GENERAL OBJETIVE:
From a stamped sheet wax mold silicone rubber with which the casting resin is performed is obtained.
For the resin plate with the engraving from hexagonal plate obtained rubber, said resin is used in the selection of materials.
The materials required are:
- 1 kg of resin 70x60
- Catalyst K-2000
- A plastic container 1000ml
- Bast
- Thinner
- A bamboo barite
- Wax unmold
The steps to produce it are:
1. Using a soft sponge wax release agent applied to the container, especially putting the mold walls and the bottom of this. When finished applying the wax mold release should be cleaned with Thinner hands to avoid soiling the rubber.
2. Silicone rubber plate obtained above is placed inside the container. Plate silicone rubber should be attached to the container walls, ie, they should not be spaces between the container wall and the plate silicone rubber to prevent the resin from moving through these holes and get to the bottom of the container .
3. the resin to flush out is prepared. According to the dimensions of the plate and the thickness is desired to have the resin, the amount of resin required is calculated using the next Equation
Length = 420 mm
Width = 250 mm
Desired thickness = 3 mm
resin= 420x250x3 = 315 mm3=315 ml
4. is placed in the plastic container 350ml 70x60 resin.
5. According to the instructions given by the manufacturer to prepare the resin 70x60, you must add a catalyst in the following ratio, per 100 g of resin are added 1 g of catalyst equivalent to 80 drops of catalyst. However drops are suppressed and only 100 drops are added; this because when the resin is cured is heated and this may cause the resin plate breaking.
6. 100 catalyst droplets are mixed with the resin, using barite bamboo, and making moves in the form of 8 for 2 minutes, scraping the vessel walls and the bottom of it; these movements are for the purpose of thoroughly mixing the resin and catalyst, as well to remove bubbles generated.
7. mixture over silicone rubber mold is empty and with a needle prick bubbles generated.
8. It is expected to cure the resin a bit and this in a semisolid state to place the soul.
The first test was performed only with resin and the result was a rigid plate, but very fragile to handle and make use of it.
Composities
Design and make a 3D mold (~ft2), and produce a fiber composite part in it
While the second plate made using fiberglass and aluminum core for strength and flex to it
The plates with the hexagonal engraving made stamping made of above described polyester resin carried inside aluminum core, ie between the plate made of the resin will take an aluminum plate as shown in Figure 8. 3. this in order to reinforce the resin plate both this does not sag as to have a greater impact resistance when performing swaging function beeswax. Besides the aluminum core will connect plates stamped with the elements that compose them.
- Orange represents the first resin layer bearing the engraving hexagonal
- The blue color represents the aluminum plate
- The pink the second resin layer
Figure 8. 3 Name plate for stamping
The following material and equipment used to manufacture aluminum core
- Smooth aluminum plate 4 gauge (6.05 mm thick) of 230 mm long and 400 mm wide (Metales Díaz, see the May 12, 2012)
- Bits 1/8, 3/16, 5/16 and ¼ "
- Taps 3/8 "
- Screws and standard cord flat hexagonal head.
- Nut for screw
- Grease or oil
- Bast
- Hammer and hit point
- Flexómetro
- Drill
For plates made of resin and aluminum core carry subsequently fit their corresponding elements, they will be placed on the aluminum plate screws according to the elements. It is important that the screws are tight and rights to perform the subsequent coupling; for this will be made to threaded holes made in the aluminum plate thus entering coiling screws to the plate.
The steps to make the threads are:
a) With the Flexómetro measure and mark the places where the screws are placed, considering each element to be assembled.
b) With the point of the hammer blow and where each screw is placed is highlighted and this brand will allow the bit between more easily.
c) Using the drill and drill a smaller extent the plate at each marked location is bit, then it changed it will drill and the hole by drilling being greater extent than the previous one until you reach the desired size.
d) To place the rope to the plate and that is the measure of the screw so that it is screwed exactly and no play between the rope and screw standard tables for according to the screw thread, scuttle consulted with the drill properly and use the correct reference machuelo.
e) Once having the proper machuelo fat or oil to machuelo placed and the hole previously done and proceed to the rope. It is important to remember remove burrs generated stop not affect the rope.
f) Once the rope ended the tap is cleaned with Bast and proceeds to the next string.
The result is a plate with screws such as that shown in Figure 8. 4 and which will be encapsulated in resin 70x60 plate as shown in Figure 8. 3
Figurre 8. 4 Alma aluminum
Place Alma
a) In the previous emptying of the polyester resin when the resin has a sticky consistency, metal or soul you want to use it is placed. In Figure 8. May 1 resin layer already finished solid state shown.
b) the resin is allowed to dry above the metal for about 1 hour.
c) a second resin casting is performed by following the steps described in section 8.3.1pero taking into account the following considerations.
d) Place a layer of fiberglass before placing the aluminum core as shown in Figure 8. 6
e) Add two tablespoons of calcite to the resin
f) Add to resin catalyst 10 drops to 350 ml as when the resin interacts with a metal is heated more than the resin when applied alone. Applying is catalyzed only 10 drops more slowly, ie, it will take longer to harden the resin but prevents the metal plate and buckling.
Move the resin and catalyst as eight to remove bubbles.
g) to flush the sun and place a box over the mold to prevent adhesion of impurities.
h) Wait cure for a day.
Figure 8.6 Layer Fiberglass on the resin