Injection Forging—Process and Component

Injection forging is a process in which the work-material retained in an injection chamber is injected into a die-cavity in a form prescribed by the geometry of the exit (Fig. 1). The process is characterized by the combination of axial and radial flows of material to form the required component-form. In the 1960s, some interest was generated in injection upsetting [1]; it was developed with a view to extruding complex component-forms. The process configuration has since been the subject of research spanning fundamental analysis to the forming of specific components; branched components and gear-forms have been produced. The single-stage forming of such component-forms has been achieved by injection techniques; these forms were previously regarded as unformable by conventional processes. Currently, the nett-forming of some complex component-forms has been achieved by Injection Forging [2]. To date, several names have been used to describe this configuration—injection forming, injection upsetting, radial extrusion, side extrusion, transverse extrusion, lateral extrusion, and injection forging [2–22].

COMPUTER-AIDED DESIGN,
ENGINEERING, AND MANUFACTURING
Systems Techniques And Applications
VOLUME
V I
MANUFACTURING
SYSTEMS PROCESSES
Editor
CORNELIUS LEONDES
CRC Press
Boca Raton London New York Washington, D.C.

Modulus of Elasticity

There are different techniques that have been used for over a century to increase the modulus of elasticity of plastics. Orientation or the use of fillers and/or reinforcements such as RPs can modifl the plastic. There is also the popular and extensively used approach of using geometrical design shapes that makes the best use of materials to improve stiffness even for those that have a low modulus. Structural shapes that are applicable to all materials include shells, sandwich structures, dimple sheet surfaces, and folded plate structure.
Plastics
Engineered
Product
Design
Dominick Rosato and
Donald Rosato
Elsevier Ltd, The Boulevard, Langford Lane, Kidlington, Oxford OX5 lGB, UK
Elsevier Inc, 360 Park Avenue South, New York, NY 10010-1710, USA
Elsevier Japan, Tsunashima Building Annex, 3-20-12 Yushima, Bunkyo-ku, Tokyo 113,
Japan

Mechanical Properties of Metals (2)

6. Brittleness.

It is the property of a material opposite to ductility. It is the property of breaking of a material with little permanent distortion. Brittle materials when subjected to tensile loads, snap off without giving any sensible elongation. Cast iron is a brittle material.

7. Malleability.

It is a special case of ductility which permits materials to be rolled or hammered into thin sheets. A malleable material should be plastic but it is not essential to be so strong. The

malleable materials commonly used in engineering practice (in order of diminishing malleability) are lead, soft steel, wrought iron, copper and aluminium.

8. Toughness.

It is the property of a material to resist fracture due to high impact loads like hammer blows. The toughness of the material decreases when it is heated. It is measured by the amount of energy that a unit volume of the

material has absorbed after being stressed upto the point of fracture. This property is desirable in parts subjected to shock and impact loads.

9. Machinability. It is the property of a material which refers to a relative case with which a material can be cut. The machinability of a material can be measured in a number of ways such as comparing the tool life for cutting different materials or thrust required to remove the material at some given rate or the energy required to remove a unit volume of the material. It may be noted that brass can be easily machined than steel.

10. Resilience. It is the property of a material to absorb energy and to resist shock and impact loads. It is measured by the amount of energy absorbed per unit volume within elastic limit. This property is essential for

spring materials.

FIRST MULTICOLOUR EDITION

A TEXTBOOK OF

Machine

Design

(S.I. UNITS)

[A Textbook for the Students of B.E. / B.Tech.,

U.P.S.C. (Engg. Services); Section ‘B’ of A.M.I.E. (I)]

R.S. KHURMI

J.K. GUPTA

EURASIA PUBLISHING HOUSE (PVT.) LTD.

RAM NAGAR, NEW DELHI-110 055

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PRESS FITS

When one object such as a shaft is assembled to another by forcing it into a hole that is slightly too small, the operation is known as press fitting. Press fits can be designed between similar plastics, dissimilar plastics, or more commonly between a plastic and a metal. A typical example occurs when a plastics hub in the form of a control knob or gear is pressed on a metal shaft. The position is reversed when a plastics sleeve or bearing is pressed into a metal bore.

Press fits are simple and inexpensive but there are some problems to look out for. The degree of interference between the shaft and the hole is critical. If it is too small, the joint is insecure. If it is too great, the joint is difficult to assemble and the material will be over-stressed. Unlike a snap fit, the press fit remains permanently stressed and it is the elastic deformation of the plastics part that supplies the force to hold the joint together.

When plastics materials are exposed to permanent stress the result is creep. This means that as time goes by, the force exerted by the press fit becomes less, lthough not necessarily to a significant extent.

There are two other pitfalls for press fits. Manufacturing tolerances on the shaft and hole must be taken into account to see whether the two extreme cases remain viable.

And when the joint is made between dissimilar materials, an increase in temperature will change the degree of interference between the parts. Remember too, that at elevated temperatures the effect of creep will be greater.

One way of countering the effect of creep in a shaft and hub press fit is to provide a straight medium knurl on the metal shaft.

The plastics hub material will tend to cold flow into the grooves of the knurl, giving a degree of mechanical interference between the parts. The frictional effect is also greater because the surface area of the joint has been increased by the knurl.

DESIGN GUIDES

for

PLASTICS

Clive Maier, Econology Ltd

Plastics Design Group - Plastics Consultancy Network

British Plastics Federation

pdg

plastics design group

December 2004 Edition

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