Transcript of Syntactic Foam for Plug Assist Module 2 Agenda 1.Plug assist materials 2.Basic design concepts.
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- Slide 2
- Syntactic Foam for Plug Assist Module 2
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- Agenda 1.Plug assist materials 2.Basic design concepts
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- Why Use a Plug? Plug assist tooling helps stabilize the process
Aids material distribution Allows thinnest possible starting gauge
thickness Allows design detail Reduces cycle time Allows
temperature optimization Aids part clarity Reduces overall process
cost
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- Materials for Consideration CategoryMaterialProsCons
Historical/Traditional materials Wood, Felt, Wood/Felt, Wood/Foam,
Foam or Felt covered forms Good Insulator Ease in machining Cost
Durability/Dimensional stability Mark-off/Part repeatability Temp
resistance AluminumTemp/process control Durability Surface
characteristics Temp/process control Increased cycle time Process
Cost Solid Polymers (traditional) Delrin, Nylon, Urethane,Cost
& availability, Ease in machining / toughness Surface
characteristics Durability/dimensional stability Poor insulators
Temp resistance Solid Polymers (high performance) Polysulfone,
PEIImproved temp resistance Toughness/strength Surface
characteristics Durability/Micro- cracking/Crazing Poor Insulators
Cost Engineered Plug AssistSyntactic foamExcellent insulator, Ease
in machining Surface finish choices, Durable Learning curve for use
Initial cost Many choices
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- Physical Specifications Material Color Service Temperature
Thermal ConductivityDensity Flexural Toughness (ASTM D790) Typical
CNC Finish (in) CTE 0F0F 0C0CBTU/hr-ft- 0 FW/m 0 Klb/ft 3 kg/m 3
PsikPaRax10 -6 in/in 0 Fx10-6 m/m/ o C POM/Delrin
3501762.54.3881409 4785 Nylon 3501761.72.945720 60110 Aluminum -
1442491672675 2240 Oak 500? 0.10.1745720 59 Felt
0.040.069Substrate? Polysulfone 3001480.150.26781249 3156 PEI
3401710.100.17801281 3156
HYTAC-WWhite3501760.070.11436902.718.6542241
HYTAC-WFWhite4502320.110.19558804.732.4281832 HYTAC-WFTLight
Green4252180.110.19609604.531242037
HYTAC-FLXPink3501760.070.11467407.652.4222342 HYTAC-FLXTDark
Green3501760.10.17508057.249.6212036 HYTAC-C1RSlate
Blue3501760.070.134674011.377.9223563 HYTAC-B1XLight
Blue3501760.110.194572111.680393868
HYTAC-XTLMauve3501760.100.194572123.7163.432 58
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- Understanding HYTAC Thermoset Co-Polymer Thermoplastic Low
price Low CTE Low TC Ease of machining Excellent material
distribution
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- Understanding HYTAC Thermoset Co-Polymer Thermoplastic Low CTE
Low TC Good matl distribution Brittle & dusty Excellent matl
distribution Easiest to polish Excellent matl distribution Most
durable
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- Starting reference point: material safe means it is easy to
remove material but impossible to put it back. Contact with plug
and sheet: more contact = more carry. Basic Design Concepts
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- Plug Design Possibilities* *Courtesy of Computer Designs, Inc.
Whitehall, PA ORIGINAL DOGBONE 7 0 TAPER,.750 RAD. SIDES 3 0 TAPER
1.25R TOP 3 0 TAPER FULL TOP POCKET 3 0 TAPER.750 X 30 0 CHAMFER
TOP
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- Geometry Change Expected Effect. 3 0 TAPER.750 X 30 0 CHAMFER
TOP 10 0 TAPER, HOLLOW FLOOR 3 0 TAPER 1.25R TOP
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- Putting it all Together
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- conor.c@cmtmaterials.com +1 508 226 3901 End of Module 2