Molding of auxiliary elements for molding of the power steering gear's polymers body made of PDCPD material

Every year the polymer and composite materials are being used in a growing number of elements using in automotive industry. During research for a modern solution to replace commonly used steering housings, solutions have been sought to reduce weight and cost of production. Bodies are made of traditional materials, such as steels or aluminum, which is why the choice was on modern polymer materials from the PDCPD materials group. Polymer composite materials loom large increasingly important role in the automotive industry. Materials from the DCPD and PDCPD group have been nowadays used to produce elements of the external surfaces of vehicles, like bumpers or parts of body of a car. However, regarding to a very good mechanical property, it was decided to use the PDCPD material as the body material of the passenger car steering system body. The technology of "wraping in a casting process" of the whole worm and wormgear assembly with polymeric material will be applied. In this process, the elements will be pre-set(arranged), will be encapsulated with the elements of the mold and the casting process will be carried out. The prerequisite for a correct implementation of the process is to keep the mold from leaks of fluid polmere material. This would not be possible without the use of auxiliary elements (fixing elements). Therefore, the manufacturing process of bodies made of PDCPD material requires an auxiliary element, without which the casting could not take place. These elements are also made of PDCPD material. At the beginning, CAD 3D forms were prepared. The next step was to design the mold making process. After the molds were formed, it was possible to proceed with the casting process. The modling process of the PDCPD material was associated with a number of tests required to determine the casting parameters. Process is quite different from the traditional casting of metal materials. Also, the casting process parameters, temperatures, pressures could influence the correct process of casting. Research and results were described in detail in this paper.