Week 9 - Project 1 - Door Trim Lower with Engineering Features
AIM :
To create a solid body of a given Door Applique and to create the Locators and Heat Stakes on it as per design standards.
INTRODUCTION :
• Heat Staking
Heat Staking is a pulsed-heat process to join two or more parts out of which one at least is made of plastic. The process is to deform the plastic material using heat and force at a set process time. The bond is made by partially de-forming the plastic part in order to fix the other.
Heat Staking makes it easy to bond metal to plastic and is commonly used in high volume/low cost applications such as automotive, IT and consumer appliances. In Manufacturing Of thermoplastic components,it is often necessary to join the thermoplastic to a part of a dissimilar material,weather it can be a metal,dissimilar material or the other material.Thermal staking is an assembly method that uses the controlled melting and reforming of a plasticstud or boss to capture or lock another plastic or a metal component of an assembly in place.The plastic studs protrude through the holes in a component to be locked in a place.the heated thermal tip contacts the top of the stud ,which melts and fills the volume of the tip cavity to produce the head,locking the component in a place. The progressive melting of the plastic under continous pressure forms the head.When Staking,the right combination of heat and pressurefor the applications is critical.
Advantages of Heat Stakes:
• Accurate control operating within a small process window.
• Local heating resulting in no damage to surrounding materials.
• Processing of glass-filled materials.
• No mechanical vibration.
• Many heat-stake shapes possible through custom designed tools
4 way locators
In any kind of assembly before fixing the part to the mating part we need to fix the position of the part with respect to the mating part. In these cases we need to follow some engineering principles. In this project we are going to follow the 3-2-1 Principle. Any Part which has to be fixed during welding or machining process has to be fixed is having 12 degrees of freedom.
Creating 4 way locators and Heat stakes :
4-way locators mean you prevent movement at 2 axis (+X, -X, +Y and -11) on the plane. Generally you have cylindrical pin on the fixture and circular hole at workpiece part.
Heat Staking is a pulsed-heat process to join two or more parts out of which one at least is made of plastic. The process is to deform the plastic material using heat and force at a set process time. The bond is made by partially de-forming the plastic part in order to fix the other.
