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By Robert L. Weckman
DuPont engineering resins that are reinforced with glassZytel nylon and Rynite thermoplastic polyester resins in particularincreasingly are displacing die cast aluminum, zinc, and magnesium in structural applications. The driving forces to do so include reduced weight, dielectric strength, corrosion resistance, and the savings resulting from both multifunctional design and the elimination of many finishing operationsdeflashing, etching, plating, painting, drilling, tapping, etc. Typical applications where DuPont polymers successfully replace die cast metals include marine propellers, power tools, automotive hardware, and office chair bases, arms, and back and seat supports. The high tensile strength and toughness of glass reinforced Zytel (GRZ) permit designers to match the load-bearing strength of die castings with relatively minor changes to cross sections and wall thicknesses. Matching
stiffness, howeverthat of an aluminum housing as an examplecan be more difficult since its elastic modulus is roughly ten times that of GRZ and five times that of our stiffer Rynite resins.
Counter-clockwise twist on computer models (Figure 2) is similar to that exerted on legs of an office chair base when casters are perpendicular to their axis.
Z Rib Beam
X Rib Beam
Enclosed Beam
Figure 1. Finite element models of these beams, identical in their outside dimensions, were analyzed under identical torques (11 N m) applied at one end while the opposite end was held in a fixed position.
analysis software has been written for PC mini-computers. Although programs such as MSC Pal 2 cant handle the number of elements and complexity of an ANSYS or NASTRAN analysis, they can be useful for quick comparisons of simple structures. The four hollow rectangular beams in Figure 1 have walls that are 5.1 mm (0.2 in) thick, and identical outside dimensions of 305 x 51 x 51 mm (12 x 2 x 2 in). The first beam is a hollow U channel, the second contains a Z rib pattern, and the third an X rib pattern. The fourth beam has four longitudinal walls with a closed permimeter such as might be injection molded with the aid of a long core pull, or produced by lost core molding or blow molding. All ribs used are 1.8 mm (0.07 in) thick, or about one third of the adjoining walls thickness. This wall thickness ratio minimizes sink marks and is used successfully on many commercial applications. Cross ribs, i.e., ribs at 90 degrees to the long axis, should be avoided since they produce exaggerated sinks and are less efficient than diagonal ribs in torsion.
Finite element models of each case were analyzed under identical torques of 11.3 Newton meters (100 inch pounds), applied counter-clockwise at one end, while the opposite end is held in a fixed position. Model dimensions are similar to those of office chair base legs (photo on page one), and 11.3 N m (100 in lbs) is a typical torque exerted when a chair caster is perpendicular to the leg axis (Figure 2). The twist angle contour plots generated for the four beams by finite element analysis appear in Figure 3, each plot linked to the beam under study by a color legend for rotational deflection. No surprise that the closed box (case 4) is the stiffest structure we assign it a twist value of 1 and rate the remaining beams relatively. The X diagonal pattern is next best, rating a twist of 1.87. In third is the Z rib pattern at 2.23. A distant fourth is the open box (beam 1), rating a twist of 9.
The superiority of closed structures will inevitably result in more products designed for blow molding or lost core molding. If you are designing a new product, keep diagonal ribs in mind. And remember: DuPonts design resources can help you make the most efficient use of our engineering resins and keep you ahead of the pack.
Bob is a member of the DuPont global design team and operates out of the DuPont Canada office in Mississauga, Ontario. This article was originally published in the Summer 1988 issue of Engineering Design magazine.
Conclusion:
This exercise demonstrates that adding diagonal ribs can increase the torsional stiffness of a hollow beam by four times.