Rotheiser Joining of Plastics
1. Auflage 2015
ISBN: 978-3-446-44595-6
Verlag: Carl Hanser
Format: PDF
Kopierschutz: 1 - PDF Watermark
Handbook for Designers and Engineers
E-Book, Englisch, 626 Seiten
ISBN: 978-3-446-44595-6
Verlag: Carl Hanser
Format: PDF
Kopierschutz: 1 - PDF Watermark
The third edition of this comprehensive handbook emphasizes the relationship between the assembly methods, the materials, and the plastics manufacturing processes, thus enabling the reader to identify the best design/assembly method for a given application. The book has been completely updated and a new chapter on laser welding of plastics was added.
All principal fastening and joining methods used to assemble plastic parts today are described with their particular advantages and disadvantages. Assembly method limitations for a given material and/or a given molding process are discussed in great detail. This is very much a "how-to" book, offering a wealth of hard-to-find detailed information.
Contents:
- Rapid Guidelines for Assembly of Plastics and Efficient Use of the Handbook
- Designing for Efficient Assembly
- Cost Reduction in Assembly
- Design for Disassembly and Recycling
- Assembly Method Selection by Material
- Assembly Method Selection by Process
- Adhesive and Solvent Joining
- Fasteners and Inserts
- Hinges
- Hot Plates/Hot Die/Fusion and Hot Wire/Resistance Welding
- Hot Gas Welding
- Induction/Electromagnetic Welding
- Insert and Multi-Part Welding
- Press Fits/Force Fits/Interference Fits/Shrink Fits
- Snap Fits
- Spin Welding
- Staking/Swaging/Peening/Cold Heading/Cold Forming
- Threads: Tapped and Molded-In
- Ultrasonic Welding
- Vibration Welding
- Laser Welding
Autoren/Hrsg.
Fachgebiete
Weitere Infos & Material
1;Dedication;6
2;Foreword;8
3;Preface;10
4;Acknowledgments;12
5;Contents;14
6;Introduction;29
7;1 Rapid Guidelinesfor Joining of Plastics and Efficient Use of This Handbook;34
7.1;1.1 Efficient Use of ThisHandbook;34
7.2;1.2 Rapid Guidelines for Assembly of Plastics;35
7.2.1;1.2.1 Adhesives (Chapter7);35
7.2.1.1;1.2.1.1 Liquids: Solvent-Based, Water-Based, and Anaerobic Adhesives;35
7.2.1.2;1.2.1.2 Mastics;36
7.2.1.3;1.2.1.3 Hot Melts;36
7.2.1.4;1.2.1.4 Pressure-Sensitive Adhesives;36
7.2.2;1.2.2 Fasteners and Inserts (Chapter8);36
7.2.3;1.2.3 Hinges (Chapter 9);37
7.2.4;1.2.4 Hot Plate/Hot Die/Fusion and Hot Wire/Resistance Welding (Chapter10);37
7.2.5;1.2.5 Hot Gas Welding (Chapter11);38
7.2.6;1.2.6 Induction Welding (Chapter12);38
7.2.7;1.2.7 Insert Molding (Chapter13);38
7.2.8;1.2.8 Multipart Molding (Chapter 13);39
7.2.9;1.2.9 Press Fits/Force Fits/Interference Fits/Shrink Fits (Chapter14);39
7.2.10;1.2.10 Solvent Joining (Chapter7);39
7.2.11;1.2.11 Snap Fits (Chapter15);40
7.2.12;1.2.12 Spin Welding (Chapter16);40
7.2.13;1.2.13 Staking/Swaging/Peening/ColdHeading/Cold Forming (Chapter17);40
7.2.14;1.2.14 Threads–Molded in (Chapter18);41
7.2.15;1.2.15 Threads–Tapped (Chapter18);41
7.2.16;1.2.16 Ultrasonic Welding (Chapter19);41
7.2.17;1.2.17 Vibration Welding (Chapter20);42
7.2.18;1.2.18 Welding with Lasers (Chapter21);42
7.3;1.3 Assembly Methods Selection by Size;42
7.4;1.4 Assembly Methods Selection by Joining Time;44
8;2 Designing for Efficient Assembly;45
8.1;2.1 Avoiding Part Distortion;45
8.2;2.2 Inside Corner Stress;46
8.3;2.3 Ribsand Bosses;47
8.4;2.4 Draft;48
8.5;2.5 Shrinkage;50
8.6;2.6 Fitments;52
8.6.1;2.6.1 Drawing Conventionsfor Plastic Assembly;52
8.6.2;2.6.2 Importance of Tolerancingfor Assembly;54
8.6.3;2.6.3 Special Drafting Practices for Plastics;55
8.6.4;2.6.4 Procedurefor Establishing Tolerances;59
8.7;2.7 Design Practices for Looser Tolerances in Plastics;60
8.7.1;2.7.1 Three-Point Location;61
8.7.2;2.7.2 Hollow Bosses;61
8.7.3;2.7.3 Crush Ribs;63
8.7.4;2.7.4 Flexible Ribs;64
8.7.5;2.7.5 Inside/Outside Fitments;65
8.7.6;2.7.6 Step Fitments;65
8.8;2.8 More Relaxed Tolerances for Large Parts;66
8.8.1;2.8.1 Drillin Place;66
8.8.2;2.8.2 Oversize Hole with Washer;66
8.8.3;2.8.3 Criss Cross Slots;66
8.8.4;2.8.4 Separation of Functions;67
8.8.5;2.8.5 Corner Clearance;67
8.9;2.9 Semidovetail Joint;68
8.10;2.10 Minimizing the Effect of Misalignment on Appearance;69
8.11;2.11 The Plastic Product Design for Assembly Checklist;69
8.12;2.12 Testing;69
9;3 Cost Reduction In Assembly;73
9.1;3.1 Introduction;73
9.2;3.2 The Micro Approach to Part Reduction;73
9.2.1;3.2.1 Combining Parts Through Materials;74
9.2.2;3.2.2 Combining Parts Through Processes;75
9.3;3.3 The Macro Approach to Part Reduction;76
9.3.1;3.3.1 Multiple Material Processing;80
9.3.2;3.3.2 Coextrusion;81
9.3.3;3.3.3 Coinjection Molding;82
9.3.4;3.3.4 Multipart or Two-Color Injection Molding;82
9.4;3.4 Elimination of Fasteners;82
9.4.1;3.4.1 Multiple Parts per Fastener;83
9.4.2;3.4.2 Press and Snap Fits;83
9.4.3;3.4.3 Integral Hinges;84
9.4.4;3.4.4 Combining Fastener Elimination Concepts;84
9.5;3.5 Holistic Design;86
9.5.1;3.5.1 The Overall Design Considerations;86
9.5.2;3.5.2 The Thread Design;87
9.5.3;3.5.3 The Processing Considerations;88
9.5.4;3.5.4 The Tooling Considerations;88
9.5.5;3.5.5 Execution;89
9.5.6;3.5.6 Toward Holistic Design;89
10;4 Design for Disassembly and Recycling;91
10.1;4.1 Introduction;91
10.2;4.2 Design for Disassembly;92
10.2.1;4.2.1 Reopenable Assemblies;92
10.2.2;4.2.2 Permanent Assemblies;96
10.3;4.3 Design for Recycling;97
10.3.1;4.3.1 Simplification;98
10.3.2;4.3.2 Assembly Method Selection;98
10.3.2.1;4.3.2.1 Reopenable Methods;98
10.3.2.2;4.3.2.2 Permanent Methods;99
10.3.3;4.3.3 Material Selection;99
10.3.4;4.3.4 Additives;100
10.3.5;4.3.5 Contaminants;101
10.3.6;4.3.6 Material Reduction;101
10.3.7;4.3.7 Identification and Disassembly Instructions;103
11;5 Assembly Method Selection by Material;104
11.1;5.1 Thermoplastics Versus Thermosets;104
11.2;5.2 Amorphous Versus Semicrystalline Thermoplastics;105
11.2.1;5.2.1 Postmolding Shrinkage;106
11.2.2;5.2.2 Coefficient of Linear Thermal Expansion;106
11.2.3;5.2.3 Weldability;107
11.2.4;5.2.4 Solvent Sealability;107
11.3;5.3 Thermosets;107
11.4;5.4 Assembly Method by Material;108
11.4.1;5.4.1 Properties and Assembly-Related Data for Selected Materials;114
11.4.2;5.4.2 Adhesives;147
11.4.3;5.4.3 Using the SPI Tables;147
11.5;5.5 Material Databases;189
11.6;5.6 Material Suppliers;189
12;6 Assembly Method Selection by Process;191
12.1;6.1 Introduction;191
12.2;6.2 Blow Molding;191
12.2.1;6.2.1 The Process;191
12.2.2;6.2.2 Assembly Considerations;192
12.3;6.3 Casting, Potting, Encapsulation, and Embedment;193
12.3.1;6.3.1 The Processes;193
12.3.2;6.3.2 Assembly Considerations;194
12.4;6.4 Coextrusion;194
12.5;6.5 Co-Injection Molding;194
12.6;6.6 Cold Press Molding;194
12.6.1;6.6.1 The Process;194
12.6.2;6.6.2 Assembly Considerations;195
12.7;6.7 Compression Molding;195
12.7.1;6.7.1 The Process;195
12.7.2;6.7.2 BMC: Bulk Molding Compound;196
12.7.3;6.7.3 SMC: Sheet Molding Compound;196
12.7.4;6.7.4 Assembly Considerations;196
12.8;6.8 Extrusion;197
12.8.1;6.8.1 The Process;197
12.8.2;6.8.2 Coextrusion;198
12.8.3;6.8.3 Assembly Considerations;199
12.9;6.9 Filament Winding;200
12.9.1;6.9.1 The Process;200
12.9.2;6.9.2 Assembly Considerations;201
12.10;6.10 Gas-Assisted Injection Molding;201
12.11;6.11 Gas Counter Pressure Structural Foam Molding;201
12.12;6.12 Injection Molding;201
12.12.1;6.12.1The Process;201
12.12.2;6.12.2 Assembly Considerations;202
12.13;6.13 Lay-up and Spray-up;203
12.13.1;6.13.1 The Processes;203
12.13.2;6.13.2 Assembly Considerations;203
12.14;6.14 Machining;204
12.14.1;6.14.1 The Process;204
12.14.2;6.14.2 Thermoplastics;205
12.14.3;6.14.3 Thermosets;205
12.14.4;6.14.4 Assembly Considerations;206
12.15;6.15 Pultrusion;206
12.15.1;6.15.1The Process;206
12.15.2;6.15.2 Assembly Considerations;207
12.16;6.16 Reaction Injection Molding (RIM);207
12.16.1;6.16.1 The Process;207
12.16.2;6.16.2 Assembly Considerations;208
12.17;6.17 Resin Transfer Molding (RTM);209
12.17.1;6.17.1 The Process;209
12.17.2;6.17.2 Assembly Considerations;210
12.18;6.18 Rotational Molding;210
12.18.1;6.18.1 The Process;210
12.18.2;6.18.2 Assembly Considerations;212
12.19;6.19 Structural Foam Molding, Gas Counterpressure Structural Foam Molding, and Coinjection Molding;213
12.19.1;6.19.1 The Processes;213
12.19.2;6.19.2 Assembly Considerations;214
12.20;6.20 Thermoforming;216
12.20.1;6.20.1 The Processes;216
12.20.2;6.20.2 Thin-Gauge Thermoforming;217
12.20.3;6.20.3 Heavy-Gauge Thermoforming;217
12.20.4;6.20.4 Pressure Thermoforming;218
12.20.5;6.20.5 Other Forming Processes;218
12.20.6;6.20.6 Assembly Considerations;218
12.21;6.21 Twin-Sheet Thermoforming;219
12.21.1;6.21.1 The Process;219
12.21.2;6.21.2 Assembly Considerations;220
12.22;6.22 Transfer Molding;220
12.22.1;6.22.1 The Process;220
12.22.2;6.22.2 Assembly Considerations;221
12.23;6.23 Process Selection;221
12.23.1;6.23.1 Thermoplastic Open Shapes;223
12.23.2;6.23.2 Thermoset Open Shapes;224
12.23.3;6.23.3 Hollow Parts;225
12.23.4;6.23.4 Profiles;225
12.23.5;6.23.5 Ultra High Strength;226
13;7 Adhesive and Solven tJoining;227
13.1;7.1 Advantages and Disadvantages;227
13.1.1;7.1.1 Advantages;227
13.1.2;7.1.2 Disadvantages;229
13.2;7.2 Basic Theory and Terminology;230
13.3;7.3 Methods for Measuring the Wettability of a Plastic Surface;232
13.3.1;7.3.1 Contact Angle Test;232
13.3.2;7.3.2 Wetting Tension Test (ASTMD-2578-73, Wetting Tension of Polyethylene and Polypropylene Films);232
13.3.3;7.3.3 Adhesion Ratio Test (Tentative ASTM D-2141-63R);233
13.3.4;7.3.4 Water Spreading Test;233
13.3.5;7.3.5 Dye Stain Test;233
13.3.6;7.3.6 Ink Retention Test;233
13.4;7.4 Surface Treatments;234
13.4.1;7.4.1 Solvent Cleaning;235
13.4.1.1;7.4.1.1 Solvent Immersion;236
13.4.1.2;7.4.1.2 Solvent Wiping;236
13.4.1.3;7.4.1.3 Solvent Spray;236
13.4.1.4;7.4.1.4 Vapor Degreasing;236
13.4.1.5;7.4.1.5 Ultrasonic Vapor Degreasing;236
13.4.1.6;7.4.1.6 Ultrasonic Cleaning with Liquid Rinse;236
13.4.2;7.4.2 Abrasive Methods;236
13.4.2.1;7.4.2.1 Dry Abrasion;237
13.4.2.2;7.4.2.2 Dry Abrasive Blast;237
13.4.2.3;7.4.2.3 Wet Abrasive Blast;237
13.4.2.4;7.4.2.4 Wet Abrasive Scour;238
13.4.2.5;7.4.2.5 Detergent Scrub;238
13.4.3;7.4.3 Surface Energy Treatments and Process Selection Factors;238
13.4.3.1;7.4.3.1 Chemical Treatment;238
13.4.3.2;7.4.3.2 Corona Treatment;238
13.4.3.3;7.4.3.3 Plasma Treatment;240
13.4.3.4;7.4.3.4 Flame Treatment;240
13.4.3.5;7.4.3.5 Process Selection Factors;241
13.4.4;7.4.4 Shelf Life of Surface Treatments;241
13.5;7.5 Design for Adhesion;241
13.5.1;7.5.1 Shear Stress;242
13.5.2;7.5.2 TensileStress;242
13.5.3;7.5.3 Cleavage;242
13.5.4;7.5.4 Peel;243
13.5.5;7.5.5 Adhesive Joint Designs;243
13.5.5.1;7.5.5.1 Load-Bearing or Non-Load-Bearing Joints;243
13.5.5.2;7.5.5.2 Lap Joints;244
13.5.5.3;7.5.5.3 Butt Joints;249
13.5.5.4;7.5.5.4 Screw and Glue;252
13.6;7.6 Adhesives;252
13.6.1;7.6.1 Acrylics;259
13.6.2;7.6.2 Anaerobics;259
13.6.3;7.6.3 Cyanoacrylates;260
13.6.4;7.6.4 Epoxies;260
13.6.5;7.6.5 Hot Melts;261
13.6.6;7.6.6 Phenolics;261
13.6.7;7.6.7 Polyurethanes;262
13.6.8;7.6.8 Polysulfides;262
13.6.9;7.6.9 Pressure-Sensitive Adhesives;262
13.6.10;7.6.10 Silicones;263
13.6.11;7.6.11 Solvent-Based Adhesives;263
13.6.12;7.6.12 Water-Based Adhesives;263
13.7;7.7 Solvents;264
13.8;7.8 Adhesive and Solvent Assembly Techniques;266
13.8.1;7.8.1 Fixturing;266
13.8.2;7.8.2 Clamping;267
13.8.3;7.8.3Application Methods;268
13.8.3.1;7.8.3.1CapillaryMethod;268
13.8.3.2;7.8.3.2Dip or Soak Method;269
13.9;7.9 Adhesive and Solvent System Selection;270
13.10;7.10 Glossary;272
13.11;7.11 Sources;274
14;8 Fasteners and Inserts;277
14.1;8.1 Advantages and Disadvantages;277
14.1.1;8.1.1Advantages of Using Fasteners;277
14.1.2;8.1.2 Disadvantages of Using Fasteners;277
14.2;8.2 Basic Design Considerations for Fasteners;279
14.2.1;8.2.1 Creep Effects;279
14.2.2;8.2.2 Stress Relaxation Effects;280
14.2.3;8.2.3 Notch Sensitivity;280
14.2.4;8.2.4 Craze Resistance;281
14.2.5;8.2.5 Stiffness Considerations;282
14.2.6;8.2.6 Differentials in the Coefficients of Linear Thermal Expansion;282
14.2.7;8.2.7Loss of Properties Due to Moisture;283
14.2.8;8.2.8 Clamp Load;283
14.2.8.1;8.2.8.1 Strain Method;283
14.2.8.2;8.2.8.2 Torque Method;284
14.2.9;8.2.9 Vibration Resistance;285
14.3;8.3 Methods of Using Fasteners with Plastics;285
14.3.1;8.3.1 Press-in Fasteners;286
14.3.2;8.3.2 Self-Tapping Screws;287
14.3.2.1;8.3.2.1Strength of PlasticThreads;287
14.3.2.2;8.3.2.2Thread-Forming andThread-CuttingScrews;289
14.3.3;8.3.3 Special Screwsfor Plastics;292
14.3.3.1;8.3.3.1NarrowThread Forms;292
14.3.3.2;8.3.3.2AlternatingThreadHeights;292
14.3.3.3;8.3.3.3Asymmetrical Thread Forms;292
14.4;8.4 Selection of Self-Tapping Screws;292
14.4.1;8.4.1 Cost Criteria;293
14.4.2;8.4.2 Fail/Drive Ratio and Differential;293
14.4.3;8.4.3 Strength Criteria;294
14.4.4;8.4.4 Thread Cutting or Thread Forming;295
14.4.5;8.4.5 Tapped or Molded-in Threads;295
14.5;8.5 Threaded Inserts: Advantages;296
14.6;8.6 Boss Cap;297
14.7;8.7 Helical Coil Inserts;297
14.8;8.8 Self-Tapping Inserts;298
14.9;8.9 Press-in Inserts;298
14.10;8.10 Glue-in Inserts;299
14.11;8.11 Expansion Inserts;299
14.12;8.12 Molded-in Inserts;300
14.13;8.13 Ultrasonic Inserts;300
14.14;8.14 Heat-Installed Inserts;303
14.15;8.15 Induction Inserts;304
14.16;8.16 Hermetic Seals;305
14.17;8.17 Studs;305
14.18;8.18 Insert Design Considerations;306
14.19;8.19 Uor J-Clips;306
14.20;8.20 Tee Nuts;307
14.21;8.21 Machine Screws;307
14.22;8.22 Tapping and Stud Plates;309
14.23;8.23 Plastic Screws;309
14.24;8.24 Screw Heads and Washers;310
14.25;8.25 Boss Designs;310
14.25.1;8.25.1Design Criteria;310
14.25.2;8.25.2BossSinks;311
14.25.2.1;8.25.2.1 Coring;311
14.25.2.2;8.25.2.2 Location;313
14.25.2.3;8.25.2.3 Support;313
14.25.2.4;8.25.2.4 Material;314
14.25.2.5;8.25.2.5 Surface Treatment;314
14.25.3;8.25.3Weld Lines;314
14.26;8.26 Self-Threading Nuts;316
14.27;8.27 Twist Nuts;316
14.28;8.28 Press-on Nuts;316
14.29;8.29 Spring Clips;317
14.30;8.30 Push-in Fasteners;317
14.31;8.31 Rivets;317
14.32;8.32 Sources;319
14.32.1;8.32.1 Fasteners and Inserts;319
14.32.2;8.32.2 Threaded-Insert;320
14.32.3;8.32.3 Thermal Insertion Equipment;321
14.32.4;8.32.4 Induction Insertion Equipment;321
14.32.5;8.33.5 Ultrasonic Insertion Equipment;321
15;9 Hinges;322
15.1;9.1 Advantages and Disadvantages;322
15.1.1;9.1.1 Advantages;322
15.1.2;9.1.2 Disadvantages;322
15.2;9.2 One-Piece Integral Hinges;322
15.2.1;9.2.1 The Living Hinge;323
15.2.1.1;9.2.1.1Living HingeDesign;324
15.2.1.2;9.2.1.2Living HingeMolding Considerations;327
15.2.1.3;9.2.1.3Living Hinges by Other Processes;331
15.2.2;9.2.2 The Mira Spring Hinge;333
15.2.3;9.2.3 Standard Hinges;335
15.2.4;9.2.4 Tab Hinges;336
15.3;9.3 Two-Piece Plastic Hinges;336
15.3.1;9.3.1 Ball-and-Socket Hinges;337
15.3.2;9.3.2 Two-PieceLug-and-Pin Hinges;337
15.3.3;9.3.3 Hook-and-Eye Hinges;338
15.4;9.4 Three-Piece Hinges;338
15.4.1;9.4.1 Three-Piece Lug and Pin;339
15.4.2;9.4.2 Piano Hinge;339
15.5;9.5 Latches;340
15.5.1;9.5.1 Snaps;340
15.5.2;9.5.2 Rathbun Spring;340
15.6;9.6 Number of Hinges and Location;340
16;10 Hot Plate/Hot Die/Fusion and Hot Wire/Resistance Welding;341
16.1;10.1 Advantages and Disadvantages;341
16.1.1;10.1.1 Description;341
16.1.2;10.1.2 Advantages;341
16.1.3;10.1.3 Disadvantages;342
16.2;10.2 Materials;343
16.3;10.3 The Process;344
16.4;10.4 Types of Hot Plate Welding;348
16.4.1;10.4.1 Low Temperature Hot Plate Welding;348
16.4.2;10.4.2 High Temperature Hot Plate Welding;348
16.4.3;10.4.3 Noncontact Hot Plate Welding;349
16.5;10.5 Hot Plate Welding Joint Designs;349
16.6;10.6 Equipment;351
16.7;10.7 Hot Wire/Resistance Welding;352
16.8;10.8 Sources;353
17;11 Hot Gas Welding;354
17.1;11.1 Advantages and Disadvantages;354
17.1.1;11.1.1 Advantages;354
17.1.2;11.1.2 Disadvantages;354
17.2;11.2 The Process;355
17.2.1;11.2.1 Tack Welding;355
17.2.2;11.2.2 Permanent Hot Gas Welding;356
17.2.3;11.2.3 High Speed Welding;357
17.2.4;11.2.4 Extrusion Welding;359
17.3;11.3 Joint Designs;359
17.4;11.4 Welding Practice;361
17.4.1;11.4.1 Appearance Problems;362
17.4.2;11.4.2 Cracking Problems;363
17.4.3;11.4.3 Distortion;363
17.4.4;11.4.4 Fusion Problems;363
17.4.5;11.4.5 Penetration;363
17.4.6;11.4.6 Porosity;364
17.4.7;11.4.7 Scorching;364
17.5;11.5 Testing the Weld;364
17.5.1;11.5.1 Nondestructive Testing;364
17.5.1.1;11.5.1.1 Visual Examination;364
17.5.1.2;11.5.1.2 Leak Tests;365
17.5.2;11.5.2 Destructive Tests;365
17.5.2.1;11.5.2.1 Tensile Test;365
17.5.2.2;11.5.2.2 Bending Test;365
17.5.2.3;11.5.2.3 Rod Removal Test;365
17.5.3;11.5.3 Chemical Test;365
17.5.4;11.5.4 Spark Test;366
17.6;11.6 Applications;366
17.7;11.7 Sources;366
17.7.1;11.7.1 Welding Rods;366
17.7.2;11.7.2 Welding Equipment;366
17.7.3;11.7.3 Welding Rod And Equipment;367
18;12 Induction/Electromagnetic Welding;368
18.1;12.1 Description;368
18.2;12.2 Advantages and Disadvantages;368
18.2.1;12.2.1 Advantages;368
18.2.2;12.2.2 Disadvantages;369
18.3;12.3 The Equipment;370
18.4;12.4 The Process;372
18.5;12.5 The Coil;373
18.5.1;12.5.1 Single-Turn Coils;373
18.5.2;12.5.2 Hairpin Coils;373
18.5.3;12.5.3 Multi-Turn Coils;374
18.5.4;12.5.4 Split Coils;374
18.5.5;12.5.5 Other Types of Coils;375
18.5.6;12.5.6 Coil Positioning;375
18.5.7;12.5.7 Flux Concentrators;376
18.6;12.6 Materials;376
18.6.1;12.6.1 Polymers;376
18.6.2;12.6.2 The Electromagnetic Material;376
18.6.2.1;12.6.2.1 Molded-in Pre-Forms;376
18.6.2.2;12.6.2.2 Hot Melt Electromagnetic Materials;377
18.6.2.3;12.6.2.3 Liquid Electromagnetic Materials;378
18.7;12.7 Joint Designs;378
18.8;12.8 Encapsulation;381
18.9;12.9 Film and Sheeting;381
18.9.1;12.9.1 Intermittent Sealing;381
18.9.2;12.9.2 Continuous Sealing;382
18.10;12.10 Inserting Metal into Plastic;382
18.11;12.11 Sources;383
19;13 Insert and Multipart Molding;384
19.1;13.1 Description;384
19.2;13.2 Insert Molding;384
19.2.1;13.2.1 Advantages of Insert Molding;384
19.2.2;13.2.2 Disadvantages of Insert Molding;385
19.2.3;13.2.3 Design with Threaded Inserts;386
19.2.4;13.2.4 Mold Considerations for Threaded Inserts;389
19.2.5;13.2.5 Custom-Designed Inserts;391
19.2.6;13.2.6 Outserts: Inserts Larger than the Moldment;395
19.2.7;13.2.7 Hermetic Seals;396
19.2.8;13.2.8 PreparationofInserts;396
19.2.9;13.2.9 Decorative Inserts;397
19.3;13.3 Multi-Part Molding;399
19.3.1;13.3.1 Description;399
19.3.2;13.3.2 Advantages Particular to Multi-part Molding;399
19.3.3;13.3.3 Disadvantages Particular to Multi-part Molding;400
19.3.4;13.3.4 The Process;400
19.3.5;13.3.5 Materials;403
20;14 Press Fits/Force Fits/ Interference Fits/Shrink Fits;405
20.1;14.1 Advantages and Disadvantages;405
20.1.1;14.1.1 Advantages;405
20.1.2;14.1.2 Disadvantages;405
20.2;14.2 Press Fit Engineering;406
20.2.1;14.2.1 Engineering Notation;406
20.2.2;14.2.2 Geometric Factor;408
20.2.3;14.2.3 Changes Due to Temperature Variations;408
20.2.4;14.2.4 Hoop Stress;409
20.2.4.1;14.2.4.1 Metal Shaft in Plastic Boss;409
20.2.4.2;14.2.4.2 Shaft and Boss of Same Material;409
20.2.4.3;14.2.4.3 Shaft and Boss of Different Plastics;409
20.2.4.4;14.2.4.4 Quick Methods;410
20.2.5;14.2.5 Assembly and Disassembly Forces;410
20.2.6;14.2.6 Dimensional Changes Due to Assembly;411
20.2.7;14.2.7 Relationships;411
20.2.8;14.2.8 Equation Limitations;412
20.3;14.3 Safety Factor;417
20.4;14.4 Processing;417
20.5;14.5 Material Selection;418
20.6;14.6 Part Design;418
20.6.1;14.6.1 Heavy-Duty Press Fits;418
20.6.2;14.6.2 Light-Duty or Reopenable Press Fits;419
20.6.3;14.6.3 Other than Round;420
20.7;14.7 Case Studies;421
20.7.1;14.7.1 Determination of Changes in Diameter Due to Temperature Variations;421
20.7.2;14.7.2 The Geometric Factor for Use In Press Fit Equations;422
20.7.3;14.7.3 Determination of Design Stress and for a Metal Shaft in a Plastic Boss Maximum Allowable Interference for a Metal Shaftina Plastic ;422
20.7.4;14.7.4 Dimensional Changes Due to Assembly;424
20.7.4.1;14.7.4.1 Metal Shaft in Plastic Boss;424
20.7.4.2;14.7.4.2 Plastic Shaft and Metal Boss;424
20.7.5;14.7.5 Determination of Design Stress and Maximum Allowable Interference for a Shaft and Boss of the Same Material;425
20.7.6;14.7.6 Determination of Design Stress and Maximum Allowable Interference for a Shaft and Boss of Different Plastics;426
20.7.7;14.7.7 Determination of Assembly and Disassembly Forces;428
20.7.8;14.7.8 Determination of Torsional Holding Capacity;428
21;15 Snap Fits;429
21.1;15.1 Advantages and Disadvantages;429
21.1.1;15.1.1 Advantages;429
21.1.2;15.1.2 Disadvantages;430
21.2;15.2 General Applications;431
21.3;15.3 General Engineering Principles;431
21.3.1;15.3.1 Allowable Dynamic Strain;431
21.3.2;15.3.2 Corner Stress Concentrations;432
21.3.3;15.3.3 Engineering Adjustments When Both Parts Are Elastic;433
21.3.4;15.3.4 Finite Element Analysis;434
21.4;15.4 Cantilever Snap Fits;434
21.4.1;15.4.1 Cantilever Snap Fit Designs;434
21.4.2;15.4.2 Cantilever Snap Fit Engineering;437
21.5;15.5 Cylindrical, Ring, Perimeter, or Annular Snap Fits;443
21.5.1;15.5.1 Cylindrical Snap Fit Designs;443
21.5.2;15.5.2 Engineering of Cylindrical, Ring, Perimeter, or Annular Snap Fits;445
21.5.2.1;15.5.2.1 Maximum Permissible Interference;445
21.5.2.2;15.5.2.2 Transverse and Axial Forces;445
21.6;15.6 Torsion Snap Fits;448
21.6.1;15.6.1 Torsion Snap Fit Designs;448
21.6.2;15.6.2 Engineering of Torsion Snap Fits;448
21.7;15.8 The Injection Molding Process;451
21.8;15.9 Molds for Snap Fits;452
21.8.1;15.9.1 The Basics of Injection Mold Construction;452
21.8.2;15.9.2 Ejection and Cooling Systems for Stripping Molds;454
21.8.3;15.9.3 Cores for Nonstripping Molds;456
21.8.4;15.9.4 Snap Fit Details in the Mold Cavity;458
21.9;15.11 Case Studies;461
21.9.1;15.11.1 Cantilever Snap Fit Determination of Permissable Deflection;461
21.9.2;15.11.2 Cantilever Snap Fit Determination of Radial and Mating Forces;464
21.9.3;15.11.3 Annular Snap Fit Determination of Maximum Permissable Interference;465
21.9.4;15.11.4 Annular Snap Fit Determination of Maximum Design Strain;465
21.9.5;15.11.5 Annular Snap Fit Determination of Transverse and Axial Forces for a Snap Fitment Located Near the End of the Tube;466
21.9.6;15.11.6 Annular Snap Fit Determination of Transverse and Axial Forces for a Snap Fitment Located Remote From the End of the Tube;467
21.9.7;15.11.7 Self-locking Angle;468
22;16 Spin Welding;469
22.1;16.1 Description of Spin Welding;469
22.2;16.2 Advantages and Disadvantages of Spin Welding;469
22.2.1;16.2.1 Advantages;469
22.2.2;16.2.2 Disadvantages;470
22.3;16.3 Spin Welding Process;471
22.4;16.4 Materials;473
22.5;16.5 Design for Spin Welding;475
22.5.1;16.5.1 Overall Design Considerations;475
22.5.2;16.5.2 Joint Designs;475
22.6;16.6 The Equipment for Spin Welding;477
22.6.1;16.6.1 Drill-Press-Based Spin Welders;477
22.6.1.1;16.6.1.1 Tooling for Drill-Press-Based Inertial Welding;477
22.6.1.2;16.6.1.2 Tooling for Drill-Press-Based Pivot Tool Welding;478
22.6.2;16.6.2 Commercial Inertia Spin Welders;478
22.6.3;16.6.3 Commercial Direct-Drive Spin Welders;480
22.7;16.7 Sources;482
23;17 Staking/Swaging/Peening/ Cold Heading/Cold Forming;483
23.1;17.1 Advantages and Disadvantages of Staking/ Cold Forming;483
23.1.1;17.1.1 Advantages;483
23.1.2;17.1.2 Disadvantages;484
23.2;17.2 Staking;484
23.2.1;17.2.1 Cold Forming of Stakes;485
23.2.2;17.2.2 Hot Air/Cold Staking;487
23.2.3;17.2.3 Ultrasonic Cold Forming;488
23.2.4;17.2.4 Hot Die Forming of Stakes (Thermal Staking);490
23.2.5;17.2.5 Ultrasonic Hot Forming of Stakes;490
23.2.6;17.2.6 Laser Staking;491
23.3;17.3 Stake Design;491
23.3.1;17.3.1 The Stud;491
23.3.2;17.3.2 Stake Heads;492
23.4;17.4 Swaging;495
23.5;17.5 Sources;496
23.5.1;17.5.1 Thermal Staking;496
23.5.2;17.5.2 Hot Air/Cold Staking;497
23.5.3;17.5.3 Laser Staking;497
23.5.4;17.5.4 Ultrasonic;497
24;18 Threads: Tapped and Molded-in;498
24.1;18.1 Advantages and Disadvantages of Integral Threads;498
24.1.1;18.1.1Advantages Commonto Threads of BothTypes;498
24.1.2;18.1.2 Disadvantages Common toThreads of Both Types;498
24.2;18.2 Drilled and Tapped Holes in Plastics;499
24.2.1;18.2.1 Advantages Unique to Tapped Threads;499
24.2.2;18.2.2 Disadvantages Unique to Tapped Threads;499
24.2.3;18.2.3 Drilling Holes in Plastics;500
24.2.4;18.2.4 Reaming Holes in Plastics;501
24.2.5;18.2.5 Tapping Holes in Plastics;501
24.3;18.3 Molded Threads in Plastics;504
24.3.1;18.3.1 Advantages Unique to Molded-in Threads;504
24.3.2;18.3.2 Disadvantages Unique to Molded-in Threads;504
24.3.3;18.3.3 Thread Design;504
24.3.4;18.3.4 Molds for Threads;506
24.3.4.1;18.3.4.1 Stripping Molds for Internal Threads;507
24.3.4.2;18.3.4.2 Collapsing Core Molds for Internal Threads;508
24.3.4.3;18.3.4.3 Expandable Cavity Molds for External Threads;510
24.3.4.4;18.3.4.4 Split-Cavity Molds for External Threads;510
24.3.4.5;18.3.4.5 Unscrewing Molds for Internal Threads;512
24.3.4.6;18.3.4.6 Unscrewing Chuck Plate Mold;512
24.3.4.7;18.3.4.7 Molds for Parts with Less than One Turn of Thread;512
24.4;18.4 Sources;513
24.4.1;18.4.1Collapsing Cores and Cavities;513
24.4.2;18.4.2 Unscrewing Chuck;513
25;19 UltrasonicWelding;514
25.1;19.1 Advantages and Disadvantages of Ultrasonic Welding;514
25.1.1;19.1.1Advantages;514
25.1.2;19.1.2Disadvantages;515
25.2;19.2 General Applications;516
25.3;19.3 The Principle of Ultrasonic Welding;516
25.4;19.4 Materials for Ultrasonic Welding;517
25.4.1;19.4.1 Additives and Contaminants;520
25.4.1.1;19.4.1.1 Colorants;520
25.4.1.2;19.4.1.2 Fillers, Extenders, and Fibrous Reinforcements;520
25.4.1.3;19.4.1.3 Flame Retardants;522
25.4.1.4;19.4.1.4 Foaming Agents;522
25.4.1.5;19.4.1.5 Impact Modifiers;522
25.4.1.6;19.4.1.6 Lubricants;522
25.4.1.7;19.4.1.7 Mold Releases;522
25.4.1.8;19.4.1.8 Painted Parts;523
25.4.1.9;19.4.1.9 Plasticizers;523
25.4.1.10;19.4.1.10 Regrind;523
25.5;19.5 Part Design for Ultrasonic Welding;523
25.5.1;19.5.1 Overall Ultrasonic Welding Considerations;523
25.5.1.1;19.5.1.1 Strength Requirements;524
25.5.1.2;19.5.1.2 Appearance Requirements;524
25.5.1.3;19.5.1.3 Rigidity Considerations;524
25.5.2;19.5.2 Joint Fundamentals;527
25.5.2.1;19.5.2.1 Part Alignment;527
25.5.2.2;19.5.2.2 Uniform Vibration Travel Distance;527
25.5.2.3;19.5.2.3 Minimal Initial Contact Area;528
25.5.3;19.5.3 Energy Director Joints;529
25.5.3.1;19.5.3.1 Butt Joint;529
25.5.3.2;19.5.3.2 Joint Layout;531
25.5.3.3;19.5.3.3 Textured Surface;533
25.5.3.4;19.5.3.4 Step Joint;533
25.5.3.5;19.5.3.5 Tongue-and-Groove Joint;534
25.5.4;19.5.4 Shear Joints;535
25.5.5;19.5.5 Hermetic Seals;539
25.5.6;19.5.6 Scan Welding;539
25.5.7;19.5.7 Stud Welding, Staking, Swaging, and Spot Welding;541
25.5.7.1;19.5.7.1 Stakingand Swaging;541
25.5.7.2;19.5.7.2 Stud Welding;541
25.6;19.6 Fabric and Film Sealing;546
25.7;19.7 The Ultrasonic Equipment;548
25.7.1;19.7.1 The Basic Principles;548
25.7.2;19.7.2 The Power Supply or Generator;549
25.7.3;19.7.3 The Converter or Transducer;550
25.7.4;19.7.4 The Booster;550
25.7.5;19.7.5 The Horn;550
25.7.6;19.7.6 The Fixture;552
25.7.7;19.7.7 The Controls;553
25.7.8;19.7.8 Equipment Frequency;554
25.7.9;19.7.9 Automation of Ultrasonic Welding;556
25.8;19.8 Sources;556
26;20 Vibration Welding;557
26.1;20.1 Advantages and Disadvantages;557
26.1.1;20.1.1 Comparison with Ultrasonic Welding;557
26.1.2;20.1.2 Advantages of Vibration Welding;557
26.1.3;20.1.3 Disadvantages of Vibration Welding;558
26.2;20.2 The Process of Vibration Welding;559
26.2.1;20.2.1 Linear Vibration Welding;561
26.2.2;20.2.2 Orbital Vibration Welding;561
26.2.3;20.2.3 Angular Vibration Welding;562
26.3;20.3 Materials;562
26.4;20.4 Vibration Welding Part Design;565
26.4.1;20.4.1 Basic Considerations;565
26.4.2;20.4.2 Joint Designs for Linear Vibration Welding;566
26.5;20.5 The Equipment;569
26.6;20.6 Sources;570
27;21 Welding with Lasers;571
27.1;21.1 Advantages and Disadvantages;571
27.1.1;21.1.1 Non-Contact, Surface, Direct, or Butt Laser Welding;571
27.1.2;21.1.2 Laser Staking;572
27.1.3;21.1.3 Through TransmissionInfra-Red Laser Welding;572
27.1.4;21.1.4 Advantages of Through Transmission Laser Welding;573
27.1.5;21.1.5 Disadvantages of Through Transmission Laser Welding;575
27.2;21.2 The Process of Laser Welding;575
27.2.1;21.2.1 The Laser;575
27.2.2;21.2.2 Basic Through Transmission Laser Welding Methods;577
27.2.3;21.2.3 Spot or Contour Welding;578
27.2.4;21.2.4 Simultaneous Through TransmissionInfra-Red (STTIr) Laser Welding (Also Known as Simultaneous Line or Flash Welding);580
27.2.5;21.2.5 Quasi-Simultaneous Laser Welding;581
27.2.6;21.2.6 Mask Welding (Leister Patented Process);582
27.3;21.3 Materials for Laser Welding;583
27.3.1;21.3.1 Material Properties Affecting Laser Weldability;583
27.3.2;21.3.2 Effects of Refraction Properties on Material Selection;585
27.3.3;21.3.3 Effects of Pigments, Fillers, and Additives on Light Transmission;586
27.3.4;21.3.4 Laser Welding Transmitting Materials;587
27.3.5;21.3.5Compatibility of Plastics for Laser Welding;589
27.4;21.4 Joint Designs;589
27.5;21.5 Equipment;591
27.6;21.6 Applications;592
27.7;21.7 Sources;593
28;References;594
29;Index;601
