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MIM Case Study – Banjo Fitting

MIM Case Study – Banjo Fitting. Application : All-Terrain Vehicles Brake System Functional Requirements : Structurally intact; Withstand 13.8 Mpa (2,000 PSI) Pressure (proof test) Competing Technology : Machining Overall Size : Overall length 40 mm, bolt retain section 13.5 mm

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MIM Case Study – Banjo Fitting

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  1. MIM Case Study – Banjo Fitting • Application: All-Terrain Vehicles Brake System • Functional Requirements: Structurally intact; Withstand 13.8 Mpa (2,000 PSI) Pressure (proof test) • Competing Technology: Machining • Overall Size: • Overall length 40 mm, bolt retain section 13.5 mm • I.D. 2 .0 mm, wall thickness as thin as 0.7 mm • Part Weight: 11.6 grams (barbed), 15.0 grams (straight) • Material: MIM-17-4 PH, H-1100 Heat Treat

  2. MIM Case Study – Banjo Fitting Key Requirements: 1. Hermetic at 2,000 psi 2. Free fluid passage in the 2 mm ID 3. Bolt sealing surfaces free of flash and parting line 4. Make both part types in same mold base 5. Reasonable corrosion resistance

  3. MIM Case Study – Banjo Fitting Contoured, flash & parting-line free sealing surfaces on both sides of 6 mm bolt hole 2 mm ID for hydraulic fluid passage Gate

  4. MIM Case Study – Banjo Fitting Bolt Head Width : 13.5 mm Shaft Length 33 mm

  5. MIM Case Study – Banjo Fitting Thin wall on barbed component needed to withstand 2,000 psi & maintain hermeticity. O.D - 3.4 mm I.D. - 2.0 mm

  6. MIM Case Study – Banjo Fitting Notch in 6 mm Bolt ID pins (both sides of tool) captures 2 mm ID pin Parting line in center of 6mm bolt hole creates smooth surfaces for crush washers Interchangeable tooling insert that allows both barbed & straight features to be molded

  7. MIM Case Study – Banjo Fitting • Why MIM? • 17-4 Material more than adequate for strength & corrosion requirements • 2 mm ID, difficult to machine, is straightforward for MIM (straightness not an issue) • Molded bolt hole surfaces create smooth mating surfaces for crush washers • Both part types easily made in the same tooling • MIM consistency created few problems in production

  8. MIM Case Study – Banjo Fitting • Conclusion • Application worked well for MIM. • An example of how some of the “easy” attributes of MIM can be very useful to end users

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