Project of the week is a Transformer Bobbins that is injection molded from Natural Rynite FR-530 Polyester resin. This material is used in Class 180 (H) insulation systems and has excellent strength, stiffness, impact resistance and is low cost. This part is roughly 1-5/8" x 1-1/2" x 61/64" in size with a 0.052 wall thickness. We had to machine in the slots at different widths to accommodate different gauge wire winding that the customer wanted to experiment with. We machined about 1320pcs after a slot width was confirmed.
End Mills were solid carbide from RTW Carbide Cutting Tools, this material contains 30% glass and High-Speed End Mills should be avoided. A better choice would be the use CVD Diamond coated tools; we also used coolant to avoid the glass dust from spreading everywhere. Small tip here (Use the felt paper from the grinding machines to capture the glass waste at the coolant tank) do not let that recycle back to the machine coolant nozzles. We used Mic6 aluminum plate for fixturing in order to hold down and orient the parts as shown above. A small, machined cap in picture 5 was used with a .002 to .005 compression gap to prevent over distorting or over tightening the bobbins. Overall slot tolerance was +0.010 / -0.000, and the machine finish were fine. We would like to thank our customer for allowing us to share this project with people who value the manufacturing talent that is out there... If you have similar projects like this and would like to receive a quote from us, please reach out to us for further information.
