Plastics Engineered Product Design Dominick Rosato docx

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 [...]... widely adjusted and ease of 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... to an actual product In addition, certain basic tools are needed, such as those for computation and measurement and for testing of prototypes and/or fabricated products to ensure that product performance requirement are met A single individual designer may not have all of these capabilities so inputs from many reliable people and/or sources are required 4 Plastics Engineered Product Design Inputs... environmental load stresses Product loads range from short-time static, such as tensile, flexural, torsion, etc., to long time dynamic, such as creep, fatigue, high speed loading, motion control, and so on In this book, plastics design concepts are presented that can be applied to designing products for a range of behaviors An inspired idea alone will not result in a successful design Designing is, to a high... consumer and business-to-business accounts About the authors Dominick V Rosato Since 1939 has been involved worldwide principally with plastics from 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... (aesthetics) Unless these are in balance, the product may fail in the market place The successhl integrated product is the result of properly collecting all of the required design inputs While plastic product design can be challenging, many products seen in everyday life may require only a practical, rather than rigorous approach They are not required to undergo sophisticated design analysis because they are not... families of plastics or even on the many various types within a single family that are reviewed in this book Each plastic (of the 35,000 available) has specific performance and processing capabilities - 1 Overview 7 Figure 1.2 Use o f plastics in recreational products range from unsophisticated types to high performance types such boats (Courtesy o f Plastics FALLO) 8 Plastics Enqineered Product Design. .. about 90wt% thermoplastics (TPs) and 10%thermoset - 1 Overview 9 (TS) plastics USA and Europe consumption is about one-third each of the world total These two major classifications of thermoplastics (TPs) and thermosets (TSs) in turn have different classifications such as virgin or recycled plastics Virgin plastics have not been subjected to any fabricating process NEAT plastics identify plastics with... complex engineering equations and analysis in the design of products For over a century plastics with its versatility and vast array of inherent plastic properties as well as high-speed/low-energy processing techniques have resulted in designing and producing many millions of cost-effective products used worldwide The profound worldwide benefits of plastics in economics and modern living standards... performance in all kinds of environments, 7 adapt well to 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... property or combination of properties The final product performance is affected by interrelating the plastic with its design and processing method The designer’s knowledge of all these variables is required otherwise it can profoundly affect the ultimate success or failure of a consumer or industrial product When required the designer makes use of others to ensure product success Plastic plays a crucial and . 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-. I auct w tosatc & Donalc 2 ELSEVIE Plastics Engineered Product Design Dominick Rosato and Donald Rosato ELSEVIER UK USA JAPAN Elsevier Ltd, The Boulevard,. accounts. About the authors Dominick V. Rosato Since 1939 has been involved worldwide principally with plastics from designing-through-fabricating-through-marketing products from toys- through-commercial