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making parts by compressing & sintering various metallic and nonmetallic powders into shape
Briquetting machines- used to compress the powders into shape Powder metallurgy is most applicable to the production of cylindrical, rectangular, or irregular shapes that do not have large variations in cross-sectional dimensions. Examples- splines, gear teeth, axial holes, counterbores, straight knurls, serrations, slots, keyseats
Gates location should be anticipated during design & located in the heaviest section of the part. Avoid gating into areas subject to high stress levels, fatigue, or impact.
Undercuts parts with undercuts should be avoided. Parts with external undercuts normally cannot be withdrawn from a one-piece mold
Assemblies continued
Press & Shrink Fits- inserts may be secured by a press fit or the plastic molding material may be assembled to a larger part by a shrink fit Heat Forming & Heat Sealing- most thermoplastics can be reformed by the application of heat & pressure Mechanical Fastening- molded parts must have sufficient strength to withstand stresses encountered with fasteners Rivets- conventional rivets can be used with plastics Boss Caps- a boss cap is a cup-shaped metal ring that is pressed onto the boss. It is designed to reinforce the boss against the expansion force exerted by tapping screws
Assemblies continued
Adhesive bonding-adhesives permit a strong, durable fastening Ultrasonic bonding- parts transmit ultrasonic vibration to small, hidden bonding areas, resulting in fast, perfect welds Ultrasonic Staking a stud molded into the plastic part protrudes through a hole in the metal part. The surface of the stud is vibrated with a horn having high amplitude and relatively small contact area. The vibration causes the stud to melt and re-form into the configuration of the horn tip
Assemblies continued
Friction or Spin welding-the faces to be joined are pressed together while one part is spun & the other is held fixed. Frictional heat produces a molten zone that becomes a weld when spinning stops
Drawings
1. Can the part be removed from the mold? 2. Is the location of the flash line consistent with design requirements? 3. Is the section thickness consistent? 4. Has the material been correctly specified? 5. More on page 386