This case report illustrates the production of specific rubber bellows made from high-grade EPDM material, custom-designed to achieve the client's objective in terms of durability and resistance to oil. The project had a massive process in terms of both design and manufacturing phases so the bellows obtained should effectively fulfill functional and production requirements.
Introduction:
Rubber bellows are widely used in several industrial applications for flexibility and to protect machine parts. In this project, the client required special grade EPDM because of its superior properties. This material had to be selected because it is resistant to damage from exposure to oil and keeps the product life very long, which is a critical requirement for the bellow to be used in the intended application. The bellows further needed accurate motion capabilities to be effectively operational in both compressed and extended conditions without deterioration.
Approach:
The approach centered on considering the following aspects:
- Material selection: EPDM had been selected based on the objective of being durable as well as resistant to environmental stressors in the form of oil. This would ensure that the product would have long durability and remain operational for a more prolonged period.
- Design Optimization: The design of a bellow had to provide for certain movements so that it could function properly in all positions, compressed or extended, open or closed. Design decisions were to facilitate functionality, durability, and manufacturability.
Product Development Strategy:
Design Process: The design was executed in-house, beginning with calculations for movement requirements and dimensions in both open and closed states. Key considerations included:
- Angles and Diameters: Very precise calculations of the angles, top diameter, and bottom diameter so that the bellow would function appropriately.
- Clearance Requirements: Determination of clearance between the bellow and other adjacent machine elements so that interference or damages do not take place.
- Motion Testing: The bellow's motion and clearance were demonstrated by a CAD software presentation to the client. This resulted in client approval before the production of the mold.
Mold Development: The process of developing a mold for the bellow was a challenge because of the complex design, along with an expected large volume of production. Some of the other aspects of mold development encompassed:
- Multi-Cavity Mold: The mold was an utmost multiple-cavity mold to enable efficient production. This ensured that the production was fast and efficient.
- Ejection Mechanism: Tooling was ergonomically designed to prevent damage when the bellows are ejected from the mold.
- Manufacturing Efficiency: The mold was designed with reliability and regular supply of quality, considering the expertise of the design team.
Conclusion:
The project was realized in accordance with all of the client's stringent requirements for durability, performance, and production efficiency. The use of a special grade of EPDM enabled the bellows to provide outstanding oil resistance and elongated operational life. Precise design and efficient mold development ensured the seamless functioning of the product, considering the fact that a large number was required and delivered on time.
The client was highly satisfied with the final product, appreciating the material quality, innovative design, and efficient production. This collaboration underscored the team's expertise in developing custom-engineered solutions tailored to specific industrial needs.
