ME / TM 3263 Design for Manufacturing & Assembly A/P Lee Kim Seng

Exercise 2

1. Indicate whether true or False for the followings: (4 marks)

(i) In mould design, it is preferable to align projections in the direction of the moulding or
at right angles to the moulding direction lying on the parting plane in order to eliminate
the needs of mould mechanisms, such as sliders & lifters. True or False

(ii) The design of part stiffeners or ribs should be at least equal to the thickness of the part
or more in order to minimise cooling problem. True or False

(iii) Press fitting and riveting, are two of the most widely used self-securing assembly
techniques used in both plastic and metal parts. True or False

(iv) Ultrasonic welding is widely used in the welding of plastic parts but not in metal parts.
True or False

2. The mechanical properties of the thermoplastics are usually substantially lower than that
of the metal, suggest how would you, as a designer, tried to enhance the mechanical
properties of the plastic for some applications without changing the types of plastic?
How will the action taken by you affect the working life of the mould? (5 marks)

3 A trainee designer was given a part file as shown in the figure below. He designed a
single cavity two-plate mould using a sprue gate. However, it was observed that the
parts contain ‘sink’ marks. With the aid of sketches, briefly explain the likely sink mark
areas and how you would modify the part to improve the plastic flow and reduce the
sink marks? (5 marks)

Wall thickness = 2mm

Height of cup = 100 mm

Diameter = 60 mm
Gate Base thickness = 5 mm

4. Why is snap fit widely used in plastic part assembly? Briefly discuss the pros and cons
of using snap fits. (5 marks)

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ME / TM 3263 Design for Manufacturing & Assembly A/P Lee Kim Seng

5. The figure below shows a plastic part design with 2 cantilever snap fit element, briefly
discuss the cost effect on the mould. With the aid of sketches, suggest how you would
try to modify the part to enhance the design thus reducing the cost of the mould?
(6 marks)