'qohi
pprEc'afrd
qoha '
to rpproci*cdttrat.
lpprEcist
tha,
,i'"v- :r kIi wiir.now
noiv bo
t;;';;ii;;,",;;;;!'t;;;;:
' pof,rtrod
Eo*la-"liiii"d nav-.'
top. ithor. donri-eraions
i;;.-ih;
warc
D otuceistno
- ..' .;;;;;;
rdorrtjoo'
rr''
coillld6rttroot
co
or
or
n1Aten6l
.^d
.rtu.!
ldrmdunrrbla
dimculli3
it
roai
lpad{rcf,d
-;rr
lrdd
tnll,mouotabro
difficultis
atmosi
--:.;-,
-h;-^^
. io3'
i.-'ii;;;;;;;;;;;,';it;'/t
'rateri6l
I3 of.
and co.r!. thr.$ickn6t of scrion
i}.ii iii":ini suii k nra i
:l-iotv onerrocessi! to b' considrod
h
ln
inpdnlnct
-,;:.|t
ip'in!ry
lo'
tha
conlponent-.
Procssslng
nec6ssry
becones
hrrling
ct'lnceen
<iitrisrra
:
pranics
lot
;.
$s
coolins
trt clo
not
wido
tnos4eds6,
.rim6
t'gve
!
to
ae;e['rr
.t6cr,
seracir ,.1t"nliii-to'pioccisini,
to ft6
iha-l . .dts-onty-of$rryp6 6r et6rtiG'.v'irabrebur aftf proc.liins i! aroponronal
i:i;;;;;i;;;t;;-or
ot rtt,muimuln tiickness'caus'
rno
,-:;irr# or ta uls! rrumierot prosesser
;i;;;d";":,;i;;;,;;;coii,nq
'q,!r
lsrrv
:+.iot.tho
Irhr"1919
wnrch
lrs
rno$
ot
tho
d,!p!!
drlp!!
r:.
llts.reriat

ttqond afticla;n
i.h,lha i;;;;,;.;;;i;.i;i;.i;;d'
1*l-"111r..;"J
*.f:j:.::,,,!"3:"::::.9-l**q:=
d1d!h;nrltili:ltjon rho prcaessitii cost
..,,g"ne.argU]n .ach pt;cs3!. .-i.
t.!rt/,, tt',s,,n.! atlr.r Orop.lisstO,
incr6'3sr !! cohDonat rhrcrruss
';;;;;;;;1;;;;l;;ih;;;;-tai
ptdic!
!
mucr
n';v h!v'
sans
sona::,'incr.,o6set
thsvsr6 _ 'tors
ippaannce'tt
.. prealing
t,
] iii iiiii-iii";iid-;"v
v6ry thict 6ectloN gros6rn othr
lnEld (og tnnsp!rum acrytic!, 'h'rDlv

-'ii-is-iraqtonrvrounotr.t som.or th6 . potvstvrB.6,

dci rt mavl" g*'tb.l: !-.. :l?t.:::.1,-":::
ull!.tto dudns
whilh mgy vorum!whichrio Dralticr
: ,.-fiau'sJ hrsr'iyr;tish"diurhco
-"i":^l-"::::.9:T:.:
##,-il;l;;.1;;;';i,-;;;"i*.

p'o-c'!!inq'rhu'' ir mouldir not

notla pmirt! rc ottain wnh !om'
;;;d ;ni;l; *a as pteos.gshspor
' !o thst it conlain!
suffciontlypro.surizod
mareriat;prcc$sodin cndn.ways..d
lsnhaiic .D0.5' !.e srvenpEcosnco
r6quirod
hargriat4h!n
i!
ro eiv66
r65
ir msy o'iy h6 possibrrro ma-krsomE
li-ri i-p"ii'v ir*r,.'^"t u"!rs". F"|'
tunnatt.mp.Bru?e
at
comptat1
fabriction
mthods_or
it
io.piex
st'"pes
,
Jiii"-ri r"- ili-jii.J"iirjl;a".,,y.
'il'autdins
mouldinsresuhs.ll thg
. t.s3-ihtnJull
irar-rietri
crugrormavhavero.harmdni:e a.e'usrd.ft6ig 116someor the hany
withthebodysty|ng'o.tnthgconsumeraspeclsoldesigning|orproductioninsud.ac6igei!enoughwhndlgnou|di

o' househotd prastics.

mari*i piece
auruures

;:li:"J;i iil"t?##&'"""'""#"'

|
I
I

i .. rql
(%)\
Shrinkageof Plstics
Tablo4. Aftgr-moulding

a8s
Acetal hompolymr

Nylon 66
Nyton 6
Nylon 11
Nylon 66 (9la!3 fll.d)

-----__-----l3-ri----l

05
05
2a
2A
n

|
I

=--'-1

04-o8
0'5

PPO

o6
07
07

-^

1.5-t
I s-r 8
a
05
05
- .-or------]03
------=a=--1 r !-50
------.,.....jg------l

.:i, .

3h!p6 by corugttion of dishing.id, tiom

ths point ol vi.w ot procesling,it much
asierro cop. whh thln rhickon.ngor

|
I

th.y shol l d be d$i E nrd ro b 6 I ol t h6

s.nralw .l l ti i ckn.$ B os s. ! lor f it ins
devic! shoutd b. 3,millrlv dslisned ln
.dditlon, th. hol6 shodd pon6l6t. inro
th6 g3..nl wlll to + ot rho wall thick.e3s.
In ihlt %y.ink m!*! on iht llrlaco
oDNlirg th. rib or bot! wi br mininiz6d.

|
|

1!-2!
.^-1
20-40

P\,/C (dgld)
?VC (plasticl2.d)

13-23

-----------1
_
0'6-18
12
12
05-14
0 5-r'4
-----_------fi---__----

|
I

matt i! lormod lvh6n ths .urLc. it hsrd

.noush to @lhlrard tn6 drawinE-inetfecr
a vordi 3 oroduced8nd thr3mly pt e! nt
w i l hi n t hs m ould, 'g
.. s.. ot w eakn3s
{3e6 bal ow )
of uni torh scr lon
Mai nrena;co
i 3 d6skE bl b6$uss ot t he
thi ckne3s
difi.rnti.l cool ns efiect produced
!6rwe6n rhin lnd rhicr( !6ctons.

For ; sirnltr.6i!on. thtck.nins ot tfi6

.ds.t o. nm ol coripon ! i! not
d.s,r'bts. Th sr.ltr mlsi ol m.t.ri!l tt
rn. adga und.ryoc! . biggd cnlng! in
ovtull dim.nsiont lhtt tha mmllnd.r of

th' tf?l!l! itjlTq{..t-"_.,Tll9""

c.o!.t bowlng.Tumlnoot,tr rn .d9.
(.uch rr rh rim of ! bowl)wlll produt.
dl! rllcattary dlfn.rr, an dLct tft.t it
prrtlculrdyw6B luurtrrtadIn v.cuuhtom.d

dltDollbl!

b.akt6.

".'
::

bsrrn
b";"ii
.1n!a,1
1r';.
.' io.,;sti-r';

"d"*l cr nd-.:..
ntEpidly

od",.rib ,i..r:t ..;i..*:in ;";

,,;;l;l;;a*

For p ldcticat.ajons
","(q b6cds6 !t rho rby incored plocssing_irsjng
'ii;,,r; m6 wrong

ooldingiho mblsorla: . amntud

. -- r"i"pe,srr,e.,
condruct,on
or 6.
oi
6-moutd)
mourd)
. .:-pressr:rei
prasir,;:
reopenrures,
. mnhodof condruct,on
,nr
il i;;;.1;;.
,""o raer_
lqal: T!r"gl:
6ly.tgvdnbnom3liry:)shlrptyrnotedcorner!m-syb-o_noc;$ri.-..orbirh6wr""-eil,;";.rr*rd;iih;
tq ia lor;.iry houd. ij
r!
dard
..rl;6r,
sharp
corneamay l cgn occlEionajtioccurbecrus6rr L
or 24ro 4A.tourshill i .-;.nd.
dlirsdfor r.r$Eric or.pt:clt rar3o;!.] conrrd6r6d
desirabr;;; csEa hioh-,h,,.r
..b
rcn n 3 rr 6|l8( t llonE
lsllmlt.dbyrh.inhsrEr.hgenr!|,.cohp/omils6uctssqtvino.
r r m l t.d b v rh .i n h s rEri !.h g e n rl t,.cohp/omi l s6uctssgtvi ns. gooe
ooOerna
rna iitt iirt Las
r,,..in*i"*
sri fl a now o r Dion; "
('r
"il"-.jj-'
.dtrnr't ti pl!srl"'-ot .ou'"., tho
r rrdiulln com6'ot Ot6Otn (l+;mi..
ir,r" ," ,t
ii;;;-#il;;

wi .produc. rn lcclptabra gnd w;nh.' r

fild.st &hounr of.'rhrlntagg't!k6! pb.'
wrdrln tur 6rn fas.horfr but l! can : : .witt.
$rll. |mprovo.ncnl
tmprovo.ncnr
in implct prrfo.rnsnco,
tn
prrfo.rnsnco.
: . prDcessing produ&
contino! or ditnlnrshing..aro ror mlrt
clr
*ress otren
-..
dorC. rrDrs 4 rftrcr|'. th' tftor.mootdino by rh. tomai'on ot void, or by $s

or.h'zn-hstrEss..
rnEration
rhe
lllll:_s:- !-'-:oT-oEry:.9..liq*
.lf l:.s &o 3h'inklss to'm.'c.n ohenbobvi.t6dby th6oso
f9"1._L-"1T
oEilmng-rn. .n0 otr c$on of
ot prop.iy

9r6rr.n
rh6.r, Difi.r.rlill lhdnkass whiclr can
occur, lor.rEnpts, in a contrs-ted
houldinq or in ,n onrudod s.ction ot
non_unirom.thictn*s, calsss wsDing o(
bowins. arrhoush mainronanceof unironn
icknes! horpsro redlc bowing and
/aai.s, tho problmis sssntislrvs
p.ocosengon 8nd can onlv bo ovscone
. by proper p.oc.ssi.g methods.

Thornal oxpansion End water

' ?bsg.ptioo
Plaslica*p8nd on heali.g considerabty
more rhan do hst.ls. wood .nd sro.e.
Fig 8 giv! soms crmplr.tivo figures,
Thi! propony crete! probtmsspsciatty
wh.n plr3tic! lro usdin .$ocidtion whh
6Etals !5 in light e.gin..ring appticrrions.
Dini.nrions cln also bs !ffBctad wkh
so|na hrlerirls, .otably nyloN, .crylics
.nd c.llulolica by lhs lbsorDrionot
w.ir. T.bl 5 giv.s fgurr! lor th
lqlllibdum moiltu co.tonr lor 6 nunb.r
ot warer-.bsorbertm.l.rials lnd Fis 9
illustr.lBs rh6 chlnge i. dim.nsionswnich
t.k. pl6c6in nylon 66 !. wn6r is
lbsorbrd. Nylon I behve! in ! sjnil.r
mann6r.nd it hly b6 .lrJmd thrt oth..
mdodll! which Ebslrb moistur. wiu
' h!v. in rh6 !!mo way ahhoughthrb
-,'rr.rs to b. linl. poblishodintorhlrion
!vribbl..
, Oliviordy,'cnln!93 in dimrnsiom ol
ihit na$rttt dd c!r! crE t6 probloms fot
tlra.&lJgrDr irfld prsGtgror lliLo end if '
v!.y.da.6 tol6rmc.r rrl |rid down ir h
not alw'ys.!ry to irrta tha prop.r
dlolidnc.r |tl. a!y, hould d3Jcn,
' .1.-

controfledcooting sft"'
orocesling.nd by proceesind6r the
comd temp@rrre (genr.ti,s
reclmmendedby the;w mat ,i!t
supprier).rr srourd be omphasizedhere
rhat.rrho!!h a void nnoi bo seer and
rherefororhs codponont may 5pp!r io
be saristadoryir ca. causei'npiit taiturs.
on th6 orhs h5.d a sink m.t c6n be
3oenand lhooghit may causerhe
cohpon ro bs rEjeciedon accoLrnt
of
sppeaEncsit is nor likgly ro calse s
brcakdownin sryica.

E hct d:siiE raiiirs o. 'rrtctr.'

,.

p!fiirdfily
trnprovrr!

nolcJr-$|l.ttrY!
l! lfirrcr

*n, ao t .tt!rd4 Ddrb. :1 t

r.
..,_,,,...,.,. ''
i;,.,,:::i,.;-;ri1

d"iii

"irri producsr rrEs in ri,

firing h mourd
floutdino. lr nay
flouldino,
nav thBrEfora
thBrEforec66.
con6 r$.,,
!bor!
tr'ii",o*.r*"o
ord, bh..nv
proc6llsd siv;, r,idt", ;ripi-a r,rrong6

ir,"nrnen,s,,.,-r{.is,ea"oaory
proce!'ad.
i. rad it i'-ofronio;;d dlrt

dorignor prccssinghrv6 ,! mucr, if not

.",;"t"{;;
il;;i;;;;;;;;#;;
ro ! o,nerenrhsrsnlr.
Minimizing processing taurts
ii ri,e *.i",s i.**i"qir"ur";s
ar"
tulit'u.derstood by ihs'd;sisnor nany or
do'subseqlont rslts which ise can be
Finifrked or .vef avoided.For ex.npt6.
stnk ma.ts wi atwsys show uo on a nai.
potishedsudace.In tacr targe.potished
irarareasare test avoiaeatn' ptisrtjs
tlsr ds rhey arc in paint work. tf s

i;*,ffir,il**;;f1;*;;;
*;,,.;;;';1',.,.i,
jl'*'=-*ft
:',.:',"i.:.-, J..,:;,,,_..;

h;#W,i'#
Iffi$ilf#t${{,",tr",9',ffi1";;ffi

#ffi**ffiimffi

H-gffim$t'ffi#*
;"
**+1*r'*:'',

'ffiffi

fli:::::''tl{ir:"#;*}{":
$n-gtnt$:q,qr*

:*sE'[',"ri'i"*,,
Er;'r':'"::
#,-.ffifii1ffi':ti"ffi"ljli

,r;#'ffiffi;ffi,
ql,affiffi{lffi,.
i.l'*1i-ffi-'".f1,1.
la'*:zugg,trm-[,

@,**

r;.,I II

l:.. -

i'l'" ;;dl-t" i:s;" r;,-l

,r,;,i"n"'

od erc-

;-,i;i;r !n

ulur .16 tquied 6d des:rnus!:

.ttr$ 116 Dlrronhg 8nd rpacirl matgriala: ::'&t.
illto rccqunr
botil tim!
|!t. idto
rccount lou
tino and::
and j I- :
-j.;i;e1;;;;;;;;;;;;;-;i;,;;;a.
.. :: ii'pu',t,i".
rg',iei givenin

rre

it'r'l

.rs 6 roisheiido
ri attttmss
.r'..'
rItttl
ir
c t!.r::;j :f,1 5vi6
00p
r.tonndbutpol yol sfri gs.P V catc'ub6
tl bl o.rs6roushl
rrdol oadfd
a3si4r
#na.'-.:'
iiii,iii'Ji"'r-'p-ityi"i{;"iii'pi,"
;::. n! oe;e'"llv .v.ilsbri h th. fanoeClOo.
"tcl,
::-|nd rholld bE usd onrv in de.ldinq' .'
uso;t-

proisct
is tuasiblo
Fnco
dot6iti
6rs,+1-L':
' g ;o d t.PPvC.:-::i,-*to
v C .r.:r:,.:' :to f2fi5o
5 o p apaiionn!,
i ionn!.trri
codot6i
ti 6rs.j
..:..w "ii'wi!$sr!
hsthsrttroi gcti
sf.ssbl
6!n.twlnd
o f itwoii - :::
,outlng i! 'nor
not _.rnt ::- Dublishdfrorfltms lo !1fi6in tI6 ws6kly -. i: r|/nn6rnuoy l nsy .rso 36rv6il! !. 1!4!0
prel! rnd rabr6 7 indi6ro!..'. t'br6''n norpins.to!1618| [r't cnlica ot
-.i...T-d_modhly
qr"i.1llo
:
pii"tt"cJFGldii,
apiit
rr'oi'
ro:::1j1":*li,:i-:"1,i.,
.. .,
. .
. :..
;:i..'r0Jr-!y!1f-'!j9l,l
|rflnc.-!lq!!:r:
'n.rs.ar.
I I du$ ba ft prlsr:sd tt6t lor de5irin8
In ftlking con comptdaoclteriti ttl.ral!
ti6ra rnry ba;_ '-...
,
fot p6ttormanc6in pll'uc! tlo comtlttr
Th6y g.trllllti l6at :: pr oth6r.n!r6ri!b th. tdwdlnside3 ol
ran-.ot mt!ilB pro96ruet !n.l 5dlco
i.tle pvc gutl6rtng !l!!dcr rnult b tttln {nto tccounl ll a
co.ndirlons
muttbs tsten into-sccounlrnd
airuct cnrngc troftmrillto plaltic! i.
mry'!tdiul!e:,non luppon, Pllltlci mry
llfsro1c. shouldba m!d. to tne manv
b.tns nrd;witno!! r-d.!|g;ins, fi.
lJ'crpin:lvi, a'ttrrrii nw mmrirtr *
.niclo! lnd o$or Psbliction!!v!ihbl6
w.igit rlvhq .nd nsnc! colr !.vlng cln
rr tuiift.d goo.tso rhc marlrilt .nd
on ln. .t,bJcL
b| .ignifc!n1. T!b|.8 giv.! ti6 dnsiti!,
,ro;!.. .conondcamun bs tslan inlo
ot r numb.r ol Dllsricslnd roma motal!
.cco0ril
Th. d.rigrlr loot{n! lor colt $vingr In lor compnl$n.
Cholng lh6 raw rnatlrlal
ol|ltlcr .!n ,omltims! find littlo
Two oth.r conrprrilon!!r usslolwhen Th. p.lvilion of d6tail6dinfo.mfiion on
rulrifdltior for usinglhom puraly on tho
d6dgning in planlca.Th! flst ot $e8e i!
m!!!rbl! ch.rrcterinic! i! outlids rho
r!! of nw fi!t.ri!l!, h i! oflsn tho
lh. volumacon (con pr unlt voluhe)
lcoDaof th8s6anicle3.xc.pt in3obr 13
niddrn ao.t lrving! which aro dos!
obtalnodby mulliplyinglha cosi p.r unn
thla ohdructoristic!inf ulnce prccessi.g
imporilni-tha f.c! thrt docorationis
wtght by th. danliry. Tho seco.d is the
llowv.r ir i. possiblto compil! limplg
uMsc6tl1ry or ihat ! bonu! qullity 8!ch
co!! pr unir of ltiffnals obtrined by
chscklilt ol lh. m.in cn.lEcisriltics of
ar nigh .l.ctrical rudnanca in ! lo!dplsaticsrsl.t6d to servicBcondliioirs!o
dlvtdingth. co p6r unit votwnoby th
b6dngmsmborobvi6ta!tha n.d fo.
thst, with tho ,id ot 3 propnisguidoor
modutLr3of olrlticiry.
ldditionll olsclrhllinlulation. Tlss6, 6nd
Voturncosi! sr6 norma y expressed 6ncvclold6dirthe conect choiceol
mrny othr t clorr, mult b taksn into
dratrialc8n be made.
ir p6nc6pr cubic incn or pnceper
account whon .lr3srinE rhr viabiliry ot
Ths cisck lirr is compildon th
cubic centimotrsnd BtitfnosscosB in
any proj.t in pl8ltica.
porca pr poond torco i.ch$ or pencF
brri3 th6! thsro nay bo 3omovsr
pr 1m,000 pound forc inch!. T6ble I
riding charrcterislicaeirher ol n6tsrial
or sorvicewhich narrow! th6 choice
Raw tnatldal costs
Eiv! som6 complEtiv. figurBusing
tha .v.oE! 3hon.torh modllus .t about bslorc comin! to tho fi.61dcisionin
Pric.r ot phstic! m6t6rhl! Jor tunhsf
proce$lng li in $ rung. f100-t15m
20'C. Obviously,ir workins out derig.
te.ms ol srre.gth, stilfn6ls or othel
m6ch6nicrlproprny. Th. llst can b6 made
TABI.E7
und6f36vsnh6.dingsto which th6
mnomoniS
c F A M E E T i s l pplld.
SAFETY:Th. fi|lr considsrationis
whoihrtlr. mlrldrl c.n br $lsly used
lor$6 sp.clfic lpplic.tion. ll tho mqt6ri6l
Ir toric or conulns .ddirivs ot a toxic
nltur. th!rc !t! obvioE liditltionr.
Sinlhrly, if ri3 co.3q!.r.cs ol
krlkdown could ba. h.2.d ro hllrh o.
ABS (moulding
lif. th.r. b 6n ov.riding linitation ol
choica,.
ACETATE
CELLULOSE
ECONOMICS:
It th! u$ of Dllnici
lncn!!e! th6 cosl of m lrticl. wlthout
lmprovi.! Iq 9aafotrnlnca thlr! is no
- o.r. lor aiploylng rh! m!iarl!|. Howavar,
at h6 aholdy b6a! .t:t.d, riar. mry b.
hidd.n co3i a!v{n!! whld m*..tha uta
' of pl!3iic! .conomildly potrlblc. Amorg
tiata lra tha bonrr| plltrnbt
ol ptlnic.
aldr |. bull!.in colcur Cactlaal r!.bunca
.nd ..ia ol proc!.sing.
AESTHmCS: Th. choic. ol tnnsr!runl
pldjcr ir lim,tad ro a r.hwtly sttld
calluloJcd
nonb.r o{ |hdadslr-{crylic!,
polyc.ftonrt!, pvq tltl ,.d Polyrtyon.
.|. $i hrin on.r-.rd wnan ! funh*
clunctari.tic |Uc! .. w.lttar G!'rl!nc!
it dd.d th! choic. i. v.ry lhltld Ind..4
Som. m.t!ri6b cm ont b! eDpli.d h
dlrt colour rlthotigh mort of thsn Jr
'!v.il-h lr ! widr n'lor ot anr&tiv.
colotlrr Trr .t'bc! hqdnaar ot pbltica

idtrr tronrArtit
- strirS
(Gtyli.
vrry

= 'r:'., '

rlumirriirn':: :;i

$..r) lo
|'n .nd_wrrl j I
pdrdhybi.t bf ftflitlro^:
: (br|{!|rtv
.r
r ::11'- f_\-

s,

.' -

j r"

v.i,:,-\,:i;:'. iJ .-,;aii;-?:.iI, -,:'..1

(:Y1

:--:--. j--=:;l_,4;.':j".
1. .;p;$$Iirtiqr-+5i:.'.,,.'.''-:-:.-.'$'.,;;,'';r;y,:fiii;:li::i-'l.q
lyrqlqoon'crroil,
'' _''ii1i:.,1:;1
r'ii;5ig:il;.-:;?.';
11,
,; i.
?::.i)!:::i
t-i-; !:"r;11j F:j=li,'-r:-:, i..
-i;";;i..;;i,ilt*
;i'.o,"rl
l. -:":':!n

'r
hffi*,*"mxni#6:.-*YJtH*ir"nF**'":ig,:il#*,-j:#j*
r';

ffiffi'ffiTffi;'FF*',#,.um";rrr*,t
.ui{$p6';1fr""64

rn$qrr,r.1116
modutu,
lndr'p!c! j-.!,lcryricrJ"t"r"iE;..'iiiiiiii*;a.i'.'fi:'j:j:;s"ib"."l'rnfll!..9:''::

,i".1'"li::g.f:",."1";f"*:,
iHg#*:5ffi,'#:1,*i.:t'''ii#ii,!i,G'r"1itli'v'llii3ji""i,'
jiif.ii'il'diG?!?jil"e.,!i!,ifui,ri',

ffiFE:?4&1*i,ilr"iif*i,,-,'

;6f.,mlil,*x"i";i;:i^j,

tbE.tot 6.rcout;orgd! coodirioii | , . r co-^trt&r, tr.dr. l.rup rhouldb pdckld. :,hlgh9d

crn ta rcce_ptea.
no*svii, wirr, .
ht$r 6itha b. drorrnhtbv prrcrtcii 'i , tnroporv.uvEns$ctt ..d ..!l.d ror
"c!r6

m*i,'ffi

l*'mi:
+',il'"-$*4*:rt*,i,.;lf'tr1','#ji

'I.-::."J'n.a.rJ.iiij-rirliJrlii*:,
d;._fii;il;;ffilfjft.h"#,T:"
:iiffi;"'i,:,i;;iiilPilf"T:i.,19i'
_
mo|lrurrconrant
n.6ddto..ffctani-.

r! t6..r6cl ot w.!rho.. rraiatooinJ_

*.ffi*!*$tT"l;$iff'''$:rsffi6s'$Eff
l"$F#,,;#'.ililii1i.,,.nvirctmontll conditioG but evnru.Iv

. clraful wltch dould bo kept lor !n!.

chorca
o'p.ocs,,ns
msnod
3ii""'1*:ffTT::11*';.il:,, a|ftousn
i :HT;#[:,I1,:,#::":liliT,:1','i,T'
vtrv oft6n$ proc6s!to b.
tiu-otia
*u"r
.oroo.nr
,"r,r
"..
m!t$j!t!
lnd
ii'"
'nto
""lrry-"rr-ii

j
filill"ffi::"Xi;lffi,T:,:'l'":'"
: :t':*#i:i*i,j:ff^ilfur:11,*:m""*::.*s:;1",il1.h:"".i,.::::
- ;'T::i#'":i';:,:*':'[",::f;::"
cuuE o! u!'d ro ofodu..
:s:xr"ll:r**il$'."1i':;i-"'
docompo'l.or.
,ii tsy!.
h":*"11*l:i''d.l["-i't::i.!ii
ot orrdi:.d m!na;
ou"iousty, orcooporoa
"r!cd!'
;;;;;
";';;
*:*"*i:l*"*"*:*li.""",
r? mri;ii*kir*',r.m,",.
#:[iitj'i1"i.""'ilij?;,ir
ni;il;
il;;;ffi;ir,i
[j.;,.;i
", il.il:.:9.,,.ir1,:-i..1"."t[i:"1;
T*],liii;i:""iffiit;lf.#ii""T
po:r
our!,d.
ll:,T;lfftl,il'3:i:1i::,#lrt1"j'*
sr6
shld
uniirrins
coldudors
r,r"
,-l-s.-ry.:."."r
uu".. _"
or lr.crricrrylnd
canb roundrdr
,.p";!;lJ ,r,i ii,.,Jjn1:ii"s.,i'".",""
. il
"T:2.'$?fflii"*5:i:'::
"
".
srnerrrrvtnonJrnb6r5
ruouirodrh'
inIo
;Er..t.!roff.ctonco;'o;;;i;v]r;;'incrs!3'ngr.t.'ce."ntty'l.;wn:rgi"i-;

. . l . n !nyh6v.|owp 6rmilvki s$ ; hid; r . gr jndingit ' n. D! t n! |is t h3 n t ! k E n

vortrscs.irr.;;;;;;;i'
..! orearoown

lJ r",,10r" u. tJi'i,Tiio;H,iil;i;h

raistivhy cln b. ! nui!!nc.. ri;!ds!

tis
compononrio build up !n .llctr$trtic
ch.rg6 whidl c.n lttruc! dust 6nd d|n.
Althoughtii! c.n b6 ovrcomalnd hrv
orry.b6 I.nuir.nc ln rom! lppric.rionj
In otndrt lt can conltifirto ! dlng.r!hh!r
rn uat or nrndfino,
THERMALPRoPEiTtEs:Tfi. fnll h6..IIn6
cov.rt tuch.fi.cr! !! ot!!! rlnlhion
poht lnd b.h.viour !! high or tow
rlmparlturl!, Agrin, th6 .isrt! rhlv nor
' quit .ndghdorwlrd b.c.rr!! ot ri.
.rr t*an torhart to pan.v!i! ! fir!3!
ot prlrticr nll..l!|, Thur ! cohponrnr
rf,tu!! d rhon t.rina !t r.t.tiv.ty
-firy
nrgnt.mp.r ura! wh.r.r! ! long.l
P.r'od .l I muclr lowar r.mo..ituro
could cru{ brutdown. tr .ddilion, I
cohpon.nt which cortC.r nridu.t lslt
Dy b.lng jitcoot.d) i! |'|or! tit.ty ro
-(.J on n.rlDg rhrn I rEar.-h. mouldidg.
u{

rtrerrrrtivory
wnrrnrni iumiJ

.,.",pr'".

TABLE 8

"r

tri"r,iiii.v iijiluy
""l

ri:

c'prrdmdrunnins
costslnd
"'achm'rv

:. Colt/Unlt
atltnaa!.
p/im.mhIin
ACEfAL HOMOPOLYMEB

166

ACITAL COPOLYMES

153

ACFYLIC
obt!intd,
wh.r. rh. two lin.! cro3l i! rn'

ACETATE
CEILULOSE

'*r*$"g*:**1,+'sr::

PP0 (modifed)
NYroN 6E (drv)
N V r oN 66 (ol assfi rl ed-3oz,dry)

lffii,m:r''
[*h";il:'1,"i.*:i

N V r oN I {drv)
Nvr.lN

S ldl.!!

fll6d--252, drv)

Dr lI V 'A i g O N A T E

*t*:[$:*'''nl"
-

(generslPUrFo3)
POLYSTYRENE
o ^ r Y FTH Y IE N (l
E ow densi ty)
POt-VgtXVtel.te(high d6n!it,

i*1f,i#+u'ft:',"t*'fl"PVC (.isid)
erlelOUCr'tOUtOtttCPOWOtn

uaenrOnvnOeXvott'outa"o)

ffi#fi$ffi
t

t31

o76

46

o52
o78

3n

ot7
o17

25
36

o24

o(B
1.07

125
40

145

100

15

1.16

o21

otz
0,21
o1/t5
o34
005

0-32

o2

16

o33
o38
o50

10

o33
o24
016

1.6
35
80

q53

11.0

oo54

!. 10.

h
s:l
i.

A dtnpla rpp.olch to cotdng lo'

ffi

ffiffiw,il'ffi#
#*Hffimmffi*r

T
i

tr:$;*+tt'i*.1,l;ll''lt,
c",i,"",iii'ii,i,i,';
I _,,r"r*
#ii.:i, -

li[4:x,:"'m:
,/flii*;'i,tgll-it
;l
!
I
_l

_ uri.r proc!s63such.3 she6r

ra b n cr[o n6ndv r c uumt o rh i n , h a v s
o-urputr.lss lthjtarty d6Fenda;t upon
d!
r !t6 o f h 6! r r r an3r d; nd; ;;;i ;;:;;
"'.

I::;.11il?,:";:tili+:il"t'.'"'J"T;3
| |

l.r"rf*f'I L
/,i*}i#ji.:,

I _ .H6vingput n..t inro th6 ptastic!

jj:rl1""*{i{trjr
i#irlt;',
@

filniJ*i;",i,'""*#_''l*E:'"
,n.n proc..ling
th.hoi.nino

:^""'$":&TT:jl:

inih!.;oud!

lfflg,-t+ftl*t'*TiT:*
sipr,;1pg*im

:#?#;rHl"##iffT:r',:"

'fifriffiffiilffi',#,-lo firltch 6.
. 'r r .l\ro[ dBlrtL
' 'qqow clp.ciry ot r m.crtn. wirrr

'iffi'*"k#ffiffirit__ rrry!,u,
'
:;

! I sr .xtruci!..
. _.

FIGURE ftl_

. .-j

_. . ,
1:

ia_-

!:':

r;-:

i:i-

tf.fl
i*,#l,,'ff TJ=';fr

trE

'

bean : :r n..ds ro b. .nonis.d overt mid:nufi1

ol
nouta.rowover.ra hrs or.eadv

diicu'sio. tn rt ir, rt's

I ;i;;;;t-#

ro@ doutdins3.
Th. d.lisnorrnourd'
t! -.
poinrd
procr'o' .. po'nraa
!,cra,er
ierTt!L1,ll?.'l1l
an'cro.
monan -1..1093,
ourin.sn
outinan
rho!,"*'i
ii,
_ :, I| ''nor,
inJ il;l;:;-il:i;li
racrr:irrr'as.nes.
"i
-_: It rltElyl:1d_lis-":_ry-d:!-is:-:l_.9:19
3impl..nd rn. m.nn!. h wh'ch ,
prasric!
nor
sIrlishltodlrd
do
b.hlvo
in
!
,fl;ddiis
in
w,ll !a considorEd

.: I.hhfiion

/ ::. Ibi.rr dEr.ir,;pdtiurlrty

itrretarion
ro
m'nn6r.som6or$encha'e.iiomlorid..:lfL!,91.t_r'9.1".!r9!i9^t?.'y:1
rrgl,r
e;er..dne
b,ittreps.ticlo!teviscous.llr9"-"I",1:;i;;;t
l
9l
thl:! L-:..:l:ll9j!:-r1[1.1-.,.-9:_":'tv
'-:
";to;_
minyco.ponenr" widetempr.rur.r'ns.othrshave?..9Jll"jl1l!d;"d-111:r::I1.1!1q!*^
Artrouetr
:
I comlonenr:

I tor di r"tnlE;ng t;dusny;m madoby

bbw:
I oir'".in"tioa" *itt !s xirusion,

thirstrtt
,h.rp |nchin!pointlnd change
ol tmpoatur..
over! v'y lw desruo3

mal lll lhs ditere.ccbtwentte

tucces!or railur.ol I pojecr lnd ir is

tor rhi! reasonlhat rh! .risin.r .l!!bnio9

Arr sr6 rtlecrdin llow by rh! rats !r
pltstict component6wltich .rt to ba
which thoy !rc !h..red 6nd bentvt as
nado bv injectotr molldins it iflll
non'Ndwlonian,psoldo'plasticffuids
adviled to .r!dv lho Proctt3 in &m.
Tho proces3i. c8pitaiintenlivo.
Mach,ne!cost kod 3000ror t on oonca detail.
ln this aniclg the prin.ipls3ol rl.
iulrt..lromdlic prsss to 4250.000snd
processarc ou iid, brlic moutd d6is.
warpr coohno
I parosrrs!16 oniidsradlror|9 w'$
'
;;;;;"i.-I stdns and coo,ingsy3rens ro 6void
t-r
i ;| mourdi nsprcb[eftsadtn.se. 'e!
l . , .t l l
__,^.1 concrud.sw i rh ! D i ,efcorr enr on r hmak,nsol p.otorrpe noqlds.
He.ter bands\ Ih
, -.-.^..,,_

;;utdiir !rc_ whe considrabto

nu|nb.r3ol alicls aro rqutr.d,mado to
I tiilh dd.. of lccurEcyind conlainr.s
fin!-d.rrii iniectionmould'.o i! tne
orlf!rcd
' tnj.cno;ollcess.
douldins ,3 bas'crtly a s,mple
lf

I
|
I
I
I

ti e U a ,
\
J2*+H7l

| tn;uoton moutding:rho Foce.s

IV
I
I
I
I
I

ll

.:: t.reV:::a

ll
I
lFbda.,l.
ll
J

\
frrd
pFs

|
Moutd

f-

F<t'(<{;E/;4*{

l**
|
I

i l

a,.;-rk
lI
"-".'.'-t-+
- Sc.e* ua'ct / |ndfeul,cnuol
iro-oGir.ii
Lmitswnches p|p6
redr6lrda) r-------'---__-_l

r'

ro! holrdabre
!tar. lnd a hourd
I sorren.d
pl3srca
into wh,c\

th6solten.d
I
's
I injecrEdlnd wh6 'tcoo,slnd sorJ'fii
prcvrded
roropsn'nsa.c
Il Mensar6
-'^",-. ti nrourd.nd tor rocr.ng,r n rh.

I iiJ iJ o ' " " . ; n " " . r h 3 i 3 se n s.,,i b ' o

iO CO I
,

l #j#,",r#!#:r.ft:

Eec'cmoror.pump,vah,,6.nrc,urismeE
Wl rmers
| ot:li:::i:ii,1#'i!;r,'*."h"::
rh6prasrics
inrorh.noutd.Ti
..

,,/l

I
|

arr.^rh..r

i . i rl "rt.r.

| sy3&m ot lecficaly operaldrjmec lr|d

I valve3contol3 th6 sequncaol

renoe1rta/
regulalors

.;i.""?,:';i}",'ffi
n:""T,ii'::j:;j,i:i
lulomaticallyr! rn, d.sired lening Th.

cycl6 ol op.ratons i. $own in Fig ltl.

M.Ebl

E
17

er,nser

(th{

Nr.L.hEii]6tn.{'.d.n.d
Ni.l.rch6hh
i.d...n
.dr

NEr.knMtod

l!. Bet !r.!.

22 r. vrt
zr
-^

rsbtt

rhl.

hr1d

dt

h.?rrrd

u.|4.b.l

1t sr.e .rn* in N.r.,..rmir6

M'd-rt l
1a tdng do

za l1 3H'."rir.L.i@i6.b'(iv{.i..|

.lo xt.r cr

rt

f.fu*+
'.

<o

< - iue

t--"

- hv' .*'@
. Cot"lh'j"'\e ..:\",. t4q"
to

J-

:'$,'.i;tf't;. I,=- .- r ;.
S.

---'

l-ii',

*oovcn
i*,-t,':t'l0
t'--j'".,,'.J-*

.n-;;nlJ-'d''rr"'"in0.",,,,t
l
"o^,"0,,..,o,u,r,",.r,u.*roitj..i
. .: r :t r 9roclrsr
E q$li.d to ri! hjcr"oacrlind.r 6nd . , mrQnlr
mr!!d!l n
in 0.
rh. Eyrnqer"
groclrs. Wfiar
cylindsr.
wn:r aro
ar6 rn.
$. rmp|Jstuonrr
imptc.rjo b
ro d,3
d,. I
pbatidgrd

Bol
fttarial6nr6r! th
dd. Tn rlt of iniec on it depend.nr
ir_dr nt6.'t xnidr fr6surised tydraulic
{rtd 13.vdl$|3 (ttui it. rho hydraulic
P('tlt c.prcjty) rnd Bnouu b_!-6onst,nr
.tn. yrno|oCtrh. D6dodol fUins.
':Wt
: WD.n
n ih. mouldls tull.
tult,prcssrro i!
:. fi|lhllitud fot. f!.rho. priod 30 tirr
' .ny thdnL!. rrhich occu6ln tha mould
lt tlta iot mnaalll ir cool.d crn ba mrd.
o9 tfdn $. rltidlr in ihs cylindor.lr i!
obviorr!thrt, rt loon as m.redll in lny
P..! ot t!. .ilnnel system which
cenn.ctl tli6 cylind.r to rho mould caviry
i*ta!, no lunhsr 0ow ol m.r6.ial can
talr rl.ce and the n6rr oDerlrio.|!n
Dagit.A procals tim6r then op.6res thr
sct w in th. pl.lticising cylindsr which

Lockirgol rh. mould cln be djE.Uy iy

nesnr ol ! iydraulic rldr or indir.crly
ulinq . rosglghoch.nlsm. Anorh6r .syEton u!o! r toggt. mechanismtor
op.ning.nd closingth m_ogld.finll
locrlns bln! by n;rn! of ! l.A. .m!
hyd.ruticrlm h.vlno ! vcry srron troks.
ln ,llth!. m!ch!ni.m, ihs d.sign l!
such $at th. rninj|numpo6!ibl. hyddulic
flujd hasro bo movd ,r 6!clr rtrot!. lr
will rko b. rppr.cl.rad thrt movi4 the
mr3s ot m.r!l ot which th6 moving part
ol tho mouldconsi.rr loserhr whh $e
wEightol th. plalon llself presnt! roms
prcblcn! ot cont.ol,Too rapid o clo3ure
cao damlgmouldrnrting surlacesbut
roo slow , clo3i.g sroks wrstos time.
Hofa thE togglohech!.ish sco.ss oyer
rDt tos rnd conveys gEn!16. hat.i.|
rh. rah systembecaussby its naturc
from tha ferd hopp6r ltonq rhe scrw
b o rhrh sbgi nni ng
3nd rhe nd ol th6
69h$ wh.G h i3 hodredaid sofiensd.
stroksar. 3low, Wirh dkecr hydutic
Whln th! nrrcrill omrgeslrom rh
locki.g n is nec.ss!ry ro h6vs switches
rctlw ntlht, Inro rhl rona !t rh6 nozzlg
to slow down rh6 ap6dol movementot
lnd ol th. ctlinder tho p.essurir cxeftj
rhe p srenar rhe snd ol rhe srrol so
disph.ss rh. 3c..w bdckwardsin tf6
rh .t rh ehoul d prn! w i l ' com6togorhr
cyljnder
and lhe . ert s h o rrs a c c u mu ta te d g e .i t

M..nv/hil6 rhe dar6dal in rhe mould is

cloling and when solid can b ejecrEd
Iom ih6 molld. Th6 rotarionot ih. scrsw
bving b!6n stoppedby an adju3tabl
limit lwitch on its backwardmovment,
t'1. coolingtim.r swirch oper.ias, causing
th.|nould ro opEn lnd j.cting tie
nouldin9.Witi tully.auromaricop.ation,
at aoonr! lho piec6 i3 salaly ojsctd th!
mouldclo3!3 lnd thr cyc16raslads. ll rn
opantor i! ahployed lo r6fiov6 rh6
nouldin!3, th. clo3insol rhe mould 9u!d
rom6lly frlans rhe cyclo .utomarictlly.
oit f.nt m.chine.y ma.utacru.s6 h6v6
thir own Danicllar rnodifrcarions
ro rh6
rn in d.3iEn.Thus, the provisionol .
hyrl..dic n!i., !rcssure 5c!.nulrtor
.rubL! a smu.r prBsslrr6punp to b.
o!.d l.d lnjlcrio^ cln b v6fy rapid.Th6
l|t ol injsctioncan !o slowad dow. by
tb u!. ol a llow conrrol valv. in rh.
trtrtura lin' llm6rl or swirci!3 can b6
btDducld to alut th! prlssur. m.y be
v.d.rl duringinj.cilon lrd ! rlpid. high
tr!.tur. pc,iod .t ilr! !t.n c.n b.
r!6..ded by . !ow pr.ssur6 holding

Tabl. 10
Faull

lnrine6; desjsningcompon rrr torl

i.jecrion moltdi.gl Th. 6nt i! rtr!!, nor
r.ine inro n.coum ri.itatio inp;s.d
.. on conponnrsby rh. n tur ot ttr
. pt!.!6 rh.mservcr,,ijccdod ft| nuii!
L ! proc!3. which clo bo op.!6d wiirtr
! hish d.sE o! p.scilion $ tltlt |'v
nlmber ot p6nr cr^ bo |||!do 6_acttytit.
.rch other Th !.Eo6d ii, in on6 .!n!.,
tI6 conv666 ot tlt. ornc d|.r bac.s$ n
ir rolribr. ro obrainvdri.rrbnrof ti'n,
romperaruo,Fresrureand inj.crion ..i6
rho p6c!r i! !t!o open ro I graat dr!
ol vadarionwhich c:n b! r.fecled in tnc
qoatiryot rhe finishedprodcrs, Thus
properd.3ign .nd proce!! conrrcl rru
borh essenrirtlor luccas! in iniccrion
mouldlng.T6bre10 b.iorrr'na n*rcs somc
ol the tu!lts thdr cln occlr In iniction
nouldln9 and !hen prcbrtl. cal63s.
Principl6 ot mould dsign
Thi sa3psctot ,nj ecr' oino llc ns is
perhapsbe3rcon3i der.d
i n ihelor m r t a
check.l i sr
w ,th comments
6n e. ch poin!
Otaiiedrnoulddelign may b ertr6n6ty

C6uae
L.ct ol prossuri s.ti on

Ov.Fpacklngol crviry

6. Micl ml|ks,r9lash
ma*s lnd brcwn
a3ymmt'ic rction!

10. Jot!ng

amp.ng5on w3ll or
Estricrion on cnrc.ir!

' bd'l c.n b. rdjust.d by g.aring to giv.

thl or low rp6.d .otrlior but hlt rh6
. dLadvtntlg. dllr il it rlllls ih. motor

itt]l. a.r.$r movBsbockwarddurin! tha

'plsljcistion p6do.l !rains! . hydrallic

R..!ir. rrr. rr poini

6l ry.nnorry:rh..

High nre ol led lrcm

Rootionot rn. 3cr.w c.n b. by n3o.s

ol.lydr!|llic or !n ol.ct.icmotor Thg

irry br drrr.gcd.Hydrrulicnotort c.n

bat!ntroll.dby m..na ol o llow convol
vdvi in dt. rupplyUn.!.d !llh! do6s
i:,rFlaruraanydrmtgr. In sofla mlchin.r

rnc.rseinJ.p.essu!
Incretse
moud emp.

4. foor sur,rc. finish

5. 8L'rnma*!
6. Mech.nical,ticki.s

R6rnedy

t2. l.mhrtion or
'rli||nine'
5.'/'L i'i.c.ioa natCiE

lash

hcompl6t. n.rring ol
mararirl in cytind.,

racrca3shclrint tjrm

dudnginioton

r!|.; r.ducr brlow.lP

siceptionoirerrr*rochrs.prc|
|

JE EI\jEI
j::1:::,!i: '-..

n$:fliou#',i'TJ":iili.il'i-Jin""' whrn canr'lrat: coroev rcr(rsotr

1, 'iiu,-i"tio tr.'n t"i'"6 problhswold
polition.Tbe3..nar! iale requir
[owiot dcom
' l-"',i iii.tt. occ" $/hnmlted6l
"

l-:,:'
j

lstics i:*n';;J:?,';',ff..":tT"'1ffio
Ir
,;mf",'l,lfi1il*i*lll.
1"friT,ifiT#lU
"",., !"J'!!Tnoli',1%1ff;H1;
i ;f i..i'i'..:..:
-,",i,.4,:_ttiFl{""j:g':
ii##'*,:itirn;,ul'r;to_x,"
Il.. laf fESt, l lt3
i.-

!itlt'.

'r-

,,

.;i" i-.r l- i-i$r. -.- _ -

,B: ;:

':j .., r ' : ,

!,i, :sil;;*;;;i

ii:'

:i,

*"

wr,tchrr,irsnior"is

l"",iii, Xiiiali
"""rtv
i:"j;;*
,'6.n "i',i-'i'is
.!v'w;.lt
o'.ottier
or
0$6r
ilpffi;;;;i';;;,t"*;ii
'
n-wi*rln
i init' to lvoid jsttins
ourrnicr:o
i ndii r rlwayrb.!t lor mlrritltoiow
r.th.r
i.cdonr.rh.r
ri'inn*3.cdon
io iiiir";"
. ir,iliii
ir'i.iei i,
r,omi,
i,.i'nr

iianvi"o vcru.
oilieNsrijrls aNo rounaHcrs,
4"r". ."n.id'dns moutd arro'"iniurnuti ue toa" in noulddsign
to roii'riJiriei'-ouiatneshrink!8'o.lths
a&n iii-.--"ii'po"r* i, is nsc633arv
marsilt wntchwtttui greatsrIn $e
;_rr; lun $!t tfi. rnicls 13,In tlct
i!
h.j/.brr .t|d thrt inpcrionmoulding
arr"ci;onoi no* itranin rt'etransvcrs"

HlHji!9?i":"f*:l"i';Hjl"l'
w6s
Thi!

Problem
! tonq tbln lod
.v.nturlv lttv6d bv mouldingth two
;i.c6! inisqEllYw th ! shon, rcund
aonnoculgpl.cs which couldlhln D .
cold.dllYrnto liv lhl requlrodlngthol

t'l#uno

lteel A
A ttpic5lmosld
ttpic5tmosrdai'
chromiumlteer'
chromiu'n

h Fig-15 wlt'r! ri!| ol rho

illu-sr'rted
trilr!ot cons|'usoon
vr os3.ma
ANDASSEMELY
oFMoulo
Du.6 idontjonh!:r
-^qi:r^G.|.llPf!ry-11-Y-9llo-L
-^DEsrGN
Le.r.vNENls:

bo.siv.nro th. dim.nsion!ot lhg

componcngol thrnould
Individuar
thoir6s-smDrvroj?don hourdine 'nc
ol !'n'r'ltrs ! verv
mlchi'es!rc
"ptbrs
th.
highhydroEtaric
Pte35u.6.wi6in

rrr'eJsnro' hadequ'te
holrd
o"
iot"^n.".
iililiii'i.iJ'tri
'nd 'd
ns thsdouldwirr"i"h r"a
toctoccur
irrd.i; L"irrrorttrr mouta 't'o'ro
w'rr"!e andllow
-rts'
o!,insIn th'! i!,.marerisl
ioiiiu-'ii"a"r .t'rra"re,i"tics
rhi'
sudtce!should
matrne
lho
in
wo'kins
in"ot"d
eili"
tlna ir,i
'cros3
plsEE
roLld
lrk
tne
oans
or
th'
lat!
";tis
rhe
crota ri-rrc
t"

liiii;ii i,iilld. ;;;i;; ;i mrnutaiurs

ii rxiirllc, r ror'eunitofl racr'on"o
t...0. lv
J"ii'ifii1ii-u"it
asremutv
iitirioi rnaiubsrquent
irtir"it r*rrtet co,tiponentmlv
to Dd
r. mr..r dlficutrre .nd rums out'9pe'r
l-rlirr-iiimpre piopasiton n crse i"
! c o mP o n * l l " 1 1 1 " 1 .
e o ini' c onc . m d

'

ol cat'h6den.d mid !I!t a;d

:?-.-- ,-rt'd'ncd nicr
$!t6 !'s
^.
--- or
-. .-.,---.
b,:sh'i for *^-'

p|lced
snnior (plnpolnt grtes) thotild !o

.itir*
ril"g. tmpr"l"o' r"|'
ii:prdacr'.lur tr'E.o
tpPros
- arE
Iildivi.trr!fatii:
friiirGriirc
-#, ol"idt ojtigrou|a,lont
.t"
and$63
i"Jrt"*
-tti.t'
lirnirii ti rrrinlscion.ourds
iliii,ii'ii:i,iiii,iiii1.mi,i,r'J"fi'ria-inlihrr
:
;;;;;*SUriiiiun,

Eieclo'pin'. lrrippe/-ollta bi'sh'lnd

p..',ton !3 to lllow

r'^li;ii';

iiii"i*y

"onsiae6riott
'c.v
sn'cle or rhe
n lhe secono
neniiJneJ
pa,ric,tEavro inrs"tion
'eii""'appry
rn
o u r di ns. _
.^"

'";Xl;;

^.'

o,

,0.
"o*rr^r.r,o"

ro be sfiectdhu5: be 3tro^9 enough'r

witn't'nd (he lorces esnedted wiFou:
o.Ll i l j l ;..
^,.i -.-r,." r,^, ^- *. *

o'9?ioiljo, hsrin*ecnecr
o'+"Lsh

,*rrto',"t
^no

CONTnOL:Wh.n comFoncnl3h'Po rno

!'r! havbandet6nnited,ths lmounl
ol hs.t to ba dii.itatd lrEm th nouro
!ra.ch tho! crn b. pt6ci3.ly c6lculEteo
TlF ima ovcl. c.n ba 63lim6te!rrcn a

Spruele

Ph gtB

Standardtsde)gat

"^i'sil"*'
7"'Ti#%:l"li':
:ff!i.,**
1S) md coolin! channsl!dssrgnoro
rlkr lwEv th6 halt in thg t'm lvarlore'
ln thj! wry ti mouldcoolingcan o6
!|rch ihal rho mouldi9 .l lh6 opamum
t.mD.tatur! throughoulthe cYcl
elECIOR SYSTEMS,Oltn madrn'
frn mritat lor conlidaBlion l' mouo

;fl"":"'iffi
faro:".
J#i"'"f
*:El;,l"'ir'
h'cnrnes
Most
Dl.
aont
dtnrallEr|

Finggate
m

Si

"onnrcn

g@" (coutt.sy ICI Pltnics Diviion)'

aoiooad wtrh ruttonary rocr ot crosr

h;|ii b.hlnd dt. movlng Pllt3n wnlcn. .

io""H[::':
ffitr,il$;Hf;$f
d urlulubly Plt6d pnumrlcor.
f
i;rullc

ttlnd.tt lir ol.ctor' or

'l6cror!

1""'lgi.':'T'1".
Htr$rY,l',[H"tf
alnnoct d lo tha irad Pl!$n mly,Do
;
-

m'fgm'grn;:l!'*"

,rrclnt or .iFtg.! cln 9l.ol :l-I,r::e^t

b
9I

i9":',"
ffi;d#tx*$,'J'"f
Sff#fifrHl;",*o'"'
.",
ffihT ffii*"i'"iJi"'i;.'

flStffiar,sffiru*:,

1
I
I
I

.ii1-,.- l',t;l:*,';

r*"if"'Hfff#iii;ffi;# ;; r f;lffi ffiTF*.;'- ;';+t

i" rrrEccr:O crtlroc ai. 6h.r r.16o{ i i! on r tdieci whid is r'!rr ori.6 d.,
gt t'h |'tC ti.

ftftrt
f tttl

.-

.' .. I

C!i!-lrL

,,. los 6ec-r d|}d. 1/15h 4!m.ts. gat it .. br .qiD..B: 'C.r) chrDrootsb.
indiclr6d. lt must b3 pointed oul th6t

obtli.ed?

Thi! rlDi.ct

wls .tisclE!d

*:ii'.1*;y{,,
i.
llT,trlosf Ncs :l'jH':l:$'.'"ffi1H:
ffifl'#?T;ri.tK.rJtP*

:r
l -:I i +..-. '
j j
.
-_:.i._
.
."i .' i.d-:-'.t. - ':.
...
-,'ir: - , i a : :- .
.J : - .
i:.:.
- .-1
,,-i-,.,..::::*":r lfu,lo:l ,.
-Yll!ry
i:
MT!y:
': tnould
mFrunt ||l!.ctr or
dctEn. Mould

b. llnl. publishdi6forhar,on.Pororyp.
courla open l! ro m!1. ! vory 16r!. !!tG
. Mouldi:ool,n! b t6o co plsr t lubjocl l^iec-tbnmouldr .'. tequontly rcqoi'o
ii::io odt to a.s6. rho rcaiibitiry oi I
ro d airiiwidin a.ulr inihla .nict;
proioq .nd rof this rcrson urcr$|odor
bur onoq.n!ru| ru|. must bs ob$w.d:
method! o, .nould conrtrucrior !E or
Alwly! rpply ina m.ttin!fi cooling 6!
rh. rolnt ol.n!ry ot marerialinlo thc ' - inlerett O^a ..viE{ ot rh tn.$ottt ot
:: - t n v.6r..qow
d
6 t' d
.nd ttr
l i no.r
li.
oubltld
tn ed in '?lan,.!
cooling
ar iti.
'?lan, i
itot
drnd
tht td.t
t.r!t .oo
v.6r..sowa!a! publ

o:trmrvor ti. m!te.i!rrow' rt t ;ot

-.tillic6ry @ lrrum, thlr 6dsqu!& o" ortoinddy. ,
li,',rJ
!!9r ?!Tl!!i-phgf ,lre'! rh.ir
"ooriinii
"rn of cooront
throueh
! ;r!rn
?:::?ry-ry-T,1|- T-"-':-:-'-"9-.:.19 ctcur'rids
6drircughrhenoutdbor'r!'
chlnneli-dn
1T,,!ll "fI!l ?*:.11! 91:j Tovrjr..
drit3pdphory
:lT-ylT
n.vr oul|ri,J?1."J,-:.'11i''"-..1:-:jJ',y
rnroulnl'o srp! orwnrcn

air crt 6caPth.56 ventslre t.'dom

!91:"ji:9T1'T':.I:
1'l'L,-::11:::
:i-T-olll: !!:" 6::'Jl1|ellp-"1';1"j,ji'-l
':1

lrl 1110.t
:9t:
:'i !!i'-I"t

:" l::f;:r9"

!!

-"
-"1'-!"1-- h
I !:e.ano
cllc$lrron wrlr snow ini, :,-"lT!'j-, ,P1!9-",'!!?
1i-'ll:y","--'l'l:':.,"1'X,,',1t'l'
ar
wrn
'3ciprng

T:r,:::lf:::"."9_.-:-"-":

Y"ll"!11 1' YT:' ,:i'y -"1-l..,"

lillLY9l c""rtl9l T9'l!-:-'-::1lPl--Y1:!lrf
:h.e9:i0j'!':i::. l":' .
lnd m's cln lead-lo
p:'ll, y1:1'-1i':
11 ?'l:11i'
to rnenourocan3r3ob
occurs.
Dam41'-'i.e,
"-

Mouldcoglingandgatjngsystoms

The commonesrlods ol g6tesars tho3

illusrarod in Fig. lq Garsh.vs rwo
mrin lundionr i ( 1) t6 p ro v i d .a n n try
iilo rhs mould cavity which.whn
dltlnll h.s &lidified lrd rhe runner
ryrlln i3 removod,will not lsavg 6n
usv sc.r on tle moulding.(2) lo provida
| .lstnction wh6.. th6 shsar.al ol tio
m!r..i!l i! ihcFasadiust Driorto its
To tulfill th6 fiBt crlt..ion, th. gte is
alwrF mlde !s sm.ll rs possiblebot
tn.l!13 rh.n th. problsmot whth.r to
i.crlls. ri. g!t. !iz! ii it i3 lolnd
difisll! ro fill !n. molld, !n tiis r63poci,
th. hnd llrgth of $e gat6 is ot paramoont
i|noorurca lor rho pr63surodrop i!
dir.ctly Dropomonllto rh6 gats ln9th.
Tho l.nd lengthor ths gats sholld
th.dlor. b! m!d6.r shon rs th. d.!io.
ol tha mouldlnd th..trangth ot lh6
r tarirla ot con3trlcrion will tllow tnd
!.n...lty !h! ir btw6.n 0 oil(l rnd 0O0
-,i
iac||'
Suning tlt!! for g6t6! crn b.
cllcr,lardby rcl.r6nc6 lo th. t'ro
gr.9hs, Fllt 17 lnd 18. The lorm6rrclgrr
to gre. whici consistol.ound hol.3 6nd
rlE l6t1or10 .lirs. (Not rhar r di.phralm
gat! cln b. thoughaol !s , slh ol lontth
. .1.)F.o,nrh. Errph ol viscoiiiict lnd .
$.!r rrtls in Fic. a
th. !PPfotrilt. .hlo| r!1.
lor dl. mala.lalir chos.n, Th6 mo!!d
lllli|tg marrnlm rrto, tilr r! tha mltimum
ini.ction rln tpaclti.}dlor rho m.clrin6by

aP'l re3

M!.y merhodr ot prolotypo t oting aie

mwt,ihbr..sdid ftoD;iipr. m.chini.cin $rt m.t!l (arlminium

o.
b,.3s)rhdueherecrrcdeposilion.
c.!r,.;
in :inclErurnhium
lrroylnd h.r!r r!fe.'

for cngin../in!
h iiirciion moutdins
ot
lpplic.rionsrhorr.rdy mdinrononc!
ot rhe
sirit weishtrno oime;sions
mourdins;
i! ot impon..ce.rhi. is bst

rpnying ro.rh. u3eor pory.srel!,

.poxrdc;andh.d orasreG.
In m.ny ot
thesonethodstho u'e or . srand!.d
borsterin wiich ro c6iryrhe mourd

th6 nourd leldi !;d snsu .s rhlr no

hot !pot! devsl;p ln it during opetation.
Mata;lar!lntnulctorercwlll supPlv
i.tormttion on tho tecomm.ndedmolld
rmparatlreand thsoshourdb6 cro3eiy
adh;cd to lor bss! resulri,

oivilion h.vo devroplda nedrod or

dakins larsemolrd! by ri. t!m6 tpr.yii?
technique.nd are p.e!,r.d ro sde
limiled guida.ce oi the lubject.
.ach m6thoddt protoQ/pinqias ir3
limiutions and il shouldslwavi b.

dimgisio;3andtheslpprvor coollit
irow
ba.dequ!t6to qivturburent
shourd
cord w.te, rrc; rhm;inssupprv
backto ! rftcklewi not give
rhronled
props!tenpe,6t,J.
contrcrs.d a ;ourd
is aiwavs
ionooraruricontrotter
Thrsc'rculate
coolsnr
fecommandd,

ers6,oneee:swh.t od6p.vs
evervthine
.or' P.odlcrronmolrdsor i,eh quar,ry
cainorb. che.p;.eithe:shourd0.6
erpcta chaproordes,gn.dtor makinq
a rew d6'n p.ororypdourdine.to
!r.nd up ro rnakr.oto,oo(ror 20,Cf,!
components
Howver.
bv tfe ex.rcise

s i ri er
th fo u hths cool i n!channelsad
h e 6 tsl to, cool si t to !he desi red
rlmierEturebetor re.circulstingil.
Bavingobtainadtn6 corecr conditions
rhv shouldrhnbe mainrainedtor ths
run.
d u fl i o n ol ths producti on
Th iubiect ol moLrdcoolifs ir d6art
with in the book: "lnjection rnd T.!nsf.r
Mo u l d i ng
6nd P l l stl caMol l d Osi gn'by
John Bownlnd J, D. 8obi63on,publishd
b y 8 u ! i n.!s B ook!l i mi ted!! f2@ ,

oi a l i tni ngenui ty
and by h iving. good
w orki ngknow l edge
ol l h6 p. oess. s. r h:
.9inerrnt.sstdi. p.od!ci.g a.rrclss
i . pl l sti cscan ohsn go ! lcng way
towads solvinghis oY/nprcblefts.

Slit widths

e
F
3

100

1000 .

10000

Sateof nn]U f il&E crh+sc.

t.u.

Fsht

bt tu rqw

t.rtt

d. I

f r f4A
r f15t R
R'Ra *",
U A) W *

&

&ra

^'ntr

{RfiA

J9

3rd'd r,tk

\2

T..r

2\2

!t)

(Dr rir,

,drr b{tr

o@ @ @ Go,<)

rqd

_EF-.8+

S{b'.

I.rrrdn

o(4oi.l

ffi@@,r
rru, |[rr,rL,tn'd dJ r,rkr nnn

E-C

-EF=
Conye/sron
ol raw malerialsinlo dillerentsleetshapes.
t udfod SrrrcsSroofCorp.fhe

<:/

Mal.ng,Shaping,6id Iloarg o, Stoet9th d. t3it, p.

Z)

Ttre rotthe

dt oetals.

16,7.re$

i :l -'i i

br:I
tr-rt{aEri.

o, U:. tarm. GdJi

H--*if
Mitt.

. .t M,i.qhn

i. . TFlia

mle rollt!.q

of Eetels.

\..

).

0)

l rc. r e

ld.(r or Ro ina nlrLlN.

Tl. \l'fn'.lru(hrol
phnh tt. rli.
,:h..F
(i) Fdx.rd
rtflclldl
dxnnr (.ld ellinr
{(n i.r.rlrar '. rnn.r!.Ir
rtrm,D..r i iot rnl.r f,.h.rl
I t r l . hos r t f ir iit ! . t ut i l r h r n r F . r $ l

COLUXNAR
cRY3t^l:|

. ,!lxE3

r-|RG olJI{.xTO
ctYslALS
0? riArx!3!

DUt to conrtFt
tro. r ,r

1l|. Crti.l Sruin

. . \ir6

.a. r,,

lnd

l, 8.ll fo4Fd lnr.t Pu.)

'I
3. Bl6r:.d It d.t.d dl6

t2. aau fo.E d (cond tut

!. Trih6qlG.fo!.Ithttq)

a. Ftnl.hfor$d In clo&ddl..

Int.rmldi.tr lttg.r In fotglngtwo dlll.r.nl prdt (a) H-!.crion. (b)

crrnkrhllr,lhala lnlahrdirta sl!9a! ua iinpodrnt for dialtibutingih! nstarial!nd
tillingth. di. csvitilt prop! y Cflnl.lhrftt rt. .l!o n!d. by clltlng proc.!!.,. aa
lhown In Flc, 5.39.

-f-I;(:z7
t.,-\
|

r"'-_-l..L::E)
\-:=-J

Wh..l blul .tu! int {o4in3

St!o.! in lho
hlnutactura ol r rrilroadwhaal,
Whoalarra rllo mrdt bYclrting, !a
lhown in Fis3.5.21(r)lnd (b).
Sourcr. Copyioht 1964by Unild
Slltr! StaalCorporstion.

\-.t

t --rr
wh{l .{t r hlllna
-F:*

/'r--T\

sE4-f-r;vZ

.)

Whol bl.nt dLt t..onil l.ldnt

EaLtn.l

Strndatdtrnnlnologylor
vlrious faltur.s of ! typicrl lorgiflg dla.

-\' l
.n ! b.lnl ?utch.tl

Wh..lbh

Whxl bl*t b.foo fo!tl!!

.nd Ini.n.l

U/hrl dtlr mln!

.hO rhsllr

r!

A OV ANTAGES ANO I I M I ' ATI O NS

Op.n-di. torgrng

Clos6d-di. torEing

O F CO M M O N

FOFGING PNOCESSES'

Compr6siv. iorces (produqed by h.nd

toors o. m.cn.nrcai hamd4) .r.
aDo/i.d rocalv rc hear.d m.!al srock:
Itnla or no lar.tl coniin.nad 6
invotv.d. Deln.d sh.o. k achi6v.d by
tsrnrng lnd or.lpularing wortpr*.
ComprBliv. torc8 (prcduc.d by.
nocharac.i h.dn.r in I h.cn.n'c!t or
hydrauricp..s) ar..pori.d ov.. rh.
.nfir. sudrc. ol h66r.d mlrlt srocr.
rorcr.g m.tal inro a di. caviq ot d.!n!d
3h.D.. Th.r.... !4.6t rtp.! ot
closd.di.lolg'ngr

Um[.d lo smplosh!o..:
quanrfi.r: wrd. rang.

urili:rtion ot dan.l:

trcd0ciio.

lo,.E.c.si dacntnriqlo
li.rl sh.p. n.c.sdry; slo'a-p6du*on tai f.hriv.ly
poorqrilizrrionol h.r.iri:
high drgr!! oi skillr.qun.d
Highroolcor lor smltl
q$ntni..; h.chining clrln

r.t.; good

Ut ringl!- rmpr.sion di.. .nd pioduc.s

F.n. wnh 3on.whrr 9.n.rrii2rd

M&hining ro lin.r th!p.

n.caaaary;thicl waba.nd

U$. pr.block.d ml*pim.

dulripr.-imtt.$|on di..

Son.wh.t high.r tooi co.t

.nd

Ulll mi.i um drdtt (oft.n 0'l

8.quir. innictt. rooling

.nd .l.born. Drovirion,ot
lrmovrn9 to.ling fro6 rool!

Sidillr ro uo$r torging.rc.pr m.rrl ir

Good.udrc.tn.ngri; H..d voluh. lnd !h.p.
cold,Wif! !o to lbour 1 in. in di.d.t.r
lihit d; int.m.l fl.rr..
h.y
L l.d ro dj. i. FsnchF.d. $d
b. l.t.t criticll !oi.n; dz.
porrion.d wrrhon. md Frotruding;
thir
.nd |nslh.ooht ooi !nd.. toE. ot punch
,nd i. torn.d brrwxn di. ..d lunch

l;

ti)(rRuSlaN.

Ftt. L Dit .t .ttnE on.

ng.2. I"dir.ct .x t'ion.

FA-1. lapad .xtrutioa.

Fit. t. tack\ad .xtt tio,r.

FE. 6. Forrth! o coDttord bf co,nbin A dir.ct ad bd.t rvd

Ftt. 5. H t-dtolht i..xt

d! 5{

tuti6.

vrcrxr^E FLU|0