bulk molding compounds, inc
DESCRIPTION
Bulk Molding Compounds, Inc. ‘Complete Composite Solutions’. BMC Injection- Molded Motor Brackets. BMC vs. Die Cast Metals. ADVANTAGES. Reduced Cycle Times / Reduced Manufacturing Cost Thermal / Dimensional Stability Noise Reduction Weight Reduction - PowerPoint PPT PresentationTRANSCRIPT
Bulk Molding Compounds, Inc.
Bulk Molding Compounds, Inc.
‘Complete
Composite
Solutions’
‘Complete
Composite
Solutions’
BMC Injection- Molded Motor Brackets
BMC Injection- Molded Motor Brackets
BMC vs. Die Cast MetalsBMC vs. Die Cast MetalsBMC vs. Die Cast MetalsBMC vs. Die Cast Metals
• Reduced Cycle Times / Reduced Reduced Cycle Times / Reduced Manufacturing CostManufacturing Cost
• Thermal / Dimensional StabilityThermal / Dimensional Stability
• Noise ReductionNoise Reduction
• Weight ReductionWeight Reduction
• Elimination of Costly Secondary Machining Elimination of Costly Secondary Machining OperationsOperations
• Lower Tooling Costs / Longer Tool LifeLower Tooling Costs / Longer Tool Life
• Greater Design FreedomGreater Design Freedom
= 30-50% Cost Savings over Die-Cast Metal
• Reduced Cycle Times / Reduced Reduced Cycle Times / Reduced Manufacturing CostManufacturing Cost
• Thermal / Dimensional StabilityThermal / Dimensional Stability
• Noise ReductionNoise Reduction
• Weight ReductionWeight Reduction
• Elimination of Costly Secondary Machining Elimination of Costly Secondary Machining OperationsOperations
• Lower Tooling Costs / Longer Tool LifeLower Tooling Costs / Longer Tool Life
• Greater Design FreedomGreater Design Freedom
= 30-50% Cost Savings over Die-Cast Metal
ADVANTAGESADVANTAGES
Thermal / Dimensional Thermal / Dimensional StabilityStability
Thermal / Dimensional Thermal / Dimensional StabilityStability
RIGIDITY AT ELEVATED TEMPERATURESBMC Composites vs. Engineering Thermosets
RIGIDITY AT ELEVATED TEMPERATURESBMC Composites vs. Engineering Thermosets
Thermal / Dimensional Thermal / Dimensional StabilityStability
Thermal / Dimensional Thermal / Dimensional StabilityStabilityBMCs offer significant acoustical insulation BMCs offer significant acoustical insulation
over metalsover metals
Automotive valve cover conversion from aluminum
to BMC
Automotive valve cover conversion from aluminum
to BMC
25% Reduction in Valve-25% Reduction in Valve-train noise in BMC !train noise in BMC !
Part Weight Part Weight ReductionReduction
Part Weight Part Weight ReductionReduction
Part Weight Part Weight ReductionReduction
Part Weight Part Weight ReductionReduction
• BMC Polyester : 1.7 – 2.05s.g.
• Die-Cast Aluminum : 2.6s.g.
• Die-Cast Zinc : 6.9s.g.
• BMC Polyester : 1.7 – 2.05s.g.
• Die-Cast Aluminum : 2.6s.g.
• Die-Cast Zinc : 6.9s.g.
Lower Specific-Gravity with Lower Specific-Gravity with BMCBMC
Lower Specific-Gravity with Lower Specific-Gravity with BMCBMC
• Reduction In Assembly / Unit Weight
• Lower Raw Material Content $
• Reduction in Shipping Weight / Cost $
• Reduction In Assembly / Unit Weight
• Lower Raw Material Content $
• Reduction in Shipping Weight / Cost $
No Secondary MachiningNo Secondary MachiningNo Secondary MachiningNo Secondary Machining
• BMC Parts molded GATE FREE. No Secondary Gate Removal
• No material overflows required for BMC. No secondary trim-die operation required
• Critical dimensions / tolerances typically held as-molded. No secondary machining operations required.
• BMC Parts molded GATE FREE. No Secondary Gate Removal
• No material overflows required for BMC. No secondary trim-die operation required
• Critical dimensions / tolerances typically held as-molded. No secondary machining operations required.
Package At Press!Package At Press!
Tooling FriendlyTooling FriendlyTooling FriendlyTooling Friendly
BMC Polyesters are very “tooling-friendly” BMC Polyesters are very “tooling-friendly” offering the following advantages over offering the following advantages over metals:metals:
BMC Polyesters are very “tooling-friendly” BMC Polyesters are very “tooling-friendly” offering the following advantages over offering the following advantages over metals:metals:
• 4-5 Times Longer Mold Life
• Higher Cavitations
• Significantly lower PM & Repair Costs
• Allows for use of more complex moving actions (Slides etc.)
• Allows for use of manifold systems for material delivery to cavities
• 4-5 Times Longer Mold Life
• Higher Cavitations
• Significantly lower PM & Repair Costs
• Allows for use of more complex moving actions (Slides etc.)
• Allows for use of manifold systems for material delivery to cavities
Greater Design FreedomGreater Design FreedomGreater Design FreedomGreater Design Freedom
The flow characteristics The flow characteristics and related moldability and related moldability of BMCs allows for the of BMCs allows for the
formation of more formation of more complex part complex part geometries.geometries.
This gives the part This gives the part designer increased designer increased
freedom to:freedom to:
• Incorporate the net-Incorporate the net-shapes required to shapes required to optimize the part / optimize the part / assembly designassembly design
• Reduce the number of Reduce the number of components through components through consolidation of parts consolidation of parts
The flow characteristics The flow characteristics and related moldability and related moldability of BMCs allows for the of BMCs allows for the
formation of more formation of more complex part complex part geometries.geometries.
This gives the part This gives the part designer increased designer increased
freedom to:freedom to:
• Incorporate the net-Incorporate the net-shapes required to shapes required to optimize the part / optimize the part / assembly designassembly design
• Reduce the number of Reduce the number of components through components through consolidation of parts consolidation of parts
Commutator End Brackets / End BellsCommutator End Brackets / End Bells
Fan End BracketsFan End Brackets
Clamshell Motors Clamshell Motors
Motor End PlatesMotor End Plates
“ “Cup” Style Motor HousingsCup” Style Motor Housings
Fan / Diffuser End CapsFan / Diffuser End Caps
Brush PlatesBrush Plates
Brush Cartridge HousingsBrush Cartridge Housings
Commutator End Brackets / End BellsCommutator End Brackets / End Bells
Fan End BracketsFan End Brackets
Clamshell Motors Clamshell Motors
Motor End PlatesMotor End Plates
“ “Cup” Style Motor HousingsCup” Style Motor Housings
Fan / Diffuser End CapsFan / Diffuser End Caps
Brush PlatesBrush Plates
Brush Cartridge HousingsBrush Cartridge Housings
Motor Bracket Motor Bracket ConfigurationsConfigurationsMotor Bracket Motor Bracket ConfigurationsConfigurations
Commutator End Bracket / End Commutator End Bracket / End BellBell
Commutator End Bracket / End Commutator End Bracket / End BellBell
• Integrated Brush Box Features
• As-Molded Bearing Bore, Brush Boxes & Field Pads
• Integrated Brush Box Features
• As-Molded Bearing Bore, Brush Boxes & Field Pads
Fan End BracketsFan End BracketsFan End BracketsFan End Brackets
• Integrated Airflow Features
• As-Molded Bearing Bore & Field Pads
• Mounting Points Suitable for Motor Assembly
• Integrated Airflow Features
• As-Molded Bearing Bore & Field Pads
• Mounting Points Suitable for Motor Assembly
Clamshell Motor HousingsClamshell Motor HousingsClamshell Motor HousingsClamshell Motor Housings
As-Molded Bearing Bore
Advantages in Small Hand-Held Applications
Weight Reduction
Noise / Vibration Reduction
Ground-Path Insulation
As-Molded Bearing Bore
Advantages in Small Hand-Held Applications
Weight Reduction
Noise / Vibration Reduction
Ground-Path Insulation
Motor End PlatesMotor End PlatesMotor End PlatesMotor End Plates
• As-Molded Bearing Bore
• Weight Reduction on Large Motor Configurations
• As-Molded Bearing Bore
• Weight Reduction on Large Motor Configurations
““Cup” Style Motor Cup” Style Motor HousingsHousings
““Cup” Style Motor Cup” Style Motor HousingsHousings
• Reduced Number of Components in Assembly
• More Consistent Motor Alignment
• As-Molded Bearing Bore, Brush Boxes & Field Pads
• Integrated Airflow Features
• Reduced Number of Components in Assembly
• More Consistent Motor Alignment
• As-Molded Bearing Bore, Brush Boxes & Field Pads
• Integrated Airflow Features
Fan / Fan / Diffuser End Diffuser End CapsCaps
Fan / Fan / Diffuser End Diffuser End CapsCaps
* Accommodates
the formation of
more complex /
efficient airflow
geometries
* Accommodates
the formation of
more complex /
efficient airflow
geometries
Brush Plates / Cartridge Brush Plates / Cartridge HousingsHousings
Brush Plates / Cartridge Brush Plates / Cartridge HousingsHousings
Superior Properties over ThermoplasticsSuperior Properties over ThermoplasticsSuperior Properties over ThermoplasticsSuperior Properties over Thermoplastics
BMC Motor Bracket MaterialsBMC Motor Bracket MaterialsBMC Motor Bracket MaterialsBMC Motor Bracket Materials
BMC Materials currently supplied into BMC Materials currently supplied into motor bracket applications:motor bracket applications:BMC Materials currently supplied into BMC Materials currently supplied into motor bracket applications:motor bracket applications:
BMC 400
BMC 620
BMC 1412
T40-(18)
T40-(20)
T40-(25)
BMC 400
BMC 620
BMC 1412
T40-(18)
T40-(20)
T40-(25)
BMCI can custom-formulate materials as-necessary to meet specific BMCI can custom-formulate materials as-necessary to meet specific applications.applications.
BMCI can custom-formulate materials as-necessary to meet specific BMCI can custom-formulate materials as-necessary to meet specific applications.applications.
Case Study #1Case Study #1Commutator End Bracket Commutator End Bracket
ConversionConversion
Case Study #1Case Study #1Commutator End Bracket Commutator End Bracket
ConversionConversion
Material Cost / Part:
Molding Cost / Part:
Secondary Gate Trimming:
Secondary Machining:
Scrap @ 3%
Total Cost / Part:
Material Cost / Part:
Molding Cost / Part:
Secondary Gate Trimming:
Secondary Machining:
Scrap @ 3%
Total Cost / Part:
$.19
$.281
$.01
$.035
$.015
$.531
$.19
$.281
$.01
$.035
$.015
$.531
$.14
$.225
-
-
$.011
$.376
$.14
$.225
-
-
$.011
$.376
AluminumAluminum BMCBMC
30% SAVINGS30% SAVINGS30% SAVINGS30% SAVINGS
Case Study #2Case Study #2Commutator End Bell Commutator End Bell Conversion/RedesignConversion/Redesign
Case Study #2Case Study #2Commutator End Bell Commutator End Bell Conversion/RedesignConversion/Redesign
Material Cost / Part:
Molding Cost / Part:
Secondary Gate Trimming:
Secondary Machining:
Scrap @ 3%
Brush Plate (2nd Part):
Total Cost / Part:
Material Cost / Part:
Molding Cost / Part:
Secondary Gate Trimming:
Secondary Machining:
Scrap @ 3%
Brush Plate (2nd Part):
Total Cost / Part:
$.08
$.22
$.01
$.035
$.001
$.217
$.563
$.08
$.22
$.01
$.035
$.001
$.217
$.563
$.133
$.23
-
-
$.011
-
$.374
$.133
$.23
-
-
$.011
-
$.374
AluminumAluminum BMCBMC
Brush Boxes incorporated into BMC part as 1-Piece Design
Brush Boxes incorporated into BMC part as 1-Piece Design
34% SAVINGS34% SAVINGS34% SAVINGS34% SAVINGS
Mounting Hardware for BMCs Mounting Hardware for BMCs Mounting Hardware for BMCs Mounting Hardware for BMCs
Self-Tapping Screws
Thread-Cutting Never Thread-Forming
“BT”-Style or “Type-23” Style recommended
High-Low thread preferred
Hole diameter +.002” p/s over root-diameter of screw
Minimum thread engagement 2 ½ X screw diameter
Hole depth 125% to 150% of screw engagement depth
Mounting boss diameter minimum 2X major screw diameter
Self-Tapping Screws
Thread-Cutting Never Thread-Forming
“BT”-Style or “Type-23” Style recommended
High-Low thread preferred
Hole diameter +.002” p/s over root-diameter of screw
Minimum thread engagement 2 ½ X screw diameter
Hole depth 125% to 150% of screw engagement depth
Mounting boss diameter minimum 2X major screw diameter
Design Considerations for Design Considerations for BMCBMC
Design Considerations for Design Considerations for BMCBMC
Minimum Recommended Wall Stock .070”
Recommended Nominal Wall Stock .100” - .125”
Minimum draft 1-degree P/S (Excluding Bores & Brush Boxes)
Consistency of Wall stock
Core-out Thick Sections Wherever Possible
Fillet Radii Wherever Possible
“Line-of-Draw Features Wherever Possible
Minimum Recommended Wall Stock .070”
Recommended Nominal Wall Stock .100” - .125”
Minimum draft 1-degree P/S (Excluding Bores & Brush Boxes)
Consistency of Wall stock
Core-out Thick Sections Wherever Possible
Fillet Radii Wherever Possible
“Line-of-Draw Features Wherever Possible
The BMC AdvantageThe BMC AdvantageThe BMC AdvantageThe BMC Advantage
Faster Cycling
Longer Tooling Life
No Costly Secondary Machining
Weight Reduction
Noise Reduction
Dimensional Stability
Design Versatility
Faster Cycling
Longer Tooling Life
No Costly Secondary Machining
Weight Reduction
Noise Reduction
Dimensional Stability
Design Versatility
BMC offers cost savings without
sacrifice.
BMC offers cost savings without
sacrifice.