Project of the Week of 04/20/09

Project of the week is an Upper Motor Housing Cover injection molded from Rynite FR-543 Polyester resin. According to our records this part was originally molded in Polybutylene Terephthalate. This part is roughly 3-1/8" x 2-1/4" x 5/16" in size with a 0.035 wall thickness. This part is used on a motor housing that is also molded in Rynite to protect it from water, oils and chemicals while resisting the high heat generated in power overloads. Back story to this part was an operator error, this part was injection molded without the necessary inserts that produce the holes, slots and side wall cut-outs. We machined an entire order of 2500pcs, saving the lot from being re-grinded or scraped.

End Mills, Bull Mills, Chamfer Mills were solid carbide from SGS Tool, this material contains glass and High-Speed Drills, or tooling should be avoided. A better choice would have been the use diamond coated tools; we also used coolant to avoid the glass dust from spreading everywhere. Small tip here (Use the felt paper from the grinding machines to capture the glass waste at the coolant tank) do not let that recycle back to the machine coolant nozzles. We used Mic6 aluminum plate for a window style fixturing in order to hold down and prevent the thin walls from cracking during machining. Overall part tolerance was +/- 0.015 the machine finish with chamfer edges and machining marks for this part was expectable. We would like to thank our customer for allowing us to share this project with people who value the manufacturing talent that is out there... If you have similar projects like this and would like to receive a quote from us, please reach out to us for further information.