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I auct w tosatc & Donalc 2 ELSEVIE Plastics Engineered Product Design Dominick Rosato and Donald Rosato ELSEVIER UK USA JAPAN Elsevier Ltd, The Boulevard, Langford Lane, Kidlington, Oxford OX5 lGB, UK Elsevier Inc, 360 Park Avenue South, New York, NY 10010-1710, USA Elsevier Japan, Tsunashima Building Annex, 3-20-12 Yushima, Bunkyo-ku, Tokyo 113, Japan Copyright 0 2003 Elsevier Ltd. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means: electronic, electrostatic, magnetic tape, mechanical, photocopying, recording or otherwise, without permission in writing from the publishers. British Library Cataloguing in Publication Data Rosato, Dominick V. Plastics engineered product design 1.Plastics 2.Engineering design %.New products I.Title ILRosato, Donald V. (Donald Vincent), 1947- 620.1’923 ISBN 1856174166 No responsibility is assumed by the Publisher for any injury and/or damage to persons or property as a matter of products liability, negligence or otherwise, or from any use or operation of any methods, products, instructions or ideas contained in the material herein. Published by Elsevier Advanced Technology, The Boulevard, Langford Lane, Kidlington, Oxford OX5 lGB, UK Tel: +44(0) 1865 843000 Fax: +44(0) 1865 843971 Typeset by Land & Unwin, Bugbrooke Printed and bound in Great Britain by Biddles Ltd, Guildford and King’s Lynn Contents Preface, Acknowledg-ement About the Authors Chapter 1 OVERVIEW Introduction Materials of construction Thermoplastics Crystalline & Amorphous Polymers Liquid Crystalline Polymers Thermosets Crosslinked Thermoplastics Reinforced Plastics Thermal Expansions Ductilities Toughness Tolerances/Shrinkages Compounds Prepregs Sheet Molding Compounds Bulk Molding Compounds Commodity & Engineering Plastics Elastomers/Rubbers Morphology/Molecular Structure/Mechanical Plastic behaviors Property Densities Molecular Weights Molecular Weight Distributions Viscosities and Melt Flows Newtonian/non-Newtonian Xlll xvii 1 1 5 10 11 12 13 15 15 17 17 18 18 18 19 19 19 20 20 21 22 22 23 23 23 24 iv Contents Melt Index Viscoelasticities Glass Transition Temperatures Melt Temperatures Drying Operations Rheology & Mechanical Analysis Processing-to-Performance Interface Processing and Moisture Fabricating processes Orientations Postformings Coexuusions Coinjections Gas-Assist Moldings Micromoldings Blow Moldings Complex Consolidated Structural Products Extrusions Injection Moldings Thermoformings Foams Reinforced Plastics Calenders Castings Coatings Compression Moldings Reaction Injection Moldings Rotational Moldings Variables FALL0 approach Chapter 2 DESIGN OPTIMIZATION Introduction Terminology Engineering Optimization Design Foundation Problem/Solution Concept Design Approach Model Less Costly Model Type Design Analysis Approach Computer Sohare Viscoelasticity 24 25 26 26 26 28 29 30 31 33 34 34 34 35 35 36 37 37 38 39 40 40 41 41 42 42 42 43 44 44 46 46 46 57 58 61 62 62 63 64 64 65 Contents v Polymer Structure Viscoelasticity Behavior Summary Relaxation/Creep Analysis Viscosity Rheology and mechanical properties Static stress Hooke’s Law Tensile Stress-Strain Modulus of Elasticity Flexural Stress-Strain Compressive Stress-Strain Shear Stress-Strain Torsion Stress-Strain Direct Load Shear Strength Residual Stress Dynamic/Static Mechanical Behavior Energy and Motion Control Dynamic stress Isolator Torsion Load Rapid loading Impact Impulse Puncture Friction Erosion Hydrostatic Cavitation Rain High performance Reinforced Plastic Orientation of Reinforcement Orientation Terms Basic Design Theory Fiber Strength Theory Fiber Geometry on Strength Stiffness-Viscoelasticity Creep and Stress Relaxation Conceptual design approach Design Analysis Pseudo-Elastic Method Theory of Combined Action 67 67 68 70 71 73 74 75 76 78 80 83 84 86 86 87 88 89 91 92 97 101 102 104 105 106 109 109 110 111 113 113 115 115 116 120 126 129 129 130 130 132 135 vi Contents Overview Stress-Strain Analysis Plain Reinforced Plates Composite Plates Rending of Beams and Plates Structural Sandwiches Stiffness Stresses in Sandwich Beams Axially-Loaded Sandwich Filament-Wound Shells, Internal Hydrostatic Pressure Basic Equations Weight of Fiber Minimum Weight Isotensoid Design Geodesic-Isotensoid Design Chapter 3 DESIGN PARAMETER Load determination Design analysis process Reinforced Plastic Analysis Stress Analysis Stress-strain behavior Rigidity (EI) Hysteresis Effect Poisson’s Ratio Brittleness Ductile Crazing Stress Whitening Surface Stresses and Deformations Combined stresses Creep Fatigue Reinforcement performance Chapter 4 PRODUCT DESIGN Introduction Reinforced Plastic Monocoque Structure Geometric shape Modulus of Elasticity E1 theory 135 136 139 144 151 154 154 155 156 157 157 158 159 159 159 161 161 165 167 168 170 170 171 172 173 1 74 1 74 177 177 178 180 189 195 198 198 200 202 202 203 203 Contents vii Plate Beam Rib Folded Plate Plastic Reinforcedfloamed Plastic Euler’s Formula Column Torsion Sandwich Gear Bearing Grommet Gasket Shape Design Contact Stress PV Factor Overview Filament Wound Shape Netting Analysis Cylinder Sphere Tank Fabricating RP Tank Underground Storage Tank Hopper Rail Car Tank Highway Tank Very Large Tank Corrosive Resistant Tank Pipe Thermoplastic Pipe RP Pipe Leaf Spring Special Spring Cantilever Spring Torsional Beam Spring Spring Hinge Press fit Snap fit Tape Packaging 204 207 209 211 211 213 216 218 220 222 223 230 234 2 34 235 235 237 237 237 238 239 24 1 243 244 244 245 249 254 254 254 256 256 257 263 264 273 274 275 276 277 278 280 283 [...]... Stress Concentration Coefficient of Expansion Bolt Torque Effcct Impact Barrier Vehicle Oil Pan Attachment Design limitation and constraint Chapter 5 28 5 28 7 28 9 29 1 29 3 29 5 306 307 307 311 311 3 12 313 315 316 318 320 322 322 324 324 325 326 329 330 331 3 32 333 334 334 336 337 337 339 340 340 34 1 COMPUTER-AIDED DESIGN Technology overview Computers and people Geometric modeling Design accuracy and efficiency... Books Standards Engineering Information Information Broker Engineering Societies and Associations Designs Databases Websites Training programs Chapter 7 409 410 411 4 12 413 414 415 418 42 1 424 425 426 428 428 429 430 43 1 43 1 4 32 4 32 4 32 434 DESIGN RELIABILITY Testing Classiflmg Test Laboratory Quality control Quality and Reliability Total Quality Management Quality and Design Statistics Testing; QC,... Lower Lower Lower Lower Higher Highest Highest Lowest High High Lowest Highest Their UL (Underwriters Laboratory) continuous-use rating for electrical properties is as high as 24 0°C (464"F), and for mechanical properties it is 22 0°C ( 428 °F) permiting products to be exposed to intermittent temperatures as high as 315°C (600°F) without affecting performance properties Their resistance to high-temperature... designing-through-fabricating-through-marketing products from toysthrough-commercial electronic devices-to-aerospace & 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 & in-plant programs and adjunct professor at University Massachusetts Lowell, Rhode Island... Thus the technically correct term to identify the materials is plastics Of the 35,000 types available worldwide there are about 20 0 basic types or families drat are commercially recognized with less that1 20 that are popularly used Examples of these plastics are shown in Table 1 .2 Summation of the plastic families with their abbreviations Acetal (POM) Acrylics Polyacrylonitrile (PAN) Polymethylmethacrylate... 351 351 353 355 360 360 361 3 62 364 364 365 366 368 368 369 370 371 3 72 373 374 375 375 376 376 377 377 379 PLASTIC PERFORMANCE Overview Influencing Factor Selecting plastic Comparison Worksheet Temperature Thermal Property Thermal Conductivity Thermal Expansion/Contraction Hyperenvironment Flammability Steel and Plastic Test 381 381 384 385 387 393 393 396 400 400 4 02 406 406 407 x Contents Smoke... engineer of Massachusetts Involved in the first d plastics airplane (19M/RP sandwich 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,... (WAC) Polyvinyl alcohol (WA) Polyvinyl butyrate (PVB) Polyvinyl chloride (WC) Polyvinylidene chloride (WDC) Polyvinylidene fluoride (WF) Within these 20 popular plastics there are five major TP types that consume about two-thirds of all TPs Approximately 20 wt% are low density polyethylenes (LDPEs), 15% polyvinyl chlorides (PVCs), 10% high density polyethylenes (HDPEs), 15% polypropylenes (PPs), 8% polystyrenes... mass production methods, 8 wide range of color and appearance, 9 high impact to tear resistance, 10 decorative to industrial load bearing structures, 2 Plastics Engineered Product Design 11 short to very long service life, degradable to non-degradable, 12 process virgin with recycled plastics or recycled alone, 13 simple to complex shapes including many that are difficult or impossible to form with other... processing, plastics can be designed to produce simple to highly integrated conventional and customized products While it is mature, the plastics industry is far from having exhausted its product design potential The worldwide plastics industry offers continuous innovations in plastic materials, process engineering, and mechanical engineering design approaches that will make it possible to respond to . 20 4 20 7 20 9 21 1 21 1 21 3 21 6 21 8 22 0 22 2 22 3 23 0 23 4 2 34 23 5 23 5 23 7 23 7 23 7 23 8 23 9 24 1 24 3 24 4 24 4 24 5 24 9 25 4 25 4 25 4. efficiency 28 5 28 7 28 9 29 1 29 3 29 5 306 307 307 311 311 3 12 313 315 316 318 320 322 322 324 324 325 326 329 330 331 3 32 333 334