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Fundamental concepts coupled with practical, step-by-step guidance
With its emphasis on core principles, this text equips readers with the skills and knowledge to design the many processes needed to safely and successfully manufacture thermoplastic parts. The first half of the text sets forth the general theory and concepts underlying polymer processing, such as the viscoelastic response of polymeric fluids and diffusion and mass transfer. Next, the text explores specific practical aspects of polymer processing, including mixing, extrusion dies, and post-die processing. By addressing a broad range of design issues and methods, the authors demonstrate how to solve most common processing problems.
This Second Edition of the highly acclaimed Polymer Processing has been thoroughly updated to reflect current polymer processing issues and practices. New areas of coverage include:
Chapters feature problem sets, enabling readers to assess and reinforce their knowledge as they progress through the text. There are also special design problems throughout the text that reflect real-world polymer processing issues. A companion website features numerical subroutines as well as guidance for using MATLAB®, IMSL®, and Excel to solve the sample problems from the text. By providing both underlying theory and practical step-by-step guidance, Polymer Processing is recommended for students in chemical, mechanical, materials, and polymer engineering.
DONALD G. BAIRD, PhD, is the Alexander F. Giacco and Harry C. Wyatt Professor of Chemical Engineering at Virginia Tech. His research centers on the use of fundamental non-Newtonian fluid mechanics to develop improved processing operations for polymers and polymer composites. Among his many honors, the Society of Plastics Engineers has awarded him the International Award, the International Award for Research, and the International Award for Education. A holder of seven patents, Dr. Baird has published some 300 refereed publications.
DIMITRIS I. COLLIAS, PhD, is with the corporate R&D department of the Procter & Gamble Co. in Cincinnati, Ohio. He earned his PhD degree from Princeton University. With twenty years of industry experience in polymers, polymer processing, packaging, paper, and activated carbon, his current research focuses on developing renewable materials and processes for key products in the company’s portfolio. Dr. Collias holds fifty-four issued U.S. patents and is inventor or co-inventor in more than thirty U.S. patent applications.
Chapter 1 -- Importance of Process Design 1
1.1 Classification of Polymer Processes 2
1.2 Film Blowing - Case Study 8
1.3 Basics of Polymer Process Design 11
References 13
Design Problem I - Design of a Blow Molding Die 14
Chapter 2 -- Isothermal Flow of Purely Viscous Non-Newtonian Fluids 16
2.1 Viscous Behavior of Polymer Melts 17
2.2 One Dimensional Isothermal Flows 24
2.3 Equations of Change for Isothermal Systems 39
2.4 Useful Approximations 50
2.5 Solution to Design Problem I 56
References 66
Problems 67
Design Problem II - Design of a Parison Die for a Viscoelastic Fluid 80
Chapter 3 -- Viscoelastic Response of Polymeric Fluids 81
3.1 Material Functions for Viscoelastic Fluids 83
3.2 Non-linear Constitutive Equations 95
3.3 Rheometry 119
3.4 Useful Relations for Material Functions 128
3.5 Rheological Measurements and Polymer Processability 133
3.6 Solution to Design Problem II 136
References 142
Problems 145
Design Problem III - Design of a Dry-Spinning System 156
Chapter 4 -- Diffusion and Mass Transfer 158
4.1 Mass Transfer Fundamentals 161
4.2 Diffusivity, Solubility and Permeability in Polymer Systems 181
4.3 Non-Fickian Transport 202
4.4 Mass Transfer Coefficients 204
4.5 Solution to Design Problem III 211
References 216
Problems 221
Design Problem IV -- Casting of Polypropylene Film 233
Chapter 5 -- Nonisothermal Aspects of Polymer Processing 234
5.1 Temperature and Pressure Effects on Rheological Properties 235
5.2 The Energy Equation 240
5.3 Thermal Transport Properties 259
5.4 Heating and Cooling of Non-Deforming Polymeric Materials 264
5.5 Crystallization, Morphology, and Orientation 293
5.6 Solution to Design Problem IV 315
References 320
Problems 324
Design Problem V -- Design of a Multi-layered Extrusion Die 336
Chapter 6 -- Mixing 338
6.1 Description of Mixing 340
6.2 Characterization of the State of Mixture 345
6.3 Striation Thickness and Laminar Mixing 371
6.4 Residence Time and Strain Distributions 402
6.5 Dispersive Mixing 425
6.6 Thermodynamics of Mixing 445
6.7 Chaotic Mixing 446
6.8 Solution to Design Problem V 450
References 458
Problems 465
Design Problem VI -- Coextrusion Blow Molding Die 475
Chapter 7 -- Extrusion Dies 477
7.1 Extrudate Nonuniformities 478
7.2 Viscoelastic Phenomena 480
7.3 Sheet and Film Dies 491
7.4 Annular Dies 497
7.5 Profile Extrusion Dies 502
7.6 Multiple Layer Extrusion 506
7.7 Solution to Design Problem VI 520
References 525
Problems 528
Design Problem VII -- Design of a Devolatilization Section for a Single Screw Extruder 541
Chapter 8 -- Extruders 543
8.1 Description of Extruders 544
8.2 Hopper Design 549
8.3 Plasticating Single Screw Extruders 555
8.4 Twin Screw Extruders 592
8.5 Mixing, Devolatilization, and Reactions in Extruders 602
8.6 Solution to Design Problem VII 625
References 635
Problems 638
Design Problem VIII -- Design of a Film Blowing Process for Garbage Bags 655
Chapter 9 -- Post Die Processing 657
9.1 Fiber Spinning 658
9.2 Film Casting and Stretching 706
9.3 Film Blowing 717
References 745
Problems 752
Design Problem IX -- Design of a Compression Molding Process 760
Chapter 10 -- Molding and Forming 762
10.1 Injection Molding 762
10.2 Micro-Injection Molding 776
10.3 Compression Molding 777
10.4 Thermoforming 786
10.5 Blow Molding 801
10.6 Solution to Design Problem IX 812
References 821
Problems 824
Chapter 11-Proces Engineering for Recycled and Renewable Polymers
11.1 Life Cycle Assessment
11.2 Primary Recycling\
11.3 Mechanical or Secondary Recycling
11.4 Tertiary or Feedstock Recycling
11.5 Renewable Polymers and Their Processing
Notation 839
Appendix A -- Rheological Data for Several Polymer Melts 870
Appendix B -- Physical Properties and Friction Coefficients for Some Common Polymers in the Bulk State 891
Appendix C -- Thermal Properties of Materials 892
Appendix D – Conversion Tables 968
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