|
+Week Long Manufacturing Part Design Class :.
Combines Plastics, Die Casting and Forging into a one week intensive.
Course Duration:
40 hour workshop
Tuition: $2500 USD
Overview: The course includes each of
design engine's plastics
class,
die cast class and forging
class into this forty hour one week
intensive. Refer to those specific web pages for precise course material.
This class is not for Pro/ENGINEER beginners. Training material for this
one week design intensive has been designed to provide a working knowledge
of both the molding and forming industry and includes more than half of
the hours utilizing modeling techniques in Pro/ENGINEER. This class does
not cover the actual writing of CNC code for numeric controls or Sheet
metal as those are separate design engine classes.
Take ten minutes to review this course overview.
Triple clamp Pro/ENGINEER model converted to the Diecast process from
a machined from billet model.
Prerequisites: Significant knowledge
of Pro/ENGINEER or another parametric 3-dimensional CAD modeler.
Die Casting short list of Topics:
- The process, die cast molds, tooling, processing factors, Nominal
Walls, - Radii and draft angles, Ribs, Weldlines, stress, cooling metals,
bosses, undercuts.
- Also snap fit, FEA, Design recommendations, overview of flow mold
analysis software.
for complete list of course material see the design
engine
die cast class.
A Harley Davidson Die Cast stylized part showing example of a chrome A-side
surface.
Short List of Die Cast Discussions:
- Discuss cooling time as related to thick sections of aluminum. Discuss
internal voids and fundamentals of other problems that occur from improper
piece part design.
- Discuss using parametric modelers in general and discuss examples where
using variables with a parametric modeler can save problems in the future
complete with in class examples.
For a more complete list of course material of this class refer to
the design engine
die cast class web pages.
Die Cast Aluminum Pro/E model. In this Pro/ENGINEER tutorial the user
will create ribs that are offset from the parting line instead of what
is shown. This is also a Copy Geometry tutorial all a part of this die
cast part design class.
Pro/ENGINEER specific:
- Discuss draft in it's many forms complete with examples of split draft
etc.
- Learn to use surfacing and discuss it's usefulness with die cast part
design.
- Learn to use top down design with examples in Pro/ENGINEER.
- Adding draft to parts that currently have no draft.
For a more complete list of die cast training material of this class
refer to the design engine
die cast class web pages.
There is a great deal of HTML course material students take back with
them from this workshop.
Pro/ENGINEER tutorial that shares modeling technique for creating
shut off geometry.
Die Cast parts from a dual cavity mold. Notice the flash, runners and
gate.
Die Cast Pro/ENGINEER model of a motorcycle foot peg utilizes unique modeling
technique.
Plastic Part Design Topics:
- Product Development & Prototype
- Mold Filling, Gating & Weld Lines
- Mechanical Behavior of Polymers
- Shrinkage, Warpage & Part Ejection
For a more complete list of plastics course material of this class
refer to the design engine
plastics
class web pages.
Plastics Discussions:
- Discuss basic design elements in plastic part design. Holes, ribs,
thin wall features, bosses, nominal wall, and fill.
Discuss general rules for hollow boss design and discuss best practices.
Learn about thin steel or thin blade areas and discuss ways to avoid.
- Designing undercuts and discuss advantages and disadvantages as relative
to costs
- General disclaimers on drawings such as "brake all sharp corners".
In this exercise participants will add draft and prepare any number
of parts for the plastic injection molding process.
Discussions with respect to Pro/ENGINEER:
- Light surfacing and its use with plastic part design.
Discuss top down design with examples.
- Adding draft to parts that currently have no draft.
Discuss making parts moldable that others created.
- Tips tricks and techniques for starting and completing plastic parts
using Pro/ENGINEER.
For a more complete list of course material of this portion of the
manufacturing week long class refer to the design engine
plastics
class
web pages.
 After
discussing live hinges in some detail participants in this course will
look at suggestions for specific materials and modify or create a live
hinge that will meet spec sheets supplied.
Forging Topics:
- Overview of the forging process complete with tooling, and outside
machining operations.
- Forging is process by which metal is heated and is shaped by plastic
deformation by suitably applying compressive force.
- Discuss the progression of a forging process.
- Open Die Drop hammer forging.
Discussions:
- Discuss alloys with respect forging.
- Compare cold forging to hot forging & warm forging.
- In detail steps of the forging process
- Discuss strengths and weakness of outsourcing.
For a more complete listing of course material see the design engine
forging
class overview pages.
-
Short List of Plastic Tutorials :
(watch instructor perform in realtime these models before participants
create the models)
Motorcycle Brake Lever
Pivot Bracket
Harley Rod
Motorcycle Kickstand
Harley Davidson forged Rod before machining features are added in Pro/ENGINEER.
Completed Honda 600rr forged brake lever with 7 degrees draft. Screen
shot is from Pro/ENGINEER.
Pro/ENGINEER specific:
- Discuss top down design with examples on forged parts.
- Discuss adding draft to parts that currently have no draft.
- -Discuss making parts ready for the forging process that others created
i.e. technique, draft, strike direction.
For more complete course description refer to the design engine
forging
class class web pages.
The piston on the right is a forged piston with a separate coat of powder
that is used as a bonding agent to seal the aluminum from absorbing
water.
|
