Plastics Materials and Processing

by Strong, A. Brent

• ISBN13: 9780131145580
• ISBN10: 0131145584
• Edition: 3rd
• Format: Paperback
• Copyright: 2005-06-06
• Publisher: Pearson

Summary

This book is designed to introduce plastics to a wide range of non-chemists who need to either gain, improve, or refresh their knowledge of plastic materials and manufacturing. It fully discusses both materials and manufacturing processes in a carefully-constructed and logical presentation. While providing a fundamental overview of a broad spectrum of topics, this bookrs"s high level of detail makes it valuable as a professional reference manual.Complete examination of materials, processes and performance of plastics includes many recent developmentsat the molecular, micro and macro levelssuch as conductive polymers, nano technology, biodegradable polymers, bio-based raw materials, twin-sheet thermoforming, and health considerations of plasticizers.Appropriate as a reference manual by manufacturing engineers, chemical engineers, plastics engineers, mechanical engineers, industrial engineers, or any other engineer working in a plastics-oriented company.

Table of Contents

Introduction to Plastics	1	(24)
Definitions of Plastics and Polymers	1	(4)
History of Plastics	5	(5)
Raw Material Supply and Pricing	10	(3)
Strategic Materials	13	(1)
The Plastics Industry	13	(3)
Uses of Plastics in Modern Society	16	(5)
Case Study 1.1---The Development of Nylon	21	(4)
Polymeric Materials (Molecular Viewpoint)	25	(48)
Introduction	25	(1)
Fundamentals of Matter	26	(5)
Bonding	31	(8)
Basic Concepts in Organic Chemistry	39	(9)
Polymers	48	(3)
Formation of Polymers	51	(12)
Thermoplastics and Thermosets	63	(2)
Copolymers	65	(1)
Case Study 2.1---Modifications to Improve Teflon® Processing	66	(7)
Microstructures in Polymers	73	(46)
Introduction	73	(1)
Solids, Liquids, and Gases	74	(1)
Polymeric Solid State: Amorphous and Crystalline	75	(5)
Polymeric Liquid State	80	(1)
Polymeric Gaseous State	80	(1)
Thermal Changes in Polymers	81	(14)
Polymer Length	95	(1)
Molecular Weight	96	(9)
Melt Index	105	(3)
Shape (Steric) Effects	108	(2)
Case Study 3.1---Mechanical Properties of Polyethylene (PE) as Functions of Density and Melt Index	110	(9)
Mechanical Properties (Macro Viewpoint)	119	(32)
Introduction	119	(2)
Mechanical Properties in Solids (Elastic Behavior)	121	(2)
Mechanical Properties in Liquids (Viscous Flow)	123	(6)
Viscoelastic Materials	129	(3)
Plastic (High-Strain) Stress--Strain Behavior	132	(7)
Creep	139	(2)
Toughness, Impact Strength, and Hardness	141	(3)
Reinforcements	144	(1)
Fillers	145	(1)
Toughness Modifiers	146	(1)
Case Study 4.1---Testing of Trash Containers to Predict In-Use Performance	146	(5)
Chemical and Physical Properties (Macro Viewpoint)	151	(46)
Introduction	151	(1)
Environmental Resistance and Weathering	152	(4)
Chemical Resistivity and Solubility	156	(10)
Permeability	166	(5)
Electrical Properties	171	(5)
Optical Properties	176	(5)
Flammability	181	(8)
Plastics Identification	189	(2)
Case Study 5.1---Using Carbon Black to Protect Polyethylene from UV Degradation	191	(2)
Case Study 5.2---Conductive Polymers	193	(4)
Designing with Plastics	197	(26)
Introduction	197	(2)
Design Methodology	199	(4)
Layout/Drawing	203	(1)
Constraints	203	(6)
Material Choice	209	(5)
Prototyping	214	(4)
Case Study 6.1---Design of Plastic Stakes for Concrete Tilt-up Walls	218	(5)
Thermoplastic Materials (Commodity Plastics)	223	(38)
Introduction	223	(1)
Polyethylene (PE)	224	(11)
Polyethylene Copolymers	235	(4)
Polypropylene (PP)	239	(3)
Polyvinyl Chloride (PVC)	242	(5)
Polystyrene (PS)	247	(4)
Alloys and Blends	251	(6)
Case Study 7.1---Typical PVC Formulation	257	(4)
Thermoplastic Materials (Engineering Plastics)	261	(34)
Introduction	261	(2)
Cellulosics	263	(2)
Polyamides or Nylons (PA)	265	(5)
Acetals or Polyoxymethylenes (POM)	270	(3)
Thermoplastic Polyesters (PET/PBT)	273	(4)
Polycarbonate (PC)	277	(2)
Acrylics (PAN, PMMA)	279	(2)
Fluoropolymers (PTFE, FEP, PFA)	281	(5)
High-Performance Thermoplastics	286	(3)
Case Study 8.1---Making Nonstick Electrosurgical Blades	289	(6)
Thermoset Materials	295	(42)
Introduction	295	(2)
Crosslinking	297	(7)
Thermoset Types, General Properties, and Uses	304	(2)
Phenolics (PF)	306	(3)
Amino Plastics (UF and MF)	309	(3)
Thermoset Polyesters or Unsaturated Polyesters (UP)	312	(8)
Vinyl Esters (VE)	320	(1)
Epoxies (EP)	321	(4)
Thermoset Polyimides	325	(1)
Polyurethanes (PUR)	326	(5)
Case Study 9.1---Thermoset Composites for Wrapping Utility Poles	331	(6)
Elastomeric (Rubber) Materials	337	(26)
Introduction	337	(4)
Aliphatic Thermoset Elastomers	341	(9)
Thermoplastic Elastomers (TPE)	350	(2)
Fluoroelastomers	352	(1)
Silicones	353	(2)
Processing of Elastomers	355	(2)
Case Study 10.1---Elastomeric Lining for a Pump	357	(6)
Extrusion	363	(68)
Introduction	363	(7)
Equipment	370	(14)
Normal Operation and Control of the Process	384	(9)
Extrusion Problems and Troubleshooting	393	(5)
Design for Extrusion	398	(21)
Special Extrusion Processes and Products	419	(4)
Case Study 11.1---Extrusion of Irrigation Tubing	423	(8)
Injection Molding	431	(70)
Introduction	431	(3)
Equipment	434	(26)
Normal Operation and Control	460	(1)
Critical Operational Parameters and Techniques	461	(7)
Injection Molding Problems and Troubleshooting	468	(6)
Design for Injection Molding	474	(11)
Modeling and Computer-Aided Mold-Flow Analysis	485	(2)
Special Injection Molding Processes	487	(2)
Case Study 12.1---Estimating the Cost of an Injection-Molded Pocket Knife	489	(6)
Case Study 12.2---Mold Costs and Selection	495	(6)
Blow Molding	501	(28)
Introduction	501	(2)
Extrusion Blow Molding	503	(6)
Injection Blow Molding	509	(4)
Plant Considerations	513	(1)
Blow Molding Problems and Troubleshooting	514	(1)
Design for Blow Molding	514	(6)
Special Blow Molding Processes and Products	520	(4)
Case Study 13.1---Making Soft-Drink Bottles	524	(5)
Thermoforming	529	(42)
Introduction	529	(2)
Forming Processes	531	(16)
Equipment	547	(3)
Plant Considerations	550	(1)
Normal Operation and Control	551	(2)
Thermoforming Problems and Troubleshooting	553	(2)
Design for Thermoforming	555	(8)
Film Thermoforming Processes and Products	563	(3)
Case Study 14.1---Plastic Windshield Protective Film	566	(5)
Rotational Molding	571	(28)
Introduction	571	(5)
Equipment	576	(5)
Operation and Control of the Process	581	(3)
Troubleshooting	584	(2)
Design for Rotomolding	586	(7)
Case Study 15.1---Trash Cart Manufacturing	593	(6)
Casting	599	(28)
Introduction	599	(3)
Casting Processes	602	(13)
Equipment	615	(2)
Operation and Control of the Casting Process	617	(1)
Casting Problems and Troubleshooting	618	(1)
Design for Casting	619	(3)
Case Study 16.1---Casting a Polyester Thermoset Part in a Silicone Mold	622	(5)
Foaming	627	(30)
Introduction	627	(4)
Creating Foams in Resins	631	(2)
Shaping and Solidifying Foams	633	(11)
Rebond	644	(2)
Design for Foams	646	(1)
Applications	647	(3)
Operation and Control of the Foaming Process	650	(2)
Case Study 17.1---Foam Insulation	652	(5)
Compression Molding, Transfer Molding, and Related Processes	657	(30)
Introduction	657	(1)
Compression Molding	658	(11)
Transfer Molding	669	(5)
Design for Compression and Transfer Molding	674	(1)
Control and Operation	674	(4)
Reaction Injection Molding (RIM)	678	(1)
Cold Forming, Sintering, and Ram Extrusion	679	(2)
Case Study 18.1---Manufacture of Automobile Body Panels	681	(6)
Polymeric Composite Materials and Processes	687	(52)
Introduction	687	(8)
Matrix Materials	695	(3)
Reinforcements	698	(7)
Composite Material Properties	705	(6)
Manufacturing Methods for Composite Parts	711	(23)
Plant Concepts	734	(1)
Case Study 19.1---Filament Winding of the Beech Starship Airplane Fuselage	734	(5)
Radiation	739	(24)
Introduction	739	(1)
Directed Ultraviolet (UV) Radiation	740	(1)
High-Energy Microwaves	741	(2)
Electron Beam Radiation	743	(7)
Gamma Radiation	750	(1)
Plasma Polymerization and Reactions	751	(3)
Properties, Materials, and Applications	754	(4)
Case Study 20.1---Making Shrink-Tubing Using Electron Beam Crosslinking	758	(5)
Finishing, Adhesion, and Assembly	763	(38)
Introduction	763	(1)
Runner System Trimming and Flash Removal	764	(2)
Machining	766	(2)
Nontraditional Machining	768	(1)
Shaping (Postmold Forming)	769	(1)
Mechanical Joining and Assembly	770	(5)
Adhesive Bonding	775	(8)
Nonadhesive Bonding	783	(5)
Joint Design	788	(2)
Coating and Decorating	790	(6)
Case Study 21.1---Comparison of Adhesive-Bonded and Metal Attachments	796	(5)
Operations and Management	801	(24)
Introduction	801	(1)
Safety and Cleanliness	802	(2)
Plastic Resin Handling, Conveying, and Drying	804	(3)
Plant Layout	807	(1)
Quality Assurance	807	(7)
Management	814	(3)
Supervision and Employees	817	(4)
Case Study 22.1---Establishing QC for a PET Bottle Plant	821	(4)
Environmental Aspects of Plastics	825	(28)
Introduction	825	(1)
Source Reduction	826	(2)
Recycling of Plastics	828	(7)
Biocompatible Materials and Degradation	835	(3)
Landfills	838	(1)
Incineration	839	(1)
Regeneration	840	(1)
Total Product Life Cycle	841	(4)
The Future	845	(2)
Case Study 23.1---Recycling Solid Wastes	847	(6)
Appendix 1 Typical Properties of Some Engineering Materials	853	(2)
Appendix 2 Cost Estimating Form for Injection Molding	855	(1)
Appendix 3 Plastics Design/Selection Matrix	856	(1)
Appendix 4 Impact Toughness Guide	857	(1)
Appendix 5 Plastics Identification Chart	858	(2)
Appendix 6 Process Procedures---Startup, Steady-state, and Shutdown	860	(6)
Appendix 7 Plastic Machining Guidelines	866	(2)
Appendix 8 Sample MSDS Form	868	(3)
Glossary	871	(36)
Index	907