Automotive Plastic Part Design
3-days Seminar: March 3, 4 & 5, 2009.
Seminar Hours: 8:30 a.m. - 4:30 p.m. (registration first day at 8:00 a.m.)
Greenville Technical College - Buck Mickel Center, Greenville, SC (click here for written directions)
216 S Pleasantburg Drive
Greenville SC 29607-2522 USA
Room 202

To register click HERE Instructor

This three-days in-depth automotive seminar will provide information on material selection, design procedures, processing techniques, and the assembly methods required when designing with plastics in the automotive field. Attendees will focus on what to expect from a polymeric material and discuss in detail methods and methodologies used to make the design process as easy as possible and fully comply with FMVSS. In addition, this course will enable the automotive OEM and his supplier (1st, 2nd, or 3rd-tier) to have more effective communication. The OEMs will learn how to initiate their concepts on a solid, communal basis, thus allowing for cost-efficiencies and fewer second thoughts when they understand the scientific basis, and the fine tuning that comes with experience. A large number of automotive case histories will explain the step-by-step procedures to successful and robust designs.

Ideal Learner This course is targeted at automotive designers, product managers, project managers, research engineers, material engineers, graduate and undergraduate students, or anyone involved in the development and manufacture of automotive plastic products and systems. Its content is intended for a variety of automotive segments such as interior systems, infotaiment, powertrain, safety systems, chassis, exterior trim, front end modules, crash management, electronics, and any other automotive and transportation applications which use plastic resins. A number of case histories will show you step-by-step procedures to successful and robust designs. Plan to attend and come prepared with questions to ask or experiences to share.

Seminar Outline

Plastics Materials and Automotive Technologies North American Automotive Plastics Usage by Segment Interiors: Infotaiment, Instrument Panel Exterior: Mega Front End Module Underhood: Upper Engine Module, Brake-by-Wire, Steer-by-Wire, Active Suspension Powertrain/Chassis: Hybrid, Run-Flat-Tire, Fuel Cells

Understanding and Selecting Plastic Materials Resins: Thermoplastics & Thermosets Structures: Crystalline, Amorphous & Liquid Crystal Polymers Inherently Conductive Polymers (ICP) BioPolymers: Poly Lactic Acid (PLA Polymers) Light Emitting Polymers Electro-optic Polymers Carbon Nanotubes Reinforcements: Glass Fibers, Aramid, Fibers, Carbon Fibers Fillers: Talc, Mica, Calcium Carbonate, Wollastonite Additives, Effect of Additives, Physical Properties Elasticity, Toughness, Plasticity, Notch Sensitivities, Mechanical Properties Moisture Sensitivities, Processing Shrinkage and Post-Processing Shrinkages Thermal Expansion and Contraction, Creep, Stress Relaxation Automotive Thermal Characteristics Automotive Chemical Characteristics

Material Initial Selection & Screening Thermal Behavior, Automotive Chemicals Dimensional Tolerance & Burning Impact, Specific Gravity & Cost Engineering Properties, Snap Fits & Hiving Hinges Assembly Methods

Understanding Safety Factors What is a Safety Factor? Using Safety Factors in Automotive Design Design Safety Factors: Static, Dynamic, Time Related Processing Safety Factors Reliable Automotive Brands Operating Condition Safety Factors: Legal Aspects of Automotive Business

Rules for Proper Automotive Plastic Part Design Boss Design for Different Type of Polymers Boss Design Layout, Ribbing: Dimensions, Junctions Automotive Case History: Mercedes Benz E-Class Seat Trim Wall Thickness, Fillets, Part Stiffness, Undercuts Draft Angles: Core Vs. Cavity, Texturing

Strength of Materials for Plastics Stresses: Tensile, Compressive, Shear, Torsion, Elongations (Strains) True Stress and Strain Versus Engineering Stress and Strain Poisson's Ratio, Modulus of Elasticity-Which One to Use, and How to Use It

Non-Linear Considerations Material: Linear and Non-Linear Polymer Models Geometry: Linear and Non-Linear Models Finite Element Analysis (FEA) and How to Use It Design Optimization Tools: BMX, ISight, TRIZ Theory of Solving Problems Inventively, Conclusions

Ultrasonic Welding Equipment, Type of Vibrations, Ultrasonic Cycle, Troubleshooting Design: Shear Joint, Energy Director Joint (Tongue & Groove) Fixture Design Ultrasonic Stake Designs: Flash, Hollow, Spherical, Knurl Ultrasonic Spot Welding, Swaging, Stud

Heat Staking Post Design: Round Solid, Round Hollow, Cross, Angled

Hot Plate Welding Process, Equipment, Joint Design Advantages & Disadvantages Joint Area Strength Capability Automotive Case History: Mercedes-Benz M-Class Windshield Washer Bottle

Vibration Welding Equipment, Process, Phases, Cross-thickness Joint Design Welding Glass Reinforced Polymer Fixture Design

Laser Welding Equipment, Surface Heating, Through Transmission Infrared Welding, Staking Joint Design, Single Movement Mode, Continuous Illumination, Mask Welding Automotive Case History: Ignition & Trunk Keys

Electromagnetic Welding Equipment, Induction Coil Materials, Bonding Agent Joint Design Automotive Case History: Mitsubishi Motors - Power Steering Fluid Reservoir

Bonding Failure Theories: Adhesive, Cohesive Substrate Wettability Tests Drafting Symbols for Bonding What is Surface Energy and How to Improve It Surface Treatments: Corona, Plasma, Flame Bonding Stresses: Tensile, Compressive, Shear, Peel, Cleverage Joint Designs Automotive Case History: DaimlerChrysler CCV Vehicle Stress Cracking, Adhesives, Solvents

Automotive Painting Adhesive Promoters, Primers, Base Coat, Top Coat Painting Considerations, Painting Work Flow Power Wash Parameters Automotive Case History: Mercedes-Benz E-Class Wheel Hub

Press-Fits Material Properties, Geometric Definitions, Safety Factors, Creep, Loads Press-Fit Theory Design Algorithm Methodology Case History: Cassette Deck Solution and Discussion: Case A, B, C, and D Automotive Case History: DaimlerChrysler 300M - High Output 3.5l V-6 Engine Fusible Core Injection Molding, Upper Intake Manifold Background Design Requirements, CAMPUS Database Material Properties, Summary: Geometry/Material Properties Algorithm, Conclusion Case History: Examples of Successful Press-Fit Designs

Living Hinges Design for PP, PE, Common Living Hinge Design Design for Engineering Plastics, Living Hinge Design Analysis Elastic, Elastic/Plastic, Plastic Hinge Designs Automotive Case History: GM World-Class Electrical Connector Step-by-Step Design Analysis Automotive Case History: Delphi Ignition Cable Bracket for V-6 Engines Molding Hinges, Processing Issues, Coined Hinges Class Exercise: Design, Material Selection & Processing, Tooling Oil-Can Terminology & Concepts, Oil-Can Designs Incorporating Living Hinges Software Demo for Designing Living Hinges

Snap Fits Material Considerations, Design Considerations Assembly Positioning, Assembly Motions, Yield Criteria Safety Factors Cantilever Snap-Fits Snap-Fits: Instantaneous Moment of Inertia, Angle of Deflection, Self-Locking Angle Automotive Case History: One-Way Continuous Beam with Rectangular Cross Section Finite Element Analysis Example Case History: Hewlett-Packard Omnibook Annular Snap-Fits: Shallow Groove, Deep Groove Case History: Pen & Cap Torsional Snap-Fits: Round, Round Hollow, Square, Triangular Automotive Case History: GM World Class Electrical Connector Deformable Rib Design, Springiness Rate, Automotive Recyclability Symbols for Plastics Assembly-Disassembly Assists, Over-deflection Prevention Tooling for Snap-Fits, Issues with Snap Fitting Case History: Injection Blow Molded Bottle Assembly Serviceability, Conclusions Software Demos for Snap-Fits

Automotive Integral Seal Design Design Issues: Integral Seal - Design A, Integral Seal - Design B Structural Analysis: Step 1 through 7, Material Model Engineering Stress-Strain Curve True Stress-Strain Curve - Plastic Region Analysis Results: Total Displacement, Von Mises Stress Detail Simulating Leak Through Seal 1, Simulating Leak Through Seal 2 Processing Issues, Drying, Melt Temperature, Injection Pressure Injection Rate, Screw Forward Time, Mold Temperature, Cooling Time, Screw Retraction Tool Design: Mold Closed - Part Filling Mold Opening Phase 1 - Gate Breaks, Mold Opening Phase 2 - Slide Moves Part Ejection, Sprue & Runners, Gates: Tunnel (Submarine) Gate Features, Pinpoint Gate Venting

Troubleshooting Air Traps, Black Specks, Burn Marks, Dark stripes Flashing, Flow Marks, Hesitation, Jetting, Parts Not Releasing from Tool Peeling, Sink Marks, Shrinkage, Splay, Sprue Sticking, Unfilled Parts (Short Shots) Unmelt, Warpage, Weld lines

Over-molding + InMold Assembly Reasons for Multi-Material Part Design & Material Selection Indexing (Rotating Platen) Tool Mold with Core Retraction InMold Assembly Case History: FitLogic Case History: Louver Assembly Case History: Mercedes Tumble Valve Bearings ABS, ASA, CA, EVA, PA, PC, PE, PMMA

Tooling Considerations Gate Design: Direct (Sprue), Edge (Standard), Film, Fan, Tunnel (Submarine), Pin (Point), Ring, Sprue, Spoke, Disk, Tab, Diaphragm, Valve, Hot Runner Sprue Design: Reverse Taper Puller, Z Sprue Puller, Ring Sprue Puller, Sprue Design Formula Runner Design: Runner Cross-Section Runner Layout: Herring Bone, H-Type, Star

Processing Issues for Design Engineers Melt Temperature Profile, Screw Design, Boost Stage Fill Speed, Hold Stage, Tool Temperature & Back Pressure Reducing Part Weight & Size, Increasing Part Weight & Size, Venting

Fasteners Self-Threading Recessed Driving Heads, Tread Forming Clamp Load Vs. Time, Torque Vs. Penetration Depth Type AB (Standard Thread), Type B (Standard Thread), Type C (Standard Thread) Hi-Lo, PT (Plastic Thread), Free Body Diagram Pullout Load Vs. Engagement Area Assembly Stress, Plastic Boss Design for PT Fasteners RS Plast, Delta PT , Polyfast, and Plastite Thread Designs Automotive Case History: Threaded Assembly Calculation Weld and Meld Line Present into a Plastic Part Weld Lines in Parts made of Reinforced polymers Thread Cutting: Type BF, T, Hi-Lo, RS Duroplast, and Duro PT Pilot Hole Design detail

Plastic Part Design on the World Wide Web

Free review of attendees' projects

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