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High Density, Complex Shaped P/M Assemblies Via MIM for Chassis Applications
Technical Paper
2004-01-0496
ISSN: 0148-7191, e-ISSN: 2688-3627
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English
Abstract
A metal injection molded (MIM) assembly consisting of three parts used in an electric door locking mechanism is presented as an example of what is achievable by the MIM process when Design for Manufacturability (DFM) principles are applied to MIM. The net-shape assembly greatly reduced the labor content over a machined design. The assembly presented considerable challenges for MIM due to the need for high dimensional accuracy (mating parts, sliding fits), geometric tolerances (squareness, flatness, and parallelism), surface finish (for cosmetics and anti-friction), and the complex shape of the components. This paper will show how design optimization, preproduction testing, processing methods, and quality control methods were used to achieve the high process capability requirement. Material selection justification for optimized strength and cost will also be shown. The high density (>96% of theoretical) produced by the MIM process coupled with the ability to heat treat parts to a desirable toughness and strength level allowed for a simple, compact design capable of passing UL requirements. This cost saving approach can offer the same benefits and design possibilities to numerous applications in automotive design.
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Citation
Brasel, G. and Sago, J., "High Density, Complex Shaped P/M Assemblies Via MIM for Chassis Applications," SAE Technical Paper 2004-01-0496, 2004, https://doi.org/10.4271/2004-01-0496.Data Sets - Support Documents
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References
- Material Standards for Metal Injection Molded Parts MPIF 2000
- Sago J.A. Newkirk J.W. “Improving Toughness in Metal Injection Molded Parts,” Powder Materials: Current Research and Industrial Practices Marquis F.D.S. TMS 1999 235 246
- Sago J.A. Newkirk J.W. Brasel G.M. “Improving the Impact Toughness of Metal Injection Molded Parts,” Advances in Powder Metallurgy & Particulate Materials - 2000, Part 4, MPIF 2000 61 72
- Sago J.A. Newkirk J.W. “Effects of Processing Parameters on the Impact Toughness of Metal Injection Molded Parts,” Advances in Powder Metallurgy and Particulate Materials - 2001, Part 4, MPIF 2001
- Sago J.A. Brasel G.M. Newkirk J.W. “The Effects of MIM Processing Control Parameters on Mechanical Properties,” Advances in Powder Metallurgy and Particulate Materials - 2003, MPIF 2003
- Luzadder, Warren J. “Fundamentals of Engineering Drawing for Design, Product Development, and Numerical Control” Seventh Prentice Hall 1977 301