Plastic :-Plastic materials contain a mixture of molecules.

GUSETS:
The major portion is made up of large molecules known as Polym Gussets can be considered as a subset of ribs and the guidelines that ap
ers.Polymers are long chain molecules formed due to ply to ribs are also valid for gussets. This type of support is used to
there acting together or polymerization of different reinforce corners, side walls, and bosses.
organicmaterials called monomers.
Their composition always includes atoms of carbon, joined Guid line for guset
together,by primary covalent (electron sharing)
bonds, to other atoms like hydrogen, oxygen,nitrogen, fluorine, silicon The height of the gusset can be up to 95% of the height of the boss or
, sulphur, chlorine,etc rib it is attached to
Gusset base length is typically twice the nominal wall thickness
Sources of plastics :- coal, petroleum & natural gas. Calcium carbid
e, ethylene, propane, benzene DOG HOUSE :
etc. are starting chemicals for producing synthetic resins. Dog house is used for mounting the plastic part on BIW panel with the
help of Christmas clip.
Plastic types: 1) thermo plastic 2) thermosets
ADVANTAGE :
Thermo plastic :- Single step polymerization process.Remelted and The dog house is utilized during the JIT plant assembly process as a
reprocessed (linear/branched chains) E.g. PE, PP, ABS, PC, Nylons preliminary locator to “hang” the part prior to engaging supplemental
etc.Thermo sets :- Two or more steps for polymerization process mechanical fasteners.
Cannot be reprocessed (cross-linked chains) E.g. Epoxy, PU,
melamine, Polyester, Phenolic etc. DISADVANTAGE
The hidden design creates additional tool cost and complexity (slide
Thermo sets :-Two or more steps for polymerization process.Cannot action necessary to create dog house)
be reprocessed (cross-linked chains).E.g. Epoxy, PU, melamine, This fastening technique holds a part securely, but when removi
Polyester, Phenolic etc. ng part for service ability, the part or the tree may get damaged.

DENSITY :- SNAP
PP : 0.91 g/cm cube polypropylene Reasons to Use Snap – Fits:
PE : 0.95 g/cm cube polythelene It Reduces assembly costs Are typically designed for ease of assembly
Abs :1.05 g/cm cube acrynytrile butadine styrene and are often
PA : 1.13g/cm cube nylon easily Automated
PC: 1.2g/cm cube poly carbonate Replaces screws, nuts, and washers Are molded as an integral compon
ent of the plastic part No welding or adhesives are required
CORING OUT :- Coring out is removal of material from thick They can be engaged and disengaged
sections of part hence maintaining uniform wall
thickness and avoiding defects.Coring out helps to maintain uniform Things To Be Aware of When Using Snap – Fits: Some designs require hi
wall thickness.Leads to lesser usage of material. Often stronger de gher tooling cost They are susceptible to breakage due to mishandling an
sign by INcreasing rigidity. Lesser cost. Avoids sink mark and void d abuse prior to assembly Snap-
s. fits that are assembled under stress will creep It is difficult to design s
napfits with hermetic seals. If the beam
DRAFT Draft is the angle between the part ejection direction and and/or ledge relaxes, it could decrease the effectiveness of the seal.
the surface of the part.
Minimum draft 0.5 degree Gap and Flush Requirements :
Inspection Problem:
PARTING LINE
Interior components of a vehicle, such as the instrument panel and trim, are
Draft is the angle between the part ejection direction and
inspected for fit by the manufacturer and inspected after they are assembled
the surface of the part.
in vehicles.Measuring gap and flush on these parts is difficult because
UNDERCUT : of the unusual surface contours and nominally small gaps. Mechanical tools
Under cuts are any design features that creates hindrance to the nor are almost impossible Touse because of the flowing contours and the small to
mal opening of the mold. non-existent gaps. Manual tools like feeler gauges depend too much
on the operator's individual abilities.
RIBS : Usually used for improving part stiffness. Requirements:
Measurements - Interior gaps can be as large as 6.0 or 7.0 millimeters and as
BOSE : for locating mating parts small as no gap at all.
For attaching fasteners The gap design can have square-edges or very large radii and the panels can be
flat, curved or at a
Guid line for bose 90° angle to each other. Flush measurements are difficult because of the complex
The wall thicknesses should be less than 60 % of nominal wall to surfaces at the
minimize sinking. joints. The measurement instrument must be flexible in its methodologies to
The base radius should be a minimum of 0.25 x thicknes accommodate all of these features.
The boss can be strengthened by gussets at the base and by Instrument - Inspection of the entire instrument panel or all assemblies in
attaching it to nearby walls with connecting ribs.
interior needs to be done
at one time for efficiency. One inspection routine should contain all of the
HEAT STAKE
measurements required,
Staking is a process suited to connect parts made from dis
and the operator should be able to follow the routine without confusing the
similar materials e.g. plastic to metaL
locations of the
measurement points. Each measurement must be tracked to a unique identifier
or label and recorded in a data file.
Checking pts of Part- TYPES OF MOULDING
Draft Analysis –
* main tooling direction ➢Injection Molding
*slider direction ➢Blow Molding
Thickenss- ➢Compression Molding
➢Extrusion Molding
*Min. Thickness - (0.8mm) ➢Rotational Molding
*max Thikness - not more than 1.2 mm at the ➢Transfer Molding
bottom of the fixation.
SPRUES GET: Sprues deliver the resin to the desired depth in the mold,
Sink Mark - if the bottom thickness of fixation usually the parting line
is more than mainpart thickness then provide
thickness trap ( create surface 3 mm or 4mm SHUT OF ANGLE
offset abve the srface for tooling purpose) The amount of angle open to die draw on a given contour or surface required
Thickness Trap- wall thickness is 40% of part to obtain a condition to seal off betwwenn cavity and core blocks , around the
Periphery of the part cavity .the greater angle – the more robust yhe tool will
thickness
be
* Crack - tangency Shut off angle 7 degree is rexcoomnded
* Avoid_Sharp Corner for easy material flow Maximum 15 degree / minimum is 5 to 8 degree
* undercut( slider) X 2+25mm+5mm (
clearance) PARTING LINE
* mtd to slider 90 degree , if angle varries it It divedes core half and cavity half
will be 12 to 15 degree max. the parting line is the plane in which the two halves
of the mold meet. To the extent possible, all features
should be oriented perpendicular to the parting line to
1) if thickness increased after swip or any
facilitate removal from the mold. Normally, the parting
operation for clearing surface in draft then line is transferred to the surface of the part as a witness line
offset that surface directly, that surface
clear in slider .
2) always save part with ( ctrl+R ,iso
position)
3) Dont ever modify A-surface intentionally, PLASTIC TO PLASTIC 3 MM
4) PDRS - PAD / DRAFT / TAPPER / RADIUS / SHELL PLASTIC TO BIW / SHEET METAL 5-6 MM
5) Where ther is no. of chamfers - give draft RESTING PART 0-0.5 MM
directly.\
1) Avoid sharp ages
2) maintain constant thickness
3) do all possible offset
4)maintain tangency
5)where there is small bend use spline
6) join all the surface b4 draft analysis
7 differance copy paste & Power Copy ---
- In copy paste-- part paste as it is ( same
direction / same axis system) , in power copy-
we can change the directionn and location /
axis system of the part.
8) THICKNESS is always increased at the bottom
side \___\ at the time of swip & in curvature
condition its increased at the center of the
curve. and min at the start pt.
9) thickness variation -0.5mm at upper side& 1
mm at bottom side is permissible
10) Maintain tangency in any condition, always
check after join , swip , and any surface
creation.
11) measure at any point - any surface &
picking point
12) topDown - at the exact location where part
is resting
bottom up- zero location part built up
13) front axle center where we concider the
vechile axis center pt.
14) if the curve & tangent split condi
tion ocur then after solid give fillet at last
( min. fillet 0.5 - max. fillet mm )
BLUSH: BURN :
DEFINITION: Dull discolored or whitish area on the surface of the part, usually at the g DEFINITION: Discoloration usually black, brown or dark yellow/brown depending upon
ate. severity. Feels rough and crunchy. Frequently accompanied by short sh
ot in burn area.
CAUSE: Shear stress between polymer molecules during injection. The gate may be t
oo small or injection speed too fast. CAUSE: Usually indicates a need for more venting or heat buildup in tool. When air is
trapped in the tool and cannot escape, the extreme pressure causes the air to
LOCATION: ignite, burning the edge of the part.
Usually at the gate. May also occur where there is a sudden change in part thickness.
LOCATION:
CURE: Most often seen in deep, blind ribs where a lot of air can be forced into a small space
Adjust injection speed and if necessary adjust gate dimensions. An independent water
circuit in the mold that allows pinpoint temperature control at the gate can also help. CURE:
Add more parting line vents near burn or vent pins in deep ribs. Vent pins are just eject
oR
pins that fit a little loose. They may also have a flat ground down one side to let the air
escape.

FLASH: SHORT SHOT :

DEFINITION: DEFINITION:
Excess plastic squeezing out perpendicular to the part at parting line. Missing plastic or features that are not fully formed. Missing corners or features have
a smooth, rounded appearance.
CAUSE:
1. Plastic injection force exceeding the clamping pressure of the press. CAUSE:
(Over packing.) Under packing, low injection pressure, trapped gas.
2. May happen at first shots while mold is being dialed in.
3. Poorly constructed or worn out mold. LOCATION:
Areas of the part farthest from the gate, thin areas or delicate features.
LOCATION: Generally the last part of the mold to fill.
Along any parting line.
CURE:
CURE: Make sure the tool is adequately vented and push more plastic in.
Run the mold in a bigger press. Relieve areas of the parting surfaces that are not
immediately adjacent to the part. Leave 0.500 in. of shutoff land around the part.

SINKS: WARP :
DEFINITION: DEFINITION:
Depressions or dimples in the part that are usually adjacent to thick The failure to maintain flatness of a plastic part that was intended to be flat. Distortion f
areas. In clear parts, bubbles can be seen in thick areas. These rom the intended shape of the plastic part.
bubbles can be the precursors of shrink.
CAUSE:
1.The underlying cause of most part warpage is the shape of the part itself. The patter
CAUSE: n, shape, and
As the plastic cools it shrinks. If there is an area that is proportionally thicker than the thickness of ribs on the part as they undergo shrinkage have the greatest effect upon
rest of the part, then the plastic will shrink more in the.thick spot causing it to collapse warpage. These effects
inward. can be controlled to some degree by differential cooling of the mold (a different temp o
n the cavity than on the core). 2. Over packing can induce warp.
LOCATION:
1. Wall perpendicular to ribs or bosses that don't conform to the 66% rule. LOCATION:
2. Inconsistent wall thickness. i.e. Thick areas adjacent to thin areas. Present to some degree in most Injection molded parts but most easily detected on lar
ge flat parts.

CURE: CURE:
Maintain constant wall thickness by coring out. If you must have thick areas lead Alas there is no cure for this one, only control. Differential mold cooling can get you
gradually into them. Follow the 66% rule for wall thickness. Keep it down to 60% parts that are flatter.
or less if you can. A cooling fixture that the part is placed into immediately after ejection can also straight
en the part. However
these effects are usually temporary and upon being subjected to elevated temps or
time parts will return to their
natural shape. Your best bet is to follow the 66% rule and minimize rib height. Flat part
s are more susceptible to warpage than curved parts.
MATERIAL ADVANTAGE DIS APPLICATIONS
ADVANTAGE
ABS Processablity Slightly hygroscopic required dry Ip upper / panel
Impact strength Poor weathring Bezel
Surface finish (paint grain ) Consol
Thermal stability Glove boxes
Low shrinkage Knee bolster
Pillar trims
PP Light weight • High shrinkage •IP panels
Economical • Paintability •Bezels
Chemical resistance •Consoles
Impact strength •Glove boxes
Tensile strength •Pillar trims
Hinge properties •Airducts & Vents
Low moisture permeability

PC/ABS • Low temperature impact strength Hygroscopic – requires drying •IP upper
•UV stability •IP retainer
•Flame retardance •Bezels
•Processability •Knee bolsters
•Pillar trims

PC • Transparency • Poor scratch resistance •Headlamp lenses

• Good performance at • Poor chemical resistance •Tail lamp lenses
higher temperatures •IP cluster lens
• Excellent Impact •Glazing films
strength • Dimensional stability •Bezels
• Stain resistant •Handles/Knobs
• Excellent creep •Vents
resistance
• Good pigment ability

NYLON • Good performance at higher temperatures • High shrinkage •IP panels

•Low coefficient of friction • Hygroscopic – requires •Bezels
•Excellent chemical resistance drying •Consoles
•Impact strength •Ashtrays
•Creep resistance •Glove boxes
•Biologically inert •Pillar trims
•Performance can be •Air ducts & Vents
substantially upgraded with glass reinforcement •Latches
• Flame resistance •Under the hood
components

ACETAL • Excellent combination of strength, stiffness and • Cost •Ashtrays

toughness • High gloss •Gears
•Excellent chemical resistance •Electrical switches
•Creep resistance •Handles/Knobs
•Flame retardance •Under the hood
•Low coefficient of friction components

TPE/TPO •Soft feel, Non slip surface • Poor tear resistance •IP skins
•Low fogging •Mats
•Dimensional stability •Airbag covers
•Bondability with polyolefins •Cupholders
•Grips & Handles
•Bumpers