Plastics Engineering Third Edition

This book presents in a single volume the basic essentials of the properties and processing behaviour of plastics and composites. The aim is to give engineers and technologists a sound understanding of basic principles without the introduction of unduly complex levels of mathematics or chemistry and thereby set plastics in their proper context as engineering materials. This textbook pioneered the approach whereby both properties and processing of reinforced and unreinforced plastics are covered in a single volume. It assumes no prior knowledge of plastics, and emphasises the practical aspects of the subject. In this third edition over half the book has been re-written and the remainder has been updated and re-organised. Early chapters give an introduction to the types of plastics which are currently available and describe how a designer goes about the selection of a plastic for a particular application. Later chapters lead the reader into more advanced aspects of mechanical design and analysis of polymer melt flow. All techniques developed are illustrated by numerous worked examples, and problems are given at the end of each chapter - the solutions to which form one of the appendices. Cover......Page 1 Half Title Page......Page 2 Title Page......Page 4 Copyright......Page 5 Table of Contents......Page 6 Preface to the Third Edition......Page 12 Preface to the Second Edition......Page 14 Preface to the First Edition......Page 16 1.1 Introduction......Page 18 1.2 Polymeric Materials......Page 19 1.3 Plastics Available to the Designer......Page 23 1.4 Selection of Plastics......Page 35 2.1 Introduction......Page 58 2.2 Viscoelastic Behaviour of Plastics......Page 59 2.3 Short-Term Testing of Plastics......Page 60 2.4 Long-Term Testing of Plastics......Page 62 2.5 Design Methods for Plastics Using Deformation Data......Page 65 2.6 Thermal Stresses and Strains......Page 78 2.7 Multi-layer Mouldings......Page 83 2.8 Design of Snap Fits......Page 88 2.9 Design of Ribbed Sections......Page 91 2.10 Stiffening Mechanisms in Other Moulding Situations......Page 98 2.11 Mathematical Models of Viscoelastic Behaviour......Page 101 2.12 Intermittent Loading......Page 112 2.13 Dynamic Loading of Plastics......Page 127 2.14 Time-Temperature Superposition......Page 133 2.15 Fracture Behaviour of Unreinforced Plastics......Page 136 2.17 Energy Approach to Fracture......Page 138 2.18 Stress Intensity Factor Approach to Fracture......Page 144 2.19 General Fracture Behaviour of Plastics......Page 148 2.20 Creep Failure of Plastics......Page 151 2.21 Fatigue of Plastics......Page 155 2.22 Impact Behaviour of Plastics......Page 164 3.2 Types of Reinforcement......Page 185 3.3 Types of Matrix......Page 187 3.4 Forms of Fibre Reinforcement in Composites......Page 188 3.5 Analysis of Continuous Fibre Composites......Page 189 3.6 Deformation Behaviour of a Single Ply or Lamina......Page 199 3.7 Summary of Approach to Analysis of Unidirectional Composites......Page 205 3.8 General Deformation Behaviour of a Single Ply......Page 212 3.9 Deformation Behaviour of Laminates......Page 219 3.10 Summary of Steps to Predict Stiffness of Symmetric Laminates......Page 223 3.11 General Deformation Behaviour of Laminates......Page 225 3.12 Analysis of Multi-layer Isotropic Materials......Page 235 3.13 Analysis of Non-symmetric Laminates......Page 240 3.14 Analysis of Short Fibre Composites......Page 243 3.16 Strength of Fibre Composites......Page 249 3.17 Fatigue Behaviour of Reinforced Plastics......Page 255 3.18 Impact Behaviour of Reinforced Plastics......Page 257 4.1 Introduction......Page 262 4.2 Extrusion......Page 263 4.3 Injection Moulding......Page 295 4.4 Thermoforming......Page 323 4.5 Calendering......Page 330 4.6 Rotational Moulding......Page 335 4.7 Compression Moulding......Page 340 4.8 Transfer Moulding......Page 343 4.9 Processing Reinforced Thermoplastics......Page 344 4.10 Processing Reinforced Thermosets......Page 345 5.1 Introduction......Page 360 5.2 General Behaviour of Polymer Melts......Page 361 5.3 Isothermal Flow in Channels: Newtonian Fluids......Page 363 5.4 Rheological Models for Polymer Melt Flow......Page 368 5.5 Isothermal Flow in Channels: Non-Newtonian Fluids......Page 371 5.6 Isothermal Flow in Non-Uniform Channels......Page 374 5.7 Elastic Behaviour of Polymer Melts......Page 380 5.8 Residence and Relaxation Times......Page 384 5.9 Temperature Rise in Die......Page 385 5.10 Experimental Methods Used to Obtain Flow Data......Page 386 5.11 Analysis of Flow in Some Processing Operations......Page 392 5.12 Analysis of Heat Transfer During Polymer Processing......Page 408 5.13 Calculation of Clamping Force......Page 418 Appendix A - Structure of Plastics......Page 430 Appendix B - Solution of Differential Equations......Page 442 Appendix C - Stress/Strain Relationships......Page 443 Appendix D - Stresses in Cylindrical Shapes......Page 446 Appendix E - Introduction to Matrix Algebra......Page 448 Appendix F - Abbreviations for Some Common Polymers......Page 451 Solutions to Questions......Page 452 Index......Page 518 Back Cover......Page 530 Cover 1 Frontmatter 2 Half Title Page 2 Title Page 4 Copyright 5 Table of Contents 6 Preface to the Third Edition 12 Preface to the Second Edition 14 Preface to the First Edition 16 Chapter 1 - General Properties of Plastics 18 1.1 Introduction 18 1.2 Polymeric Materials 19 1.3 Plastics Available to the Designer 23 1.4 Selection of Plastics 35 Chapter 2 - Mechanical Behaviour of Plastics 58 2.1 Introduction 58 2.2 Viscoelastic Behaviour of Plastics 59 2.3 Short-Term Testing of Plastics 60 2.4 Long-Term Testing of Plastics 62 2.5 Design Methods for Plastics Using Deformation Data 65 2.6 Thermal Stresses and Strains 78 2.7 Multi-layer Mouldings 83 2.8 Design of Snap Fits 88 2.9 Design of Ribbed Sections 91 2.10 Stiffening Mechanisms in Other Moulding Situations 98 2.11 Mathematical Models of Viscoelastic Behaviour 101 2.12 Intermittent Loading 112 2.13 Dynamic Loading of Plastics 127 2.14 Time-Temperature Superposition 133 2.15 Fracture Behaviour of Unreinforced Plastics 136 2.16 The Concept of Stress Concentration 138 2.17 Energy Approach to Fracture 138 2.18 Stress Intensity Factor Approach to Fracture 144 2.19 General Fracture Behaviour of Plastics 148 2.20 Creep Failure of Plastics 151 2.21 Fatigue of Plastics 155 2.22 Impact Behaviour of Plastics 164 Chapter 3 - Mechanical Behaviour of Composites 185 3.1 Deformation Behaviour of Reinforced Plastics 185 3.2 Types of Reinforcement 185 3.3 Types of Matrix 187 3.4 Forms of Fibre Reinforcement in Composites 188 3.5 Analysis of Continuous Fibre Composites 189 3.6 Deformation Behaviour of a Single Ply or Lamina 199 3.7 Summary of Approach to Analysis of Unidirectional Composites 205 3.8 General Deformation Behaviour of a Single Ply 212 3.9 Deformation Behaviour of Laminates 219 3.10 Summary of Steps to Predict Stiffness of Symmetric Laminates 223 3.11 General Deformation Behaviour of Laminates 225 3.12 Analysis of Multi-layer Isotropic Materials 235 3.13 Analysis of Non-symmetric Laminates 240 3.14 Analysis of Short Fibre Composites 243 3.15 Creep Behaviour of Fibre Reinforced Plastics 249 3.16 Strength of Fibre Composites 249 3.17 Fatigue Behaviour of Reinforced Plastics 255 3.18 Impact Behaviour of Reinforced Plastics 257 Chapter 4 - Processing of Plastics 262 4.1 Introduction 262 4.2 Extrusion 263 4.3 Injection Moulding 295 4.4 Thermoforming 323 4.5 Calendering 330 4.6 Rotational Moulding 335 4.7 Compression Moulding 340 4.8 Transfer Moulding 343 4.9 Processing Reinforced Thermoplastics 344 4.10 Processing Reinforced Thermosets 345 Chapter 5 - Analysis of Polymer Melt Flow 360 5.1 Introduction 360 5.2 General Behaviour of Polymer Melts 361 5.3 Isothermal Flow in Channels: Newtonian Fluids 363 5.4 Rheological Models for Polymer Melt Flow 368 5.5 Isothermal Flow in Channels: Non-Newtonian Fluids 371 5.6 Isothermal Flow in Non-Uniform Channels 374 5.7 Elastic Behaviour of Polymer Melts 380 5.8 Residence and Relaxation Times 384 5.9 Temperature Rise in Die 385 5.10 Experimental Methods Used to Obtain Flow Data 386 5.11 Analysis of Flow in Some Processing Operations 392 5.12 Analysis of Heat Transfer During Polymer Processing 408 5.13 Calculation of Clamping Force 418 Backmatter 430 Appendix A - Structure of Plastics 430 Appendix B - Solution of Differential Equations 442 Appendix C - Stress/Strain Relationships 443 Appendix D - Stresses in Cylindrical Shapes 446 Appendix E - Introduction to Matrix Algebra 448 Appendix F - Abbreviations for Some Common Polymers 451 Solutions to Questions 452 Index 518 Back Cover 530 Referex This book presents in a single volume the basic essentials of the properties and processing behaviour of plastics and composites. The aim is to give engineers and technologists a sound understanding of basic principles without the introduction of unduly complex levels of mathematics or chemistry and thereby set plastics in their proper context as engineering materials. This textbook pioneered the approach whereby both properties and processing of reinforced and unreinforced plastics are covered in a single volume. It assumes no prior knowledge of plastics, and emphasises the practical aspects of the subject. In this third edition over half the book has been re-written and the remainder has been updated and re-organised. Early chapters give an introduction to the types of plastics which are currently available and describe how a designer goes about the selection of a plastic for a particular application. Later chapters lead the reader into more advanced aspects of mechanical design and analysis of polymer melt flow. All techniques developed are illustrated by numerous worked examples, and problems are given at the end of each chapter - the solutions to which form one of the appendices. (A cura dell'editore) In this third edition over half the book has been re-written and the remainder has been updated and re-organized. Early chapters give an introduction to types of plastics available and describe how a designer goes about the selection of a plastic for a particular application. Later chapters lead the reader into more advanced aspects of mechanical design and analysis of polymer melt flow. All techniques developed are illustrated by worked examples, and problems are given at the end of each chapter; solutions to which form one of the appendice