Molds & Tooling
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PSU Notch Sensitivity and Fracture
Problem Phenomenon
PSU products fracture at right angles or sharp corners due to stress concentration; cracks propagate at notches during assembly and use; strength is far below expectations.
Cause Analysis
PSU products are quite sensitive to notches; stress concentration factors at right angles or sharp corners are high; the superposition of internal stress and notches accelerates fracture; under impact loads, notches become crack initiation points.
Solution
①Use arc transitions at right angles or sharp corners; ②Structural review to eliminate all sharp corners; ③Low-stress process to reduce initial stress; ④Notch impact testing to verify the design.
Key Takeaway
PSU notch sensitivity requires an absolute fillet principle in design; arc transition is a zero-cost strength improvement; stress management coordinates with structural design.; After confirming effectiveness, solidify the parameters and practices into the work instructions to prevent recurrence
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