Mechanical Design: Injection Molding and Sheet Metal Design

1. Introduction to the Injection Molding Course: Hello and welcome to the course. Become an injection moulding proof in this course, I'm going to teach you injection molding process right from the very basic level. This course you are going to get the working knowledge off injection moulding. You are going to learn applications, advantages, types, even about the injection molding process. But my main focus would be on design considerations and defects. What other car considerations of designer should keep in his mind when he is making the CAD model? What are the defects? Okay, a designer would be usually getting in the moulded product and how we can avoid those defects. So my main focus would be on these two points. The courses start from the very basic level. It would help. Big nurse are fresh graduates immensely. Okay, I have taught in a little different way so that you are able to re collect all the points when you are designing your product. Are when you are answering a question later. Injection, mold process In the interview, even professional professionals from other domains would be benefited. Okay, If you are working in some other industry and you are switching toe injection mold industry , the schools will help you because I am discussing many technical points here. And even if you are working in the injection moulding this to yourself, you will find something, you hear? Okay, this course has something for all. And who would be benefited? Well, product designers, industrial designers, mechanical designers, manufacturing ingenious experts from all these no means because you would be designing of ah, product. Very injection molding process is going to be used. So if you're not a real off the process of self, how you can suggest it, Okay, how you can design a part for that process and I'm going to update the scores with interview Kushner's what? They can ask you an interview and what should be your answer. So you will find something new here, Okay, in this section every week. So if I never any student, is updating us like he got so and so a question that we're going to update in the resources section are we may record a lecture on that particular point and upload on the platform. Okay, So, coming out of the curriculum part, well, we're going to start with an introduction process mold types of injection molding process advantage and disadvantage is materials, application designed constitutions and defects. In the first lecture introduction, we are going to discuss about injection mold and its brief history. Okay, In the second step, you are going to learn about different stages off injection moulding. Then in the third lecture, you will get working knowledge of mold design. What are the different components? Okay, in your mould and how they actually work? Well, they do not actually work. Material will pass through those components, such as proof on a gate. So how the whole thing is okay inside a more that what you are going to get in this particular lecture, Then I'm going to discuss voter different types off injection molding process is okay. Term across injection molding over molding, insert moulding, heart render and coroner molding. Okay, then in the fifth luxury, you will learn about the benefits and drawbacks off injection molding process. Okay. In the six lecture, you will learn about the materials. Well, the six lecture and seventh lecture both are going to be very small. Okay, you are going to learn about the different materials. Well, I'm not going to discuss all the materials just few few materials only as the list is very big. I'm going to discuss what commonly used materials and same goes for your application. Also, I'm going toe show you some typically use off your injection molding process. Okay, I'm going to show you a few products, which for victory use injection molding process. Okay, the earth and my intellectual very important design considerations. Here you will learn about different cad considerations, which you need to keep in mind. Violin making a cat motor considerations such as uniformed wall thickness least wall thickness. Okay, Vault Ignace transition, Boss ribs, go set scoring fillets draft and undergirds. So these 10 considerations are the future designer should keep in his mind. I'm going to discuss about these in the eighth lecture. Then in the last lecture, I'm going to discuss boat defects that can offer in a moral product in the fact that Israel lines on it lined flash short, short webpage sink marks, jetting, burn marks, flow lines, wives surface delamination, discoloration and is ejected pin marks. I'm going to discuss for these defects. What are the causes off these and how they can be sold? So that's what you are going to learn in this course. If you feel like you would be benefited than enroll for the course and become an injection moulding expert, thanks for your time and she in the courts. 2. Lecture 1 - Introduction to Injection Molding: Welcome to the first class are for advanced injection molding goals. In this class, I'm going to brief you about injection molding process. Injection molding is the most commonly used manufacturing process for the velocity components are used to manufacture thin walled products for a wide variety of shapes and sizes. In this process, you would be injecting a molten material into a cavity. When it is cold or when it gets solidified, you will eject and you will get your required part. The process is completed it. But the basic principle of injecting the molten material into a cavity, into a mold is still same. And further process, you need basically three components. I injection molding machine, raw material and the mold. Okay. In injection molding machine yourself, you would have a clamping unit. Okay. Then you would have injection unit which will be injecting material, and you would have a mould also. So these three components would form your injection molding machine. Now, before jumping on to the process, let me brief you about It's history and some basic basic you should be aware of. So that when you are facing an interview, when you are appearing in an interview, you are able to answer questions such as why tooling cost is high for injection molding machine revived, we need to go for high volume products, okay, in injection molding process. First, let's discuss voters history. The first machine was invented and bit ended by job and hired brothers in 1872. In 1998, cellulose acetate was successfully used or go farther first shame. And in 1940, 46. Most other thermoplastics were used in this process. And in 1960, industry started using thermoset plastic also. Well from interval point of view, you need to know this history so you can skip this motion also. But you should understand these two points. What I am going to discuss now. The first one, that production volume should be high. I would say the production volume is high. You far this process. Why we gave the production volume high to make sure that our whole processes economical. And second thing, tooling cost is I bought these things are interrelated because tooling cost is high, so we have to keep the volume high. In case if you don't go for high volume, then Bob, your final product would be very costly. Okay? Now let me just explain you this thing with a very simple example, okay, are in layman terms. So now you must be having discussion that why this tooling cost is high-end volume should be high orbit dueling Gauss's i. But why we are saying like volume has to be high. So I'm going to explain you this one in a very simple way. Just imagine like you want 1 million parts, okay? 1 million parts. Let say ten left vars. Okay, although I have not explained you the process, but you might have got some rough idea that we are injecting what? We're injecting molten material in the well, we're injecting this molten material in the mold. Right. So like when you have injected it, then what would happen? Then? Cooling. Okay. Then cooling process will go on and then finally you will inject your part. Okay, this is like injection, then you're cooling and then you have like ejection. So basically a mold will undergo your heating heating and cooling cycle, right? Heating and cooling cycle. Now, let's say you want 1 million parts, okay? Just assume you want 1 million parts than lack parts, okay? And you're more or less single cavity volt. Okay. Means you can only produce one part at a time, okay, this single gravity mold. So what would happen? Your tool, your mold will undergo 1 million heating, heating, and cooling cycles. This is going to have a rate. So if you're mold is not strong enough, okay. If your mold is not strong enough to withstand, okay. One lack of like 1 million heating and cooling cycles, what would happen? It would fail. Ok. If it is not strong to withstand these 1 million, these heating and cooling cycles over do double-edged fulfill. So we will be making our mold very strong August so that it can withstand the, the cycles. Okay. Now to make that strong mold, to make that strong mole, you will be using high, high resistant material quality. Material quality is going to be like in terms of everything, Allah properties, ok. So it is because of this strong mold, your cost on your tooling cost is i. Okay? Now just imagine that if you have, like you want just to 2 thousand pieces, okay? Let's say if you want just do 1000 pieces, now, your mold has to undergo two totals and times, ok. This one heating and cooling cycle. But instead of using some simple material, you use very high-quality material. You make that mould, you know, of same quality like 1 million. Let's say you have made that mold or gave it can resend 1million heating and cooling cycle. So if you're mall can withstand your 1 million heating and cooling cycles. But you are just manufacturing to motto than pieces. What will happen? You are per piece cost. Per piece, cost. Would be very high. Okay. It would be high. Why it would be high? Because here you are US spent too much on your mold, okay? And you are not able to recover your costs from these number of pieces. So this has to be like hi, okay, you cannot use injection mold far some Verner Von toes and 2 thousand fighters and even many companies will ask you to go far. 30-40 thousand, okay, means even if you order something off 10 thousand bases, they will say, okay, you are per, per piece cost is going to be high. Okay? Why? Because you are going to make very strong mold, okay? You are going to make very strong mode. Father sung all you are going to Blake, use materials. Those materials would be able to withstand Your those heating and cooling cycles. So you are investing too much unmoored and you can only recover your investment if you are. Number of PCs are like if your number is in millions, if not millions, at least it should be a 100 thousand. Then 20 thousand means fine. You may be able to compete with others, but if you want to be competitive, then you have to go with millions. And if you just do not do some case study, do some research on this injection molding. You will find like many Chinese companies, they, they are leading in this particular domain. Why? Because whenever they manufactured anything, they manufactured it in millions. And since they had manufacturing in millions, thereby herpes costs would be less than a dollar, okay? So small players won't be able to manufacture in million, Their purpose cost. What would be like, let's say in terms of Indian or visit would be let's say, 3040 rupees. But Chinese broader broadcast just five rupees only. So they would feel from that point of view, okay. Now if you say like Okay, no, no Golem, I will, I won't make a strong word modal there. I will just make some, some of the local relativity as overdue would happen. Let's say you want to K pieces, okay, 2 thousand BC. And you are making mold with some low quality materials over toward heaven. Your mold may not withstand 2 thousand pieces and it may fail. It may fail after, let's say one tos and only. So it will be your loss only. Okay? And so like when you were a number of pieces are less so sometimes even manufacture works suggestion something okay to overcome this particular issue. So whatever saying is like, since injection mold is heating and cooling process of the molten material. And same for the mould also. So we have to make strong mould. So that strong mold because of bad particular thing, our tooling cost is high. Okay? Tooling cost is high. Now you can only recover this tooling costs when you're. Number of pieces when your production volume is high or given your production volume is high, if you don't go, go for high volume production, what would happen? It would be your loss. You have per piece cost would be too much. Okay. Like once all these classes are or I'm going to even include a short lecture on one case study, the once by ADA code from a vendor. Although we do not manufacture that product. Okay. But we had the court for something very simple that I will be discussing in whatever main classes, our lake, what was our classroom event photos and species total then 5 thousand these are 10 thousand pieces. Okay? How the cost and overall budget for changing in that. Okay. So this you have to keep in mind if if anyone is asking you in interview like why we go for high-volume production in injection mold. So you have to say, because to link ourselves, I envy can only go to link us when our volume is high. You have more, you have made a mold which can withstand one leg cycles. Okay. Madu adjustment, vectoring doodles and BC. So it is your loss only men if someone says, Okay, can we make more with some low quality material which cannot withstand, then what would happen? It would feel, there's just imagine one thing. Suppose you have stainless steel and you have aluminum. So if you're making a mini won't be used, but let's say, okay, just imagine, okay, just for sake of example, I'm telling. So let say you are making a mold within aluminum. How many cycles it will send it would be it won't be that costly compared to most stainless steel wool. But how many cycles it would withstand? A 100 to a 100 like depending on and under material. Okay. Let's say a 100. So what would happen after that? You will fail. Then you would do it again. Your time will be western zone eddie design recommendation. Now just imagine you have made a movie standards when it costs too much, and then you are just manufacturing tutoring services. Again, it is waste of money. Okay? So if you, if, if your production volume is not high, then you think of some other process. Nowadays we have many other options like we have, we have 3D printing. Okay? So you can think of that also, or you can think of, think of, you know, think of some other process also. If product can be done with your CNC, are with some other molding browser you can think of that particular product. So some tradeoff is going to be there, but this is very common Gaussian, which is also an interview like vibe production volume should be high, are viable tooling cost is i. So simple answer is that it is as it is heating and cooling thing. Okay. This process is there, so mall has to withstand DO these cooling cycles. So if you do not make someone votes would have network fail. So to make us wrong mole, you would be spending a lot of money and to recover that money you, your volume has to be, hey, that is the simple thing is, okay, so this is more than enough. From basics point of view. We need not to learn, you know, from your academic point of view, like in college is like they will means I'm not going to teach you about this injection molding from the w0 you might have learned in your college or in your university. I'm going to explain this one in a little different way. So my u whole lake teaching would be based on like how I have dark discourse from Interview point of view. Okay. I may not be telling few things in detail, but at the same time, if you know those things like whatever I'm telling here, you will be able to crack and review on injection mold data. Again, that there is one more thing. It doesn't mean that like whatever I'm telling here is the only thing. Okay. When you join an industry, PLA plastic product design industry are injection molding industry. You will learn many things. Ok. Means you few thing you will learn in industry only, you cannot learn in any on-demand online course, okay? Not all the things can be coded. Few things students are always learn when they work in industry. Ok guys. So there's a laborious introduction part now, we will jump onto our injection molding process second class of events. Thank you very much. 3. Lecture 2 - Industrial Process: In the second lecture, we are going to learn about molding process itself. Ok? So before learning this process, or actually five stages before jumping onto those stages, that mean brief you about the machine. This machine has three units are I would say three sections. The first section, you you're clamping unit okay. Which is going to Columbia, two halves of the mold. This is up to you at this point. Then you have your moral unit where your two halves of the mold would be clamped. And third one, you injection unit. Okay. This figure is life as self-explanatory. So there, there are many things in your model and then in your injection unit not mentioned there. So food things I am going to discuss in utero lecture also. So just keep one thing in my lake. You have that plastic resin, rubber material that would that would be fed into your harbor these from this hopper, it will come to the discussion. And in this portion it will get your heated and it will become your molten plastic would be injected in your a mold or Gertrude as he progressing through this injury unit. Distance. Just ignored other things. From industrial point of view. You should know these things only. Okay? Then in more like data footings right down, just keep two things in mind, core and cavity. You have locating rings grew and NOR gate. While I'm going to discuss those in your third lecture, mold. Okay, so second unit or your mold, whatever material is being injected by the injection unit that would be getting filled in your mold only. Okay. In that cavity part, then guide you have clumping universal clamping unit operation would be before you injection. Okay. Lamp clamping unit has to Columbia two halves of the mold. This is how this operation is done. Okay, so now let's jump on over stages. There are fights, disease clamping, classification, injection cooling and ejection. So on some websites have seemed like doctor saying forced edges only clamping injection cooling ejection on some website you will find the justification also, okay. For on liberty, instead of climbing, they would write classification. I have written alpha. There is no harm in learning about these five stages via I'm writing all these stages, okay? You are going to inject the material in the total state aid. So what is required before this injection? What is required? You are going to melt your material. So that would be happening here, partial justification. And you are going to melt the material and injected in the mold so that mall has to be clamped. So I have written both here. Okay. You should not have any second thought on this one, whether it is stated that not just learn it, they may ask you, okay, and in, and in some website you will find steady something like developing stage also. Like some, some people would say, OK, after you have injected and material, you have to make sure that it is filling our luck, everybody's okay. It is filling our luck on yourself. You're also they will apply some pressure also. So that is something like defending unit. Well, I read somewhere that name. No need to, you know, keep those things in mind. These are basic stages, glam plus irrigation injection, molding, ejection. Just keep this in mind. And they would be asking you quotient, okay, on the stages only. Okay. Now let's do one thing. Let's learnable dial this one waiver. So first one a year clamping. You have got the idea. You are going to clamp your two halves of the naive mole core and mold cavity. Okay, the force with which you Kalam these two halves of the die, that is GAR law, you're clamping force. Ok? And this clamping force has to be greater than separating. False. Okay? Separating force is exerted outwards, okay. Under mold. So this clamping force has to be some factor of safety greater than your separating goals. Let's see like how this clamping is done. So Sorts of this video is your custom parts without Mac, you can check this one on the left side also. Okay? So just very simple operation. This is just for representation purposes. Actual gambling will depend on your machine, okay? So you have guard idea, like you are going to clamp your moles. 1.5 of the mold would be attached to your injection unit and do your clamping unit. Ok, so one would be faced and one would be able to slide. Okay, that's how this thing works. And how much time you are going to take for this clamping. That time? Depends on the machine. Okay. If it is larger machine, you need greater clamping force. So you are going to take more time. This time can be estimated from the dry cycle time of the machine. Okay. Did this particular name what it is dissected time there drying cycle diagram is typically a method of machine performance that indicates that buying foreign machine to perform the actions in necessity to manufacture apart. Well, that is something like technical definition. In layman terms, the preparation day, my vote say. So. Imagine you have produced one part and before producing the second part, you are going to do some operations rate, some preparation. You make clean it up so that norm so that there is no issue with your material or, you know, some wives are nor did. Well, there are some defects, ok, for those defects, you need to make sure few things. So you are going to, you know, take care of those things are, I would say preparation. We are going to do some preparation before men are producing your second part. So tag preparation time, I would say like easier dry cycle time. Drying cycle time is always less than your actual cycle time of the machine. Okay? Now we have lambda over mold. What would be the next step? Classification. You are going to melt your material. That's all. So how you are going to do it? Well, you are going to put your grain yields in your hopper. And then these ureters would heat it up with your material would melt, and then you are going to inject it. Okay. That's what your purification processes there. Okay. You can read the statement that is up to you. Just keep in mind in classification, you are going to melt your material. What is the third one? Now? Clamping is done, your job classification is done. What is going to be turned on? You are going to inject it, right? So we are going to inject your material. That's nothing technical thing. So again, read this statement that is up to you. I'm just going to explain you in very simple way so that, you know, you need not to cram anything here. What is important aid is like injection time. How much time you need to inject your material. Well, injection dam is always difficult loop calculate accurately due to the complex and changing flow of molten plastic into the mold. Okay. Because there are so many things air in this process. Well, I'm saying like it is simple process but many things. Ok. So one of those things is like you have your need to make sure that you are multimodality filling all the sides are like cavities. You had to take care of many things and far those things. Because of those things, it becomes very difficult to calculate your injection dying. Okay. But you can always do something. You can always have some rough idea with the help of your shot volume, what a shot volume. The material you injected okay. Injection, power and pressure. Okay. As I explained, the material you inject in your mold, that is called a huge shot. And the shot volume includes the volume of all apart cavities, as well as the volume of the system which delivers the material. And the shot volume must be less than the capacity of the machine being used. That, that is up on technical point l, which you need to keep in mind. And the amount of material forming the parse related to that total short volume because he daughters shot volume is going to be different. And the material which is actually used for your part is going to be different. And that particular amount of material which actually got used far your part, the final part is called as material use. So, so till now, how many towns we have learned clamping force. Ok, the force you need to clamp your thing. Mold than dry cycle time. Unlike some preparation time, then shot amount of material you have used for an injection. And the actual amount of material which God used is called a your material use material yield. Okay? So in introduced they can ask you these about these terms. So sometimes, as I said, you know, like somebody you need to apply pressure to make sure that you are molten material is reaching the all parts of the cavity that is called a you're developing. I have written that bind here itself, but on some website, you will find an unmanaged tutorials. Many websites like many to NSA developing is also separate process. Values up to you how you take, take this one. I feel like this is part of your operation, like processing only. So no need to enroll this one as you are separate Universities. Okay. So, so far how many steps? Three steps, clumping plus certification and injection clamping means you are clamping your mold certification. You are melting gear material and in injection. Well, the name says you are injecting it. The third stage is your cooling. So once you have injected your material, you are going to V8 far value or material to get solved if I, okay. So well that URI is like you have to give your tool in Lake that pressure until my your material cools and set hard in the molecule. So just read the thing. I'm going to discuss only important point. The moral cannot be opened until the required cooling time has elapsed and you have to follow this step. Cooling time can be estimated from like from the thermodynamic property of the plastic and the maximum wall thickness. Well, I'm not discussed about while thickness. So how much time you need to wait for your cooling? That will depend on your property of the plastic rate. It is common sense only. And how much thickness, how tickles your part. Okay. Well, I can't say exactly how thick, how, how much is have all technical debarred next organism. No need to learn anything else. And once you have bought a school, you are just going to eject it, right? So again, some some duties. Did you just read it's up to you. So far. Ejection you are going to make you a fuel injection system. Okay. Because what happens is like sometimes when you are 1.5 of the day is getting separately from the other half. Your part may not separate on its own. You have to push some pins. Those bins are called as ejector pins. And then those pins are pushing your part, they will leave a mark. Those marks are called as your ejected pin marks. Okay. Ejector pin marks. Well, that is a kind of defect I have discussed in your last lecture. So at this point are fine. Just keep this thing in these things in mind. Like clumping Plus Certification, injection, cooling and ejection. Nasa. That's how this whole process would really feed it. If an introvert, if they ask you about the injection, will tell me what is injection mold process simply say the name itself says injection mold means you are injecting some material into the mold. That material has to be in molten state, so classification is a first step. Our second, you can discuss what clamping also wants. It is injector, you have to wait for some time. So that is cooling state and once it has cooled down, you have to inject it to your ejection stage. Ok. If they ask you like considerations, what are the things we need to keep in mind far during this whole operation? Well, I'm going to discuss all those things in your design consideration class second, last class and defects class, okay, those glosses are very, very important of this course. You should not miss those glasses. Okay guys. So damn soluble. This injection molding process, very simple process. Just pause the video, make a North of important point. Okay? And when men like you are appealing and interview or like whatever your scenario is, just try to make use of those nodes. Okay guys, so thank you very much. Now in the next class we are going to discuss about the mould. 4. Lecture 3 - Mold: Welcome to the third glass of our course. In this class, we are going to discuss about the model itself. I'm not going to discuss in detail whatever is important for you guys to understand the process. I'm just going to discuss those things only. Okay? So, so far we have garde idea. Like there are five stages. You are going to inject the material into your mole, okay? Now it is not that simple, like simply sum you, you are like injecting it. Okay. Just like that, know, there are few things ok. Material will pass through some channels, flow channels, okay, I am going to discuss those things only here. So just focus it. Not other things are very clearly visible. You may not be absolutely slaves, but anyway, I will try my best. Material means from that injection nozzle material will come to your locating ring here. From locating ring, it will come to your crew vehicle. It has Pru froms through it will go to your summer, Anna. Okay. From RNA, it will go to your gate. And from gate it will go to your part cavity decile guys. Okay. And once it has cooled like some ejection Benezet. Okay, that's how this thing works. And farther cooling thing, like we have some cooling channels also. Like to do. Make sure that, you know, cooling is fast. Movie implies some system for that answer will get. This is a very basic. Now, just understand this one. Same thing video this exploded view. As I was saying, like first you have this one locating ring. Okay. Locating ring, then your sprawl bushing, then your spruce there. Okay. Screws here, this whole thing, screw is this one. This one, this whole thing would be fitting in this one here. Then is pro, is connected to your retina. From a donor you have gate and from gated would feel fit in your cavity. Okay. Call cavity whatever you say. And this system is far your that ejection thing are clumping thing before injection. It would be a clamping it the system will be used for your clamping. And after part has cool down, the system will be used for your discipline ejection. Okay. Now, just focus on this particular picture. What I said from injection nozzle, your material will come to your locating ring where that locating ring would be. That locating ring would be on darpa fewer. This one screw will get this particular spool. Ok. material will come to this Brew and it will go to these runners. One, somebody would come here somewhere. Do you ever go there? Okay. Like this. From these runners, it will go to the small gifts and from this model gears, it would fit in your cavity and you are part would be the, this is what you should know. Okay, you should not learn definition. You should not try to sketch that diagram. Just everything you useless. Okay, not only to learn this injection mold process on your academic point of view, the video Qatar tune your college or university. And I'm going to repeat everything again now. So first you are going to clamp your mold. Two halves of the mold would be Claire connected to your molecular amping unit, other half would be connected to your injection unit. Nasa, you'd have claimed it. After that. You are going to put material in your hopper. From that, it will come to you that reciprocating screw where it would be a he did meditate and pose to your injection nozzle from injection nozzle to your locating ring, which would be on top of us, prove or disprove froms through your material will flow to move. Material will flow to that Annette. From rendered to the gate, gate to the cavity. Material will fill out the sides. They are going to be some defects. We would learn those later. Let's say if everything is going fine, material would fill your cavity. Once it is cooled, then you would eject your part. Hello guys, this is your process. Okay? Now this, this particular, particularly your four cavity mode for cavity. Sometime you have to cavity sometime you have four. You can have even more, and so you can have even 11 also. We do not suggest to one why? Because it is, it is not cost effective. Okay? So if you search online, you will find many things like cooling rings. Then you're locating ring. Then there is some theory for you're locating ring also. That is to refer use plural so far your gate also how you run it also. What should be the size of your gate verse should be the size of your spruce. Blake. Directions for everything. There are considerations for everything. But as I said in the promo video that this course will help those guys who are not from, not from this field. Okay, who are bigness, who are fresh graduates so far, fresher for a beginner. What I'm telling you, what I'm telling here, that is more than enough, okay? And Adobe on us like we cannot include all the things in the course because there are so many things which you would learn when you are practically doing something, okay. Means even lake. Like when you design something, you have to take it on many things in the CAD itself. Okay? So those are a few things you cannot explain those things come by experience only. But whatever I'm telling you that is the basic, you must have knowledge of that basic. Ok. So that celebrate the small part. Again, I'm repeating. You have anything in your mold, okay. Locating rings, Pru ran NOR gate. Then you have your valid cavity is there, then the betas and cooling results in your mold, ok? Then there is one more core mold cavity. Cavity means where your cavity is their core means the other half, which is on top ADH, which is on the right side, will give a label setup. Okay? So these are the basics obey. In layman terms, material can be used through from school. Do you render front runner to your gate? Not from R1, R2 your cavity, but it passes through gate. Gate is very small opening and there they are. A few considerations. Well, I'm not discussing in detail. Okay. But if your gate position is not proper, Dios Peru height is not proper or not is not rubber. In incorrect design, is there, then what happens? There is going to be some defect, okay? What are those defects? How they can be rectified that I'm going to discuss in the last class. Okay guys, so that was all about over this more glass. Now in the next class we will learn about your injection molding are different types of injection molding processes. Okay, guys, thank you very much. 5. Lecture 4 - Types: In this class we are going to learn about injection molding process, okay? So you have got the idea, what is the whole process rate? You are going to inject something. So like whatever processes I am going to discuss, the basics is same. Basics is involved those processes. The first type of thermoplastic injection molding, and second is your overruling. Then insert molding, heart runner and cold under injection molding. Well, you can say like Carter enter injection molding and 51-year-old cauldron and injection molding. But since these defense or very, very small difference, lake runner will be hot in your heart runner and render will be cooled. Means is not going to be in heat exchange. So that's why I mentioned those in your fourth only has discussed what are these one by one. So first one-year thermo plastic injection molding. Well, whatever I explained right from glass Von Till now, everything you your thermoplastic injection modelling. Ok. What is the special thing like you are using thermoplastics here you are using thermoplastic materially. Nasa varied can be used from far everything. Okay. Okay. Far everything. This is the common process. So it can be used for whatever like obligations are there, whatever application are there for your injection mold, same model. You will follow your thermal velocity injection molding because bodies domes are synonyms, I would say. Okay. Thermo glossing, injection molded TAM is not different from your injection molding. Okay. So I'm not going to discuss in detail because I was discussing, wow, this indirectly about this right from the classroom. And I have already explained like value should be high. Your, your retooling Gauss's I saw your volume has to be high so that I have discussed it is cost effective than other Obama plastic manufacturing processes. Okay. Coming on to the second one that is u over molding from the name itself. You can get some ideas like there is some kind of double molding here. Okay. When you do injection molding with two or more plastic materials are elastomeric materials. It ensured over molding. Okay. Base layer. Like you have done injection molding the first step. And then when you do the injection mold on the same part, again, it becomes your over molding. So base layer would be molded with lecture number one material. And then you are going to again molded videos and second material, okay. And under same part, so it will become u over molding. Okay. You're gonna use same are you going to different plastic resin so great to achieve a specific textural, okay. The common example allies is your toothbrush. If you were not availed of toothbrush, just go and check whether it is over molding product or single molding. You will find one plasmic material and then on top of it, there will be one more layer for, you know, properly. So that this year over, over molding. And guys, benefits are like, Well, the first benefit is always grip. Second benefit to you, ergonomics. Like in case of electrical products, it could be helpful because you're going to insulate them. Waterproof seal, it, dampen, vibrations are absorbed zone. So there are many, many benefits. But there is one thing like it is a two-step process. So that could be our disadvantage also. Okay. But, you know, some parts will require your like poor material. So it is up to you how you take whether as advantage or disadvantage are it would depend on your material, on your part. Also, in case of toothbrush, you need to material so it has to be all modelling. You can't say it is a disadvantage. Okay, guys. The third one, insert molding. Okay. Well, over molding, Roger. Two-step process. Insert molding is single-step process. Okay. Inserts are pleased into the mold and then injection molding process is done. That's all. Again, I'm repeating. You are going to put your insert in the mold. Then you are going to inject material. That material will wrap around that insert. You would get your part. I hope you have got it. Okay. If you have not got it, then just look at these figures. I am sure now you might have gotten off what I was saying. So these are the inserts. Ok. These are the inserts. This one. So they might have plunged in the up position, required position. And then they did that injection molding thing. So this process became your insert molding. And now you have seen that picture. So you have got the idea for which product it would be used. So like hairy cell fan you can see. And those Inserts would we made from your bra steel, stainless steel or whatever like requirement is there. Okay, guys. So this is your third one, insert molding. And your fourth one, as I already explained, like if runners are heated, it becomes your heart runner injection molding. And if they are not Hadu, then it becomes your cauldron and injection molding. Okay. When you do not want any margin of error in your part, then you would be hitting it. Okay? What heating will do? Now you have VD ID, right? Your molten material is passing through many things. Spruce runner gate. So when they are heated ran, those runners are hated. What would happen? You are material flow would be smooth. Okay? Technical definition would be different, but whatever I'm taking r, whatever you would find in the technical definition, Mozart going to be some meaning is going to be same. Okay? So I'm explaining in a very simple way in alignment on so that you can easily, well, I won't say Graham, you can easily memorize. Okay. So when you are runners are heated, it would make sure like your Molly's, your molten material reaching all the cavity is your flow is smooth, okay, for that purpose only we heat. And when we are heating your nurse, or it means you are implying some kind of heating mechanism that would increase the cost. Ok guys. So these were the five different types. Okay. First one, thermal velocity injection molding, which is him means injection molding process and thermoplastic both are same. Okay. That's why the word thermal velocity written there because we are using the geothermal blushing material. Second one, you over molding. Okay. Means you are modelling on the part again. Third one, you insert molding. You are putting inserting your mold and then filling it are injecting your multi-material. So your insert molding process hotter or colder or another you are hitting your honor, that would be your heart runner. And if you're not hitting it, then it would we're colder and injection molding. So these five, like different types of processor processes are there. Now let's jump onto what advantages and disadvantages section. That's all guys. Thank you very much. 6. Lecture 5 - Advantages and Disadvantages: So guys, in this class we are going to discuss about the advantages and disadvantages of injection molding process. First, we will start with your advantages. Well, the efficiency is very high in your injection mold process. You have lower unit costs. You have high production rate, you have low labor costs, okay? So all those sectors contribute to your, to your higher, high-efficiency, complex part designs. Ok, you can even design intriguing details. You're gonna even more intricate details also with injection mold, molding process, okay. Scrap can be recycled. Validate is very minimal waste here. Even if there is something then that can be recycled. So that is another added benefit. Okay. There are two types of material. Thermosetting, thermoplastic, thermo settings, once they become hard, they can be melted again so that they won't be able to, we won't be able to recycle them again. But if you have you thermoplastic material in your injection mold, then scrap can be recycled. Okay. Good dimension, consistency and control. Closed-door tolerances on smaller modelling decayed parts is possible when we are using injection molding process. The greater level of automation also allows for a much higher degree of consistency of a part. Okay? So like in processes such as rotational mould, you do not have that much control. You cannot even go into great detail. Okay? Whatever like drawbacks have data of other processes, molding processes. All those are benefits there. And you understood about insert molding. So that thing is only possible in your injection mold lonely. Okay. In monotony, other processes and the main thing like surface finish, welding, you need to do some post processing operation. Okay. You need to do some finishing operation. But surface finish is far better than other processes. It is excellent. Actually. Coming out to your disadvantage is very high initial dueling costs, as I explained in the start and I had it didn't run world high. Initial tooling cost is high, but that is only for the initial state. We also have the, have the tool. Maybe today it is Haifa you, if you keep using it again and again, then it won't be high for you. Ok, So the initial investment is required, if you will, for any injection molding product, then guys part design restrictions are there? Well, I was saying like you can go for complex models and now I'm saying like some data, some restrictions. The restrictions are, you have to take it a few thing, you have to take it a few design considerations if you do not take out those considerations, yeah, they're going to be some defects, so you cannot just design blindly, okay? You will have to take it a few things. What are those few things? You'll have to watch my last two lectures, design considerations and defects. And the final thing is, I have already explained in the first class it is not economical for low volume production. Why? Because of initial investment, because of high tooling cost. Okay? So it has more benefits or advantages, definitely outweigh the disadvantages. If you, if your production volume is high, then that in the initial dueling cause, I don't think like that is any point here. Only thing like part design restrictions are there. You have to go for uniform thickness, you have to take it off your draft, you have to take it off your filler. Do you have to take it off your your ribs? Gazette goring? Many, many considerations are there, but that's what you do rate as a designer, you should be aware of considerations and when you are designing a part, you are going to use those considerations. Okay? So Rexall guys about this one. Now let us discuss about the materials using your injection molding process in the next class. So that's how guys, thank you very much. 7. Lecture 6 - Materials: In this class we are going to learn about materials used in the industry. The biggest advancement in, in this industry has been about the materials. Nowadays we have thousands of formulations available for making plastic raw material. All thermoplastics are used, some thermos arson elastomers are being used in the industry. And you didn't, you do not decide a material based on that desired property or the final part, you have to keep the property of the material also in mind before deciding whether to go with data or not. Okay? Coming onto materials, you cannot memorize all, but you should memorize. Memorize at least ten materials from this list. These are the common, commonly used materials. In any case, you should know, you should name these materials in the interview. First of all, AVS. Well, that should be on your, you know, on top of your list. Pp polycarbonate, both as GB and LTB nylon as it'll acrylic, cellulose, acetate, and polyvinyl chloride, even polyester. Also. Many times students have been asked in the past like name and if I IV materials, which you can use an injection mold process, you should not be quite there. Just say AB, SBP polycarbonate, SG, VLDB, nylon, acetyl acrylic, just like that. Make a list of whatever I'm mentioning here. Then guys, they may give you a situation. They will say, okay, I have found to make a laptop, let say a mouse. So which material I can go far? So how you will decide it? First of all, you have to do some research here. Okay? You have to do some research here. How just search with these keywords. Injection molded products. So you will get all the products, all the pictures, okay. Like cable, Mao's, whatever like desk twin been your inboxes, whatever like prostrate things are there even I'm not able to, you know, medical anything right now because almost everything is there. If there are, you know, selected things you can do with injection mold process, then definitely I would be naming all but almost all the things. So just look around you. Whatever is whatever plaster product is there, any room except the bottle. Chances are there that would be with your injection mold process. So you search online for these materials for injection molding products. Let's say you got the picture of a mouse. So you just make a note or gave mouse injection mold process. Okay, and click on that link and check. Like what they have mentioned about the process and material. Okay. Sometime they will say pp, sometime they will even go over PCL, so polycarbonate also sometimes some of them DDL, that depends on the cost of most. Same goes with you. Lexi laptop, body, laptop. So just search on these e-commerce websites. Alibaba, Amazon, okay, or whatever other web sites are there. So users about their laptop did and you know, in that description, technical specification or description, they would mention which material plastic and whatever they XYZ thing easier. So you just make another way far Libre. We can use this material in our injection mold process. Okay, so you have to do like that. I'm going to put one paper also, okay. As a resource icon, as I said, I can't name all the material because the list is going to be too big. I would be writing about at least these 19 plus few more resource file. So you can refer that phi and just try to, you know, learn properties of these materials. What I highlighted here. Let's start with your LDP. Ok, this one. So why is the, let say if somebody is asking you to, you know, designing chemical resistant product, okay, it should be lightweight, flexible, excellent chemical resistance. Then you can suggest them to go for LDP. If someone is telling you like, I want a product which is temperature, the resistance, which is very tough. You can take exemplar electrical socket. Well, mostly Thermotoga use, but you can go for your PC polycarbonate also. Let us say they are. They want you to design a product with very high chemical resistance, very high chemical resistance. Okay, they wanted to be tough, clear. Then you can go fat, poly ether cell phone. Ok. Poly ether cellphone. This one. Okay? And this is going to be very costly compared to other materials. Let's say they are asking you to design a product which is strong flexible. Width is also chemical resistance, okay? Which is good for electro plating, okay? Which is opaque and cost is very less, okay? Which is cost effective in the industrial process. So you can go for abs, and that's why ABS is most commonly used product material in this list. Let's say they want you to design a product with WIC has good thermal properties, which is thermally stable. Chemical resistance, abrasion resistance, which can absorb moisture, which is also strong. Okay? Then you can go for this one. Polyether, ether ketone, peak shot. Your abbreviation is PQ. Ok, so you should learn the properties of few materials, important materials. Ok, let's go with your left. Say this one, an island. So this is high strength material fatigue resistance, okay? Then low friction. So when you are designing a product in which you meet these things, you can go for this one. Okay? You can go for lesser, you want transparent product, okay? Which is tough as the last transparent, then you can go far which one? Cellulose acetate. Then that this particular product. And it is used cellulose acetate is used for your sunglasses. Frames are far handles. Acrylic when you are not bothered about the brittleness of the product. Okay? In that case, you can go for acrylic. Acrylic you use for your displaced. And so if you are getting a job of designing a product, designing a display stand, okay, designing a display stand, some scratch-resistant product. Then you can suggest that this acrylic, okay. Then I discussed about this from your peak, right? Okay. Then this particular one. So if there are scaled redesign some aircraft component, your first choice should be on peak, okay? If they are asking you to design a product which is resistance to your heat, flame and which is transparent also. Okay? Then you can go for Pali thermite shortcut abbreviation you or PEA. And verity used what is its application? Electrical components. Okay. Your connector bold switches covers his surgical tools also. If you are getting a job of designing kitchenware, okay. Housings cover some other extra is that containers, then you are Gi should be your LEP. Okay. If they're asking you to design a chair seat okay. Then housing covers containers, then. And at the same time they are telling you to make sure that it is, it has good chemical resistance, ok, it is low in cost. Then you can go for a levy. Okay? So you have to learn both characteristics as well as applications. Now it's up to you. You can learn the applications only. Okay? Now, I said like when they are asking to design an aircraft component, you can go for peak so you make a note, okay, aircraft components peak. So if they are, you know, telling you to design some product related to aircraft, you can suggest like peak material if they're asking you to design nows lesser some box, box kind of product. Okay? Then you can suggest, suggest them as DIBL levy. If they're asking you to design our transparent product. Ok. Let say something like sunglasses frame. You can go for cellulose acetate if they're asking you to design involves OK vaults. So our volume has to be very like the chemical resistance of all should be very high. It should be tough, right? And it should be clear. Okay, then you can go for poly ether cell phone that ps. Ok. You can even go far. I have not mentioned PET 8. Lecture 7 - Applications: In this class we are going to discuss about the typical use of injection mold process. The application part, what you can manufacture with the injection molding process. While the list is very weak, I'm going to show you few Hit Table, telephone, safety helmet, toothbrush, ties, com, mouse. So if you have watched my previous class, I discussed about cellulose acetate. So when I have shown you like Russia, Alexei, if somebody's telling you okay, we have to design a toothbrush then immediately it should strike in your mind, okay, cellulose, acetate and one more thing in injection molding type. Then that particular grass I discuses about over molding. Okay. Then when somebody is I need to design. Took toothbrush. Okay. Our product where you are going to have to materials than that over molding process should strike in your mind. Okay, so do not watch these classes. Just for sake of watching, please make note of important points. Okay, then all the ties com mouse, as I already said. Then pulleys book a table via kitchenware been boxes, seek our bike frame goggles, frame, borderless hairdryer body, kitchen products, your TV body, your ties, staring V, syringe, ok. Paddles, chairs, very low. Commonly, this is the most common unit product, I would say in this injection molding chairs are always injection molded. Then guys, in automotive, you are veal covers, mud guard. You have airplay cleaners, splash guards, knobs, I L filters, front grill, truck parts. You have dashboard, you have bumper. Okay. Then you have a phone, DVD case, villi bins. Each bin, bin boxes. Ok. So you name a product and I don't know the percentage like what percentage that it would feature in your injection mold list. But most of the things, if I start putting pictures of Alda products, I think it would be more than five hours class. Okay. Kitchenware, housing covers, containers, electrical components, aircraft components. You are mechanical parts like filter Sanders, bearings camp. Okay. Then you have automotive parts. Okay, well, I've shown you few hair excel. You have then again, mechanical parts such as bearings, bushings gear. Okay. Then you have displaced and okay. Chair, seat. Okay. Electronic housing, food containers, ties when the list is very big. Okay. And this is what I was telling in the previous class. So users for injection mold product, you will get pictures like that. Even I I have taken these pictures from the internet only. So when you search the pitcher No, no. Let say if you have those about. We got a picture of your phone. Okay? So open that link and check vertices are material, you know, like in this phone can be made with your injection mold process. That is when you open that link also and check which material we can use. So this is your left, say that been okay, well, that box which you find in your supermarket, so you know this one. Okay, check, open that link, whatever link you get, and check what material. It could be your PP also. Ok. Can it be, you know, Y10? You should have answered. Okay. You have this one, villi bins. Okay. Your dust twins. So open that link and check what material. Okay, so do not simply, you know, look at those images, try to explore for the, that, that is what I told you in the last class. Last class was very small class. Okay. Materials. I have discussed the names and then move, move on. Or but I discuss in detail dumb. I was telling again and again, search for material. Okay. And you check its properties and check like what are the applications of a particular material. Okay. Either you do that. Are you search for injection molding products. So you'd get a hundreds of pictures. So open all those pictures and check virgin material for a particular product. Okay, in the previous slide I showed you like Dashboard, right? So when, whenever, like when you are searching like injection molding products, you would get pitcher of your dashboard, open that link and check whether the distance dashboard is off your PP are your PC, vitreous material, our abs. Okay. You're that bumper, your bonnet. Ok. So let's say we go for this one wheel covers. So you try to find a material, whether PPP see ABS vert material would be used. Ok. So this should be your activity either in materials class are your application glass. Ok. So there are some guys, I have nothing. This part is again for you guys. You have to search in detail because again, if I start naming each and everything, it would take hours for me to complete. Because right. From a small you take example of your mobile phone. Mobile phone forgot about mobile phone. Mobile phone cover. That is also an injection molding, more molded product. Take exemplar for your mouse. That is an injection mold product. Take exemple of your keyboard injection mold product. Your microphone or your speaker. Are you laptop body. Okay. Then just go to your, let's say kitchen. The body of your mixer grinder, juicer. Ok. Yours. Many tableware items. Okay. Other kitchenware items. Then jump to your Alexei living room. Whatever product you find there chances are there that would be injection molded product. Ok. So these things should be on your tapes. Material name and the application of injection molding process. Ok guys, so that's an abort this class. Now we are left with the word two most important classes, design considerations and defects. In design considerations, you will learn the like, what other things that designers should keep in mind while making the character art and defects, what defects can occur during the process and how to solve those. So decile guys, thank you very much for watching this class now jump on to the next class for design considerations. 9. Lecture 8 - Design Considerations: So whereas we are in our second last class and this is one of the most important losses. Now other important Laozi, your defects, OK, in the last class. In this class, what you are going to learn, what are the things that designers should keep in mind while making the CAD model, okay? The first consideration as a designer is you have to make sure that you have uniform wall thickness. If you have option of giving thickness of 2m and 4m m, You should not give both. Thickness is 24 volts. No, that would be the incorrect way. Okay. Like for example here, if lesser than this, for this year two, then this design would be incorrect. Either you go for your Ford, either you go for your to only one option. And that should be same. What can happen if you do not give uniform wall thickness that you would learn in your class for your final class. This is a first consultation for you guys. Uniform wall thickness. Second consideration guys is least wall thickness. Now let say you have option of 2.1.4. Again, same case. You have optional giving two MM and forum. You should not go with for usual goal with four. You should go with two only. Okay? It should be least. Okay, you reference should be least thickness. Again. What can happen with, you know, your take part, okay? Well, in layman terms, it will take more time to cool down rate. So that will be increasing the cycle name. Other defects can also occur. We will, we will learn those in our final glass. Okay? First consideration, uniform wall thickness and second cancellation list while thickness. Now you will be having been quotient. What if I cannot keep uniform wall thickness or least wall thickness fortify cannot do like that. Then what? In that case, you should go with your this particular design. You should go for your ramp, whatever you see here. Ok, this one just you need to design like that, okay? Just like that. Do not design in this way. Whereas you guys, this is like the big problem in market, like when you go for any CAD software training, they do not teach these things. But what I feel is when new learning gets out to the instructor, should, you know, teach you these basics. Okay. Because I don't know, I can't generalize it. Okay. Marked at the same time I have seen most MAN, many students actually, they would give. Thickness, whatever like feel welcome in their mind to 461, lot bothered for these things. Then same is the case with the radius also same is the case with your draft answer. Okay. You should design this ramp in this three into it if you're let's say if this is four, this year two. So what should be the length, length of this ramp? Three into 263 times that difference. If this is let us say your three, and if this your five, again, it would be U6. Okay? So this is the solution when you cannot have uniform wall thickness in your bot. The fourth consideration guises, boss. Boss is very, very important. Okay? And this is the formula that design, I will say formula for your boss. So if you see here, if thickness is, let say your three, ok, then what should be the height of your boss? Height off your boss should be five into T, So it will be your 15 MM. Okay, if taken as this one, it is going to be your five MM. Virtue would be the radius at this 0.25% of the modern day, 5% of three in this case. What should we do? This one, thickness of this boss, okay, this thickness of ours, that should be your 60% of T. Ok? So when you are designing a boss, so this is what, this is how you should design it. Coming onto your natural. Now let us see some scenarios it. So most of the time you may have designed apart in this way. Isolated was snow. That is totally wrong. You should do either in this way. Okay? You should do either in this particular way. This particularly, this is your rip, this URI this year. And I think in Catia, This is called as rib. Okay, sorry, in increas auto, This is called as rib. In Catia. This is called a your stiffness. Ok. So technical limit is little different in this gas softwares. So there is no meaning for every command in these gaps afterwards, they are given that different Command Forward purpose. To add desert our trip to your boss. What can happen if you do not add your rebar Gazette that we will learn in our defects. Ok. Then guys. Again, if you're designing a boss in Gardner, do not do it in this phase. What you see here, you, you should do in this way. You wish your boss should be at some distance from the coordinate and it should be connected with RIP, okay? As displayed in this particular feature, a should be connected with urllib. Ok, this one. So this is a false considering, consideration. This is a formula. Okay? This is a formula you should keep in mind while designing of US. And the best way to, you know, Stanton Abbas would be a gazette as less connecting leap. Okay. So if your design permits to have both things, then you go with your board. These design features, rib and asset, okay? Then guys, fifth one is Rebel self. Ok, now, you know, boss is important to have in the pot. Far boss, you need to have Gazette energy. What is our, what is our formula for RA? This is the formula for the okay. Like if your thickness is let us say thickness of parties 2m, what should be the height of your boss? Six m, m will get three into 26. What should be the distance between two ribs? Ok. R2 stiffness. It should be two into two means four. Ok? So what should be the thickness of rebuilds itself? Width of rebirth self, that should be 40 to 60% of your thickness. It the boss, okay, emboss, it was 60% of thickness. Here you have the range 40 to 60%. Okay? So I just pause the video here. Note this formula, and then keep this formula. Did this picture in front of you when you are designing a ribbon, your CAD model. The other important thing is placement or flip. You should place your ribs. Okay? Keeping in mind the load part. Now, if you understand this particular picture here. So how, how this particular bar upon this year part, this year part. So how this part would be bending if we apply force here. So it would be bending in this way rate. Okay? So if you are giving Ribbon disappears after they are shown here, what would happen? This part will fail. Ok, it will bend, multi-issue, give just two ribs in this way. This way, it will never meant. So your placement should be our orientation, not placement orientation should be perpendicular to your, you know. Band bending direction. Okay, so this is another important point you should keep in mind. Then guides you. You have Gazette, okay, the second thing far, your bosses Gazette. So I'm sure like you would be able to recall vertices Gosset in increas are fair. I think the name is reboots cell in CATI at its stiffness. And I think in your SolidWorks answer it is stiffness. In annex GAD it is read-only. And there are two options I can recall. One is like from Sayid and running's from top. Okay. This one, this gas that you can put in your with that side option, okay, you need to draw a line then automatic. This triangle will come down and taken triangle. Okay? So fomula for your GSA is this one. Thickness of gazers should be 50%, okay, if you're taking us off parties to MM, then one m, m should be the thickness of your height should be 95% of your boss. Okay? If bosses tenement height of your Gazette should be 95%, means it could be, it could be named 9.5 volts, so it could be less alto. And prefer height is always two times, okay, is always two times. The nominal wall thickness means if you have all thickness is two, height of GSA batter that you keep at four normally to go for 90, 95% of your boss. Then length of your gas at length I've gotta should be 30. Well, we have arranged at 3200% of the height of gazette. So if height of your GSA is ten, it could be length, could be ten also. Are it could be like three also. Okay. Then spacing between two gazers. It should be two times of all thickness. For example, if you are taken as is, let say three m, m. If you take this apart is three m, m, then this should be your two into three. Into three, it should be your six. Ok. So these are the considerations for your design. The other is your Phillip valley filling. In most cases we let is our radius at the corner is 25% off nominal wall thickness. Okay. In rebel, so it was him and your boss also it was him. Means see, thickness will be waiting like 60%, 40 to 60 or 50 to 60, height would be like up to 80 or 90%. And Philip, in almost all the considerations for that is mostly twenty-five percent. Okay, guys. Guys, we have coding. Whenever you have a text section, then you should go for coding. Like if you see there are two ribs are intersecting each other so that taken us are lesser. This part is two. Ok, this one is two. So at this point. Thickness will be more rate. So if you have something like that, then what would happen? You would get a defect called as your sink mark. Okay, sink mark. That defect to a wide that effect you should do coding. Okay. What is coding? Just removed the material from the thickened area. That's all. This is what you should do. It means if you cannot remove them or do you just just put a whole there? Okay. You won't be having that money, you won't be getting that defect sync mode. What is sigma? We will learn in the last class. Okay, so then, then this is again, same thing. Well, that wasn't as action narratives. So sometime you would have about where your thickness is more than what you do. You just remove the material, like what is shown here in this particular picture? Okay. So basically coding, what is coding? Removing that extra material from the thickened area. It's consideration is your fill at RRR round corners. Well, I don't know whether your printer discuss vote, fill it in in the CAD software class. Okay, means usually alleles. Okay, click on this, click on the edge and defined your radius of 51020 MM. No, we do not give radius just like that. Okay. 10-25, 34 known guys. There is formula for that. Okay. So well, I need now to expand this what it is. You know, that we avoid giving sharp corners. They always gave Philip Okay, in all the corners. Okay, now let us understand this graph. If you look at this graph, what you will get like with your increase in radius to thickness ratio, okay? Your stress concentration is reducing if you do not have any thickness et al. Okay, then what would happen to your test concentration will be more. And if you use stress concentration factor is more than defect can occur in the part. Okay. Then guys, what is the formula for that? For defining this one filter around gardner? Well, inside radius is going to be your 0.5 into thickness of the part and outside radius is going to be 1.5. So if your thickness of parties, let's say we'll let say four MM. So outside radius would be how much? Okay. Outside your fill it would be four into 1.54 into 1.5. So it is going to be your six and it will be half of your four. It would be too. That's how you should give. But I don't know whether your teacher discussed this on Iraq. Usually they will say OK, click here, click on this filter can give like 5106 to just stay like that. Well, I hope that you are getting my point. So again, it is not that easy to make a CAD model for injection molding process. You have to take it at these things. Okay? Coming out to very, very important point that your draft, it is the most important consideration. I prepared a very small and emission here. So guys know this first understandable, this one picture here. This one is straight, okay? This blue part here, mold this you will find final piece after molding, after your process, injection molding process. If you are going to remove this part, how it will come out. There would be friction here. Okay? This one is tapered. This one is tape or head. Once this starts moving out, there would be, there won't be any friction at this point. There won't be any friction here. Ok. This part may or may not come out out of your mold because of no. That gap. Okay. No tapered. But this slide very easily. That's available. This one draft farther. Easy ejection of your barred from the mold. Draft is required. How much enough is required? 12 to degree for most parts. Okay. Again, I have seen many students give draft our 5610 degree, 15 degree. Well, 50 minutes too much over your part would become deeper, but mostly students gave like 56 degree, okay. In, in the practice of self. Even if you say OK, I'm just practicing, it's fine. I will give you, I will give taper as five, so that is fine. But if you start learning all these considerations right from day one, it would become easy for you to recall them at the last moment or venue when you're designing your main part, when you are sitting in an interview. So if they ask you, okay, how much dark we degenerate, they gave say, one to two degree far thickness off your two inches far texture surfaces, we give additional 1.5 degree. Additional 1.5 degree. Okay, far heavy textures. I'm using the word heavy textures for that one. Even it could go up to use your 7.5 degree also. And draft should always occur towards the top of the mold. Okay. It should not go in the other direction. And wherever your to do to molded resection is the ok. For example, in case of a cylindrical part, okay. Something like that. You have to give your draft on both the sides. Okay. You have to give the draft on both the sides. So. Keep light from interval point of view one to two degree and additional 1.5 degree five textural surface. Ok. And it should occur towards the top. And whenever there is your, you know, your whenever your party's Valley in layman terms, is connected from both sides. Ok. Whenever you whenever you're mold is touching both sides of your part. In that case, you have to give draft on both the sides. Okay, this is very basic. Now let's jump onto our final consideration that undercut. First, let us understand what are these undergoes and then we will discuss in detail. So this is let say your bottom of the mold. This is the top of ok. And the material will fit in this gap, okay? Whatever gap you see it, material vote fit in this particular gap, okay? In this gap. So if you are ejecting this part, you will get it easily, right? Because there is no additional feature here. This is very simple. But imagine that if you have some undergrad here. Now what would happen? Your material would be filling this particular portion. Also. Your material would be filling this particular portion also. So how how it would be. So your material would be in this way. Well, it's difficult to draw with the most or going is not that clear. But anyway, your final part would have been this way rate because this is your cavity now. So after injection molding, you'll have your product and your final piece. Now how you are going to eject it. Okay? How you are going to reject it? You won't be able to. Nasa guys. That's why V suggest not to have undergoes. Okay. That is a big reason for that. So if you cannot avoid undergrad, then you have to make change in your mold. And just keep one thing in mind means you're going to say, okay, I can either write it, I will change my mood. Any change in the molar your design, would we increase the overall cost of your product because you are putting extra effort, because you're changing your moldy. Many things are there. Okay. There are two types of undergrad, internal and external. I am going to discuss both after this. External undergirds. The need side course, okay? For external hamburgers, you need side goes. So your overall tooling costs would be increasing. Okay, for simple brothers, you can do something. But for complicated products, your product costs would be increasing, your tool costs would be increasing. Let say you have a simple product like this and what you see in this picture. Okay? So how this vehicle mode of you mold? It will never. Why? Because your final part would be stuck here at this point. Okay? So as this is simple, but again, you have to put effort, okay? Whether time or resources or whatever, or our cost is going to increase, but we can manage. So for this simple external undergird product, you can change your design digital weekend, it would be easy for you to reject your part. Okay. So see changes here. Changes in US mold, self-explanatory. So I'm sure like you might have got the idea in case if you are finding it difficult and let me just jump onto the next slide. For your internet undergoes internal undergirds need your internal cold core lifters for external univ side courts, right? So for internal you need Gore lifters. And designing an opening in the side of a BAD can allow aside core to farm and internal undergrad. Okay. This is a little bit technical thing. If you did not understand, then just look at this picture. So these are your internal data, okay? For the simple product. So it won't come out right, so vibe because it will be sticking to your this top half of your mold at this point. Okay? So you would be designing your part in this way, okay. Let us change at the bottom and a little change in your molar also. So that's how you can manage it. Okay? That's how you can manage it. Okay? So I said like designing. I said like designing and opening in the side of a part. This is that opening. A lower side go to form an internal undergrad. Okay. This particular thing for guys, so this was all about your CAD consideration. So I started with your uniform thickness. Then I said lease wall thickness. Uniform means 24, go fart either two or four. Least means decide out of your two or four, go with you to then as i variable, you are uniform thickness and not washable. Go with your RAM design three into h. Then you have Boss. Okay, for boss, you need ribbon gossip. So I disposable those. Then I discussed what you're coding, removing extra material from the thickened area, then about your fill it, then about your draft. And finally I discussed about your undergoes both internal and external. So dazzle about over CAD considerations class, our design considerations. So just make a note of all the important points. Refer them whenever you are designing apart for injection molding process. Now let's jump on over finite glass, that is, defects. 10. Lecture 9 - Defects: Welcome to the final class of our course. In this class we are going to discuss about defects. What defect can occur in injection molded product? A defect can occur because of these three reasons, incorrect mold design. Gates prove Renner. Less injection pressure. Tying our cooling time are high injection force and injection pressure. Anything cuckoo result Cook could result in a defect. Okay. If your gate location is not proper, mold design is not proper defect can occur. If you are not selected, the correct material defect can occur if you are not processing the material in the right way and effect can occur. But whatever is the reason, there are some defects, okay. Usually 11 defects are there. You should know about those defects and if they are asking you about those in interview, you should be able to answer. I am going to discuss about a defect. What are its causes and what are the possible solutions so that a defect, that particular defect is not occurring in the part. The first one is your guy's valid lines or net lines. Okay. In layman terms, if different flow lines, okay. Means if if the molten material from different channels are different directions is not mixing, okay? Okay. The correct word is incomplete dissolution of molten plastic. Okay. So well, the technical definition is like it is a boundary between flows caused by incomplete dissolution of molten plastic. So if molten plastic or molten material from different directions is not fusing properly, are mixing properly, then you will get a line. That particular line is called as your vanity line. Okay? And it usually gets created like far, far out from your gate and the cause of your defect is low temperature of the mold. Okay. Because of the low temperature other mold, your molten material has not mixed properly. Okay. Well, not settled Bravo level say well have correct word would be incomplete dissolution. Okay. Coming on to the solutions. You need to increase the injection spilled. Okay. Injection speed. Increase a mold temperature. Okay. You have to reduce the molten plastic temperature. This is mole temperature. This is that molten plastic and major increase injection pressures. And if you are welding is due to the incorrect mold design, then you have to change the gate position. Okay? So this is a possible solution for your very lines. The second defector, your flash in layman terms. Extra material around your finished product is called as your flash. Just guess what could be the reason. If you're the two halves of molder not securely closed? That could be the reason injection pressure is high. That could be the reason means you can even, you know, well, I don't think it is difficult to guess. Answer. And then let's see, like technical reasons, poor quality or the mold. The molten polymer has low viscosity, injection pressure is too high and clamping force is 2V means clamping forces vk, mold has not supposed properties or material will leak out of your cavity. Okay. The first is poor quality of the mold. Again, same thing like due to some reasons your material is escaping your cavity part. Okay, next on, flash extra material weld line. The lines you are getting because of different directions of your molten material. And when that motor molten material has not fused properly with other than these two vectors, what are the solutions for your flash thickness? Now, those considerations part coming here. I said uniform wall thickness rate. So if you, if you do not have uniform wall thickness are excessive differences like 1210, then you would get flash. Ok. So you have to go with your uniform wall thickness. You have to reduce the injection speed. Okay? The second here, you'll have to take enough your pressure and you have to increase the quality of your parting lines. Ejector pins and holes. Okay. That's all these are the solutions for your flesh. Then guys told one is your shot. Shot. When you are molten material is has not filled all the cavities or mold, then you would get a result like this, what you see in this picture. Okay? That particular defect is called as short shot. Shot means shut off your required whatever is a requirement. And short is material. Okay. So what could be the reason injection pressure is very less temperature of your mold temperature your material. So means even if you don't know about the technical things here, you can still get. So let's see what I said. Tai injection pressure not sufficient injections PD so slow that. Now if injection speed is less, what would happen? Your material cooled on before, like reaching the final point. So that's all. So what is the solution for this one? Increase the injection pressure and increase injection speed and exile. And that's what I'm saying here. Okay. It means I have already do more wind shear. You have to change the shape of your mould. Mould also are your gate. Okay. And installed air vent RD guessing device sometime it is due to your guesses in your cavity or mold. So you can do like that. This one, injection pressure and injection Street. Okay. So that's our fourth consideration is your webpage. No. I said uniform wall thickness and I said like when you do not have uniform wall thickness, your defect Good. Ok, or there are two main effects that could occur in your part. One is your webpage and second one you think Mark, this is the first one, verbiage pitcher is self-explanatory means you're part is getting involved. It is getting deformed. Okay. What are the costs? Low injection pressure, thickness different. Second, this is mean value. I have mentioned here the second number, but they should be on top of this list. And means I have seen like sometimes what happens when I write these three for one students. They think of our laborious day, especially not focus on this one. That is, I think even my mistake I should, I should not write other Aldo. Otherwise I should only mentioned this one because this is a main reason for your verb is thickness difference. Valine, low injection pressure, also introversion begging also. More temperature difference, also easier for another reasons, but this is the main reason for your warping and your sink one. So whatever is our cars just increase or decrease that particular gods. That would be the solution. Okay, let, let us see the solution. Uniform wall thickness take longer cooling time. Ok? Now, now what is the theory behind this uniform wall thickness? So just keep, let say you have part like this one. Okay? So the thickness, thickness it is three. So this will take the thickness of this particular portion will take, let say, contains seconds to cool down. Okay? This will take more time, let's say 40 seconds. So this temporary time, time difference, what would happen? This has already called on, this part has already called on, and this is getting cooled. This is getting cool. So there would be formation of these stresses. Those testes will deform that whatever part. So that's why I said uniform wall thickness. Take longer cooling time, low direction speed at just ejected being position and increase backing pressure and balance cooling lines. Okay. So how it can be solved by adding that gas that I already explained you. Okay. Then guys, very important think MOD sink mark is work syncing. Mark is your depression. Okay? Why it could have been welded? There is one more thing which you can see. You have ejective bin location. I'm going to discuss about ejective Being in the final one. Okay, but you can see one more defect here. We are going to focus on this one only now, sync mode. So what's the reason for your sink mark? Introversion, cooling time, inadequate pressure in that cavity, excessive pleasure at the gate. Okay. And non uniform wall thickness, again, means if somebody is asking you an interview like what reason for sync mode? Just blindly say non uniform wall thickness. You need now to explain anything as I have written this one in the last, but this should be your point. And vertigo solution. Well, same thing. Uniform thickness. Ingestion space should be less, mold temperature should be less than increase their bagging blushing a holding tank. And I discuss about boss in the start, right? In your design considerations class. So you add ribbon desert. Next I'll you can take it off using one and sink mock mostly would be happening where you're nonuniform thickness easier. Usually there would be this non uniform wall thickness. It will be usually at the point where your boss is located. Because say, if you're, imagine like if you have this rectangular sheet here, okay? Let's see if this year some part. So you are adding a boss here. So thickness, this thickness of this whole bodies too. And this particular point, your thickness would let say B3. So chances are there you will get sync mode. So that's why you have to take this particular point. So coming on to the next one that is jetting. Jetting is word. If you see some currently lines, zigzag lines, snake guidelines, it means it is your jetting. Okay. Like as shown in this picture, what are the causes? Causes guys is like when you are when you're injection speed is too much. Okay. Poor tool design. Your j psi is our getLocation is not correct and material temperature is too high. These three are the main reasons solution. The first one, like whatever is a god, you just do the opposite of that. Gut. Reduce our material temperature. Okay, second one, material temperature reduce injection, Sweden. Good design, opening size as well as position, Taxol, 7000 year burn mark. So any changing colors of your part is been marked. So it doesn't mean like something is burned. And usually it will be happening because of some hot air which is trapped in your, in the, in the flow path in your material, molten material. So what are the causes? One causes like sharp corner. So here that fill it out down Cognos or important. Okay. Inadequate venting. Okay. So you have to increase it. Our ad if if number is less added, if size is not correct, then increases size or sex or obstacles in the flow bought. You clean your sprawl and narrow gate and high injection speed and you can reduce it high injection pressure, you can reduce it high temperature. Our vector temperature reduces. Okay, so these word marks can be avoided in that way. And then guys I actually your flow line. Well, flow line is not us some technical defect, okay. It is a visual effect. Means your part stability are structural properties not affective of this because of this defect. It, your party simply won't be simply looking good because of your flow lines. This is your visual effect. So because uneven wall thickness and variation in cooling speed, I don't know whether you notice or not, but in almost all the defects, this point is coming again and again. And this is coming again and again. That's why I, and discuss about this uniform wall thickness in detail in the last class. Okay? What are the solutions? Again, uniform thickness, add gate, add fillers, increase filled speed, Mary temperature, mold temperature, reduce injection pressure. Okay. So just do whatever it is or isn't just do the opposite of that reason. And that's how you can avoid this particular defect. The ninth one is your vital bubbles. Okay? If you have a bubble, if you have some hole inside your molded product, it means what are the reasons? Are many reasons. And one of them is, again, common, uneven wall thickness. Okay. This one is featuring in all that effects. Other than this uneven, moldy surface, long flow length, gate position, I melt temperature, low back pressure, moist material and intravenous injection pressure. How wide can be righted? Do the opposite of this one. Locate the gate at the thickest part, switch to less viscous plastic in case holding pressure that whole point and ensure that your mole parts are perfectly aligned. Ok. Then guys, surface d lamination. Okay. So if you surf, if you are able to peel out surface of your finished product, it means that is your defect and the name of that defective your surface delamination, then your material is contaminated. You will get this defect. And you know, when we eject a part from the mall VU, some released agents. So if you use your agents, if you use them excessively, okay, if you use them too much, then you can get this defect delamination. What is a solution? Just make sure that you are Mold flow lines, your like thing, material is clean, it is not contaminated. Increased the mold temperature. Okay. So other than that nothing. Then guys, you have your discoloration. Well, again, it is visual defect, okay. It won't be affecting the structural property of your finished product, okay. As discolouration will be happening because of your, I would say leftover material. One oven when you have more Leader product apart. After that, your whole process is going to repeat it in. So if something is left from the previous process, then that will result in your discoloration. Poor thermal stability of the coloring agent. Okay, as I said, like you add colouring agent also. So if thermal properties of that material or agent is not good, then you will get this defect and have all the solutions. So make sure that you are workers have clean your, you know, Harper nozzle land areas or go first find. Consider using a using a purging compounded remove excess color from the machine and ensure your supplied. Are you yourself using a color agent, aggregate thermostability or get an appointment, which I discussed in the last slide. And ensure that master batteries evenly mixed, consistent color output. So basically whatever your car just say depositor that guards who then that will become your solution. Coming on to your final defect that is ejected minmax value from the name itself. You can get the idea some marks because of your ejector pins. I'm going to explain you with the very basic animation. So if your part is getting stuck like this one here, the green on your top half of them all blue on the bottom half, had one year apart. So if fit is what you will do, you would push your part with the help of ejector pins, like this one. So those pins would leave a mark, ok, on your part. You see this picture, this is the mouse cover off my most what I'm using right now. And those highlighted areas are your ejector pin marks. Okay, in this video you can see boss also, okay. Let me just highlight it here. You can see some balls here. You can see in Coursera's added to another boss. Okay, you can see some ribs also. Know these normative here. Well, you call them ribs are GSA, that doesn't matter much anyway. So just know if you are watching this one on your system, just check your mouse, whatever that is Jacobians on. Okay. So what could be the reason for this on like when you are cooling time is less than your part has not called on properly. When you're ejecting it, that there wouldn't be any information. Ejection force is too high and it is leaving a mark on your part. So what could we distribution increases to cooling time and reduced ejection pressure, as I said earlier. And whatever is the cost, say the opposite of that gas, that would become solution. Okay guys. So these were 11 defects to work toward. Defects with visual defects. Okay. Rest all nine voyeur defects for which you need to work. Now far out of nine, I think at least six or seven defects are because of because of non uniform wall thickness are uneven thickness. Or the reasons are there great location, less injection pressures speed or high injection pressures speed. But non uniform wall thickness is almost inevitably affected. So guys, we are done with the class as well as the goals. So I have tried to cover all the things which are important for a beginner. So if you're a vast Darley field, learned everything here, that doesn't mean that you would become expert. There has many thing you would learn only when you're working in industry. Ok. And this lecture, it doesn't mean that your course is over. We are going to update this course again and again, okay? Because there are so many things we have skipped like your injection pressure, some, some calculations, okay? Clamping force, your pressure and other things. So we are going to obey this course. So keep looking, keep checking this course every week so that, you know, if anything new is dead, you are notified. Okay? So that's how guys, thank you very much for watching this course. If you have any question you can ask, you can message me here. Are you can reach us on our Facebook page. Facebook.com slash fault monster designs. Ok. So that's how guys, thank you very much. 11. Lecture 10 - How to Calculate the flat length?: Hello and welcome to the first lecture of our course. In this lecture, we are going to learn about Flatland. How to calculate the flatland are undeveloped land. So basically, you would be asking if we have CAD software, then why they didn't need to calculate it with some kind of formula. Sometimes you need to do it. Let's say if you're working in a company with only two resorts reuse, ok, then what you will do are let say if you do not have, you are, you are working as a freelancer. Ok. You are in group lesson manufacturing of sheet metal products. You do not have software you are getting drying, and the customer has not mentioned Flatland. Ok, then what you would do. So you should know the formula, how it is calculated. There are few terms involve, you know, related to flatland. You should know about those answer. So the first term is your bend allowance. Ok? Now imagine like if you have, let us say if you have something like this, let us say this is L1, length one, dc your L2. Okay, I will do. Now. What would be the flat lands of this part? That would be length L1 plus L2 plus this area. Okay, let me highlight this one. That is going to be this particular area. And this is called as your bend, a low end. So I need to add, what I need to add your bent LOINC is BA. So flatland in this case is going to be L1 plus L2 plus bend allowance. So you, I think you have an idea what it is. Now the second term. The second term is your band detection. Okay? So both these terms are, I would say both these things are used to calculate your Flatland. Now, coming onto your Ben deduction. So let's say if you have something similar, ok, you have same type of design. But now instead of calculating it from here, less if you are doing it from this point, okay? From this sort of this one, it is your L1 and from this zone to the sun, L2. So Ben detection REO, we call it as set back. Okay. Vitali test set back and just give that outspend mine. Okay. Set back. No, it is going to be L1 plus L2 without those. These are full. So it is going to be minus bend deduction. Okay, now what is bended dictionary bended actually your this part. So that is the difference between your vendor loans and you're ban detention. Formulas are different. Football. Ok, so first of all, coming onto your vendetta bend allowance, what is our formula for your vendor lawns? That is your bi into R plus k into your d. Then it is your a by 180. Now, what are these terms? That is, you know, by this radius, ok? So if you are part, let's say if this is like that, radius is what? This inside radius, inside radius up end. Okay, I will say bend radius. Ok? So that is our k is what? K is your constant. Ok? I will discuss about gain detail after this. P is what? P is your thickness. Thickness. So it is going to be some MM, 0.1 to 5.5.1 or whatever. Okay. This is your that on your sheet thickness aka Dan is what? A is your angle. Angle. And that is your angle. So if you know Bender lowest, then you can easily calculate then simple like you have to add only nasa guys and this is how you calculate it. After this, I will take examples. I will calculated with the formula and then I will compare that Flatland CAD software. Ok. I will show you like how much radiation would be the coming onto your Ben deduction here, okay? So you can calculate your band deduction in a very simple way. I can call it as your setback also. Now formalize your 0.43 into R plus 1.372 into thickness. And this is your k, k factor, this is radius and the thickness. This is one way. Second ways that you can calculate your bended action. How you can calculate in this way, two into two into your outside our offset set back, okay? Setback minus bender ones. So if you have value of bend allowance, ok, you calculate OSS B, then you will get your bended rationale. So now you will ask me like how can I calculate this one? Vertices OSS v? So formula for this one is worth ten into ten up a Y2 is what your angle. Into thickness. For us, your radius of your radius. So these are the formulas. I mostly prefer this particular one. I mostly go with this particular formula. Okay? Are I go with this form formula? Okay. This one. I don't go with your OS has been No. You will be having this quotient like voted this as V. You have to know what is always SV or SSB is basically your outside setback. Let me explaining your wisdom about your diagram. So let say from this one to this one is your L1, from this onto the Sun is your L2. Okay? And what is your OSS V0? So it is going to be your from discipline to discipline or SSB. And from this one to this one year o SSB, let say this is one, this is two. So that's, that's why it is a double, because you have to count vote. So this level, this is also very easy angle you will be knowing. You just have to pick Dan of that value into your thickness plus radius bursa. It is also very simple, but I mostly preferred design. Overall everything is clear. There is only one thing remaining, that is your K. So coming on to K Now, K is basically working, is basically your K factor. Ok. It is your constant. Ok. Now you will be asking like, what is this k factor, how, how it is calculated? So see guys gave factors calculated. It can't be calculated just like that. Okay. So some guys have calculated they have prepared table. You refer that table. That is as simple as that. Because practically how you calculate K factor, let me explain that also. So imagine that if you have this sheet, okay, if this sheet is here. Now, what happens when you are bending? This is, let say imagine that you have bending sheet in this way. Imagine that you have when dish hitting this. Now, when you have vendors heat, what happens like two forces will be acting on it. Ok. One force would be compressing. Okay? Your material, one force will be stretching it, ok. One false will become blessing. And when Ruby stacking it, but they would be 1 are they will be one axes at which no compression tension would be applied. So that can be an EVA. Ok. So the acceded, rare no compression are less attention is applied. That is called as your neutral axis. Okay? We call it as your neutral axis. No fewer things to keep in mind far new perplexes. Now first thing you have to keep in mind is that inside compression in sheet metal cannot exceed outside tension. So therefore, value of K factor cannot be more than 0.5. Okay? It is either going to be equal or less. If you say it is equal, it means your neutral axis that I will say it is incentive thickness of neutral axis exactly at your center of sheet thickness. Now how you calculate it, so see here, K is equal to your pudgy Sion. Neutral axis. Neutral axis divided by your material thickness. Okay? So when I said like you cannot calculate it that many companies I will say researchers have already calculated it. Can you calculate positional this new fluxes are valid, it is not possible even in CAD software also, leg would be that point. Rare. For somebody. I will say like tensile or compressive forces acting, it is not possible for you. So they have defined things for K factor. You just keep those in mind. The first one is that K factor cannot be more than your 0.5. That is one. Okay. Second thing you have to keep in mind, far you're gay factories, that increasing thickness, okay? If your thickness is increasing, increase in thickness, then what would happen? K factors will be less, okay? Less K factor. So it is inversely proportional. In the same way. Increase in material are less, is inversely proportional to your k vector. So it will be less only. Okay? So these two things you have to keep in mind. And other one, I have already explained that your neutral axis, neutral axis cannot go beyond your middle of shield thickness. This UKIP in mind, middle of giftedness. Okay? So practically it is not possible for you. In lab. We have tools, we can calculate K factor, okay? Calculation of gauge factor is possible in another way also through your vendor Loewenstein and through your band detection. Okay, but that is not possible in CAD software. That is not possible on paper. We can only do it when we are doing it practically. How? Imagine like you have sheet off a 100 length, okay? Imagine I've, you know, you have the sheet and you are bending it from here. Okay? So let's say now you will calculate this one. You will calculate this one, okay? So see how, how you will do it. So let's say if this lengthy you are 40 and this length is, let say your 58. 40 plus 5898. This you can easily calculate, right? So if this is the annoyed now remaining portion in this one, this one would be your vendor loans. Now see Flatland equal to your length one plus lambda two plus vendor lowest. Flatland is all much younger. Then Lenten is for the land to is your 58, okay, plus b. So you do that calculation, you have b equal to a 100 minus, let us say 98, okay? So that would be your how much? Two. So you have got b equal to two. Now you have vehicle to two. So if I jump onto your this formula, now, if you put all values less than BA equal to two, so two equal two pi, radius, radius elapses T2 plus K factor. K factor. You have to calculate, pull us your t thickness less than it is 0.5 angle, you know, because you have given angle that also can be calculated less, you get angle as, let us say 60 degree by 1180. So you have all that value you can easily calculate gain in this way. Researchers are those who are in this field. They have defined k factor as per material as particularly. Okay? So that means if you simply serves like online K factor chart, you will get value. Okay? So they have defined these values like far harder material, okay? What, what like basically you can take FAR your soft material worked VHDL, you can take for your discipline, your K, K factor, ok, practically on, practically disposable. But for some people it is not possible. So that's why it's satellite. You can calculate your K factor in which way you can calculate in this way. But this is also not possible for us, okay? Because you don't know, but positional your neutral axis. Okay? Now if you ask me, Okay, how can I calculate that? So c number, you can calculate Mendelow ones. Okay, that is only for research purpose, not like when you are doing, you know, Europe manufacturing operations. Material thickness, you will be knowing K factor you can calculate because you have, if you have this one, you have this one, then position of neutral axis also can be known. But can you do it in software? Can you written paper? There is no way. Ok. So bottom line, no, I'm summarizing everything that we'll calculate Flatland you will have to keep in mind audio set Bagwell in mind. You have another formula also. I have mentioned both formulas. It, you also need to calculate the outside set reg, and now I'm going to make it very simple for you. No, I'm going to explain you this with the help of examples so that it becomes clear to you. So imagine like if you have something like this, this slanted, let's say you're 40 and this length is less than 60. Okay? Now we have to calculate Flatland. I would be calculating it with both ways. Vendor loans, Ben deduction. Okay. And one mode, I will calculate same thing in your CAD software and then show you how much radiation is dead homeless differences did. Okay, so what is the formula for this one? Last Evangelos so far all of our vendor loans is. So formulas. How much? That is your pi into radius. And taking radius as due to m plus k factor, I am taking k factor of 0.43. I will come on this one via I've taken 4-3. I I'll make calculations would be based on 0.4. three only. Okay? But in the end, you have to check with your vendor, review a manufacturing guy are, you will have to check machines specification where you are bending it. Ok, so we are bending your sheet. So let say this is your k as 0.40, okay? Then into thickness, thickness ad would be taking as 0.5. Okay. And then, and then angle is how much a is your 90 divided by V1 AD. Now let us calculate it. How much Mendelow's I will be getting it. So late I go 3.14 into two plus so 0.43 into 0.5. That is your 0.215. Okay. Then a by 90, that is how much? That is your one by two. Okay. Now let's do everything. So it's going to be your, so this one is going to be to find 215. Now let us do everything. So when I go 3.14 into 2.215, okay. That is your 6.9551 divided by two. So I have got how much here? So that is 3.3.47755. So I will keep it as 3.5. okay, I'll just go up to one decimal place. So 3.5. So this is what, this is my band alone. Ok. Now, how much is my L1? Ok, now let us calculate Flatland. Flatland taker to L1 plus L2 plus you are bend allowance. How much? 40 plus 64 plus 3.5. That is going to be helmet. So. That is going to be 1.503. Okay? And then now let's check in cats or pay how much we would be getting. So valency it. We have this particular pot, okay, first I'm going to show you like what are its dimension? So 0.5 thickness, the bend radius two. And I can misery KDE itself. So here I go. From this one to your 80 year 40, okay. And from and from this one to your decision is how much? You're 60. Okay? So exactly same what I did in that formula. Now let's check how much in our Flatland, Let me first unfolded. So I will do it in a very simple way. That afternoon Stacy's going to eat this sun. Unfolded phase is going to be this one. And ok, so let us calculate now. So here I go from Your disruption to your desktop one, that is 1.55. Ok, how much we calculated here? 1-0 t 0.5, exactly same. Ok, so just see again 1.5503. And here how much I got? I also got helmet. You are 10 t 0.5. Okay, well, my E value was this Mendelow's love, like your 3.477. Ok. So I have taken it to one decimal place, fight, Exxon Valdez. Exactly same thing. Now if you say OK, productivity, they need some difference, dissent that run. The thing is like Homer's defect values 0.43. That is one thing. I will say one problem with softly most other gaps or they fixed k factor value. Okay, so CAN example. So if I go to properties, and how much is k factorial? 0.47. When too many decimal places? It this you cannot change. That is a problem. If you ask me OK, what if I want to give, let say, some other value, you can't do it. If you say, OK, I told you like venue increase, the thickness of your cheat. K factor would be reducing. Yes, I said light taken as if you take notice of your party's increasing, K factor value will be decreasing like that. So if you say like now, if I increase my thickness, will this case active will be decreasing? Yes. Let me show you. Let me increase this one. So hey, go to your sheet method. If i keep your taken out that let say you are too. Okay. If I keep it as to if I go to now your, Which one? This one, now see. So see your K factor is 0.3 to now, your unfolding length would be different. Now see here, that is how much? 1.66302. You can consider it as 1.702. So this is in front of you. Your software will automatically take K factor value based on the thickness. If you increase thickness case actor value will be decreasing. No. The your K factor would be more than 0.05, okay? No, this is like practical node is all company. You 3D software so you can calculate Flatland there. But what is your company using AutoCad are what if you do not have gas off the you have just started, you're designing, prototyping and designing book. You do not have software. How you need to calculate, you need to calculate in this way only. Okay, so pause the video, make notes of these formulas that this was a formula for audio vendor loads. So I calculated Flatland for a new base on your bend allowance. Now, this one was for your Which 190 degree. Okay. I will calculate for some other angle also. But let's calculate our band detection also value 90 degree value. Oh, what was our formula for ventilation? That again, I'm taking 0.43. Okay. Into your radius that is two. Then what plus 1.372 into your thickness? Naps are no. If you could calculate it, then how much it will be? 0.430.43 integral is going to be 0.6. Then what plus 1.372 into your thickness? Thickness is taken as the 0.5. okay. So that is going to be how much? 0.686. Ok? So a Vigo equal to 0.86 plus 0.686 is going to be 1.5 for six. This is our banded hatch. And now I'm going to make a very little bit change here. What I'm going to do, what is the formula of Flatland equal to L1 plus L2 minus banded action. Okay, let's do one thing. I will keep this on as 40, I will keep this one as 60, okay? And then I will subtract 1.1.5 forces. Ok? So this is going to be homeward, a 100 minus and then minus 1.546. So my Flatland is going to be your 98.4 phi four. Okay, now let's check what change I'm going to make. A really in earlier case I was calculating lent, you know, from up to this point already. Okay. Now I'm going to do one thing. I'm not going to calculate length from this point. I'm going to calculate it from, you know, in this way. This is going to my elbow and this is going to be my and then this is the aluminum illegal. Okay. I'm going to minus that. Well, I have already done here. So I'm going to make it as 40, disown as 60. And let's set how much radiation would be the real formula my values doming as an idea for five-fold, okay? And we're going to consider it as 98.5. Okay. Now, how much that Festival I need to define same pedometer again. I will give taken assets 0.05. and I have to move until a plus nine going to check like how much value right now is the, okay? So I'm going to take this part in your drafting venture. So here I go. I will keep your sheet as let's say info. That would be enough on us. So I wouldn't be going with some site you, I just want to calculate C that I mentioned right now and then I will change them accordingly. So let's delete these views. Default views I don't need actually. So here I go to your front view. So then I will jump on to this one. And as we dig this one from your site, it, I go click there. And so let's set now, how much is the value right now for us? Like me hide these. So when I go to this one from your left, say, well, I need to make sure that I'm clicking on the right point yet this month. And then let's say you're descent. So it is how much? 42 by five. Okay? So i really reduce this value way. How much? 205. So I will reduce this by 2.5 and let us take now the other also. So I will check now from your same this point. I will calculate from this one to this finite lattices to Ruben file. So I will, so I will reduce my values by 2.5, okay? And then we will say, so I just need to make a very small change. So that is going to be my these values. Okay? So I'm going to keep this one, let's see, 40. And this one also adds 40 minutes or so. And I will reduce this fun also by, let us say 60. Okay, then no less set in your kit right now. Okay? And this I need to reduce bind 5G mode mass M, then I would be done. So just looting saying baby. So I go to your net, say this 395555. I think nowadays, fine. Yes, 4060. So let us calculated here now. So I will do say well I can do it in sheet also. Okay, let me show you this time in sheet. So I will just take your unfolded you. So I will just click on this command, it unfolded you. I go to your window part and I declare, say from this one. So now let's calculate how much is our Flatland. Some validation I'm expecting now. Okay. So let's say if I calculate from your this one blew your, let's say this one. So it is 98.52. Once we calculated 98, buying 4-5 or so in software, we are getting 98.52 and it via getting 98.45. Okay? And this is the definition. And if you ask me why this motivation is it ok, because many governments acted and given find one m, m is actually not good navigation appoint random m is also a group. That is because this salt grid took your K factor 0.47. I'm taking it as 0.40. Now if you ask me how I should decide, first of all, you have to keep your, you know, what material in mind, ok, material in mind. Second-year thickness in mind. Let me show you a website. So this is one near you or sheet metal lot ME formulas and functions slash k vector. So nav expense, same thing, whatever is explained like new relaxes then, now step and everything. And they have shown you like practical way of calculating gave at the in real. Okay? You can't do these things in, on paper. So if this one formula is this one and so leave the Sun also coming onto this chart. So if you're doing air mending, okay, now see hey, if a being in bending and your material is what soft aluminum you're gave factory is going to rewind. Okay. In the same way, medium-scale pine tree. How hard stainless steel, 0.40. If you're being kind integration for your, your soft aluminum 0.88. So this value will be changing. Okay. Bays on your material based on what is on your material and your thickness. So that's why it's I'd like your company will be having something specific. So you refer that table, okay? And take that K factor value and calculate either vendor ruins your Ben deduction. Okay? Read that. You calculate your Flatland if it is Brenda Lawrence, L1 plus L2 plus b. Ok? If the event detection L1 plus L2 minus Va is L1 and L2 are different, do not get confused, okay? This is how you do. Now whatever I explain that for us, for this simple one, okay? That was the simple one. That our value is less than 4060 and this one is less than 90. What is, what is over? And, you know, different if it is like that. So let's do one thing for us. I've really changed my angle here. So I go, I gave my angle F. So here I go. So eight I go, I will give angle hated. Let say you're 60. This one might angle as now you 60. Let's see like whether our formula will work or not. So far, Lexi angle 60 degree. Okay? Now, first of all, see how much are these values, okay, let's do this thing first. Now. We will calculate as for these values. And so apparently just matter of, you know, one click OK. Let me just upgrade this one. So right now I will first calculate the bend allowance. Ok. So I will delete these two Valley. So all around. Right now, how much is our slab length video 60-degree angle 96.1. And they will know crosscheck whether LET formula we will be getting this one around cluster file. I will calculate these two. How much are these lands? Only because these are must we need to know these. So this is how much length of this one is 35.75. And this one is how much? 55.67. Okay. 35.6735.67 million. I retake screenshots of this one and put it there so that it becomes easy for me. So what is a formula that is your bi into R plus k into t. Only this one is changing 16 by 183.14 into my radius is same to this inside. Add still same two plus 0.14 into 0.05. and let say this is one by 31 by three. Now let's calculate it. So this is going to be how much? 3.14 is going to be 2.215 into one by three. So that is going to be your T 0.14 into 2.2156.9951 divided by three, that is going to be 2.32. Ok. Now bless calculated my flat land for this sheet is going to be your 35.75 plus 50.5.67 plus 2. They do. Okay, so how much this will becoming? So here I go, 35.75 plus 55.67 plus 2.32. That is going to be 93.7 for too much variation right? Now, how, why we have got this modulation less daunting. So instead of taking 60 here, if I take one county, what would happen? Now? See it. So I will do one thing. I will divide one-pointed divided by a 180. So that is going to be your 0.06, let's say 7679. I'll do the whole calculation and calculation here. Okay. So 3.14.215 into 0.67. Okay? So that is going to be how much incentive on by three i becomes 0.06 seven, okay? So my value is 4.6, let's say six valleys, 659917. So I will take it as 0.6 less say six. Okay? Now, if I do same calculation here, so how much I will be getting in setup to monthly to if I take 4.6, how much it will be. So 35.75 plus 55.67 plus 4.6. So that is going to be 96.08. So I got my flat length right now. Okay, in software, our value is how much? Our value is 96.1. Okay, what you see here, and in Lovett formula, I've got like 96. So if I take it up to one decimal place, it will be 96.1 only. Okay? Now the thing is like you have to give the same line. You will have to keep included angle in mind. Ok? Included angle. You should pick. Opposite angle, 180 degree minus included endl. Okay? Okay. So recall it as your deflected ended deflected angle lesson. So let's say if you have got part in this day, this elects a year one-term tea. So in that way, it will be how much? It would be 16, okay? If this angle is, let say you are 45, so you should take 130 minus four, that is going to be one Turkey saying you should not take that. Okay? So only difference is that if you have angle less than, are more than 90 degree, you you should do it 180 minus that angle, that will be reflected angle. And did that, you will get your correct Flatland. I have done with the formula, got 96.1 value and I didn't endure software also got the same value. So that is proved like this formula works exactly same day, exactly in the same way the video software works. Okay? So that is how you calculate Flatland off your part. Ok. Now I calculated this Flatland video bend allowance. Ok, so with vendor loans formula, you already know by R plus K into P, a by 180 is your angle. So in case of a QTL obtuse angle, in case of, let say angle less than, r, greater than, okay? Less than, or greater than, okay? Whatever is there. So you're 90 degree, you should do what? 180 minus a1, that is called as your deflected and those gun. So this formula will work. Then you will do what? Flatland equal to L1 plus L2 plus your B. So this formula will work in all the cases. Okay, so this was quite easy. Now for Ben deduction, what, whatever phosphate formula, our first formula was 0.43 into r plus 1.372 into thickness. This one's audio 90 degree. Okay? Now far those shapes, our angle is less or more than 90. Then our farmers point complicated. That is two into r plus d tan E by two a's. What is your angle? Okay? Minus two into pi r plus 0.43. When David took point 4-3 head, you need to get just go with your four also. I usually do it. In case if you have the exact value of K factor, you can take that out. So like 0.45.43.3, I do calculation based on 0.4.4 into, let say t, then your angle a by 360. Very complicated one. Now let's do one thing. I am going to calculate it. Let these values. So first of all, I should know the full length. Okay? I will first of all calibrate your full length and then I will calculate your dishonored setback value. So let me delete this now. So from your this particular point to this point, it is how much it is 40 it then from this point to this point, it is your 60 exec safety nets. So now I will do the calculation. Ok. Angle is how much angle is I think same six-step interchange. So let me check run one more time. So from a to a, that is your 64 gate. So I had to pick 180 minus 60 deflected and L, okay, angular deflection should be there. So now let's do the calculation. So this is going to be two, r plus t odd is two plus 0.5 tan. Eva, you do AES, how much? 60 were deflected angle. So 180 minus t by two, minus two into 3.14. Then again you are, is almost two plus 0.4 lessons. You can go vote three also, but I will go with four into your T. T is almost 0.5, then your angle that is almost one. Don't d by 360. Okay? So this is going to be no, let, let's do, let's do every no less do calculation. So this is going to be two plus 0.5, that is 2.5 plus two. That is going to be 0.5 in brutal, that is going to be your file. Ok, 2.5 plus two, that is going to be phi into your tan of 60. So Dan 60 value is how much? 0.3 to minus 3.14 into R2, that is 6.208. Then this one is going to be 0.4 into 0.5, 0.2 plus two. That is going to be to find two. Ok? So this is 2.2 and this will be one by three. Okay? So now what I find very easy equation five into 0.3 to that is going to be 1.6 minus. So now 6.28 into 2.2, that is your, this one is your 13.816 divided by your three is your 4.6 legs. I can consider it as 4161 or less it. Okay. I'll go with up to one decimal place, only done. So now, how much is this? So I will calculate it like minus 1.6. So consider it has three decimal places, the valleys like three, 1-0-0, 5.3.3, three. So let's go with three only. So our setback value are bended action is C. Now let us calculate flatland. So it is all much 40.08. That is your L1. Thus your 60, that is L2 minus your three. So it is going to be how much? 60 plus 40.08, that is under Bonjour, eight minus three is going to be your 97.08. How much value we have got in our car software. That was 96.1 nowadays, this much differences here. Now in these cases, like the difference is due to, usually we do not get that much difference. Okay, why? Because I was taking value as 0.480.43 is nearby, is 0.4. trees near to your, you know, 0 bytes 478, that software and these are your 0.476. Okay? I'm taking x2 by photons, so that's why the difference is there. So if you calculate this k value, you will also get the exactly same. Okay? And non-religious, my value was 0.443. Ok, here the value is urine, 0.45. Here the value is 0.47. My earlier value Vos 0.4.7. So while calculating a bend alongside of us, taking value as 0.43. So the radiation or difference was not that much, but now it is London understand that is too much actually in manufacturing. So you take this K factor depending on your material thickness and your material, and then you've got blade. So if I calculate with 0.47, I wouldn't be having this one as exact 96 Monday or not. Less than 96.2 or less than 96 but not that much difference. Mainly seven. Okay, so this is how you calculate your Flatland. So if I just make very small changes in UK vector, I will get exactly the same value. So it is up to you whether you go far, reach one bend allowance, our European dimension. Ok, so that is up to you. Well, if you have just 90 degree angle, you can go for this ON disease, like quite straightforward. Ok? If your angle is less than mode, then you go for your bend allowance. But anyway, this formula is also very simple. Your formula for band detection becomes complicated when your angle is it 90 are less. Manual angle is either less than 90 or more than 90. It becomes complex. So in that case, you can always go for bundled loans. So just do one thing now. Pause the video. Make note of these important formulas. First on your bend allowance. Bi into R plus k into t into a by one a, where a is your angle. Okay? Od is your bend radius. K is constant, vector. T is your sheet thickness. Once you know Ben the lowest, then just add this value to your other lens, you will get Flatland. Now, jump onto second 1. Second 1 is your bended action. If you don't want to calculate your Flatland, Brenda Lawrence, then you have these two options. First one, far angles. First one far 90 degree angle, 0.43 into R plus 1.372 into t. Second 12 into R plus D tan two minus two phi r plus 0.4. That is K factor into T, K by 316. Just remember one thing yet, that a is not state forward. What is a run? A D minus your angle. Why? Because we need to calculate deflected ended. So if this is the figure, then go for your band elements. With Ben deduction, you have to keep two formulas in mind. The width bend allowance just to run. And you have other formulas also. For example, like Ben delusions plus b_n detection is equal to two types into your outside SetBang. What is outside sand bag that I have already explained in the very start of this lecture. To calculate your outside setback. Again, you have formula can a by two into t plus i. And if you want to calculate K factor, then the position of neutral axis divided by your material thickness. That's how you get your K factor value. So these are five formulas you need to keep in mind for calculating Flatland of your sheet metal. So that's an abort this lecture. Now jump onto the next section. We are going to discuss all the design guidelines. First, we are going to start with extorted holes. So there are some guys, thank you very much. 12. Lecture 11 - Extruded Holes: In this lecture, we are going to discuss about x2 revolts. Extruding metal is an extreme pressure application via the lot of heat as a less friction alienated. And if holes are very close, if holes are not at the right location, then deformation Octavian can't happen. So basically you need to keep three rules in mind. Minimum distance from the edge to the whole, minimum distance between two holds itself and minimum distance between whole n. Bandage. Now we will discuss about all these one by one. First we will discussed about rule one. That means what should be the minimum distance between extraordinary Roland part. And so the rule is like you, your dissent should be at least three times. In this case I will sheet thickness is one mm. So we need to have at least three m m distance between the parties and your whole edge. If you'd give less than that, then what could happen? Your part may get deformed eight mega data when dating can happen, our deformation can happen. So on the left side that distances to M and on the right side be stances. Five more than five. Mm, very simple rule. Ok. Just make a note of this point. Then guy jumping onto our second rule, that is distance between the extruded holds itself. The rule says that it should be six times the thickness. Now my bar thickness is work one m m. So by rule, it has to be your, at least six. But on the left side that the senses 0.7. fold, okay? And on the right side of that desensitize you earn more than seven. So right sidebar, we'll be getting easily manufactured, okay? But the left one will get deformed, as I would say that the distance is kind of 0 only. It is just 0.8. Okay? So you need to keep in mind, many students I've seen, like what they do is they simply defined their bars. Okay? You will learn about these type of things in companies, okay? But as a student out, so there is no harm if you are learning them right now. Okay? Whenever students they learn CAD software, they do not bother about these things. They simply like define whole hidden data features here and date, okay? But when you work in a company, you have to keep all these things in mind. Okay, so just imagine if you're aware of all the rules and then if you are using them in the company, if you are discussing about all these in your interview, what impression you would believe in there. Okay. You can write in your resume that you are aware of all the design considerations related to sheet metal are let say plastic design then would be, what would be your impression? Ok, everyone nowadays learn Catia 30 and x gaps polynomials, all these office okay. So if I ask next, attends students, how many softwares, you know, at least it would say that I had seen because I'm involved in other trainings also, what I have seen is like eight out of ten will say, I know like Catia. And next CAD Solid Works are less H3O and scad and Gettier, at least like they would be available please or phase. So these things, you know, these things will help you stand out from other guys and they can help you in getting job. They can help you in the companies. And now let's jump onto our third rule. So third rule is distance between x2 read hole and the bandage. That this is very, very important. Okay. So it says like your dissent should be three times the thickness plus fill it radius. Radius of your fill it at the edge to read whole Ok, bottom plus your goal radius. So if your thickness is, sheet thickness is one MM, okay? Are your radius is less at 3M. For example here our sheet thickness is one mm. Radius of holy 3M. File_id radius is one m, m. So by rule of how it should be three into one, ok? Plus Philip radius that is one. Polis my whole radius that is three, so it has to be seven. Okay? So here if you see and that distance is 1.292. So like in software you can give, but when somebody's going to make this part, you, what would happen? It will fail in this sense is worth more than seven. So this is okay. Okay. So this is like your minimum distance of y, which you, which you have to give at any cost so that there is no deformation are basically your part is not getting any guy end up feeding, attaining. Okay. So that's all about our extruded holes. Now we will jump on to our next lecture that is about opioids. 13. Lecture 12 - Holes: In this lecture we are going to discuss about holds. Now you will be thinking like what other considerations for whole? This is very simple product, so you can find that out. All I need to keep considerations in mind. Yes, you have two. Why? Because see, if you are giving a very small size hole, either you're punching tool can break, your part, can deform. These two things can happen. So to avoid those two things, we need to keep these rules in mind. Minimum hole diameter, minimum, minimum distance between two holes, okay? In a perforated metal. Minimum distance between whole to bandage, minimum distance between rectangular bowls and distance between two holes itself. Okay? So all these rules have to be kept in mind. They are not very difficult, but they have to be kept in mind. Let's discuss about all these one by one. So the first one is minimum hole diameter. And this rule, and this rule is very simple. For example, like if your shield thickness is one mm, so your minimum distance should be how much? It should be one MM FOBT software methods, and it should be two MM far our methods. Ok. So here the momentum is, you know, your soft matter. So the designer has given one MMA. Okay? If you're using hot matter, then the designer has to give at least two nm as shield thickness. How much? One m. Okay. Very simple one. But you need to keep in mind. Rule number two is that the distance between holes in a perforated metal should be how much should be 1.2 times the thickness? For example, if your sheet thickness is one, then the minimum descent should be how much? 1.2 into 1.2 into one, that is going to be your one by two M M. And in this case, the distance is how much 0.63 are 0.06, 74, that is wrong. Distance is three. So here vertical, what would happen? Your part will be getting deformed. But here it would be okay. Okay. Again, very simple rule, but you have to keep in mind, as I said earlier, that make a list of all these rules. Okay, stop the video here. Make a list of all these rules. And you know, whenever you are designing a product in sheet metal, referred that list. Ok, let's jump onto our third 1. Third 1 is minimum distance between a circular hole okay. Through a bandage or reportage? No. The rule is like it should be three times the thickness. So if you are designing a hole here, then the distance between this vended who you are, this hole should be, how much should be your three m, m, d should be three m. Ok. As our chief thickness is one, so it is going to be one into 33. Okay? So hailing this gets out there. If you see this is your 2.2, we have six that is wrong. This is 5.9, less than six. This is okay. Okay. So whether you go for party or you go for your, you know, your band edge, it has to be three times thickness. Then 4s1, distance between rectangular holes. Okay, and pottage or bandage. Their the rule was three times thickness over in circular holes. The rule was three times sickness.NET is almost 315. That's a different do you need to put effort, you know, to learn this? No. Will you use it twice or thrice in your sheet metal, you know, designed x-value, you would be able to recall it at any moment. Our sheet thickness is one, so it would be 0.5 here. That distance is, you know, how much one, a deceiver, and five, so it is okay. It over, you know, our, our part will not get deformed. Now jumping onto finer one, final one is distance between two nodes. So the rules is like you need to add a radius R FU holds for us devise the sheet thickness. The CEO R1, which is two. This is your second hold gradients, which is also two. So two plus two. Okay. Then it says device into his thickness plus two into how much is our shift thickness? That is our V1. So it would be how much Tobler's tool for 04 plus 26. So it would be over six m. Ok. That's how that's well, all these were very simple, but we have to keep in mind. So why I have discussed these things in starts so that you know, you get to know even in simple features like Alexia x2 read whole lot a whole itself. We have these things to keep in our mind. And then you think about, you know, your stiffness or you think about your dimples should think about your hands. You think about your not, you think about your tabs. What would be the consideration for all those things? Ok, so that's an abort this lecture. Now in the next lecture we will discuss about bends. Nasa guys, thank you very much. 14. Lecture 13 - Bends: In this lecture, we are going to discuss about Ben's. Well, there are many things related to events. I will discuss, vote all those in our final lecture, outlook and grid Flatland. But here, here I am discussing about your minimum bend radius and Mendeleev at this point, these are more than enough, as I said, like I will be starting from the basic and then slowly I will be jumping onto your advanced things. So first we are going to cover basic sounding. So the first one is your bend radius. And the rule says like, You're bend radius should be equal to your shield thickness. If you achieved thicknesses one MM, You are giving radiates at 0.5, then it will be incorrect. If your sheet thickness is do your minimum bend radius should be to a viewer. Sheet thickness is one. It has to be one. If it is 0.5, it has to be 0.5, not less than that. Okay. They're upset about this one. Coming onto our second 1 second 1 knees bent. Relief. If you do not give if you do not give bending your part, then what can happen? There would be some kind of a they will be dealing in this area. So to avoid that dating, we give relief you garlic as vendor leaf or you call it as not to be. That is up to you. There are two things. I would say like means venue or giving this type of, you know, got cared that you will you will call it as Ben Redleaf. If you're giving same cut, let say here, it would be worth, it will be called as cold as you have not. Next our next are different. So there are two things. First one, your debt and second one, you're Okay. This worked. Okay? And this rule says like your depth should be homage bend radius. Now, my bend radius is much here when babies is two. So it has to be minimum tool again, but the designer has given four, so this is fine. The verdict should be how much? 1.5 times the sheet thickness. Okay. My take Messi is almost one. So multiply it by 1.5. It has to be at least so much one. Here we have a homeless tools, so this is fine. So that's kind of a vendor lives. There were only two things related to events. What should be the bend radius? It should be equal to your sheet thickness, at least equal to, that is important. And second one, relief. But your depth of the leaf can be called to bend radius. And your leaf, should it be 1.5 times achieved thickness. So that's how guys about our third lecture. On the fourth lecture, we will discuss about and Boltzmann. 15. Lecture 14 - Embossment: In this lecture, we are going to discuss about embracing. And boasting is a process in which V stats metal into a shallow depression. Basically imposing a used to create laddering logos, smart depressions, sampling features, as well as many other geometric features on a sheet metal part. The main mode of deformation is either stretching. Our attention due to these two stretching intention. The sheet metal part is subjective to excessive fracturing and training. And to make sure that our party is not getting field are the feature is coming properly. We have to give few rules in mind. So the first rule is the maximum depth of the sheet metal product. The maximum depth. So the maximum that should be three times the sheet thickness. If he'd taken assay is one m, then that that should be three 3M. The second rule is distance between emboss and foliage. And the rules is that you have to give at least t dammed or should thickness plus Bayesians. So let us say this is R1. So how much should be your this distance? This should be three times the sheet thickness plus R1. This is a minimum distance you need to give. Then the third rule is distance between emboss and bought ij. Rather here, you will have to give how much you have to give four times the sheet thickness. Debase VDS, ok? We will have to give the base radius plus four times sheath thickness. The fourth rule is distance between emboss and bandage. It should be three times the thickness of your sheet, but less bend radius. Next, if this is your R1 plus your radius of your Ambrose, let say this is R2. So how much it would be three times the sheet thickness. Let's say your thickness is on m n. So three into 18 would be t plus R1 plus R2. So this you need to keep in mind before defining the location of your ambles from that vent. Rule number five is about distance between two and bosses. Well, it is very simple. You have to give at least three times sheet thickness. So this should be how much three into t. If your thickness is one, then it is going to be how much? Three m, m. Okay? So you need to give these five rules in mind before defining the location of emboss in your sheet metal part. There said about this lecture. Now jump onto our next lecture that is thermal guidelines. 16. Lecture 15 - Curl Guidelines: In this lecture, we will discuss about girl guidelines. Girl enhance. Both are kind of seen. What happens in the kernel. The edge is not, you're not exposed. Okay? What you see here, that is salvage or if this edge is exposed, ok, then it will be your ham feature Nestle. The next lecture is about them. So there, you know, you can combine both. Whenever you sees something folded like this, something like this. If you can see that now in this particular picture, we can't see that. So it is what it is you're gonna feature if you can see that, that if that ad is exposed and that would be your hand feature. Okay, so let's discover, discuss about girls in this lecture. So basically you have three rules. The first one is outside radiance. The outside radius of your goal should be to time dashes thickness. If our sheet thickness is one, then the reader should read to him. Okay. Second one, the venture would be how much the bandgap girls should be? The radius of curve plus six times should thickness. Okay? So for example, if your radius of curve is let say two, okay? And your thick sheet thickness is one. So it would be two plus 68. So the event should be eight m, m. Okay. And the third one, distance between AD Jaffa hole and curb. Okay. What you see here, this should be how much? You need to add two things here, radius of curve and here thickness. Okay? If your radius of L2 sheath thickness is one, it has to be how much? Three m, m. Okay? So let's say from this edge to your dissent, it has to be your own much ramen. So what would happen if you do not give the minimum required the sense your part can get the farm lifestyle guys, these three rules are there which you need to keep in mind while designing. So they're soluble. This one, jump onto Lecture six. Ham guidelines. 17. Lecture 16 - Hem Guidelines: In this lecture we will discuss about hems. As I said in the previous lecture, that the difference between him and girdle is that in him, the ad is RVs exposed, okay. Like here, the edges exposure, but in your URL and does not exposed. Ok. That is the only difference. Now coming onto the rules, but data on how many roots. There are. Basically three rules for your open as, as well as teardrop hand. Your open ham is which one? Something like this. And your dear drove handmade like this. A rules are kind of similar only. The first rule is that the inside diameter of peer dropped or open m should be equal to you, you know, your chief thickness this inside them into, okay. What do you see it here? That should be equal to shift thickness. If he thickness is one mm, then the inside diameter should be one. But it doesn't lend from this point to this point. Okay. Head out. So this one, it should be four times sheet thickness. Four times. If shift thickness is one, then this length should be 4M. And you know what happens in software, students gave any value for 56 poetry, they give any value. Ok. But it should be four times sheet thickness. And the final one is your teardrop lamps only. That is opening, opening from this one to this one. It has to be one by four. If your shield thickness is one MM, Okay. Then it has to be 0.25 MM. Dsl guys. So decidable, so deaf, tell about our hands. Now in the next lecture, we will learn about notches. 18. Lecture 17 Notch: In this lecture, we will discuss about not. Basic rules are very simple. That you are not weights should be 1.5 times the thickness. This thickness, like this roots should be 1.5 times. The length should be how much land should be five times if your thickness is one, this length has to be, you know, your file. Gardener radius, radius defined here again. And at least karma, they should be 0.5 times to give thickness. You need to keep in mind while giving any knowledge in sheet metal product. The next one is your distance between band edge to not judge. Rule is there should be three times thickness plus incitement variance. Now, in this case, our sheath thickness is 0.5. Okay? So it would be three into 0.5 polar server inside when the radius is how much one. So it has to be how much? 2.5. at least in this case, that distance is almost one MM. So it part will see in the distance is three. So it would be opaque. Lightwaves. You have the next rule that the distance between two notches itself should be homeless to time-shifted nets, ok, through bang sheet thickness. So if your shield thickness is one lemon, OK. This would fail. This will be okay. Ok. That you need to keep in mind. In the same way, the distance between a notch and our own should be 1 times sheath thickness. Well, I'm not going to discuss about values in all the cases, okay? Because your techniques can be fined 5.8 so that, that is up to you. How much you give. You just need to keep in mind that it is 1.2 bands sheet thickness. If your sheet thickness is one, so 1.2 into one, it should be your 1.2. And this case, it is your find for projects, it will fail. It is one 5-6. And coming on to our final two rules, I have already discuss about these two in your bender leaf glass. So as I said data also when you are giving the notch, okay, in event you can call it as vendor leaf or a nought and leave the rest. Everything is same as relief debt, okay? You can call it as not a leaf that should be equal to bend radius. And not with our lesser leaf width, should be equal to 1.5 times sheet thickness. Risk calculations will depend on your values only. What do you bend radius or what he or she thickness. Okay. So although not is not very difficult to do, you just need to, you know, put up at out, just direct angle and gutted our backs out. You will get your nudge. But you cannot just do it like that. You need to give all these 78 rules in mind. Ok, So that's it for this lecture. Now let's jump on over eighth lecture. That is, dimples. 19. Lecture 18 - Dimples: In this lecture, we will discuss about all the rules related to the impulse. The first one is the diameter. Well that should be equal to or less than six time sheet thickness. Heavier sheet thickness is one mm. So diameter of dimpled should not be more than six MM. Nand gates. And inside depth of the impulse should be less than your inside radius. You'll need to give these two in mind. Ok guys, second one is the distance between part adds to your temple should be four times thickness plus nimble radius. Okay. If you have any less distance, say distances, okay? Okay. Whatever minimum was required. So part will not failure. Code one. This transmitter improved inverts itself should be four times shield thickness plus nimble radius. Well, it is not that difficult to, you know, guess like what would happen if you are giving proved him books like this, ok. Your Y1 tool as both will fail or they both will get deformed. Okay? Number four is what? Distance between whole and agile fet input. So how much that should be? That should be your three tank sheet thickness. Okay. Pretty time sheet thickness r, it should be inside radius of dimpled plus three times x3 thickness. The next one is the distance between whole and adjust the input. That is how much three times sheet thickness. If you are calculating from the edge, then it would be your, how much? It would be your three banks sheet thickness. If you are calculating it from center than a task to be inside radius plus three, then few thickness. You need to add the radius of the input. Okay? So the fifth one is this transport when slot antenna impulse, that should be your full time sheet thickness plus inside radius. If you are, you know, that ablating from edge to edge, then it will be simply your full-time pier thickness. Otherwise it would be your full-time sheath thickness plus radius. Rule number six is about, you know, your bandits and knowledge. Okay? And the rule says that it should be two times here, thickness plus dimpled radius plus meant babies. Then if you do it in real time, you're part will definitely deformed omega. So DSL about dimples. So these six rules you need to keep in mind while defining these in CAD softwares. 20. Lecture 19 - Gussets: In this lecture, we are going to learn about guessers. Gas Asada used to stand tough range so that there is no need ofs can reprocess such as welding. There are few rules which we need to keep in mind. A general guideline is that event your dessert is at an angle of 45 degree, they'll verse ten. Depth is directly proportional to the radius and material thickness. So designers should make sure that his 45-degree goes. It is not more than four times the material thickness onyx flat edge. This is the first rule you have to keep in mind. The second rule is very simple. The distance between concert and that whole edge should be at least eight times the sheet thickness. If you've she'll take it as a x1, then that distance Virginia Gazette and hold should be eight MM. So that's all about deserts. You need to keep these two rules in mind. Now jump on to the next lecture for counter Warren counter sings. 21. Lecture 20 - Counterbores and Countersinks: In this lecture, we are going to discuss about counter boars and counter sayings. First, we will discuss about comparables. Though very first rule is that the minimum distance between two controversies, eight times the sheet thickness are part thickness. If your sheet thickness is one mm, then the distance between Duke honorable should be eight m m. Then the second rule is that distance between a counter bored and Bart edge is four times the material thickness. For example, if your sheet thickness is running, then counter bore should be at least four MM away from the bart edge. If you don't give that distance, then your bot will get deformed. And in the same way we have the third rule there. The minimum distance from a counterpart to event is four times the material thickness plus the bend radius. You will have to add that bend radius eight. In the second rule, it runs four times, okay? The sheet thickness, and here it is for bank sheet thickness plus bend radius. So let's say if your Band-Aid is is 2m and your shield thickness is 1M, then how much distance we need from the event. It would be bend radius, that is two plus one into four. Okay, one MM is that sheath thickness four times. So it is going to be your 2x plus four, that is six m, m. So your counter bore should be at a distance of 67 from the band. Okay? If your shift thickness is one and your bend radius is two MM. Well, just like counter boards, we need to keep things in mind so that our material lunar get deform wild via Congress and Kinga, particular material, particular sheet. The first rule is that the edge of conversing should be at least three times the material thickness from that tangent point of the event. You need to keep this in mind that the minimum descent should be at least three times the material thickness are sheets signals from the tangent point of the event. The second rule is that you need to have minimum of 50% contact between the park. Okay. And that counters and third one is the minimum distance between two counters things is eight times the material thickness. Okay? It is just like your comparable in counter bore also we have to gauge how much distance, at least a Bangladeshi thickness here also it is same. You have to give at least eight times. Then. The other rule is also same. Distance from the counter sink to the bottom edge should be addressed for bombs in counter mode also seen. Okay? So you are counter sync should be at least four times o sheet thickness from the bottom edge. And the last one. That how much should be the distance between a Gunderson gander band? Well, this is also four times plus your bend radius, just like your counter rolls. So basically three rules are same for counter sings. Okay? Only two rules were, I would say different. Well, those rules would the maximum depth should be 3.5 times the material thickness and there should be minimum 50% contact between the BOD N counters. And so they have said about this lecture. Now, jump onto our next lecture in which we will discuss about ribs. 22. Lecture 21 - Ribs: In this lecture, we are going to discuss about two ribs. Ribs are basically required to give strength through over part. There are a few rules which we need to keep in mind. The first one is minimum distance between dual leaves. The rule is that it should be ten times the sheet thickness. But let's radius up bolded heaps. You see in this picture, if you're giving two ribs, then it is going to be your ten times sheet thickness plus this radius plus this radius. The second rule is the distance between rib and your band. Here the condition is that rabies not batter, do that bend. So the distance is how much? The sense is going to be two times the sheet thickness plus radius of this bent plus the radius of the ring. Okay? So let's say if you're bend radius is two, ok? This radius is there, say 0.5 and shifts thickness is one m m. So it is going to be two into one, that is two plus bend radius two. Pulitzer yb radius 0.5. So it is going to be 0.4.5, okay? So minimum distance has to be 4.5. The third rule is, is about that distance between pottage and well, the condition is that both up badly. And by rule, we have for key poll much descends eight times thickness. So let's say if your thickness is one, then it is going to be eight. And let's say if your rib radiuses, let say 0.5, okay, are one, whatever you have given, then it is going to be 8.5. This you need to give in mind while defining the distance between bata agenda. Okay. But both are Padlet. And it is again same thing, but he had a live band. Apartheid is perpendicular. So that distance is four times sheath thickness plus rig radius. Net surveys. That's only difference. Okay. Four bands, ship thickness. Okay. Venues, paddle it is how much? Eight times thickness. And if it is perpendicular, then it is four times thickness. The fifth rule is the distance between reading, not just the distance, the minimum distance between a and whole edge. Well, that has to be how much? Three times the sheet thickness. Okay. Three times the sheet thickness plus rib radius less if this is odd one. So it is going to be, let's say three in proven if you've taken us is one, so it would be three into one. But let's say if your radius is less than 0.5, okay, so it is going to rewind it. If you are calculating it from the center of your whole, then you have to add this radius out. So, okay, so it depends on you like how you are calculating. Coming on to the final rule. The final rule is about inside radius, maximum inside radius. Valid? Well, the rule says it should be three times sheet thickness. And the maximum depth in that case is going to be how much is going to be equal to inside radius. So far maximum that you have to look at inside radius. And maximum inside radius can be homeless three times the sheet thickness. So how do we find that? That will depend on your software? But you have to refer these six rules. You have to keep these six rules in mind when you are placing them in your sheet metal part. So that's held up for this lecture. 23. Lecture 22 - Lance: In this lecture, we are going to discuss about lands. First. Let us understand what is lensing. So basically lensing operation you share and then bent your workpiece that isn't with the help of a die. So you got some shape like this. In this process, material is removed, but it will modify the geometry of your book Bees. And lensing you use to make partial controls are used to free up materials for other operations. Are you going to use lensing to make temps when tan lowers data? A few rules which you need to keep in mind since you are doing this operation with the help of a die. So you have to keep some rules related to clearance, okay? Some distance related rules you need to keep in mind. The first one is related to that depth tough lens. Well, by rule, you need to give that depth as much as two times into thickness. So if your sheet thickness is one mm, then this particular depth is going to be how much? Two. Ok? So this much depth you need to give. The second rule is about distance between Landsat band edge. And the rule says that you have to give how much this descent, you have to give three times the thickness of your workpiece plus bend radius. So let us say few achieve thickness is one element, so it is going to be three into one plus bend radius. So it could be 23. It depends on your part. Okay, so let's have you bend radius is two, then it is going to be three plus two. That is phi. Okay? The third rule is about descends between lands. And over. Here, you have to give how much minimum distance, three times thickness. So if your shield thickness is one, it is going to be your three. Now, if you don't give this much descendant virtual happen, imagine that if you have given a whole air, okay, and then you are doing this lens incubation. So what would happen? Di e will crush this hole or die will Theory or the soul and so it will deform your workpiece at this point are imagine that you have already given, let say your lens and then you are trying to give all. So if you are punching for the soul, then virtually heaven, your lands will be getting trust. That's why we need to give some minimum distance. Okay, that is all my chair. Three into shape thickness. The fourth rule is about minimum spacing between lenses. During lensing operation, we need to have sufficient degree of clearance to make sure that our lenses are not getting crust. Imagine that if there is not enough clearance, what will happen? Let us, if you are given this land, now you are trying for a second and say, okay, instead of this location you are giving if somebody, so what would happen when you are giving this particular lens, then it would crash your this one. So we need to have minimum clearance and for that, you need to keep your punch and die in mind. Now coming on to fifth root, that is about the length of your lens. Well it says like this, 50 is going to be u, two times sheath thickness. And the length is going to be how much? Five times with okay. So let's say if this is your two, if he'd thickness is one, so this is going to be two. And then verse is going to be how much five into two? This is going to be to know five into 210. Ok? Now one more thing you have to keep in mind. I have said like verb can be to hit no. Why? Because there is minimum requirement also. The minimum requirement is that you have to give at least three MM. So if your sheet thickness is one, you can say OK, two into one. I can give two MM. No, it has to be at least three. Okay. If you achieved thicknesses two, then two into lesser t2 equal to your phone. So that is fine. Okay. Then it is up to you like, you know, you go, well, I have already mentioned, whichever is greater than so in case if it is your four, go for, for. In the same way you have rule foreclosed lens also. In gold lens also it is same two times shield thickness are 1.6 m, m, Okay. And for length, it is five times sheet thickness. But in case of openness, It was almost five times K to the year, five times she'd thickness nasa difference. So these are the basic rules you need to keep in mind so that your lands feature is not getting crust, then you are creating a new lens. Okay? So Dave said about this lecture. Now jump onto next lecture, four tabs. 24. Lecture 23 - Tabs: In this lecture we are going to learn about Tab, Tab Bs, basically a perfusion from an edge, okay. Light, This is TAB here. Let's say if you have something protruding out from this S, you can call it as tab, but you cannot give tab in your sheet metal part just like that. Okay, you have to follow few rules in mind. The first rule is that the tub tab should be how much? The width of tab is going to be two times shape thickness. So if your sheet thickness is, let's say one, then it is going to be how much? 2m m. And that depth, okay, this one is going to be how much? Five times five times width. So if your worth is coming as two, then it is going to be your ten. So you're going to have simply like give any random value 4624, just like that, no, you will have to keep this in mind. Then the second rule is about that distance between two tabs. It should we how much? It should be at least 1.5 times the sheet thickness. So if your sheet thickness is one, you need to give how much? 1.5. If it is less than 1.5, let's say fit is one, then you're part will fail. When you are giving this feature in your sheet metal work piece, it will fail. Ok, so this you have to keep in mind that it is how much 1.5 into thickness is lesser, thickness is two, then it is going to be how much? Three. So these are the two rules you need to keep in mind while giving any perfusion from the edge of the sheet metal work piece. Now, jump onto our next lecture far birth. 25. Lecture 24 - Burring Hole: In this lecture we are going to learn about, but in quotes, the first question would be, how it is different from your extruded hold? When it is different from your extorted hold as they would be some kind of word here. Okay. And adjust your flange. Okay. So that's why it is called as your burning. Or there are again, some basic rules like over extruded holds. The first one is that the height of your budding goal should be device that thickness of your sheet. If your sheet thickness is one, then this height is going to be u two into your thickness that is one. So it will be your two. In the same way. You have the diameter. No, there is no such rule like it should be this much and that much. You have to keep bolts and pins in mind. Your diameter should be able to accommodate your bin, pins and bolts. Whatever is available in, in lesser you're part company markets, so you have to keep that in mind. There is no such rule-like. It has to be two times three times the thickness, okay? You should not give that value like far. There is no bolt in the market, okay, so keep this thing in mind. The third rule is that the Agile, you're burning goal should be at least four times the band edge. Okay. Let's say this is your band edge. So it is going to be homeless four times thickness. So if your thickness is one, it is going to be a full. Okay. Coming under your number four rule, that is about distance between budding whole ledge and apartheid. Again, it is similar. It has to be your four times thickness from bend down. So it was four times your sheet thickness. And from your pottage also yearn for time sheet thickness, where rule number five is also same. You're burning hole should be at least four times the sheet thickness from your cutout. If it is near, then what will happen? Your cut out will get crest when you are giving that budding goal. Again. And let's see if you have given your borehole first and then you refine your cutout, chances are that you are burning gold will get curse when you're punching. Okay, your workpiece far red cutout. So how much the sensitive required for times your thickness? And the final rule is what should be the minimum distance between two worlds? Well, again, the rule is that it has to be at least four times thickness. So what you saw here, that distance between burr hole and other features is almost same for exemple. But whole land, your band edge four times thickness. But homeland you're cut out for time thickness. But Holon pottage for time thickness between two boreholes itself, four times. Ok. What should be the height of a road? That is going to be a device that thickness. So that's the only change here. And the remaining rule was work should be the minimum inside diameter. Well, for that there is no root. You will have to keep playing standard balls and bins, okay? And you should define that accordingly. So that celebrate this lecture. In the next lecture we are going to discuss vote, some general design guidelines. Next, I'll guys, thank you very much.