Plastic Product Material and Process Selection Handbook Part 1 ppsx

List of fig u res Overview of the plastic industries from source to products that includes plastics and fabrication processes courtesy of Plastics FALLO Highlighting load-time/viscoelast

Plastic Product Material and

Process Selection Handbook

by Dominick V Rosato , Donald V Rosato , Matthew V Rosato

• ISBN: 185617431X

• Pub Date: September 2004

• Publisher: Elsevier Science & Technology Books

List of fig u res

Overview of the plastic industries from source to

products that includes plastics and fabrication

processes (courtesy of Plastics FALLO)

Highlighting load-time/viscoelasticity of plastics:

(1) stress-strain-time in creep and (2) strain-

stress-time in stress relaxation

Examples of plastics subjected to temperatures

Guide on strength to temperature of plastics & steel

(courtesy of Plastics FALLO)

Temperature-time guides retaining 50% plastic

properties (courtesy of Plastics FALLO)

FALLO approach includes going from material to

fabricated product (courtesy of Plastics FALLO)

Example how melt index and density influence PE

performances; properties increase in the direction of

arrows

Examples of plasticized flexible PVC

Examples of rigid PVC

Guide to fluoroplastic properties

Basic compounding of natural rubber

With modifications each of these plastics can be

moved into literally any position in the pie section

meeting different requirements

Examples of plastic contraction at low temperatures

Guide to clear and opaque plastics

Examples of the weatherability of plastics

Non-plastic (Newtonian) and plastic (non-Newtonian) melt flow behavior (courtesy of Plastics FALLO)

Action of plastic in a screw channel during its rotation

in a fixed barrel: (1) highlights the channel where the plastic travels; (2) basic plastic drag action; and (3) example of melting action as the plastic travels through the barrel where areas A and B has the melt occurring from the barrel surface to the forward screw surface, area C has the melt developing from the solid plastic, and area D is solid plastic; and (4) melt model

of a single screw (courtesy of Spirex Corp.)

Schematics of single and two-stage plasticators Simplified plastic flow through a single-stage IMM Example of mold operation controls

Plastic residence time Molding area diagram processing window concept Molding volume diagram processing window concept Quality surface as a function of process variables Example of a 3-layer coinjection system (courtesy of Battenfeld of America)

Example of mold action during injection-compression (courtesy of Plastic FALLO)

Schematic of a ram (plunger) injection molding machine

Metal injection molding cycle (courtesy of Phillips Plastics)

5.2

Simplifies example of a single-screw extruder Schematic identifies the different components in an extruder (courtesy of Welex Inc.)

227

232

List of figures xxi

Blown film control

Sheet line control

Assembled blown film line (courtesy of Battcnfelt

Gloucester)

Blown film line schematic with more details

Schematic of flat film chilled roll-processing line

Example neck-in and beading that occurs between

die orifice and chill roll

Simplified water quenched film line

Schematic of sheet line processing plastic

Coextruded (two-layer) sheet line

Schematic of a three-roll sheet cooling stack

Introduction to downstream pipe/tube line

equipment

(a) Example of an inexpensive plate die (b) Examples

of precision dies to produce close tolerance profiles

Coating extruder line highlights the hot melt

contacting the substrate just prior to entry into the

nip of the pressure-chill rolls

Example of a wire coating extrusion line

Example in using a gear pump to produce fibers (left)

and example in using an extruder and gear pump to

produce fibers

Schematic of a basic three layered cocxtrusion sheet

or film system

Example of upward extruded blown film process for

b i axi ally o ri e n tin g film

Example of two-step tenter process

Few examples of many different postformed shapes

and cuts with some showing dies

Examples and performances of compounding

Example of a 3-layer coextrusion parison blow mold

head with die profiling (left) and example of a 5-layer

coextrusion parison blow mold head with die

profiling (courtesy of Graham Machinery Group)

Schematic of extrusion blow molding a single parison

Simplified view of a heart shaped parison die head

(left) and grooved core parison die head

283

285

289

291

xxii List of figures

6.5 Examples ofparison wall thickness control by axial

movement of the mandrel 6.6 Example of rectangular parison shapes where (1) dic

opening had a uniform thickness resulting in weak corners and (2) die opening designed to meet the thickness requirements required

6.7 Introduction to a continuous extruded blow

molding system with its accumulator dic head 6.8 Schematics of vertical wheel machine in a production

line (courtesy of Graham Machinery Group) 6.9 Three station injection blow molding system

6.10 Schematic of injection blow mold with a solid handle

(left) and simple handles (ring, strap, etc.) can be molded with blow molded bottles

6.11 Example of stretched injection blow molding using a

rod (left) and example of stretched injection blow molding by gripping and stretching the preform 6.12 Examples of different shaped sequential extrusion

blow molding products 6.13 Example of a suction extrusion blow molding process fabricating 3-D products (courtesy of SIG Plastics International)

6.14 Examples of 3-D extrusion blow molded products in

their mold cavities (courtesy of SIG Plastics International)

6.15 Example of a 3-part mold to fabricate a complex

Schematic of roll-fed thermoforming line Schematic example of a rotating clockwise three-stage machine

View of a rotating clockwise five-stage machine (courtesy of Wilmington Machinery)

8.2

Example of tandem extruder foam sheet line (courtesy

of Battcnfeld Gloucester Expandable polystyrene process line starts with precxpanding the PS beads

353

357

List of figures xxiii

8.3 View of PS beads in a perforated mold cavity that are

expanding when subjected to steam heat

8.4 Schematic of foam reciprocating injection molding

machine for low pressure

8.5 (a) Schematic of gas counterpressure foam injection

molding (Cashiers Structural Foam patent) (b) Example

of an IMM modified nozzle that handles simultaneously

the melt and gas (c) Microcellular foaming system

directing the melt-gas through its shutoff nozzle

into the mold cavity

8.6 Liquid (left), froth (center), and spray polyurethane

Simplified examples of basic roll coating processes

Example of knife spread coating

Examples of transfer paper coating line

Example of an extrusion coating line

388

388

389

389 11.1

11.2

Example of a liquid injection molding casting process

Example of a more accurate mixing of components

for liquid injection casting

399

400 12.1

Gating and runner systems demonstrating laminar

melt flow and uniform flow front (courtesy of Bayer)

Example of a dam gate and runner system (courtesy

of Bayer)

Example of melt flow around obstructions near the

vent (courtesy of Bayer)

xxiv List of figures

13.2 Rotational rate of the two axes is at 7" 1 for this

product (courtesy of Plastics FALLO ) 432

14.1 Schematics of compression molding plastic materials 439 14.2 Examples of flash in a mold: (a) horizontal,

(b) vertical, and (c) modified vertical Example of mold types: (a) positive compression mold, (b) flash compression mold, and (c) semipositive compression mold

Example of land locations in a split-wedge mold Schematic of transfer molding

Short to long fibers influence properties of RPs Reinforced plastics, steel, and aluminum tensile properties compared (courtesy of Plastics FALLO) Fiber arrangements and property behavior (courtesy

of Plastics FALLO) Layout of reinforcement is designed to meet structural requirements

Views of fiber filament wound isotensoid pattern of the reinforcing fibers without plastic (left) and with plastic cured

Use is made of vacuum, pressure, or pressure-vacuum

in the Marco process Cut away example of a mold used for resin transfer molding

Examples of stacked molds Examples of melt flow patterns in a coathanger and T-type die

List of figures xxv

17.7 Examples of melt flow patterns behavior 531 17.8 Flow coefficients calculated at different aspect

ratios for various shapes using the same equation

Example of the land in an extrusion blow molding die

that can have a ratio of 10 to 1 and film or sheet rigid

(R) and flexible (F) die lip land

Examples of a flat die with its controls

Examples of single layer blown film dies include side

fed type (left), bottom fed with spiders type (center)

and spiral fed type

Examples of different pipe die inline and crosshead

designs

(a) Schematic for determining wire coated draw ratio

balance in dies (b) Schematic for determining wire

coated draw down ratio in dies

Examples of layer plastics based on four modes of

molding primary and auxiliary equipment

18.2 Example of an extrusion laminator with auxiliary

Examples of major plastic families

Thermoplastic thermal properties are compared to

aluminum and steel

General properties of thermoplastic

General properties of thermoset plastic

General properties of reinforced thermoplastic

General properties of reinforced thermoset plastic

Examples of drying different plastics (courtesy of

Spirex Corp.)

General properties of plastics

Example of plastic shrinkage without and with glass

fiber

Density, melt index, and molecular weight influence

PEs performances

Examples of polyethylene film properties

Property guide for thermoset plastics

Elastomer names

Elastomers cost to performance guide

Guide to elastomer performances where E = Excellent,

G - Good, F = Fair, and P = Poor)

Example for comparing cost and performance of

nylon and die-cast alloys

Examples of processes for plastic materials

Examples of processes and plastic materials to

properties

Chemical resistance of plastics (courtesy of Plastics

FALLO)

Examples of permeability for plastics

Examples of transparent plastics

List of tables xxvii

Examples of thermoplastic processing temperatures

for extrusion and injection molding (courtesy of

Examples of film yields

Guide on different information pertaining to different

8.1 Examples of rigid plastic foam properties 334 8.2 Examples of physical blowing agent performances 339 8.3 Examples of chemical blowing agents 339 8.4 Properties of 1/4" thick thermoplastic structural foam

9.1 Example of comparing calendering and extrusion

12.1 Comparing processes to mold large, complex products 420

xxviii List of tables

15.2 Examples of reinforced thermoplastic properties 458 15.3 Examples of properties and processes of reinforced

thermoset plastics Properties of fiber reinforcements Examples of different carbon fibers General properties of thermoset RPs per ASTM testing procedures

Reinforcement orientation layup patterns Examples of interrelating product-RP material-process performances

Guide to product design vs processing methods

experimental values for properties of various

Preface, acknowledgement

This book is for people involved or to bc involved in worldng with plastic matcrial and plastic fabricating proccsscs that include thosc concerned or in dcpartmcnts of material, processing, design, quality control, management, and buyers Thc information and data in this book arc provided as a comparative guidc to hclp in undcrstanding thc performance of plastics and in making thc decisions that must be made when devcloping a logical approach to fabricating plastic products to mcct performance rcquircmcnts at the lowest costs Information and data can also bc uscd whcn compromises have to be made in evaluating plastics and proccsses Thc book is formatted to allow for easy rcadcr acccss and this carc has bccn translated into the individual chaptcr constructions and indcx

This book has been prepared with the awarcncss that its uscfulncss will depend on its simplicity and its ability to provide essential information Thc information and data prcscntcd in this book arc not intcndcd to bc used as a substitute for more up-to-datc and accurate information on the specific plastics and proccsscs Such specific details can be obtained from in-house sources, testing laboratorics, computer databases, matcrial suppliers, data/information sources, consultants, and various institutions Rcfercnccs in this book represent cxamplcs for additional sources of plastics and processcs

This book was written to scrvc as a useful rcfcrcncc source for people new to plastics as well as providing an update for those with cxpcricncc

It highlights basic plastic matcrials and proccsscs that can bc uscd in dcsigning and fabricating plastic products As with dcsigning any matcrial a n d / o r using any process for plastic, stccl, aluminum, wood, ceramic, and so on, it is important to lmow their behaviors in ordcr to maximize product performance-to-cost efficiency This book provides

xxx Preface acknowledgement

information on the behaviors and proccssing of the different plastics and primary fabricating equipment including upstream and down- stream auxiliary equipment The information is interrelated between chapters so it is best to review more than one chapter to maximize you understanding the behavior of plastic materials and processes

Designing to meet product performance and cost depends on being able to analyze the many diverse plastics and processes already existing One important reason for this approach is that it provides a means to enhance the users' skills It calls for the ability to recognize situations in which certain plastics and processing techniques may be used and eliminate potential problems

Problems that are reviewed in this book should not occur As explained they can be eliminated so that they do not effect the product per- formance when qualified people understand that the problems can exist They are presented to reduce or eliminate costly pitfalls resulting

in poor product performances or failures With the potential problems

or failures reviewed there are solutions presented These failure/ solution reviews will enhance the intuitive sldlls of those people who are already worldng in plastics Cross-referencing of many pertinent behavior patterns is included so one will better understand the advantages and limitations that can develop with improper approaches Products reviewed range from toys to medical devices to cars to boats

to underwater devices to containers to springs to pipes to buildings to aircraft to spacecraft and so on The reader's product to be designed

a n d / o r fabricated can directly or indirectly be related to plastic materials, fabricating processes, a n d / o r product design reviews in the book

This book makes very clear the behavior of the 38,000 different plastics with the different behaviors of the hundreds of processes It con- centrates on the important plastics and processes used to fabricate products The result is a complete logical approach to designing that involves the proper use of materials and fabricating processes

Information contained and condensed in this book has been collected from many sources Included is the extensive information assembled from worldwide personal experience, industrial, and teaching experiences

of the two authors totaling over a century Use was also made of worldwide information from industry (personal contacts, material and equipment suppliers, conferences, books, articles, etc.) and major trade associations For someone to collect this information would require the person having familiarity in the many facets involved in the plastic industry worldwide

Preface, acknowledgement xxxi

The information contained in this book is not available on the Internet The Internet contains an extensive amount of useful and important information that can be used but it is reviewed under many different subjects However it does not contain all the information in this book Patents or trademarks may cover information presented No authoriza- tion to utilize these patents or trademarks is given or implied; they are discussed for information purposes only The use of general descriptive names, proprietary names, trade names, commercial designations, or the like does not in any way imply that they may be used freely

While information presented represents useful information that can be studied or analyzed and is believed to be true and accurate, neither the authors nor the publisher can accept any legal responsibility for any errors, omissions, inaccuracies, or other factors The authors and contributors have taken their best effort to represent the contents of this book correctly

About the authors

Dominiek V Rosato

Since 1939 has been involved worldwide principally with plastics from designing-through-fabricating-through-marketing products from toys- through-commercial electronic devices-to-aerospace and space products worldwide Experience includes Air Force Materials Laboratory (Head Plastics R&D), Raymark (Chief Engineer), Ingersoll-Rand (International Marketing Manager), and worldwide lecturing Past director of seminars and in-plant programs and adjunct professor at University Massachusetts Lowell, Rhode Island School of Design, and the Open University (UK) Has received various prestigious awards from USA and international associations, societies (SPE Fellows, etc.), publi- cations, companies, and National Academy of Science (materials advisory board) He is a member of the Plastics Hall of Fame Received American Society of Mechanical Engineers recognition for advanced engineering design with plastics Senior member of the Institute of Electrical and Electronics Engineers Licensed professional engineer of Massachusetts Involved in the first all plastics airplane (1944/RP sand- wich structure) Worked with thousands of plastics plants worldwide, prepared over 2,000 technical and marketing papers, articles, and presentations and has published 25 books with major contributions in over 45 other books Received BS in Mechanical Engineering from Drexel University with continuing education at Yale, Ohio State, and University of Pennsylvania

Donald V Rosato

Has extensive technical and marketing plastic industry business experience from laboratory, testing, through production to marketing, having worked for Northrop Grumman, Owens-Illinois, DuPont/

~xxiv About the authors

Conoco, Hoechst Celanese, and Borg Warner/G.E Plastics He has written extensively, developed numerous patents within the polymer related industries, is a participating member of many trade and industry groups, and currently is involved in these areas with PlastiSource, Inc., and Plastics FALLO Received BS in Chemistry from Boston College, MBA at Northeastern University, M.S Plastics Engineering from University of Massachusetts Lowell (Lowell Technological Institute), and Ph.D Business Administration at University of California, Berkeley

Matthew V Rosato

Has a strong, Marine Corps influenced, skill set in information technology and software application areas, which has been helpful in constantly updating and keeping current the numerous plastic material and process selection reviews in this book He is presently a bachelors candidate at Ohio State University, and is involved in technical marketing projects with Plastics Fallo