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Finishing, Adhesion, and Assembly

Finishing, Adhesion, and Assembly. MFG 355. Material removal. Traditional Cutting, Drilling, Milling Surface finishing Issues Heat transfer Peck drilling Skip-tooth saws Increased cutting speed Slower cutting advance Hole size (shrinkage) Cutting fluids Brittle/soft Composites.

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Finishing, Adhesion, and Assembly

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  1. Finishing, Adhesion, and Assembly MFG 355

  2. Material removal • Traditional • Cutting, Drilling, Milling • Surface finishing • Issues • Heat transfer • Peck drilling • Skip-tooth saws • Increased cutting speed • Slower cutting advance • Hole size (shrinkage) • Cutting fluids • Brittle/soft • Composites

  3. Traditional Machining • Used to make minor shaping corrections • Used to trim excess material • Used often in thermoforming and blowmolding • Sometimes parts are molded oversized so that they can be machined to exacting tolerances

  4. Material removal – water jet • Typically used with the more difficult materials (composites, very hard plastics) • Water-jet can cut most materials, even composites effectively

  5. Material removal – lasers • Laser cutting burns the material away • In clear materials, holes can be cut between surfaces without affecting the surface • Focus adjustment can reduce kerf, heat distortion and depth of cut

  6. Material removal – hot wire • Traditionally used for foams • Can cut any thermoplastic • Material may flow back together

  7. Joining • Adhesive joining Definitions: • Adherends/substrates – pieces to be joined • Adhesive – glues • Applicator – the device used to put on the adhesive

  8. Chemical Etch Bath Adhesive Joining (Adherends) • Surface preparation • Cleaning • Chemical etching • Flame treatment • Corona treatment • Plasma treatment • Coupling agents • Mechanical abrasion • Especially important for some materials (PE)

  9. Adhesive Joining (Adhesives) • Liquids, pastes or solid films • In all cases the adhesive goes through a liquid phase • Chemical change • Structural • Hot melt • Pressure sensitive • Water based • Radiation cured

  10. Non-Traditional Joining • Fusion • Heat materials and force them together • Ultrasonic • Vibrate the materials to soften them and force them together • RF (radio frequency) • Similar to Ultrasonic at a different frequency • Spin/Friction stir • Material is not raised in temp to the Tm • Some of the strongest joints

  11. Non-Traditional Joining • Induction • Electromagnetic heating • Requires some metallic filling in the plastic to be joined

  12. Mechanical Joining and Assembly

  13. Finishing • Runner and Sprue Removal • By hand with wire cutters • Done by operator between part cycles • Proper gate design can reduce problems with waste removal • Flash Removal • Colder is better • Cryogenic flash removal • Traditional cutting methods

  14. Coating and Decorating • Painting (liquid or powder) • Sometimes requires surface treatments • Environmental and safety issues • Powder coating replacing liquids (solvents)

  15. Coating and Decorating • Electrostatic coating of any material • Metallizing • Can be done as a barrier coat

  16. Coating and Decorating • Printing • Similar to painting except that it is usually not the entire surface • Screen printing (UV ink cure)

  17. Coating and Decorating • Hot stamping • Appliqués • In-mold decorating • Decals

  18. Coating and Decorating • Laminating • Joining layers together by pressing

  19. Coating and Decorating • Embossing/Texturizing • Giving shape to a layer using an embossing roll or stamp

  20. Thank You

  21. Joining • Adhesive Bonding • Materials • Processes • Designs • Non-adhesive Bonding • Fusion • Ultrasonic • RF • Spin • Induction • Friction stir • Mechanical Joining and Assembly

  22. Finishing • Runner System Trimming and Flash Removal • Coating and Decorating • Painting • Printing • Metallizing • Laminating • Texturing • Post Mold Forming

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