Plastics processing data handbook

This comprehensive workbook offers a thorough review of today's high performance plastics and manufacturing processes. Focusing on common processing problems and practical solutions this book surveys fundamental processing concepts for every major fabrication technique in use today and provides extensive data on controls, instrumentation, materials and molding technologies. This second edition is fully updated with the addition of new material, new tables and new figures. Other useful features include: numerous examples of various phases of processing; a detailed review of each plastics process; the effect of changing one variable while others are constant. ВЈ/LISTВЈ Front Matter......Page 1 Preface......Page 3 Table of Contents......Page 0 01906_toc.pdf......Page 5 Introduction......Page 20 Product Requirements and Machine Performance......Page 25 Processability......Page 27 Overview......Page 28 Processing and Properties......Page 31 Plastics Memory and Processing......Page 33 Drying Plastics......Page 40 Release Agents......Page 46 Heat History, Residence Time, and Recycling......Page 47 Heat Profile......Page 48 Processing and Tolerances......Page 49 Screw Plasticating......Page 53 Processing Diagrams......Page 54 Selecting a Process......Page 56 Introduction......Page 68 Molecular Properties......Page 73 Thermoplastics......Page 74 Thermosets......Page 76 Properties Influencing Processes......Page 78 Melt Flow and Rheology......Page 96 Thermal Properties......Page 104 Orientation: Defect or Benefit?......Page 112 Selecting Plastics......Page 117 Product Design......Page 122 Design Features That Influence Processing and Performance......Page 125 Process Controls......Page 131 Timing and Sequencing......Page 134 Microprocessor Control Systems......Page 135 Problems in Process Controls......Page 136 Captive......Page 137 Troubleshooting......Page 138 Basic Process......Page 140 Machine Characteristics......Page 143 Machine Types......Page 145 Machine Variables......Page 146 Productivity and Cycle Time......Page 147 Material Movement and Setup......Page 148 Screw/Barrel Performance......Page 154 Mixing Devices......Page 158 Custom-Designed Screws......Page 159 Valves and Screw Tips......Page 161 Vented Barrels......Page 162 Shot-to-Shot Variation......Page 166 Purging......Page 168 Wear......Page 170 Output......Page 171 Basic Types......Page 172 Different Systems......Page 176 Clamping Forces......Page 177 Hydraulic and Electric IMMs......Page 178 Molds......Page 180 Types......Page 184 Runner Systems......Page 191 Other Considerations......Page 194 Process Controls......Page 196 Microprocessor Control Systems......Page 200 Melt Flow Behavior......Page 201 Parting Lines......Page 207 Screw Bridging......Page 208 Weld/Meld Lines......Page 209 Tolerances and Shrinkages......Page 210 Molding Techniques......Page 211 Coinjection......Page 212 Injection-Compression Molding (Coining)......Page 213 Continuous IM......Page 214 Multilive Feed IM......Page 217 Costing IMMs......Page 218 Troubleshooting......Page 219 Wear......Page 226 Inspection......Page 227 Rebuilding Screws/Barrels......Page 228 Basic Process......Page 230 Plastics Handling......Page 234 Barrel and Feed Units......Page 236 Types of Extruder......Page 238 Screw/Barrel Performance......Page 239 Single-Screw Extruders......Page 240 Mixing and Melting......Page 243 Venting......Page 245 Screen Packs......Page 246 Multiple-Screw Extruders......Page 248 Heating and Cooling Systems......Page 253 Barrel and Screw Materials......Page 254 Gear Pumps......Page 255 Overview......Page 259 Basics of Flow......Page 271 Special Dies......Page 273 Coextrusion......Page 275 Orientation......Page 282 Blown Film......Page 288 Flat Film......Page 292 Coating......Page 295 Compounding......Page 301 Fibers......Page 302 Netting......Page 305 Pipe......Page 306 Postforming......Page 308 Profile......Page 310 Reactive......Page 312 Sheet......Page 313 Tubing......Page 314 Wire and Cable......Page 315 Process Controls......Page 317 Downstream Controls......Page 321 Extruder Operation......Page 326 Costing......Page 329 Troubleshooting......Page 330 Extrusion Instabilities or Variabilities......Page 338 Basic Process......Page 339 Continuous Extrusion......Page 347 Intermittent Extrusion......Page 349 Melt Behavior......Page 353 Parison Thickness Control......Page 355 Parison Swell......Page 357 Pinchoff......Page 358 Blowing the Parison......Page 361 Cooling......Page 363 Clamping......Page 365 Shrinkage......Page 367 Surface Treatment......Page 369 Injection Blow Molding......Page 371 Stretching/Orienting BM......Page 374 Molds......Page 377 Plastics......Page 379 Other Processes......Page 383 Controls......Page 384 Costing......Page 386 Troubleshooting......Page 387 Introduction......Page 392 Films......Page 395 Recycled......Page 396 Fluxing and Feeding......Page 397 Processing Conditions......Page 398 Surface Finishing......Page 399 Controls......Page 400 Costing......Page 402 Troubleshooting......Page 405 Overview......Page 406 Casting......Page 407 Acrylic Casting......Page 408 Embedding......Page 409 Encapsulation......Page 410 Processing Characteristics......Page 411 Vacuum Systems......Page 412 Exothermic Reactions......Page 413 Materials......Page 414 Troubleshooting......Page 415 Film Formation......Page 416 Thermoplastics......Page 418 Thermosets......Page 419 Paint Coatings......Page 420 Films......Page 421 Fabrics......Page 424 Leatherlike Materials......Page 425 Equipment......Page 426 Overview......Page 428 Flame Spray Coatings......Page 429 Powder Coatings......Page 430 Fluidized-Bed Coatings......Page 431 Electrostatic Coatings......Page 433 Vacuum Coatings......Page 434 Electrodeposition Coatings......Page 435 Pinhole-Free Thin Coatings......Page 436 Dip Coatings......Page 437 Introduction......Page 439 Materials......Page 440 Processing Characteristics......Page 443 Mold Heating......Page 444 Postcuring......Page 445 Compression Molding......Page 446 Transfer Molding......Page 447 Molds......Page 449 Cavity Plating......Page 451 Venting......Page 452 Mold Construction......Page 454 Shrinkage......Page 455 Costing......Page 456 Troubleshooting......Page 457 Basic Process......Page 458 Foam Definitions......Page 459 Processes......Page 464 Blowing Agents......Page 465 Foamed Polystyrene Sheets......Page 468 Expandable Polystyrenes......Page 469 Expandable Polyethylenes......Page 471 Expandable SANs......Page 472 Foamed Polyurethanes......Page 473 PUR Dispensers......Page 474 Low Pressure......Page 475 Low Pressure with Surface Finish......Page 476 High Pressure......Page 477 Syntactic Foams......Page 478 Designs......Page 479 Troubleshooting......Page 480 Introduction......Page 485 Processing......Page 487 Forming Definitions......Page 493 Materials......Page 498 Other Forming Methods......Page 500 Equipment......Page 502 Pneumatic Controls......Page 505 Temperature Controls......Page 508 Molds......Page 511 Designs......Page 512 Tolerances......Page 515 Troubleshooting......Page 516 Introduction......Page 519 Processing......Page 520 Advantages and Disadvantages......Page 522 Troubleshooting......Page 523 Introduction......Page 524 Directional Properties......Page 525 Sheet Molding Compound......Page 530 Void Content......Page 531 Processes......Page 541 Open Mold......Page 543 Sprayup......Page 546 Vacuum Bag......Page 550 Pressure Bag......Page 551 Autoclave......Page 552 Resin Transfer......Page 553 Reaction Injection......Page 555 Compression and Transfer......Page 556 Stamping......Page 557 Pultrusion......Page 558 Centrifugal Casting......Page 559 Filament Winding......Page 560 Injection......Page 565 Designs......Page 566 Troubleshooting......Page 574 Introduction......Page 577 Processing......Page 578 Molds......Page 580 Materials......Page 581 Troubleshooting......Page 582 Basic Process......Page 583 Processing Plastisols......Page 584 Processing Organosols......Page 585 Dip Moldings......Page 586 Slush Moldings......Page 587 Spray Coatings......Page 588 Heating Systems......Page 589 Troubleshooting......Page 590 Wood-Plastic Impregnation......Page 591 Plastic-Concrete......Page 594 Machining......Page 595 Cutting Guidelines......Page 597 Types......Page 598 Communication Protocol......Page 600 Material Handling......Page 601 Energy Conservation......Page 604 Parts Handling......Page 605 Clean Pellets and Plant......Page 606 Drying Plastics......Page 607 Feeders and Blenders......Page 610 Granulators......Page 613 Metric Conversion Charts......Page 616 Mathematical Symbols and Abbreviations......Page 620 Properties of Water......Page 621 A......Page 622 B......Page 624 C......Page 630 D......Page 639 E......Page 641 F......Page 643 G......Page 650 I......Page 652 L......Page 654 M......Page 655 P......Page 659 R......Page 666 S......Page 670 T......Page 673 V......Page 676 W......Page 678 X......Page 679

This comprehensive workbook offers a thorough review of today's high performance plastics and manufacturing processes. Focusing on common processing problems and practical solutions this book surveys fundamental processing concepts for every major fabrication technique in use today and provides extensive data on controls, instrumentation, materials and molding technologies. This second edition is fully updated with the addition of new material, new tables and new figures.
Other useful features include:

numerous examples of various phases of processing;

a detailed review of each plastics process;

the effect of changing one variable while others are constant. £/LIST£

Booknews

The author describes the relation between plastics processing and plastic materials' product requirements and costs. He offers guidelines for maximizing processing efficiency in the manufacture of all types of products, using all types of plastics, and he maintains that a knowledge of processing methods helps one decide whether a given product can be fabricated and by what process. Appends a metric conversion chart and other materials. Annotation c. by Book News, Inc., Portland, Or.