Chassis

 

       

 

The material used for this part was called out specifically by the Customer. The original design intent was to insert mold the 2 Ground Pins, which would require the Mold Temperature to be as high as 150C (normal mold temperature is 60-80C). After our design review, we determined that this high temperature was not reasonable for the following reasons.

1. There would be a safety concern for the Operator inserting the Ground Pins into the Mold at this high temperature.
2. The cycle time would be increased due to placing the Ground Pins into the mold, which would drive the cost higher.

Our proposal was a secondary heat staking operation with a redesign of the knurl on the Ground Pin. After this improvement we were able to increase the strength of the Ground Pins and reduce the operation time and thus the overall cost of the part.