Processing Machinery
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PSU Notch Sensitivity and Fillet Design
Problem Phenomenon
[Problem Phenomenon] PSU products crack from stress concentration at right angles and sharp corners; drop tests fracture from these locations
Cause Analysis
PSU is notch sensitive; right angles and sharp corners form stress concentration points; combined with its rigid molecular chains and the characteristic that internal stress is hard to eliminate, notches become fracture initiation points; During on-site troubleshooting, verify item by item according to this mechanism, avoiding blindly adjusting the machine based solely on experience
Solution
Use arc transitions for all inner and outer corners, with fillet radius as large as possible; avoid sudden wall thickness changes and sharp-cornered ribs; polish the mold to remove tool marks to prevent microscopic notches; after adjustment, continuously sample to verify the effect, and resume mass production only after confirming stability
Key Takeaway
PSU is notch sensitive; fillet transition is a mandatory item in structural design; After confirming effectiveness, solidify the parameters and practices into the work instructions to prevent recurrence; Include this case in the defect archive as a reference for troubleshooting similar problems in the future
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