Apr 16, 2017 elites highly skilled engineering department is able to utilize design for manufacturing knowledge to ensure high quality automotive plastic parts. Since plastics shrink when cooled, it is common for parts to shrink or grip tightly to cores. Despite the design process of a plastic component is complex, this article shows simple techniques used in companies specialized in thermoplastic material manufacturing, for example ge plastics, bayer and plastic transformation companies, in the case the suppliers of auto parts. Often people who know a little about plastics tend to think primarily of injection molded parts, but many molding processes are available beyond just injection molding. It can be difficult to tell the difference between them while preparing to refinish or repair a vehicle. Design considerations draft plastic parts are always designed with a taper or draft in the direction of mold movement to allow part ejection or removal from the mold. Lay the sheet plastic on top of the original piece, lining up the traced pencil line with the part s outline. In this paper, a part of the project which aims to develop a computer aided methodology for developingdesigning of the plastic fuel tanks based on static and dynamic analysis is presented. In addition to protecting sensing systems from the damaging effects of emi, housings made from these compounds are significantly lighter than their metal counterparts, thereby reducing overall vehicle. Since the plastic shrinks as it cools during the molding process the part adheres to the mold surface. The prototyping phase was eliminated from the design. Dec 30, 2017 automotive interior plastic design course we challenge to students no one institute in pune can give same knowledge in plastic design as robspot as per industries stranded. When plastics and metals are used together and are exposed to the same temperatures, plastic parts become larger than metals. This course begins with an overview of the entire interior and then moves into focusing on the injected molded parts.
When designing plastic parts, your team should consist of diverse players, including conceptual designers, stylists, design. The instructor provides a detailed explanation of automotive design process, right from the. Plastic automotive component market 2015 yano research. Design flexibility, corrosion resistance, and favorable mechanical properties make polymer composites a logical choice for upholstery and interior surfaces. Plastic design mechanical engineering professionals. In addition, they permit attractive designs for both the interior and.
When designing plastic components for the automotive, there are many things that need to be considered to ensure a part that is both functional and manufacturable. Automotive design optimizing the flow of fuel and air into the engine, turbocharging, supercharging and increasing engine speeds are all potential methods to improve fuel efficiency. Finally, it characterizes the producers of plastic parts that will be affected by the neshap. Encourage modular design design for a base part to locate other components. Heat the sheet plastic only until it starts to change shape. Thermoplastic compounds for automotive applications. Plastics versatility allows for advanced shapes and forms without compromising the safety, comfort or stability of a car. The principal reasoning behind the list is to increase the overall quality of a plastic product. Kim 3 materials solid materials metals ceramics plastics thermoplastics thermosetts elastomers plastic. With our expertise we can guarantee a quality mold built to fit your needs in the fastest possible lead time. Ive used it for several years in design engineering and it is one of my goto texts. Nov 11, 2017 apdi will be a unique occasion to cover automotive plastic design cycle, material selection, design calculations, manufacturing and the assembly methods required when designing with plastics in. Since plastics shrink when cooled, it is common for parts. A checklist is intended for designers to be used as a support in identifying and eliminating possible pitfalls and shortcomings in a part design.
I also searched for other design books and nothing compares. Apply to mechanical designer, interior designer, design engineer and more. Embracing design modification is not just a fact of life, its a potentially a huge advantage. Greater use of plastics is vital to produce ever more energy efficient cars. Plastics have increasingly become the premier material of choice in the automotive sector, leading to enhancements in safety, performance, and fuel efficiency.
Summary of highestpriority research and development needed to enhance future automotive safety with plastics akshat patil et. A screw driven into a boss of the plastic base secures the two components. Injection molding offers high repeatability and good design. As a result, automakers continue to innovate on design. Mechanical engineering professionals, llc has extensive experience in plastics and plastic design. All types of snap joints have in common the principle that a protruding part. Automotive plastic part design seminar assembly magazine. When designing moldedin threads, avoid feathered edges and include radiused roots in order to minimize stress concentrations p and to keep the walls uniform. Eboth mating parts elastic fsymbols contents page 2 of 26 snapfit joints for plastics a design guide. Mold draft tapered walls is required to demold the formed part. Plastic design guidelines for automotive components.
As engine speeds or torque increases and component sections decrease, fatigue from rotational and vibrational stresses become an increasing concern during design. Overview plastics is key to future of lightweighting in automotive hen the u. Cole, chair, society of plastic engineers, international recycling division, describes the likely developments on the federal regulatory and legislative front that will influence the future of automotive plastics use and disposition 26 pages. The complete part design handbook carl hanser verlag. Injection molding is so popular, because of the dramatically low cost per unit when manufacturing high volumes. How the molten plastic enters, fills, and cools within the cavity to form the part largely drives what form the features in that part must take. Rtp company provides readytomold plastic compounds with emi shielding properties that are ideal for the housings of automotive sensing systems. A quick guide to determine what type of automotive plastic youre working with. Marelli automotive lighting designs, develops and integrates a wide and complete range of top notch solutions for external automotive lighting systems, as well as innovative sensors to support future adasad features including lidarsensor technology. Common features snap joints are a very simple, economical and rapid way of joining two different components. Automotive plastics play key role as automakers seek to build fuelefficient vehicles lightweight, durable plastics enable automakers to achieve environmental goalswithout compromising the advanced safety and design features todays consumers look for in their vehicles. Plastic design guidelines for automotive components free download as pdf file.
Pdf computer aided engineering can be applied to polymer industry in. Functional design factors relate to production and. Reaching the objectives of the plastic failure analysis, namely, the determination of the mode and cause of the failure, or expressed alternatively, evaluating how the part failed and why it failed, requires a scienti. Solidworks in depth effective plastic part design duration. In a joint project, the companies fehrer automotive and senco. Injection molding is the most versatile of the plastic processing techniques being very widely. Automotive plastics market size, share and statistics. Replacing metal parts with plastic is rarely a onetoone process. Apply heat until the plastic starts to develop the desired contour or curve. Automotive parts best practices ship engines, motors, transmissions, and chassis.
Freedom of design plastics have replaced glass in the headlights of the mercedes benz s class, allowing greater design freedom as well as offering a clear, easytofit, scratchresistant and strong alternative. When designing in plastics, applying radii or chamfers to sharp corners is of key importance for a parts manufacturability, dimensional accuracy and loadcarrying. Figure 21 illustrates the productive activity of surface coating plastic parts. Keywords friction welding hotplate welding plastic part design snapfit assembly ultrasonic welding.
Design calculations, empirical approach, guidelines. Truecadd remains fully operational amidst the covid19 challenges. Application of dfmea in metal to plastic replacements in. The use of plastics in automobiles has continued to grow over the past 20 years. Methodology of plastic parts development in the automotive. Automotive plastic parts design, recycling, research, and. Technological innovations mean lighter, thinner yet stronger plastics. The interior trim of an automobile consists of many different types of parts ranging from seating to plastic parts. When designing plastic components, success will depend on one prime factor. In these joints, a plastic or metal component is assembled onto a plastic base. The higher usage pattern of plastic can be easily attributed to its strength, light weight and low cost for reproduction.
Automotive oil filter snaps cordless screw driver housing, cantilever snapfit part ii. The essentials of better plastic part design youtube. Thermoforming design guidelines universal plastics. The primary reason for this is that they help to reduce vehicle mass. Plastics processing plastics can be machined, cast, formed, and joined with relative ease requiring little postprocessing or surfacefinish operations plastics melt or cure at relative low temperatures plastics require less energy to process than metals raw materials most commonly are pellets, powders. A lighter car consumes less fuel, which also translates into less exhaust emissions. Astms plastics standards are instrumental in specifying, testing, and assessing the physical, mechanical, and chemical properties of a wide variety of materials and products that are made of plastic. Significant cost savings and development time were realized by using a thermoset composite material in place of magnesium. This guide defines the two major categories of plastic, provides ways to. Plastic part design for injection molding hanser publications. Automotive interior trim training courses for automotive.
This article gave a short introduction to typical automotive plastic parts recycling in developed. Lifecycleassessmentofpolymersinanautomotiveassiststep. Threads plastic threads used for joining parts can be machined or moldedin. Manufacturing procedures of automotive parts made of polymeric materials plastics industry is very important in supporting the automotive. The top countries of suppliers are india, china, and taiwan, china, from which the percentage of automotive plastic parts supply is 1%, 99%, and 1% respectively.
Plastics recycling in the automotive industry plasticstoday. Design parts with a minimum of per side draft in order to accommodate easier ejection from the mold. A boss is a sleevelike projection, molded into the plastic base material. Almost every plastic part around you was manufactured using injection molding. Plastic design guidelines for automotive components casting.
A wide variety of automotive plastic parts options are available to you, there are 8,087 suppliers who sells automotive plastic parts on, mainly located in asia. Alibaba manufacturer directory suppliers, manufacturers. Plastics versatility allow innovative shapes, design, styling and forms visavis metals. Consumers demand surfaces with a highquality look and feel. A straight pull mold is designed so that when the two halves a side and b side of the mold separate from each other, there is no plastic. This video is a webinar on the topic plastic design for automotive applications using catia. Use a heat gun, set on high, to soften the plastic. Automotive and mechanical parts packaging guidelines and. It is projected to expand at a revenuebased cagr of 11. System solutions based on plastics reduce vehicle weight in the automobile industry and increase safety. This information can only be provided by raw materials suppliers, specialist plastics product designers and plastics processors but there is a need to get the basics of the product design right in the first. There definitely are a lot of challenges and issues for the supply base, schuster said.
When designing plastic parts, your team should consist of diverse players, including conceptual designers, stylists, design engineers. A straight pull mold is designed so that when the two halves a side and b side of the mold separate from each other, there is no plastic blocking the path of the metal in the direction of the pull. Automotive interior and plastic component design courses. Fundamental and common to all plastic part design guidelines is the plea that the designer should maintain a constant wall thickness throughout a plastic part that is to be injection molded. Basf plastics is a fully integrated, global supplier of. Automotive continues to be a key end market for plastics processors of all types for underthehood, body and interior applications. These internal mold actions are usually in locations where proper cooling is paramount for the dimensional stability andor function of the plastic part. For easier mold filling and better part tolerances, avoid design ing parts. With the sophisticated plastic part design levels demanded from todays. Automotive and mechanical parts packaging guidelines and designs. This three day indepth automotive seminar will provide information on material selection, design procedures, processing techniques, and the assembly methods required when designing with plastics in the automotive field. Design consideration for plastic part design and its. In automotive design, plastics have contributed to a multitude of innovations in safety, performance and fuel efficiency major markets.
The following is a basic guideline that can be utilized, but some rules can be cheated if needed. Oems have turned to plastics to cut vehicle weight while also reducing cost and improving safety, performance, and fuel efficiency. Injection mold slides coolant channels are typically difficult to install in slides and moving members of molds. Trantina, design with plastics, materials selection and design, volume 20, asm handbook, asm international, 1997, pages 639 to 647 the key to any successful part development is the proper choice of material, process, and design matched to the part. In automotive engineering, plastics are increasingly becoming the dominant. Designing to plastic s strengths opens opportunities for possible integration of functions, simplification, costefficiency and innovative design. Concept to finished part design process like a successful play in football, successful plastic product design and production requires team effort and a welldeveloped strategy. In addition, plastic parts are not prone to corrosion, offer flexibility and resilience for added safety, have very good thermal insulation, reduce noise and. Straight pull design parts that qualify for rapid injection molding must be designed as straightpull parts. A part made with a straightpull mold is designed such that when the two halves of the mold pull straight away from each other, there is no mold metal that wants to pass through the part plastic. A thermoplastic resin cannot replace the steel in automotive discdrum brake.
Part design guidelines for injection molded thermoplastics. Detailed plastic product design will always require detailed knowledge of the application, the processing method and the selected plastic. Plastics leading car design 3 because plastics are also champions of source reduction using less to do more their use in car design helps minimise environmental impact and save resources. Adhering to some basic rules of injection molded part design. Engineering training services automotive plastic part design. Its content is intended for a variety of automotive segments such as interior systems, telematics, powertrain, safety systems, chassis, exterior trim, front end modules, crash management, electronics, and any other automotive and transportation applications which use plastic. Whether we are designing or producing safe tools or plastic and metal technical parts, we always take into account the customers specifications, applicable legal regulations and standards, and also keep an eye on the sustainability of our actions and prevention of environmental impact. An overview of polymeric materials for automotive applications. On the one hand, injectionmoulded plastic parts offer more design flexibility.