This document discusses two types of screws used to assemble plastic parts: thread forming screws and thread cutting screws. Thread forming screws deform the plastic material to form internal threads, while thread cutting screws remove plastic material to form threads. The document focuses on thread forming screws and describes several types designed specifically for plastics, including HiLo, DST, Plastite, and PT screws. It explains how the thread design and angle of PT screws provides advantages over traditional metal screws like reducing radial stresses and increasing pullout loads when used in plastic assembly.
Design and fabrication of gearbox with inboard braking of an all terrain vehicleabdul mohammad
We design, build and test an off-road race vehicle each year. During this season, a customized gearbox with inboard braking is typically designed as a reduction after the Continuously Variable Transmission. A preliminary design was first prepared keeping in the mind, the guidelines and rules issued by SAE. Indian standards for driver space and ergonomic preference transmission type was selected and designed according to requirements of the driver. Hence after ensuring safety, the design was finalised and fabricate it. Moreover, the axle braking is to slow down or stop the vehicle safely and effectively by converting kinetic energy into heat. It is the one of the main safety of a vehicle. The goal of the project is to develop a lightweight, compact gear reduction that will increase the efficiency and durability of the vehicle. And also, in addition we have provided hydraulic braking for the drive shaft (i.e. known as inboard braking) for which the calliper is mounted to the gearbox itself. The pedal must actuate the master cylinder without any usage of cables and should be capable of locking four wheels in static condition and dynamically on paved and unpaved surfaces. While designing a brake system for a vehicle that can produce adequate braking force to meet competition regulations while being as light as possible. A budget, timeline, proof of design, fabrication and testing will also incorporate in the report.
Los tornillos, tuercas y pernos son elementos mecánicos roscados que se utilizan para unir piezas. Los tornillos más comunes son los hexagonales, pero también existen tornillos Allen y de cabeza plana. Las tuercas, que siempre deben coincidir con el tornillo, se utilizan junto con los tornillos y pernos para fijar uniones de manera segura. Los pernos son similares a los tornillos pero no llevan tuerca en el extremo.
The document discusses the benefits of exercise for mental health. Regular physical activity can help reduce anxiety and depression and improve mood and cognitive function. Exercise causes chemical changes in the brain that may help protect against mental illness and improve symptoms for those who already suffer from conditions like anxiety and depression.
Este documento describe diferentes tipos de uniones, incluyendo uniones fijas como remaches y soldadura, y uniones desmontables como roscas, pasadores y chavetas. Explica que las uniones unen las piezas de las máquinas y se clasifican en fijas o desmontables. Luego proporciona detalles sobre los diferentes tipos de uniones desmontables y fijas, así como sobre el proceso de remachado y cálculo de uniones.
The document contains several examples of calculating weld sizes and bolt sizes for different welded and bolted joints. The examples involve calculating shear stresses in welds due to direct loads and bending moments and determining necessary weld sizes. They also involve calculating bolt sizes for different bolted joints based on allowable shear stresses and safety factors. The final example calculates the necessary bolt size for connecting a steam engine cylinder head based on the steam pressure, cylinder dimensions, bolt material properties, and a preload on the bolts.
1. The document describes an experiment to construct a quick return mechanism using a linkage to transform uniform crank rotation into oscillating follower link motion and reciprocating slider motion.
2. Data was collected on crank angle versus slider displacement and plotted on a graph to analyze the quick motion of the mechanism.
3. It was found that the slider moves faster from right to left, with maximum velocity at 280 degrees crank angle and zero velocity at 240 degrees.
This document discusses visual inspection of welds and welding terminology. It covers topics like weld joint types (butt, fillet, lap), weld features to examine (size, profile, blending), welding processes (MMA, TIG, MIG), common defects (cracks, lack of fusion), and factors that can cause defects (gap size, current, technique). Guidelines are provided for visual inspection procedures and checklists for pre-weld, during welding, and post-weld activities. Diagrams illustrate key points.
Design and Analysis of Flange CouplingIJERA Editor
The approach utilizes standard design equations of these couplings and links them together in computer software to determine the design parameters of the couplings. In general, most flange coupling is available in transformation system and automobile industries. A flange coupling usually applies to a coupling having two cast iron flanges. To achieve a require goal, a design of bolted unprotected flange coupling is modeled in to a cad package named Solid works. Furthered the finite element analysis module is created in ANSYS Workbench by using ANSYS Static Structural module which has a predefined process to obtain optimum results.
Design and fabrication of gearbox with inboard braking of an all terrain vehicleabdul mohammad
We design, build and test an off-road race vehicle each year. During this season, a customized gearbox with inboard braking is typically designed as a reduction after the Continuously Variable Transmission. A preliminary design was first prepared keeping in the mind, the guidelines and rules issued by SAE. Indian standards for driver space and ergonomic preference transmission type was selected and designed according to requirements of the driver. Hence after ensuring safety, the design was finalised and fabricate it. Moreover, the axle braking is to slow down or stop the vehicle safely and effectively by converting kinetic energy into heat. It is the one of the main safety of a vehicle. The goal of the project is to develop a lightweight, compact gear reduction that will increase the efficiency and durability of the vehicle. And also, in addition we have provided hydraulic braking for the drive shaft (i.e. known as inboard braking) for which the calliper is mounted to the gearbox itself. The pedal must actuate the master cylinder without any usage of cables and should be capable of locking four wheels in static condition and dynamically on paved and unpaved surfaces. While designing a brake system for a vehicle that can produce adequate braking force to meet competition regulations while being as light as possible. A budget, timeline, proof of design, fabrication and testing will also incorporate in the report.
Los tornillos, tuercas y pernos son elementos mecánicos roscados que se utilizan para unir piezas. Los tornillos más comunes son los hexagonales, pero también existen tornillos Allen y de cabeza plana. Las tuercas, que siempre deben coincidir con el tornillo, se utilizan junto con los tornillos y pernos para fijar uniones de manera segura. Los pernos son similares a los tornillos pero no llevan tuerca en el extremo.
The document discusses the benefits of exercise for mental health. Regular physical activity can help reduce anxiety and depression and improve mood and cognitive function. Exercise causes chemical changes in the brain that may help protect against mental illness and improve symptoms for those who already suffer from conditions like anxiety and depression.
Este documento describe diferentes tipos de uniones, incluyendo uniones fijas como remaches y soldadura, y uniones desmontables como roscas, pasadores y chavetas. Explica que las uniones unen las piezas de las máquinas y se clasifican en fijas o desmontables. Luego proporciona detalles sobre los diferentes tipos de uniones desmontables y fijas, así como sobre el proceso de remachado y cálculo de uniones.
The document contains several examples of calculating weld sizes and bolt sizes for different welded and bolted joints. The examples involve calculating shear stresses in welds due to direct loads and bending moments and determining necessary weld sizes. They also involve calculating bolt sizes for different bolted joints based on allowable shear stresses and safety factors. The final example calculates the necessary bolt size for connecting a steam engine cylinder head based on the steam pressure, cylinder dimensions, bolt material properties, and a preload on the bolts.
1. The document describes an experiment to construct a quick return mechanism using a linkage to transform uniform crank rotation into oscillating follower link motion and reciprocating slider motion.
2. Data was collected on crank angle versus slider displacement and plotted on a graph to analyze the quick motion of the mechanism.
3. It was found that the slider moves faster from right to left, with maximum velocity at 280 degrees crank angle and zero velocity at 240 degrees.
This document discusses visual inspection of welds and welding terminology. It covers topics like weld joint types (butt, fillet, lap), weld features to examine (size, profile, blending), welding processes (MMA, TIG, MIG), common defects (cracks, lack of fusion), and factors that can cause defects (gap size, current, technique). Guidelines are provided for visual inspection procedures and checklists for pre-weld, during welding, and post-weld activities. Diagrams illustrate key points.
Design and Analysis of Flange CouplingIJERA Editor
The approach utilizes standard design equations of these couplings and links them together in computer software to determine the design parameters of the couplings. In general, most flange coupling is available in transformation system and automobile industries. A flange coupling usually applies to a coupling having two cast iron flanges. To achieve a require goal, a design of bolted unprotected flange coupling is modeled in to a cad package named Solid works. Furthered the finite element analysis module is created in ANSYS Workbench by using ANSYS Static Structural module which has a predefined process to obtain optimum results.
Este documento describe los mecanismos de transmisión de movimiento mediante levas. Explica que las levas son elementos mecánicos con forma especial que transmiten movimiento a piezas llamadas seguidores. Se clasifican las levas según su forma y según el movimiento del seguidor. También explica cómo graficar los diferentes tipos de movimiento que pueden transmitir las levas a través de diagramas de desplazamiento, y cómo diseñar perfiles de levas para lograr diferentes movimientos del seguidor.
The document discusses gears and gear trains. It defines a gear as a toothed wheel that meshes with another gear to transmit rotation between two shafts. Gear trains involve two or more meshing gears and can be simple, compound, reverted, or epicyclic (planetary). The key advantages of gears include transmitting exact velocity ratios, transferring large power, having high efficiency, and providing reliable service in a compact layout. Potential disadvantages are the specialized tools and equipment needed for gear manufacturing and the possibility of vibrations from errors in tooth cutting.
Dokumen tersebut membahas tentang lingkaran yang bersinggungan, mencari koordinat titik singgungan, menentukan garis singgungan, dan panjang sabuk yang melilit dua lingkaran. Dijelaskan cara mencari koordinat titik singgungan di luar dan dalam, serta menentukan persamaan garis singgungan berdasarkan hubungan antara titik pusat lingkaran dan titik singgungan.
bevel gear screw jack,high speed screw jack,quick lifting screw jack,gear ratio 1:1 screw jack features:
1. Load capacity 25kN to 500kN. When full load, worm torque high speed 92Nm to 4712Nm, low speed 46Nm to 2828Nm.
2. Lift screw diameter 30 mm to 120 mm, screw pitch 6 mm to 16 mm.
3. High gear ratio 1:1, low gear ratio 2:1.
4. Translating screw, rotating screw, keyed screw configurations in upright or inverted mounting orientation.
5. Difference from worm gear screw jack, driven spindle by spiral bevel gear sets.
5. Manual operated bevel gear screw jack by hand wheel or hand crank, or electrically operated bevel gear screw jack by 3-phase or single phase motor or gear motor.
6. Processing lift screw stroke according to clients needs. Under max. compression load, without guides 250mm to 1000mm stroke, with guides 400mm to 2000mm stroke. Under tension load, max. 1500mm to 5500mm stroke.
7. Lift screw end fittings include top plate, clevis end, plain end and threaded end.
8. Full synchronization bevel gear screw jack system, doesn't require right angle bevel gearbox to transmit torque and power, bevel gear screw jacks are directly connected by line shaftings and couplings.
9. Application in steel, pipe, tube, plate, roll forming roller adjustment, feeder straightener rolls adjustment, adjusting synchronous coil feed lines rolls, precision roller leveler, coil sheet slitter line, paint coating line, cut to length line, tension levelling line, continuous galvanizing line, beverage production line, foam concrete cutting machine, sanding machine, heavy vehicles mobile lifting platform, bottle monitoring system height adjustment, conveyor adjustment, plate saw angle adjustment, spray infeed conveyor lift system, theatre stage lifting platform, solar tracker, satellite dish antenna azimuth, raising sluice gate, screw scissor lift table, synchronized lifting system, food processing lifting system, extrusion machine, cnc steel leveling machine, blow molding machine, curing oven lifts, bolted tank, steel shuttering concrete beams adjustment, vintage industrial crank desk, solar panel tracking system, railway maintenance lifting jack, damper adjustment, continuous casting, cnc cut to length machine, robotics arm raising, palletizer, extrusion machine, motorized self-raising tower system, angle tilt adjustments with double clevis, aircraft docking system, open and close flood gates, metallurgy industry, mining industry, chemical industry, construction industry and irrigation industry.
This document summarizes the design of an intermediate gearbox for the trailing edge flaps of an Airbus A350. The gearbox assembly consists of a sealed housing, input and output shafts, two spur gears, and four roller bearings. Analysis was conducted to ensure the design met requirements for operating speed, torque limits, life, sealing, and other factors. The key stress point was identified as the shaft shoulder. The gearbox design was modeled in Solidworks and analysis showed it met all specified technical parameters, with minimum margins of 0% and maximum of 16.3%.
Unit 2 Design Of Shafts Keys and CouplingsMahesh Shinde
This document provides information about the design of shafts, keys, and couplings. It discusses transmission shafts, stresses induced in shafts, and shaft design based on strength and rigidity. It presents formulas for shaft design using maximum shear stress theory, distortion energy theory, and the ASME code. Several examples are provided to demonstrate how to calculate the diameter of a shaft given the power transmitted, loads on the shaft, material properties, and other parameters using these theories and codes. Assignments involving similar calculations of shaft diameters are presented.
This document provides information on mechanism synthesis and graphical methods for designing mechanisms. It discusses dimensional, number, and type synthesis to design mechanisms for specified motions. Graphical methods are presented for generating both motion and path generating mechanisms with 4-bar and 6-bar linkages using coupler curves. Steps are provided for graphical synthesis including selecting fixed pivot points, locating link lengths, and verifying mechanism positions. Quick-return mechanisms are also discussed.
The document discusses the process of performing a flexibility analysis on a piping system. A flexibility analysis involves calculating strains and stresses under sustained loads and thermal expansion loads to ensure the piping has adequate support, flexibility to accommodate temperature changes, and does not exert excessive reaction forces. The document provides an example analysis of a proposed carbon steel pipe system, and how adding additional supports addressed issues found.
1) The document discusses the design of shafts subjected to different loading conditions including bending, torsion, combined bending and torsion, fluctuating loads, and axial loads.
2) Formulas are provided to calculate the equivalent bending moment and equivalent twisting moment for shafts under various loading conditions.
3) Examples are presented to demonstrate how to use the formulas and determine the necessary shaft diameter based on allowable stresses.
La Unión Europea ha acordado un embargo petrolero contra Rusia en respuesta a la invasión de Ucrania. El embargo forma parte de un sexto paquete de sanciones y prohibirá la mayoría de las importaciones de petróleo ruso en la UE a finales de este año. Algunos estados miembros aún dependen en gran medida del petróleo ruso y se les ha concedido una exención, pero se espera que todo el petróleo ruso quede prohibido para fines de 2023.
Basic concept of fits and tolerances and their practical use in fitment of anti friction bearings and couplings
Machine design and maintenance engineers do encounter the problem in deciding right kind of fitment while assembling various machine elements. Satisfactory functioning of a machine is very much dependent on use of right type of fitment between its various machine elements ( parts). Below is link to a presentation wherein I have tried to summarize the basic concepts of fits and tolerances and their practical use in fitment of rolling contact bearings and coupling
Este documento presenta un manual de tornillería que describe diversos tipos de tornillos, tuercas y arandelas. Explica las características y usos de tornillos como tornillos de cabeza, tornillos ocultos, tornillos para madera y más. También describe tipos de tuercas como tuercas hexagonales, tuercas de seguridad y tuercas maquinadas. Finalmente, explica arandelas simples, arandelas de sellado, arandelas dentadas y otros tipos.
A coupling is a mechanical device that rigidly joins two rotating shafts together. There are three main types of couplings: rigid couplings for perfectly aligned shafts, flexible couplings for shafts with misalignment, and flange couplings which can transmit high torque capacities but do not tolerate misalignment or shocks/vibrations. Design of couplings involves calculating shaft diameters, sleeve/flange dimensions, key dimensions, and bolt diameters based on the transmitted power, material properties, and safety factors. Dimensional relationships and equations are used to check stresses in the various coupling components.
This document discusses the design of shafts used in machines. It begins by introducing different types of shafts like stepped, cranked, and flexible shafts. It then discusses the materials used for shafts, focusing on their strength and machinability. The document provides equations to calculate shaft diameter based on the torque transmitted. It also lists permissible stress values for shaft materials under different service conditions. Finally, it discusses how shafts experience both bending and torsional stresses that must be considered in their design.
Roll no 14 Aaditya Naik ( TOM MICROPROJECT PPT ).pdfAadityaNaik1
This document discusses different mechanisms used in farm appliances. It describes three applications: 1) A mechanical cutter using a four-bar mechanism to convert rotational motion from a motor to reciprocating motion of the cutting blade. 2) A multi-nozzle wheel spray pump using a single slider-crank mechanism to power a reciprocating pump for spraying fertilizer or pesticides. 3) A multipurpose agricultural vehicle that uses a Scotch yoke mechanism to convert linear motion to rotational motion for various farm tasks.
This document describes a finite element analysis of a thin plate with different hole geometries under tension. Circular, elliptical, and rectangular holes were modeled in the center of a plate. Theoretical stress concentrations were calculated and compared to FE model results. A convergence study determined an optimal mesh size of 25mm. Results from full and quarter plate models showed good agreement, with stress value deviations within 2% and displacement deviations within 1%.
Este documento describe un mecanismo de cuatro barras, el cual consiste en tres barras móviles y una cuarta barra fija unidas por articulaciones. Explica que para que el movimiento entre las barras sea continuo, la suma de la barra más corta y la barra más larga no puede ser mayor que la suma de las barras restantes. Además, detalla el proceso de elaboración de dos modelos prácticos de este mecanismo usando palos de balsa y tornillos.
5 shaft shafts subjected to combined twisting moment and bending momentDr.R. SELVAM
1. The document discusses the design of shafts that are subjected to both twisting moments and bending moments.
2. It describes two theories for analyzing combined stresses: maximum shear stress theory for ductile materials like steel, and maximum normal stress theory for brittle materials like cast iron.
3. It provides an example of determining the diameter of a shaft made of 45 C 8 steel that is subjected to a bending moment of 3000 N-m and torque of 10,000 N-m, with a safety factor of 6.
Multi-StageSheet Metal Fromed Bolted Fastener DesignMark Brooks
This document discusses the development of a multi-stage sheet metal fastening design that eliminates nuts to reduce costs and improve manufacturing efficiency. Testing showed that while extruded, rivet, and PEM nuts exceeded torque specifications, shear/tap fasteners only marginally met specifications, failing through thread tear. To breakthrough this technology barrier, the basics of thread forming were revisited. Roll-forming threads through compression may improve performance over cutting threads.
This document discusses various sheet metal forming processes and their characteristics. It provides tables comparing common sheet metal forming processes such as roll forming, stretching, drawing, stamping, and others. It also discusses specific sheet metal forming operations like bending, flanging, tube bending, and roll forming. Diagrams illustrate the mechanics and terminology used in these various sheet metal forming techniques.
Este documento describe los mecanismos de transmisión de movimiento mediante levas. Explica que las levas son elementos mecánicos con forma especial que transmiten movimiento a piezas llamadas seguidores. Se clasifican las levas según su forma y según el movimiento del seguidor. También explica cómo graficar los diferentes tipos de movimiento que pueden transmitir las levas a través de diagramas de desplazamiento, y cómo diseñar perfiles de levas para lograr diferentes movimientos del seguidor.
The document discusses gears and gear trains. It defines a gear as a toothed wheel that meshes with another gear to transmit rotation between two shafts. Gear trains involve two or more meshing gears and can be simple, compound, reverted, or epicyclic (planetary). The key advantages of gears include transmitting exact velocity ratios, transferring large power, having high efficiency, and providing reliable service in a compact layout. Potential disadvantages are the specialized tools and equipment needed for gear manufacturing and the possibility of vibrations from errors in tooth cutting.
Dokumen tersebut membahas tentang lingkaran yang bersinggungan, mencari koordinat titik singgungan, menentukan garis singgungan, dan panjang sabuk yang melilit dua lingkaran. Dijelaskan cara mencari koordinat titik singgungan di luar dan dalam, serta menentukan persamaan garis singgungan berdasarkan hubungan antara titik pusat lingkaran dan titik singgungan.
bevel gear screw jack,high speed screw jack,quick lifting screw jack,gear ratio 1:1 screw jack features:
1. Load capacity 25kN to 500kN. When full load, worm torque high speed 92Nm to 4712Nm, low speed 46Nm to 2828Nm.
2. Lift screw diameter 30 mm to 120 mm, screw pitch 6 mm to 16 mm.
3. High gear ratio 1:1, low gear ratio 2:1.
4. Translating screw, rotating screw, keyed screw configurations in upright or inverted mounting orientation.
5. Difference from worm gear screw jack, driven spindle by spiral bevel gear sets.
5. Manual operated bevel gear screw jack by hand wheel or hand crank, or electrically operated bevel gear screw jack by 3-phase or single phase motor or gear motor.
6. Processing lift screw stroke according to clients needs. Under max. compression load, without guides 250mm to 1000mm stroke, with guides 400mm to 2000mm stroke. Under tension load, max. 1500mm to 5500mm stroke.
7. Lift screw end fittings include top plate, clevis end, plain end and threaded end.
8. Full synchronization bevel gear screw jack system, doesn't require right angle bevel gearbox to transmit torque and power, bevel gear screw jacks are directly connected by line shaftings and couplings.
9. Application in steel, pipe, tube, plate, roll forming roller adjustment, feeder straightener rolls adjustment, adjusting synchronous coil feed lines rolls, precision roller leveler, coil sheet slitter line, paint coating line, cut to length line, tension levelling line, continuous galvanizing line, beverage production line, foam concrete cutting machine, sanding machine, heavy vehicles mobile lifting platform, bottle monitoring system height adjustment, conveyor adjustment, plate saw angle adjustment, spray infeed conveyor lift system, theatre stage lifting platform, solar tracker, satellite dish antenna azimuth, raising sluice gate, screw scissor lift table, synchronized lifting system, food processing lifting system, extrusion machine, cnc steel leveling machine, blow molding machine, curing oven lifts, bolted tank, steel shuttering concrete beams adjustment, vintage industrial crank desk, solar panel tracking system, railway maintenance lifting jack, damper adjustment, continuous casting, cnc cut to length machine, robotics arm raising, palletizer, extrusion machine, motorized self-raising tower system, angle tilt adjustments with double clevis, aircraft docking system, open and close flood gates, metallurgy industry, mining industry, chemical industry, construction industry and irrigation industry.
This document summarizes the design of an intermediate gearbox for the trailing edge flaps of an Airbus A350. The gearbox assembly consists of a sealed housing, input and output shafts, two spur gears, and four roller bearings. Analysis was conducted to ensure the design met requirements for operating speed, torque limits, life, sealing, and other factors. The key stress point was identified as the shaft shoulder. The gearbox design was modeled in Solidworks and analysis showed it met all specified technical parameters, with minimum margins of 0% and maximum of 16.3%.
Unit 2 Design Of Shafts Keys and CouplingsMahesh Shinde
This document provides information about the design of shafts, keys, and couplings. It discusses transmission shafts, stresses induced in shafts, and shaft design based on strength and rigidity. It presents formulas for shaft design using maximum shear stress theory, distortion energy theory, and the ASME code. Several examples are provided to demonstrate how to calculate the diameter of a shaft given the power transmitted, loads on the shaft, material properties, and other parameters using these theories and codes. Assignments involving similar calculations of shaft diameters are presented.
This document provides information on mechanism synthesis and graphical methods for designing mechanisms. It discusses dimensional, number, and type synthesis to design mechanisms for specified motions. Graphical methods are presented for generating both motion and path generating mechanisms with 4-bar and 6-bar linkages using coupler curves. Steps are provided for graphical synthesis including selecting fixed pivot points, locating link lengths, and verifying mechanism positions. Quick-return mechanisms are also discussed.
The document discusses the process of performing a flexibility analysis on a piping system. A flexibility analysis involves calculating strains and stresses under sustained loads and thermal expansion loads to ensure the piping has adequate support, flexibility to accommodate temperature changes, and does not exert excessive reaction forces. The document provides an example analysis of a proposed carbon steel pipe system, and how adding additional supports addressed issues found.
1) The document discusses the design of shafts subjected to different loading conditions including bending, torsion, combined bending and torsion, fluctuating loads, and axial loads.
2) Formulas are provided to calculate the equivalent bending moment and equivalent twisting moment for shafts under various loading conditions.
3) Examples are presented to demonstrate how to use the formulas and determine the necessary shaft diameter based on allowable stresses.
La Unión Europea ha acordado un embargo petrolero contra Rusia en respuesta a la invasión de Ucrania. El embargo forma parte de un sexto paquete de sanciones y prohibirá la mayoría de las importaciones de petróleo ruso en la UE a finales de este año. Algunos estados miembros aún dependen en gran medida del petróleo ruso y se les ha concedido una exención, pero se espera que todo el petróleo ruso quede prohibido para fines de 2023.
Basic concept of fits and tolerances and their practical use in fitment of anti friction bearings and couplings
Machine design and maintenance engineers do encounter the problem in deciding right kind of fitment while assembling various machine elements. Satisfactory functioning of a machine is very much dependent on use of right type of fitment between its various machine elements ( parts). Below is link to a presentation wherein I have tried to summarize the basic concepts of fits and tolerances and their practical use in fitment of rolling contact bearings and coupling
Este documento presenta un manual de tornillería que describe diversos tipos de tornillos, tuercas y arandelas. Explica las características y usos de tornillos como tornillos de cabeza, tornillos ocultos, tornillos para madera y más. También describe tipos de tuercas como tuercas hexagonales, tuercas de seguridad y tuercas maquinadas. Finalmente, explica arandelas simples, arandelas de sellado, arandelas dentadas y otros tipos.
A coupling is a mechanical device that rigidly joins two rotating shafts together. There are three main types of couplings: rigid couplings for perfectly aligned shafts, flexible couplings for shafts with misalignment, and flange couplings which can transmit high torque capacities but do not tolerate misalignment or shocks/vibrations. Design of couplings involves calculating shaft diameters, sleeve/flange dimensions, key dimensions, and bolt diameters based on the transmitted power, material properties, and safety factors. Dimensional relationships and equations are used to check stresses in the various coupling components.
This document discusses the design of shafts used in machines. It begins by introducing different types of shafts like stepped, cranked, and flexible shafts. It then discusses the materials used for shafts, focusing on their strength and machinability. The document provides equations to calculate shaft diameter based on the torque transmitted. It also lists permissible stress values for shaft materials under different service conditions. Finally, it discusses how shafts experience both bending and torsional stresses that must be considered in their design.
Roll no 14 Aaditya Naik ( TOM MICROPROJECT PPT ).pdfAadityaNaik1
This document discusses different mechanisms used in farm appliances. It describes three applications: 1) A mechanical cutter using a four-bar mechanism to convert rotational motion from a motor to reciprocating motion of the cutting blade. 2) A multi-nozzle wheel spray pump using a single slider-crank mechanism to power a reciprocating pump for spraying fertilizer or pesticides. 3) A multipurpose agricultural vehicle that uses a Scotch yoke mechanism to convert linear motion to rotational motion for various farm tasks.
This document describes a finite element analysis of a thin plate with different hole geometries under tension. Circular, elliptical, and rectangular holes were modeled in the center of a plate. Theoretical stress concentrations were calculated and compared to FE model results. A convergence study determined an optimal mesh size of 25mm. Results from full and quarter plate models showed good agreement, with stress value deviations within 2% and displacement deviations within 1%.
Este documento describe un mecanismo de cuatro barras, el cual consiste en tres barras móviles y una cuarta barra fija unidas por articulaciones. Explica que para que el movimiento entre las barras sea continuo, la suma de la barra más corta y la barra más larga no puede ser mayor que la suma de las barras restantes. Además, detalla el proceso de elaboración de dos modelos prácticos de este mecanismo usando palos de balsa y tornillos.
5 shaft shafts subjected to combined twisting moment and bending momentDr.R. SELVAM
1. The document discusses the design of shafts that are subjected to both twisting moments and bending moments.
2. It describes two theories for analyzing combined stresses: maximum shear stress theory for ductile materials like steel, and maximum normal stress theory for brittle materials like cast iron.
3. It provides an example of determining the diameter of a shaft made of 45 C 8 steel that is subjected to a bending moment of 3000 N-m and torque of 10,000 N-m, with a safety factor of 6.
Multi-StageSheet Metal Fromed Bolted Fastener DesignMark Brooks
This document discusses the development of a multi-stage sheet metal fastening design that eliminates nuts to reduce costs and improve manufacturing efficiency. Testing showed that while extruded, rivet, and PEM nuts exceeded torque specifications, shear/tap fasteners only marginally met specifications, failing through thread tear. To breakthrough this technology barrier, the basics of thread forming were revisited. Roll-forming threads through compression may improve performance over cutting threads.
This document discusses various sheet metal forming processes and their characteristics. It provides tables comparing common sheet metal forming processes such as roll forming, stretching, drawing, stamping, and others. It also discusses specific sheet metal forming operations like bending, flanging, tube bending, and roll forming. Diagrams illustrate the mechanics and terminology used in these various sheet metal forming techniques.
This document summarizes various sheet metal forming processes and provides details on bending mechanics. It includes a table comparing characteristics of different forming processes like roll forming, stretch forming, and stamping. The document then discusses bending terminology and minimum bend radii for different materials. It also covers bending mechanics topics such as the effects of inclusions and edge conditions on cracking. Springback is analyzed through definitions of terms and models for estimating springback factor. Methods to reduce springback through techniques like overbending are presented.
The document discusses different aspects of threaded fasteners including types, materials, tightening torque, and manufacturing processes. It notes that a Boeing 747 uses around 2.5 million fasteners including 70,000 titanium bolts costing $150,000. Tightening bolts to the specified torque is important as it ensures proper preload and prevents loosening over time. Common bolt manufacturing methods include forging, rolling, and thread rolling which strengthen the material compared to conventional machining.
The document discusses various topics relating to threaded fasteners including types of fasteners, materials and grades, tightening torque, and manufacturing processes. It notes that a Boeing 747 uses around 2.5 million fasteners including 70,000 titanium bolts costing $150,000. Tightening bolts to the specified torque is important as it ensures an even load distribution and prevents parts from loosening or failing. Common bolt manufacturing methods include forging, rolling, and thread rolling which strengthen the material.
Manufacturing Processes(Sheet Metal Forming.ppt)sadanand50
This document discusses various sheet metal forming processes including shearing, bending, deep drawing, and spinning. It provides examples of common sheet metal parts and describes key operations like punching, blanking, and fine blanking. Important considerations for sheet metal formability are outlined, such as material properties and tests. The document also covers design factors for efficient sheet metal forming and examples of equipment used.
FINITE ELEMENT ANALYSIS OF BEAM-BEAM BOLTED CONNECTION UNDER PURE MOMENTIRJET Journal
This document describes a finite element analysis of a beam-beam bolted connection under pure moment. 24 models were analyzed varying bolt diameter (16mm and 20mm), gauge distance (40-80mm), bolt hole clearance (normal, vertical slotted, horizontal slotted), and cleat angle. The analysis aimed to determine the influence of gauge distance on the shear capacity of the bolted connection. Each model consisted of an ISHB350 primary beam, ISHB250 secondary beam, and cleat angle, all made of steel. The bolts were 10.9 grade friction grip bolts. The analysis was performed in ANSYS Workbench to determine the shear capacity of each connection configuration.
Sheet metal forming processes Erdi Karaçal Mechanical Engineer University of ...Erdi Karaçal
The document describes various sheet metal forming processes and provides characteristics of each. It discusses roll forming for parts with complex cross-sections and high production rates but high tooling costs. Stretch forming is described as suitable for low quantity production but with high labor costs and tooling/equipment costs depending on part size. Drawing is outlined as having high production rates but also high tooling and equipment costs.
3341906 pms lab_manual_prepared by vipul hinguVipul Hingu
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Shearing is a sheet metal forming process where a punch and die are used to cut or punch a part from sheet metal. Key aspects of shearing include the clearance between the punch and die, the shape of the punch and die, and the speed and lubrication used. Other common shearing operations include punching, blanking, die cutting, fine blanking, and slitting. Progressive and transfer dies are also used to perform multiple operations on a sheet metal part in one stroke or between stations. Bending involves applying tensile stresses to the outer fibers of sheet metal to form a curve. Factors like bend allowance, springback, and minimum bend radius must be considered for accurate bending. Deep drawing uses a punch to
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Fastener
1. There are many types of fasteners which could be used to assemble plastic parts:
screws, bolts, metal inserts, clips, spring washers, etc. The difference between
screws and bolts is that bolts necessary to assemble two unthreaded components
require a nut and/or a washer, while screws form an internal thread during the in-
stallation either by thread forming or thread cutting.
In this section we will address two types of screws: thread forming and thread cutting.
Thread forming screws, as the name implies, deform the polymeric material of the
boss or hole in which they are driven. On the other hand, thread cutting screws actu-
ally remove material from the boss or hole in which they are driven to form the
thread. Thread forming screws are preferred if repeated disassembly and re-assem-
blies are required.
(a) (b) (c) (d) (e)
(f) (g) (h) (i) (j)
(k) (l) (m) (n) (o)
(p) (q) (r) (s) (t)
Figure 11.1 Types of screw driving head: (a) Phillips slotted; (b) Quadrex; (c) Torx; (d) Phillips;
(e) Uni-screw; (f) slotted; (g) one way; (h) Torx slotted; (i) Pozidriv; (j) hex socket; (k) combo
squared; (l) squared; (m) tempered Torx; (n) Supadriv; (o) Torx plus; (p) slot hex washer; (q) hex
washer; (r) hex; (s) Frearson; (t) ACR Phillips
Fasteners
1
1
2. 352 11 Fasteners
Thread forming screws should be installed by using automated fastening systems or
manual power drives with torque limiters, also called transducers, which limit the
rotation to a maximum of 800 rotations per minute. To start the thread forming pro-
cess, the screw has to be slightly pressed into the pilot hole or boss. Screws can be
removed, for servicing and repair work, and re-installed, a few times, as necessary.
There are many types of screw heads used in various industries. Figure 11.1 shows
a variety of screw heads, some very common, like the hex screw, while others are
fairly new, like the Uni-screw head developed in Britain a few years ago.
„
„ 11.1 Thread Forming
As already stated, thread forming screws, when driven in the plastic part, deform
the polymer, thus forming the thread. Type AB, Type B, and Type C screws (see Fig.
11.2) are employed to assemble metal components. None of them are recommended
for plastic components because their thread flight angle of 60° may crack the plastic
boss or the plastic hole in which they are fastened, typically at or near the weld line.
However, Types AB and B are used in highly reinforced polymers—those exceeding
35% fiber reinforcement. The Type C screw is probably the worst type to be used for
plastic components because of the very small thread pitch (see Fig. 11.2 (c)).
Gimlet
point
60o
60o
60o
(a) (b) (c)
Figure 11.2
Thread forming screws for metal
components: (a) Type AB; (b) Type
B; (c) Type C
There are a number of screws specifically designed for assembling plastic parts.
HiLo®
is a registered name belonging to the Illinois Tool Works company. This type
of screw, HiLo®
(see Fig. 11.3 (a)), combines both 30° and 60° thread flights provid-
3. 11.1 Thread Forming 353
ing good retention capability for low to medium pull-out loads. The pull-out force is
defined as the tensile load necessary to pull and remove the self-tapping screw from
the mating boss. The HiLo® screw reduces radial stress exercised against the mating
boss and at the same time has a tendency to prevent boss cracking. They require low
driving torque for installation. A similar screw, from the Stanley Engineering Fasten-
ers company, called DST (dual-spaced threads) also offers both 30° and 60° thread
flights (see Fig. 11.3 (b)).
60o
30o
(b)
(a)
Figure 11.3
(a) HiLo®
thread forming screw;
(b) DST thread forming screw
Another thread forming screw is Plastite®
, a name registered to the Research Engi-
neering Manufacturing company, which exhibits a rather unusual shank, trilobu-
lar in shape (resembling a rounded triangle—Section A-A in Fig. 11.4). With this
shape of the shank the installation torque necessary to drive in the screw is reduced
when compared with other types of screws. At the same time, the screw design re-
duces the hoop stress and the root interference friction, which in general could
cause cracking, especially for bosses having thin walls. Another feature of this type
of screw is the thread angle, which in this case is 45° or 48°. The smaller thread
angle, when compared to metal thread forming screws, which have a thread angle of
60°, penetrates deeper into the plastic boss, allowing for a higher pull-out load. The
screw is available as single flight or double flight (see Fig. 11.5).
4. 354 11 Fasteners
A A
Section A - A
D
45÷48°
(a)
(b)
Figure 11.4
Plastite®
screw: (a) side view;
(b) section A-A
(a) (b)
Figure 11.5
Trilobular Plastite® screw with: (a) single helix;
(b) double helix
Simplex Corporation also registered a thread forming screw for plastics under the
name of Polyfast® (see Fig. 11.6). An asymmetrical thread flight design which has a
total angle of 45°, of which the leading angle represents 35°, while the remaining
angle of 10° acts as the trailing angle, are this screw major features. The Polyfast®
flight design requires low driving torque from around 2.4 in.·lb (0.016 MPa) to as
much 14 in.·lb (0.1 MPa). It is most suitable for unreinforced and ductile thermoplas-
tics.
5. 11.1 Thread Forming 355
10o
trailing
angle
26o
35o
leading
angle
Figure 11.6
Polyfast® screw
Probably the best thread forming screw for plastics is the screw known as PT or
Plastic Thread (see Fig. 11.7). The thread flight of this type of screw is 30° and it is
available in single or double flight. Two of the registered designs are available from
the German company EJOT Verbindungstechnik GmbH Co. KG, under the name of
Delta PT® and from the Turkish company Keba Fastenings, under the name of K-PT®.
Both products are available from many resellers worldwide.
(a) (b) (c)
30°
(d)
Figure 11.7 Plastic Thread screw: (a) PT screw with integrated washer; (b) PT screw; (c) Delta
PT® screw; (d) RS Duroplast
6. 356 11 Fasteners
The key feature of the PT screw is the 30° flight angle (see Fig. 11.8). When com-
pared with a regular thread forming screw having 60° thread flight angle, used to
assemble metal components and some highly glass or aramid fiber reinforced poly-
mers, the PT design allows for a significant reduction of the radial stress, while at
the same time increasing somewhat the pull-out load. Figure 11.9 shows that the PT
screw design penetrates deeper into the plastic boss or hole, thus reducing the hoop
stress and improving the retention load of the assembly.
FRadial
R
FAxial
30o
60o
rST
30o
R
FAxial
15o
FRadial
rPT
(a) (b)
Figure 11.8 PT thread flight detail compared with the standard thread
Boss
dia
Screw
root
dia
Flight
engagement
(a)
Boss
dia
Screw
root
dia
Flight
engagement
(b)
Figure 11.9 (a) Standard thread flight penetration detail; (b) plastic thread flight penetration
detail
From the free body diagram shown in Fig. 11.8 the radial force for standard thread
of 60° is
(11.1)
7. 11.1 Thread Forming 357
while the radial force for a plastic thread having a thread flight angle of 30° is
(11.2)
The plastic thread reduces the radial force by 48%, lowering significantly the load
which could crack the plastic component.
From the same Fig. 11.8 we can calculate the axial load capability for the 60° flight:
(11.3)
and for the plastic thread the axial force is:
(11.4)
which represents a 12% improvement in pull-out load capability.
Another important feature of the PT screw is the shank design (see Fig. 11.10). The
cylindrical portion of the shank is surrounded by two angled planes—easy to observe
in a 2D view—having an angle between them of 140°. The stress for each of the
thread flights is obtained by dividing the screw pull-out force by the area under each
flight. Therefore, first the area under each thread flight, A, is obtained by subtracting
the screw minor diameter area from its major diameter area:
(11.5)
Then the pull-out stress is:
(11.6)
When the screw is driven and forming the thread in the mating hole or boss, the
140° angle allows for the plastic/elastic deformation of the polymer (see Fig. 11.11).
This in turn provides a rather low radial stress in the plastic component in which the
PT screw is driven, while at the same time allowing for increased load carrying ca-
pability and preventing plastic relaxation of the polymer. The boss or hole in which
the PT screw is mounted could have a very thin wall stock, around 0.5 to 0.67 of the
overall wall thickness of the plastic component.
9. 11.1 Thread Forming 359
An important aspect for proper assembly using thread forming screws is the actual
plastic boss /hole design (see Fig. 11.12). To properly align the thread forming screw
with the mating hole or boss, it is necessary that the boss or hole in which the screw
is fastened has a counter bore greater than the minor diameter of the screw by at
least 0.2 mm or 0.008 in. The depth of the counter bore varies based on the type of
polymer used between 30% and as much as 50% of the major diameter of the thread
forming screw. The installation depth for the screw also varies depending on the
type of resin used (see Table 11.1).
t
OD
d +0.2 mm
M
0.3 ÷ 0.5dM
1
o
1
o
r = 0.5t
r = 0.25t
0.67t
y
=
installation
depth
dBoss
Min 0.5t
Counter
bore
Figure 11.12
Recommended boss
design for PT screws
Table 11.1 Recommended Dimensions for Different Types of Polymers Based on dM (Major
Thread Forming Diameter) for the Boss or Hole in Which the Screw Is Driven
Polymer Inside diameter Outside diameter Minimum installation
depth
ABS 0.8 · dM 2 · dM 2 · dM
ABS/PC 0.8 · dM 2 · dM 2 · dM
ASA 0.8 · dM 2 · dM 2 · dM
HDPE 0.75 · dM 1.8 · dM 1.8 · dM
LDPE 0.7 · dM 2 · dM 2 · dM
(continuation next page)
10. 360 11 Fasteners
Polymer Inside diameter Outside diameter Minimum installation
depth
PA 4.6 0.7 · dM 1.85 · dM 1.8 · dM
PA 6 0.75 · dM 1.85 · dM 1.7 · dM
PA 6 GR 0.8 · dM 2 · dM 1.9 · dM
PA 66 0.75 · dM 1.85 · dM 1.7 · dM
PA 66 GR 0.8 · dM 2 · dM 1.8 · dM
PBT 0.75 · dM 1.85 · dM 1.7 · dM
PBT GR 0.8 · dM 1.8 · dM 1.7 · dM
PC 0.9 · dM 2.5 · dM 2.2 · dM
PC GR 0.9 · dM 2.2 · dM 2 · dM
PET 0.75 · dM 1.85 · dM 1.7 · dM
PET GR 0.8 · dM 1.8 · dM 1.7 · dM
POM 0.75 · dM 1.95 · dM 2 · dM
POM GR 0.8 · dM 1.95 · dM 2 · dM
PP 0.7 · dM 2 · dM 2 · dM
PP GR 0.72 · dM 2 · dM 2 · dM
PP TR 0.72 · dM 2 · dM 2 · dM
PPO 0.85 · dM 2.5 · dM 2.2 · dM
PS 0.8 · dM 2 · dM 2 · dM
PVC 0.8 · dM 2 · dM 2 · dM
SAN 0.77 · dM 2 · dM 1.9 · dM
It should be noted that when employing self-tapping screws for an assembly, it is
very important to use a torque limiter for the driving tool which holds the screw
socket. As shown in Fig. 11.13, the stripping zone can very easily be reached with-
out a proper torque limiter. Keeping the screw driving tool speeds between 300 rota-
Table 11.1 Recommended Dimensions for Different Types of Polymers Based on dM (Major
Thread Forming Diameter) for the Boss or Hole in Which the Screw Is Driven (continuation)
11. 11.1 Thread Forming 361
tions per minute (rpm) at the low end and 800 rpm at the high end ensures that the
plastic material is not damaged, thus providing reliable installations. The heat gen-
erated during the fastening process can break down the plastic by melting it, thus
reducing the required torque levels stipulated by the specific application. Speeds
should be kept below 800 rpm so that the polymer does not melt, thereby destroying
the plastic component. To reduce or even eliminate the eventuality of screw strip-
ping, the ratio between stripping torque and driving torque should be minimized.
Driving guns activated pneumatically have large torque variance even when a torque
controller is employed. Tolerance for such torque limiters varies between ±15% at the
low end and as much as ±20% at the high end of the required set torque. Electronic
tools, activated electrically, provide much greater accuracy in the range of ±2–4%.
Fully automated electric tools should have a drive to strip ratio of 1 to 5. For hand
tools the ratio is lower, from 1 to 2.
Penetration depth
Torque
Zone 1 - Thread forming
Zone 2 - Clamping
Zone 3 - Stripping
Zone 1 Zone 2 Zone 3
T1
T1
T2
T3
T3
T2
Figure 11.13 Screw stripping zone
As a rule of thumb, the longer the screw, the higher the pull-out forces and strip
torques are. However, the improvement in load bearing is not directly proportional
to the length of the screw utilized.
Thread forming screws are inexpensive and quite reliable, allowing assembly and
disassembly of dissimilar polymers up to 10 times. At the same time, components
assembled with thread forming screws are prone to stress concentrations at the
joined location. When employing screws to assemble components the increased la-
bor costs could become a major issue.
12. 362 11 Fasteners
„
„ 11.2
Case History: Automotive Undercarriage
Splash Shield
European original equipment manufacturers (OEMs) had to use splash shields (see
Fig. 11.14) under their vehicles in order to improve the aerodynamics and at the
same time to increase the gas mileage, the main reason being the high cost of gaso-
line and diesel fuels when compared with North America. The automobiles with
splash shields under the carriage appeared in the North American marketplace in
the 1980s. Then, a few years later, other car manufacturers, from Asia, started using
splash shields to improve the gas mileage for their vehicles as well.
Figure 11.14
Typical undercarriage
splash shield
Almost all splash shields use commodity polymers like polypropylene or polyethyl-
ene. However, in most cases, the polymers employed are recycled resins. Depending
on how many heat histories the polymer was exposed to during the manufacturing
process, the resin mechanical properties could drop by as much as 50%. When
recycled polymers are used, the number of heat histories (the number of times the
polymer passes through the injection molding press) should be kept well below
seven.
An OEM from Asia had used a recycled unreinforced polypropylene resin to manu-
facture an undercarriage splash shield for one of their vehicles. To assemble the
shield to the chassis of the vehicle a metric hex bolt without washer was used (see
Fig. 11.15 (a)). Many vehicles developed shield failures during the warranty period.
They were breaking just underneath the bolt head, holding the shield to the chassis,
at the weld line.
13. 11.2 Case History: Automotive Undercarriage Splash Shield 363
M10 Hex Bolt
Type AB
Plastic Part
Metal Part
FIN
Compressive
stress
4,118 psi
(28.4 MPa)
Washer
d
FIN
M10 Hex Bolt
Type AB
Plastic
Part
Metal Part
Compressive
stress
492 psi
(3.4 MPa)
(a)
Figure 11.15 Cross-section of a splash shield held to the chassis with an M10 hex bolt: (a)
without washer; (b) with washer
d = 5.85 mm
26 mm
AW AB
10 mm
dP
DK
TIN
Figure 11.16
Torque load applied when assembling
the bolt to the chassis
14. 364 11 Fasteners
The bolt head shape is a hexagon (see Fig. 11.16). The area under the bolt head re
presents the area of the hexagon from which the area of the bolt shank is subtracted.
The hexagon is made of six equilateral triangles. The side of each triangle is:
(11.7)
The area of each triangle is:
(11.8)
Then the hexagon area is six times greater:
(11.9)
This is how the area under the bolt head is obtained:
(11.10)
Screw tension is generated when the screw elongates during tightening, producing
the clamp load that prevents movement, rattles, and squeaks between the polypro-
pylene aerodynamic splash shield and the chassis of the vehicle. The equation defin-
ing the relationship between the applied torque exercised by the wrench tightening
the screw and the compression exercised against the PP shield by the screw is de-
scribed by the k-method relationship:
(11.11)
where TIN = torque applied by the wrench, k = friction factor, dM = bolt major diame-
ter, and FC = bolt tension generated during tightening.
The friction factor, k, consolidates all factors that affect the clamp load. Most of them
are determined by conducting proper mechanical testing. The friction factor, also
called nut factor, is not obtained from engineering calculations, but it is determined
through proper testing.
The coefficients which are part of the friction factor, k, are:
μk = Coefficient of friction under the screw head
μG = Coefficient of friction in the threads
dP = Pitch diameter
P = Thread pitch
dM = Bolt major diameter
dk = Acting diameter for determining the friction torque at the fastener head
15. 11.2 Case History: Automotive Undercarriage Splash Shield 365
Thus, the value of k is obtained from:
(11.12)
and consequently the compression load under the bolt head, FC, is:
(11.13)
This, in turn, generates the compressive stress, σC, against the polypropylene shield,
when a bolt without washer is used:
(11.14)
By using a washer having a 26 mm outside diameter, the compressive stress exer-
cised against the shield is greatly reduced.
The area under the washer is:
(11.15)
The compressive load, being the same as before, generates a much lower compres-
sive stress:
(11.16)
The compressive stress generated by the torque applied to clamp the shield to the
chassis, when using a washer under the bolt head, lowers the load by over 88%. Prob-
ably the best unreinforced polypropylene has a stress capability of around 5,000 psi
or about 34.5 MPa. The undercarriage splash shield, in this case, was made of recy-
cled polypropylene resin having a much lower stress carrying capability—about half
or around 2,500 psi or 17 MPa. Furthermore, around each molded-in hole, for as-
sembly screws, in the shield exists a weld or knit line, created by the advancing
flows of resin during the injection molding process, which could reduce the stress
capability by another 50% to around 1,250 psi or 8 MPa (see Fig. 11.17 (a)).
A weld line forms when frozen layers at the front of each advancing flow front meet,
melt, and then re-freeze again within the component being molded. The molecular
chains within the polymer orient themselves perpendicular to the flow front at the
weld line. It is the sharp difference of the molecular chain orientation at the weld
which causes the significant decrease in strength. If the gate location can be changed,
one possibility to improve the weld line strength would be to generate a weld line
followed by a meld line during the injection molding cycle time (see Fig. 11.17 (b)).
16. 366 11 Fasteners
Gate
(Melt)
Weak region
(a)
Gate
(Melt)
Weld
line
Meld
line
Stronger region
(b)
Figure 11.17
Formation schematics of:
(a) weld line; (b) weld line
and meld line
As a result of the vibration created by the vehicle when driven, the splash shield
made of recycled PP was failing because the stress exercised by the M10 bolt with-
out washer was much greater than the resin capability. The Asian OEM started using
a washer which translated into reducing the compressive stress load under the
washer and M10 hex bolt by a factor of nine with no warranty concerns.
There are injection molding processing steps, tooling changes, and plastic part de-
sign changes which can be applied to improve the weld line strength as mentioned
above. A meld line occurs when two advancing molten resin flow fronts of the molten
polymer inside the mold during the injection stage of the molding process blend to-
gether at an angle greater than 135°. Figure 11.18 shows a component where a meld
line forms.
Meld lines are stronger than weld lines and offer fewer defects that are visible of the
surface of the plastic component.
Consistent meld lines are challenging to obtain; however, it is possible to attain them
by changing the polymer injection location, also called the gate location, or by modi-
fying the wall thicknesses and achieving different fill times. This can be achieved by
keeping records of the injection molding process parameters and tool modifications
as per Appendix C and D, and by reviewing them. Other modifications of the injec-
tion molding process consist in increasing the polymer melt temperature and/or the
tool temperature, thus allowing the advancing flow fronts to integrate better. Opti-
mizing the runner system of the mold could prove beneficial as well in achieving
consistent meld lines.
The use of additives, fillers, or reinforcements in the polymer results in a tendency to
highlight both weld and meld lines. Especially glass fibers, as well as metallic pig-
ments, are good examples of reinforcements and additives which make them more
visible.
17. 11.2 Case History: Automotive Undercarriage Splash Shield 367
Gate
Weld line forms
Gate Gate Gate
Meld line forms Meld
Weld
(a) (b) (c) (d)
α
Figure 11.18 Creating a meld line: (a) the advancing flow fronts of the molten resin go around
the metal pin forming the hole in the plastic component; (b) the angle α between the flow
fronts which “kiss” behind the metal pin, forming a classic weld line, is greater than 135°;
(c) adjustment of the injection pressure of the injection molding press such that the molecular
chains move perpendicular to the flow direction; (d) during the packing and holding stage of the
injection molding process, the meld line forms
The precise strength of both weld lines and meld lines varies between 15 and 85% of
the molded polymer. In general, calculations indicate that the resin strength at the
weld line is decreased by 50% while for the meld line by just 30%.
One of the newest screws on the market to be used when a plastic product is exposed
to vibration in applications such as in the automobile industry is BosScrew™. The
design was patented by Illinois Tool Works. The distinct features for this type of
screw are the small indentations present on the 60° thread flights (see Fig. 11.19).
When it is driven into a plastic boss, the polymer tendency to creep under constant
load prevents the screw from becoming loose by interlocking it with the polymer.
Figure 11.19
Anti-vibration screw: BosScrew™
18. 368 11 Fasteners
„
„ 11.3 Thread Cutting
Thread cutting screws create threads in the mating boss or hole by either having
cutting slots or having some of their flights slotted. When they are driven into the
plastic part they cut the polymer, creating “chips” or plastic debris. The bottom of
the boss or hole in which thread cutting screws are employed acts as a debris cavity,
capturing all the falling chips.
(a) (b) (c)
Figure 11.20
Standard thread cutting screws: (a) Type BT;
(b) Type BF; (c) Type T
In Fig. 11.20 are shown standard thread cutting screws having 60° flight angles.
Type BT (Fig. 11.20 (a)) is probably the most common because has wide thread spac-
ing and a generous cutting slot. They were also previously called Type 25 screws.
The next screw type, Type BF (Fig. 11.20 (b)), also displays wide thread spacing, but
features slashed cutting flights which have clogging tendency when working with
softer polymers around 200,000 psi (1,400 MPa).
In Fig. 11.20 (c) is displayed screw Type T, also called Type 23. This type of screw in
general is used only for highly reinforced polymers having fiber content beyond 35%
or modulus higher than 1,000,000 psi (7,000 MPa). The threads that cut into the
polymer chip the resin making it difficult if not impossible to re-assemble the com-
ponents. The engagement length for all thread cutting screws has to be at least
double than thread forming screws (see Table 11.1).
For softer, unreinforced polymers, thread cutting screws having 30° flights, also
known as PT or plastic thread, are recommended. As explained in the thread form-
ing section, these flights bite deeper into the polymer, making them better for sus-
taining higher pull-out loads.
19. 11.4 Conclusion 369
Figure 11.21 shows the thread cutting screw with 30° flights named Duro-PT®. It is
mostly recommended for thermoset materials like polyesters, and the name is a
registered trademark belonging to the EJOT company. The screw has a cutting slot
which cuts the threads into the mating component, and a 30° flight angle, which
allows for rather low installation torque levels, at the same time exhibiting high
stripping loads, especially when used in thermoset polymers. Duro-PT® screws are
used in a variety of industries: consumer products (telephones, coffee makers, print-
ers, toys, etc.), appliances (washers, copiers, etc.), automotive, and others.
Shank slot
30o
Figure 11.21
Duro-PT®
plastic thread cutting screw
„
„ 11.4 Conclusion
In general, thread forming (a.k.a. thread-rolling) screws are used to assemble com-
ponents that would need to be disassembled for servicing or during the warranty
period of the given product.
On the other hand, thread cutting screws are intended for products that do not re-
quire servicing—mostly for one-time use products—because once the threads are cut
into the plastic components of the assembly, it is very unlikely that when re-assem-
bling the components the screw flights would follow the cut threads.