Plastic Design - Sumsung-Design Guide For Assembly of Injection Molded Plastic Parts

Cheil Industries Inc.
Design for Assembly

Design Guide For Assembly of Injection Molded Plastic Parts
Assembly techniques
Improving both product quality and reducing manufacturing cost
¡ Press fit assembly
¡ Self fit assembly
¡ Mechanical Fastening techniques
¡ Welding techniques
¡ Adhesive bonding
¡ Solvent bonding
Cheil Industries Inc. R&D, Application Development Center 2 Last Updated SEP 15 1999
Press Fit Assembly
Simplest means of assembling plastic parts

- use Elastic or spring like characteristics of plastics
hub
shaft
Press Fit Assembly

Materials consideration
Tensile Ductile Large latitude

stress polymer for interference
Rigid Design Manufacturing

brittle
polymer
strain
may be < related
tolerance
0.0 1.0 2.0 3.0 4.0 5.0
Tensile strain (%)
Rigid polymers are too brittle for press fit applications.

Ductile polymers are more generous when considering the effects of manufacturing tolerance.
Press Fit Assembly

Interference for Press fit
0.008
Interference limits for nylon 66 hub I = [(σD•Ø s)/W]•[[(W + νh)/Eh] +[(1- ν s)/Es]]
Room temp.
0.006 where: I = diametrical interference (inch)
50 % RH
Interference Nylon 66 shaft
σD = design stress level (lbs/inch 2)
limit - I Ø o = hub outside diameter (inch)
m/m of shaft Ø 0.004 Ø s = shaft diameter (inch)
Eh = hub modulus (lbs/inch2)
Steel shaft
Es = shaft modulus (lbs/inch2)
0.002 νh = Poisson’s ratio for hub material
νs = Poisson’s ratio for shaft material
W = [1 + (Ø s / Ø o)2]/[1-(Ø s / Ø o)2]
0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Ratio of (Shaft diameter/Hub outside diameter)
Ø s/Ø o
The amount of interference for a press fit can be determined using design equations, or
graphs, indicating the maximum recommended interference for a particular material.
Press Fit Assembly

Use of undercut shaft for press fit hub/shaft assembly
Ø i < Ø s2 < Ø s1
Ø s1 I = Ø s2 - Ø i
Ø s2
Øi
Hub reaches
final axial location
Hub is pushed over high spot (long term)
on shaft during assembly
(short time only)
Press Fit Assembly

Shaft can be smooth, textured or even knurled
Press fit
smooth shaft
Øi Øs Rate of decrease determined

Slippage
by design stress level and
torque
relaxation characteristics of
Øi <Øs the hub material
Time
Press fit
knurled or splined shaft
Knurled, textured or splined

Slippage
surfaces can result in cold
torque
flow and some mechanical
interlocking
Time
Snap Fit Assembly

Snap Joint assembly
satisfy both Design for assembly and Design for disassembly
Lead-in
angle (α)
Insertion
R
∆R
Elastic recovery
Deflection
Simple & Most versatile means of plastic product assembly
Snap Fit Assembly

Snap Joint assembly
ε = maximum tensile strain
L
R d
y = 0.67 ε L2/d
y
Cantilever snap beam

constant rectangular cross section
d d/2
y = 1.1 ε L2/d
Tapered cantilever snap beam

decreasing depth from d to d/2
Permissible deflection for the tapered beam is about 60% greater

than that of the constant cross section of rectangular beam
Snap Fit Assembly

Snap Joint assembly
3.5
Applied Load
Stress concentration factor

Stress concentration 3.0 R
at the corner
T
+σ 2.5
Neutral
Deflection
axis
2.0
-σ
1.5
1.0
0 0.2 0.4 0.6 0.8 1.0 1.2 1.4
Radius/wall thickness (R/T)
Stress concentration factors show that larger radius values tend to reduce the stress concentration
and mold filling orientation related problems, however, excessive radii can lead to complications
due to sinks, voids, shrinkage stress.
Mechanical Fastening Techniques

Mechanical fastener - Screw
Screws provide a simple, fast, and effective method

of joining similar or dissimilar materials
¡Machine screws (I.e. nuts and bolts)
¡Machine screws with a threaded metal inserts

or molded threads
¡Self threading screws

Mechanical fastener - Screw
Machine screw and bolt Machine screw and insert Self threading screw and plastic boss
£Esthetic interruption on both top and £One smooth surface obtained £One smooth surface obtained
bottom surfaces £Fewer parts required for assembly £Minimum number of parts required for
£Many parts required for assembly £Internally threaded insert must be assembly
£Access to both top and bottom of the inserted into boss during or after £Mating plastic threads formed during
part is required during assembly molding assembly
£Need locking hardware to avoid £Requires special equipment/tooling for £Minimum fastener and equipment cost
vibration loosening insert £Limited durability (mating thread is
£Durable assembly £Good overall durability plastic)
£Suitable for repeated assembly £Repeated assembly possible but limited
Radial
Mechanical Fastening Techniques clearance
Self threading screw
Through
clearance
boss Minor screw Φ
Thread Major screw Φ Thread

depth depth (%)
Utilized
Blind
pilot
boss
Pilot hole Φ
The screw type, size, and the design of the boss system are dependent upon
¡ Screw pull out resistance

¡ Clamp load requirement and decay rate
¡ Repeated assembly requirements
¡ Torque retention and vibration resistance
¡ Hoop stresses for the boss assembly
¡ Assembly characteristics such as the strip to drive torque ratio

Failure
(destruction)
Recommended Yield torque:
tightening stripping...
torque
Prestress
Torque (clamping) Maximum
torque drive torque
(clamping starts)
Start
Drive
torque
Screw engagement (turns)
Typical torque vs. turns of engagement behavior for a self threading screw
being driven into a plastic boss

Shrinkage voids
Sink mark
Blind boss
Lb Lb
Through
boss Self
threading
screw
The core pins that are used to form the holes in blind bosses should
be extended as much as possible to core out excessive material.

Lb
Lb
Lt
Lt
Lb =length of hole in the blind boss Lt= length of hole in the through boss
The blind boss core pin length is reduced to minimize the molding problems
associated with long, cantilever core pins

Low strip/drive ratio Stripping torque

= 4:1 Failure
Stripping torque Maximum drive torque (destruction)
= 2:1 torque:
Maximum drive torque stripping...
Limited Failure Wide

separation (destruction) separation
torque: (reduces risk
stripping... of stripping)
Torque Torque Maximum
Maximum drive torque
drive torque (clamping starts)
(clamping starts)
Start Drive Start Drive
torque torque
Screw engagement (turns) Screw engagement (turns)
Torque-turn curve for a self threading screw showing poor strip/drive torque ratio (left)
and high strip/drive torque ratio (right).

Correct pilot hole diameter Oversized pilot hole diameterUndersized pilot hole diameter
High strip / drive ratio High strip / drive ratio High strip torque
and but but
high strip torque low strip torque low strip / drive ratio
Torque
Turns of engagement
The boss pilot hole diameter has a significant influence on both maximum drive torque and strip / drive
torque ratio. Low drive torque and high strip /drive torque ratios are most desirable as this limits the
potential for failure during the initial or subsequent assembly procedures.

•Polypropylene homopolymer Boss Screw

500 •#6 BT thread cutting screw tensile pulls out
•0.114 inch pilot hole diameter failure
(60% thread depth)
400
3.6 turns
engagement
Failure
load in 300
tension Boss 2.7 turns
Screw
(lbs) tensile engagement
pulls out
200 failure
100 Screw 1.8 turns

pulls out engagement
0
0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14
Boss wall thickness (inches)
Tensile screw pull out results for a type BT screw and a polypropylene boss.
Welding Techniques
Molecular diffusion and entanglement
Upper part
Weld
interface
Lower part
Welded thermoplastic parts Entangled polymer chains at the
weld interface
Molecular diffusion and entanglement must occur during welding. The molecular mobility
can be the result of solvent swelling or thermal energy
£Ultrasonic welding - High frequency vibration , intermolecular friction

£Vibration welding - surface friction and/or viscous dissipation
£Spin(rotational) welding - interfacial friction
£Hot tool welding - heat conduction
£Induction welding - heating by high frequency electromagnetic field
£Resistance welding - heat conduction by conductive wire
£Hot gas welding - use hot air or nitrogen
£Extrusion welding - use hot air or nitrogen
Welding Techniques
Ultrasonic Welding Air pressure
Pneumatic
cylinder High frequency Low frequency
electrical out Electrical electrical in
power
Ultrasonic welding process is commonly supply
used for the assembly of small to medium
size thermoplastic parts Converter
high frequency electrical signal in -
weld process variables include: high frequency (ultrasonic) mechanical
weld time vibration out
horn position
weld pressure Amplitude transformer
(booster horn)
Support and Ultrasonic sinusoidal

alignment fixture axial vibration
Plastic parts
to be welded Welding horn
Horn face amplitude

of vibration
Base plate
and frame
Welding Techniques
Ultrasonic Welding
u Poor but joint design

u Excessive weld time
Butt
u Excessive weld energy
joint u Exuding melt results
in a visual defect
Butt joint u Improved butt joint design

with energy u Reduced weld time
director u Reduced weld energy
u Exuding flash (visible)
Flash u Flash trap added

trap u Reduction in weld area
u Exuding melt does not
added
result in a visual defect
u Step joint design

Step u Improved shear resistance
joint u Exuding melt does not
result in a visual defect
u Assists in locating parts
Welding Techniques
Ultrasonic Welding
Typical energy director dimensions(millimeters)

Amorphous polymer Semi-crystalline polymer
Dim. Small part Large part Small part Large part
h h 0.3 - 0.4 0.5 - 0.6 0.5 - 0.7 0.1 - 1.0
θ 60o to 90o 90o
Welding Techniques
Ultrasonic Welding
Plastic part Insufficient spreading Excessive Optimum
before welding of energy director flow of melt weld
Lower part Lower part Lower part

Lower part
Energy
director
Surface textures opposite the energy
director can improve weld quality for
joint such as the butt joint
Textured
surface
Welding Techniques
Ultrasonic Welding
Butt joint energy director:

corner consideration
Incorrect energy director design:

concentration of weld material at corner
Improved design: Optional design:

surrounding energy director surrounding energy director
follows corner radius interrupted at corner
Welding Techniques
Ultrasonic Welding
General Guidelines on the Compatibility of Various Thermoplastics for Ultrasonic Assembly
Material Notation Complete compatibility Partial compatibility
ABS A A,B,D T
PC/ABS alloy B A,B,K D
Acetal C C ---
Acrylic D A,D B,E,J,K,T
Acrylic Multipolymer E E A,D,Q,T
Cellulosics F F ---
Fluoropolymer G G ---
Nylon H H ---
Polyphenylene oxide I I,Q D,K,T
Polyamide-imide J J ---
PC K B,K D,I,R
Polyester L L ---
Polyethylene M M ---
Polymethylpentane N N ---
Polyphenylene sulfide O O ---
PP P P ---
PS Q I,Q E,T
Polysulfone R R K
PVC S S ---
SAN T T A,D,E,I,Q
Welding Techniques
Vibration Welding
Standard butt joint Standard butt joint Butt joint modified

before welding after welding with flash traps
Grooves
for welding
tools Relative
horizontal
motion Joint with
Welding flash traps
Frequency: 120 to 240 Hz.
Amplitude: 0.030 - 0.160 inch flash
Single (0.8 - 4.0 mm)
plane
parting line
Pressure
Typical joint design for vibration welding:

the butt joint, and a butt joint modified with flash traps
Welding Techniques
Spin(rotational) Welding
Variable
speed
Clutch drive
and and brake
flywheel
Pneumatic
cylinder
Controls:
Ÿpressure
Drive head Ÿspeed
Ÿweld time
Ÿhold time
Driven
plastic part
Holding
fixture
Fixed
plastic part
Welding Techniques
Lower part fixed
Butt joint
Tongue and T & G joint

Scarf joint Shear joint
groove joint with traps
Basic joint configuration for the spin welding process

Welding Techniques
Temperature Displacement
Axial force
Temperature
Axial
displacement
Rotating
Softening part
temperature
Ambient
temperature Fixed
part
Time
Start
Phase 1 Phase 2 Phase 3 Phase 4
abrasion and initial melt steady state end rotation
external friction layer formed shearing and cooling
Typical temperature and axial displacement over the course of the spin welding cycle
Welding Techniques
Induction welding
Before After Before After

Flat to groove joint Tongue to groove joint
Before After Before After

Shear joint Step joint
Typical joint configuration for the induction welding

Welding Techniques
Hot tool welding
Step1. Parts placed in upper Step2. Electrically heated
Upper holding fixture (moving) and lower(fixed) welding platen is inserted
holding /alignment fixtures between parts
Plastic part
Plastic part
Lower holding fixture
Step3. Fixtures close and Step4. The fixtures open

bring parts in contact with and the heated platen
the heated platen is removed
Step5. The fixtures close Step6. The fixtures open

and pressure is applied and the welded assembly
to weld parts is removed
Welding Techniques
Hot gas welding
Hot dry, clean
air or inert gas
Welding
Force tool
Plastic welding
rod(same material)
Beveled
groove
Force
Travel
direction
Finished
weld
Plastic parts
to be welded
Adhesive Bonding
Advantages
¡ Esthetics and design flexibility
¡ Uniform stress distribution
¡ Can join dissimilar materials
¡ Can provide weather /water / gas tight seal
¡ Flexible adhesives, compliant in shear, can compensate for

thermal expansion mismatches between components
¡ Flexible adhesives can dampen vibration
¡ Can be used with thin, flexible substrates
¡ Provide electrical and thermal insulation
Adhesive Bonding
Adhesive theory
Adhesive is Adhesive wets Temporary Finished

applied (liquid) the surface fixturing part (solid)
The adhesive must:

•Wet the surfaces to be bonded (spreading and capillary action)
•Attract surfaces effectively (adhesive strength)
•Develop into a strong solid (cohesive strength)
Water
droplet Time Time
Non-polar surface Polar surface
Polar liquid on non-polar surface: Polar liquid on polar surface:

poor wetting, eater tends to bead up good wetting, water spreads over surface

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Cheil Industries Inc.

Design for Assembly

Improving both product quality and reducing manufacturing cost

¡ Press fit assembly

¡ Self fit assembly

¡ Mechanical Fastening techniques

Press Fit Assembly

Simplest means of assembling plastic parts

Press Fit Assembly

Tensile Ductile Large latitude

Rigid Design Manufacturing

0.0 1.0 2.0 3.0 4.0 5.0

Tensile strain (%)

Rigid polymers are too brittle for press fit applications.

Press Fit Assembly

Press Fit Assembly

Press Fit Assembly

Øi Øs Rate of decrease determined

Knurled, textured or splined

Snap Fit Assembly

Simple & Most versatile means of plastic product assembly

Snap Fit Assembly

Cantilever snap beam

Tapered cantilever snap beam

Permissible deflection for the tapered beam is about 60% greater

Snap Fit Assembly

Stress concentration factor

Radius/wall thickness (R/T)

Mechanical Fastening Techniques

Screws provide a simple, fast, and effective method

¡Machine screws (I.e. nuts and bolts)

¡Machine screws with a threaded metal inserts

¡Self threading screws

Mechanical Fastening Techniques

Self threading screw

Thread Major screw Φ Thread

¡ Screw pull out resistance

Mechanical Fastening Techniques

Screw engagement (turns)

Mechanical Fastening Techniques

Mechanical Fastening Techniques

Mechanical Fastening Techniques

Low strip/drive ratio Stripping torque

Limited Failure Wide

Screw engagement (turns) Screw engagement (turns)

Mechanical Fastening Techniques

Mechanical Fastening Techniques

•Polypropylene homopolymer Boss Screw

100 Screw 1.8 turns

£Ultrasonic welding - High frequency vibration , intermolecular friction

Support and Ultrasonic sinusoidal

Horn face amplitude

u Poor but joint design

Butt joint u Improved butt joint design

Flash u Flash trap added

u Step joint design

Typical energy director dimensions(millimeters)

Lower part Lower part Lower part

Butt joint energy director:

Incorrect energy director design:

Improved design: Optional design:

Standard butt joint Standard butt joint Butt joint modified