E-Book, Englisch, 891 Seiten
Campo The Complete Part Design Handbook
1. Auflage 2013
ISBN: 978-3-446-41292-7
Verlag: Hanser, Carl
Format: PDF
Kopierschutz: 1 - PDF Watermark
For Injection Molding of Thermoplastics
E-Book, Englisch, 891 Seiten
ISBN: 978-3-446-41292-7
Verlag: Hanser, Carl
Format: PDF
Kopierschutz: 1 - PDF Watermark
This book is an indispensable, all inclusive, reference guide. New illustrations, graphs and equations have been included to provide additional clarity for complex ideas.
Contents:
- Plastic Materials Selection Guide
- Engineering Product Design
- Structural Design for Thermoplastics
- Thermoplastic Gearing Design
- Plastic Journal Bearing Design
- Thermoplastic Spring Design
- Thermoplastic Pressure Vessel Design
- Thermoplastic Assembly Methods
- Thermoplastic Effects on Design
- Thermoplastic Injection Mold Design
- Performance Testing of Thermoplastics
- Thermoplastic Product Cost Analysis
Autoren/Hrsg.
Weitere Infos & Material
1;Dedication;6
2;Preface;8
3;Contents;10
4;1 Polymeric Materials;24
4.1;1.1 Introduction to Plastic Materials;24
4.1.1;1.1.1 Beginning of Plastics;24
4.1.2;1.1.2 Polymer Families;26
4.2;1.2 Thermoplastic Polymers;27
4.2.1;1.2.1 Classification of Polymers by Performance;27
4.2.2;1.2.2 Molecular Structure of Plastic Materials;29
4.2.3;1.2.3 Acrylonitrile-Butadiene-Styrene (ABS);29
4.2.4;1.2.4 Acetal (POM, Polyacetal);32
4.2.5;1.2.5 Polymethyl Metacrylate (Acrylic, PMMA);35
4.2.6;1.2.6 High Temperature Nylon (HTN);37
4.2.7;1.2.7 Ionomer Polymers;39
4.2.8;1.2.8 Liquid Crystal Polymer (LCP);41
4.2.9;1.2.9 Polyamide (PA, Nylon);43
4.2.10;1.2.10 Polyetherimide (PEI);46
4.2.11;1.2.11 Polyarylate (PAR);48
4.2.12;1.2.12 Polyetherether Ketone (PEEK);50
4.2.13;1.2.13 Polycarbonate (PC);51
4.2.14;1.2.14 Modified Polyphenylene Oxide (PPO);54
4.2.15;1.2.15 Polybutylene Terephthalate (PBT);56
4.2.16;1.2.16 Polyethylene Terephthalate (PET);57
4.2.17;1.2.17 Polyethylene (PE);59
4.2.18;1.2.18 Polytetrafluoroethylene (PTFE);62
4.2.19;1.2.19 Polyphenylene Sulfi de (PPS);67
4.2.20;1.2.20 Polypropylene (PP);69
4.2.21;1.2.21 Polystyrene (PS);71
4.2.22;1.2.22 Polysulfone (PSU);72
4.2.23;1.2.23 Polyvinyl Chloride (PVC);74
4.2.24;1.2.24 Styrene Acrylonitrile (SAN);76
4.3;1.3 Thermoplastic Elastomers (TPE);78
4.3.1;1.3.1 Thermoplastic Elastomer Families;79
4.3.2;1.3.2 Thermoplastic Polyurethane Elastomer (TPU);80
4.3.3;1.3.3 Styrenic Block Copolymer (SBS);83
4.3.4;1.3.4 Polyolefin Thermoplastic Elastomer (TPO);85
4.3.5;1.3.5 Elastomeric Alloy Thermoplastic Vulcanized (TPV).;88
4.3.6;1.3.6 Melt Processible Rubber (MPR);92
4.3.7;1.3.7 Copolyester Thermoplastic Elastomer;94
4.3.8;1.3.8 Polyamide Thermoplastic Elastomer;98
4.4;1.4 Liquid Injection Molding Silicone (LIM®);100
4.4.1;1.4.1 LIM® Silicone Processing;102
4.5;1.5 Thermoset Polymers;105
4.5.1;1.5.1 Polyester Alkyd (PAK);106
4.5.2;1.5.2 Diallyl Phthalate/Isophthalate (DAP, DAIP);108
4.5.3;1.5.3 Melamine Formaldehyde (MF);110
4.5.4;1.5.4 Cellulosic Ester;111
4.5.5;1.5.5 Cyanate;112
4.5.6;1.5.6 Epoxy (EP);115
4.5.7;1.5.7 Phenol Formaldehyde (Phenolic, PF);117
4.5.8;1.5.8 Polybutadiene (PB);120
4.5.9;1.5.9 Bismaleimide (BMI);120
4.5.10;1.5.10 Unsaturated Polyester (UP);121
4.5.11;1.5.11 Polyimide (PI);124
4.5.12;1.5.12 Polyxylene;126
4.5.13;1.5.13 Polyurethane (PUR);127
4.5.14;1.5.14 Silicone (SI);130
4.5.15;1.5.15 Urethane Hybrid;132
4.5.16;1.5.16 Vinyl Ester (BPA);134
5;2 Engineering Product Design;138
5.1;2.1 Understanding the Properties of Materials;138
5.1.1;2.1.1 Plastics Selection Guidelines;140
5.2;2.2 Structural Design of Thermoplastic Components;143
5.2.1;2.2.1 Stress-Strain Behavior;144
5.2.2;2.2.2 Tensile Testing of Viscoelastic Materials;145
5.3;2.3 Mechanical Properties of Materials;149
5.4;2.4 Tension and Compression Curves;152
5.5;2.5 Modulus of Elasticity (E);152
5.6;2.6 Stress and Strain Analysis;153
5.7;2.7 Thermoplastics Elastic Design Method;154
5.7.1;2.7.1 Working Stress;155
5.7.2;2.7.2 Compressive Stress;156
5.7.3;2.7.3 Flexural Stress;157
5.7.4;2.7.4 Coefficient of Linear Thermal Expansion (?);158
5.7.5;2.7.5 Poisson’s Ratio (?);159
5.7.6;2.7.6 Moisture Effects on Nylon;159
5.7.7;2.7.7 Effects of Temperature on the Behavior of Thermoplastics;160
5.8;2.8 Stress-Strain Recovery (Hysteresis);161
5.8.1;2.8.1 Creep Behavior of Thermoplastics;161
5.8.2;2.8.2 Creep and Rupture Under Long-Term Load;162
5.8.3;2.8.3 Creep and Relaxation of Thermoplastics;162
5.9;2.9 Flexural Beam Stress Distribution;168
5.10;2.10 Viscoelastic Modulus Design Method;170
5.11;2.11 Centroid, Section Area, and Moment of Inertia;173
5.12;2.12 Radius of Gyration;181
5.13;2.13 Stress Analysis of Beams;181
5.13.1;2.13.1 Types of Loads;181
5.13.2;2.13.2 Normal Stresses in Beams;182
5.13.3;2.13.3 Shearing Force;187
5.14;2.14 Beam Deflection Analysis;191
5.14.1;2.14.1 Beam Deflection by Double Integration Method;192
5.14.2;2.14.2 Beam Deflection Moment Area Method;201
5.14.3;2.14.3 Applications of Moment Area and Double Integration Methods;202
5.14.4;2.14.4 Beam Deflection Superposition Method;206
5.15;2.15 Column Structural Analysis;211
5.15.1;2.15.1 Long Slender Column Critical Load (PCr);211
5.15.2;2.15.2 Column Slenderness Ratio (L / r);211
5.15.3;2.15.3 Eccentrically Loaded Columns;211
5.16;2.16 Flat Circular Plates;217
5.16.1;2.16.1 Classification;218
5.16.2;2.16.2 Stress Analysis Methods;218
5.16.3;2.16.3 Flat Circular Plate Equations;219
5.16.4;2.16.4 Flat Circular Plate Stresses;220
5.16.5;2.16.5 Theory of Flexure Comparison;221
5.16.6;2.16.6 Circular Plates Simply Supported, Concentrated center Load;221
5.16.7;2.16.7 Flat Circular Plate under Concentrated Center Load;222
5.16.8;2.16.8 Flat Circular Plate with Fixed Edge;222
5.16.9;2.16.9 Flat Circular Plate Compensation Factor for Deflection;223
5.16.10;2.16.10 Flat Circular Plate Bending under Edge Boundaries;223
5.17;2.17 Torsion Structural Analysis;230
6;3 Structural Designs for Thermoplastics;234
6.1;3.1 Uniform and Symmetrical Wall Thickness;234
6.1.1;3.1.1 Part Geometries Difficult to Mold;235
6.1.2;3.1.2 Wall Draft Angle per Side;236
6.2;3.2 Structural Rib Design;236
6.2.1;3.2.1 Rib Strength Analysis Method;238
6.3;3.3 Internal Sharp Corners and Notches;245
6.4;3.4 Injection Molded Thermoplastic Bosses;245
6.5;3.5 Injection Molded Thermoplastic Threads;247
6.6;3.6 Collapsible Core for Molding Internal Threads;247
6.7;3.7 Preferred Standard Thread Forms for Thermoplastics;248
6.7.1;3.7.1 Thermoplastic Threads Creep Effects;250
6.8;3.8 Injection Molded Products with Undercuts;250
6.9;3.9 Injection Molded Integral Life Hinges;255
6.9.1;3.9.1 Injection Molded Integral Life Hinge Design;256
6.9.2;3.9.2 Mold Design Considerations for Hinges;258
6.9.3;3.9.3 Proper Gate Design for Life Hinges;259
6.10;3.10 Conventional Types of Pin Hinges;260
6.11;3.11 Metal Inserts for Thermoplastic Encapsulation;262
6.11.1;3.11.1 Machined Metal Threaded Insert Tolerances;263
6.11.2;3.11.2 Thermoplastic Boss Wall Thickness for Metal Inserts;263
6.11.3;3.11.3 Press/Lock Slotted Metal Insert Installation After Molding;265
6.11.4;3.11.4 Cold Forged Metal Inserts for Encapsulation;266
6.11.5;3.11.5 Threaded Female Metal Inserts;267
6.11.6;3.11.6 Metal Inserts Anchorage for ThermoplasticEncapsulation;269
6.11.7;3.11.7 Metal Insert Encapsulating Process Problems;272
6.11.8;3.11.8 Special Metal Inserts Anchorage for Encapsulation;273
6.11.9;3.11.9 Electrical Lead Inserts for Encapsulation;276
6.11.10;3.11.10 Inserts Preparation for Molding Encapsulation;278
7;4 Thermoplastic Gearing Design;280
7.1;4.1 Classification of Gears;281
7.1.1;4.1.1 Gears Parallel to the Shaft Axis;281
7.1.2;4.1.2 Bevel Gears, Nonparallel and Intersecting Shafts;282
7.1.3;4.1.3 Hypoid Gears, Nonparallel and Nonintersecting Shafts;284
7.1.4;4.1.4 Gears for Straight Linear Motion;285
7.2;4.2 Standard Injection Molded Thermoplastic Gears;286
7.2.1;4.2.1 Selection of Thermoplastic Resins for Gears;287
7.2.2;4.2.2 Horsepower Equations for Gears;289
7.2.3;4.2.3 Spur Gear Terminology and Definitions;291
7.3;4.3 Properties Required for Injection Molded Thermoplastic Gears;295
7.4;4.4 Thermoplastic Spur Gear Design Requirements;296
7.4.1;4.4.1 Gating Effects on Thermoplastic Gear Roundness Dimensions;298
7.4.2;4.4.2 Multifunction Designs with Thermoplastic Gears;300
7.4.3;4.4.3 Mounting Thermoplastic Gears on Metal Shafts;302
7.4.4;4.4.4 Standard Spur Gears, Equations, and Calculations;302
7.4.5;4.4.5 Spur Gear Pitch Backlash;304
7.4.6;4.4.6 Standard Spur Gear Tooth Size Selection;305
7.4.7;4.4.7 Standard Gear Total Composite Tolerances;306
7.5;4.5 Tolerances and Mold Shrinkage of Thermoplastic Gears;310
7.6;4.6 Standard Helical Gears;312
7.7;4.7 Standard Straight Bevel Gears;313
7.8;4.8 Standard Worm Gears;315
7.8.1;4.8.1 Standard Worm Gear Analysis;316
7.9;4.10 Plastic Gearing Technology Designs;317
7.9.1;4.10.1 Spur and Helical Gears PGT-1 Tooth Design;318
7.9.2;4.10.2 Spur and Helical Gears PGT-2 Tooth Design;320
7.9.3;4.10.3 Spur and Helical Gears PGT-3 Tooth Design;321
7.9.4;4.10.4 Spur and Helical Gears PGT-4 Tooth Design;322
7.9.5;4.10.5 Plastic Gearing Technology Tooth Form Design Variables;323
7.9.6;4.10.6 Maximum Allowable Outside Diameter DO (Max.);325
7.9.7;4.10.7 Spur Gear Tooth Form Comparison;326
7.9.8;4.10.8 Mating Spur Gears Tooth Form Comparison;327
7.9.9;4.10.9 PGT Spur Mating Gears Strength Balance;328
7.9.10;4.10.10 PGT Close Mesh Center Distance Between Spur Gears;331
7.9.11;4.10.11 Maximum Close Mesh Center Distance;332
7.10;4.11 PGT Helical Thermoplastic Gearing;337
7.10.1;4.11.1 PGT-1 Helical Mating Gears Strength Balance;342
7.10.2;4.11.2 PGT-1 Helical Mating Gears Center Distance;345
7.11;4.12 PGT Spur and Helical Gears Horsepower Rating;346
7.11.1;4.12.1 PGT Gear Horsepower Equation Basic Parameters;347
7.12;4.13 PGT Spur and Helical Gear Specifications;351
8;5 Plastic Journal Bearing Design;358
8.1;5.1 Introduction;358
8.2;5.2 Materials Used for Journal Bearings;358
8.2.1;5.2.1 Babbitt Journal Bearings;359
8.2.2;5.2.2 Bronze Journal Bearings;359
8.2.3;5.2.3 Sintered Porous Metal Journal Bearings;359
8.2.4;5.2.4 Plugged Bronze Journal Bearings;359
8.2.5;5.2.5 Carbon-Graphite Journal Bearings;360
8.2.6;5.2.6 Cast-iron Journal Bearings;360
8.2.7;5.2.7 Wooden Journal Bearings;360
8.2.8;5.2.8 Rubber Journal Bearings;360
8.2.9;5.2.9 Self-Lubricated Thermoplastic Journal Bearings;361
8.3;5.3 Hydrodynamics of Lubrication;362
8.4;5.4 Journal Bearings Design for Lubrication;365
8.5;5.5 Journal Bearing Design Principles;368
8.5.1;5.5.1 Journal Bearing Nomenclature and Equations;368
8.5.2;5.5.2 Thermoplastic Journal Bearing Axial Wall Thickness;370
8.5.3;5.5.3 Mounting Thermoplastic Journal Bearings;370
8.6;5.6 Split Bushing Thermoplastic Journal Bearings;371
8.7;5.7 Self-Centering Thermoplastic Journal Bearings;371
8.8;5.8 Journal Bearing Load Carrying Contact Surface (C);373
8.9;5.9 Load Reaction Across the Length of Thermoplastic Bearing;373
8.10;5.10 Injection Molded Journal Bearings Process Defects;374
8.11;5.11 Factors Affecting Journal Bearing Performance;375
8.12;5.12 Factors Affecting Journal Bearing Dimensions;376
8.12.1;5.12.1 Length-to-Inside Diameter Ratio of Journal Bearings;377
8.12.2;5.12.2 Types of Service and Motion of Journal Bearings;377
8.12.3;5.12.3 Thermoplastic Journal Bearing Annealing Effects;377
8.12.4;5.12.4 Acetal Homopolymer Moisture Absorption Effects;378
8.12.5;5.12.5 TFE and Nylon 6/6 Moisture Absorption Effects;378
8.12.6;5.12.6 Temperature Effects on Thermoplastic Journal Bearings;379
8.12.7;5.12.7 Thermal Effects on Thermoplastic Journal Bearing Clearances;380
8.13;5.13 Journal Bearing Pressure-Velocity (PV) Limits;381
8.13.1;5.13.1 Methods to Determine the PV Limits of Plastics;382
8.13.2;5.13.2 Journal Bearing Coefficient of Friction;382
8.13.3;5.13.3 Journal Bearing Failures Due to Small Clearances;383
8.13.4;5.13.4 Definition of Different Types of Wear;384
8.14;5.14 Mating Material Hardness and Surface Finishing;385
8.15;5.15 Self-Lubricated Thermoplastic Journal Bearings;386
8.15.1;5.15.1 Vespel® Polyimide Bearings;389
8.15.2;5.15.2 Journal Bearing Pressure Equation;390
8.15.3;5.15.3 Vespel® Wear Factor Effects Caused by Temperature;391
8.15.4;5.15.4 Vespel® Wear Transition Temperature;392
8.15.5;5.15.5 Frictional Behavior of Vespel®;392
8.15.6;5.15.6 Vespel® Journal Bearings Length to Inside Diameter Ratio;393
8.15.7;5.15.7 Vespel® Thrust Bearing Ratio Between Diameters;393
8.15.8;5.15.8 Vespel® Journal Bearing Initial Clearance (cI);393
8.15.9;5.15.9 Vespel® Journal Bearing Inside Diameter (dB);394
8.16;5.16 Teflon® (TFE) Fabric Composite Bearings;396
8.16.1;5.16.1 Bearing Physical Properties;397
8.16.2;5.16.2 Bearing PV Limit Rating;397
8.16.3;5.16.3 Journal Bearing Clearances (c);398
8.17;5.17 Thermoplastic Kevlar® Reinforced Bearings;398
9;6 Thermoplastic Molded Spring Design;400
9.1;6.1 Introduction;400
9.2;6.2 Thermoplastic Molded Spring Design Considerations;401
9.3;6.3 Thermoplastic Helical Compression Springs;401
9.4;6.4 Thermoplastic Molded Cantilever Beam Springs;402
9.5;6.5 Cantilever Beam Spring Design Analysis;404
9.5.1;6.5.1 Initial Modulus of Elasticity Cantilever Beam Analysis Method;404
9.5.2;6.5.2 Stress-Strain Curve Cantilever Beam Analysis Method;404
9.5.3;6.5.3 Empirical Data Cantilever Spring Analysis Method;405
9.6;6.6 Thermoplastic Cantilever Spring Applications;408
9.7;6.7 Thermoplastic Belleville Spring Washers;411
9.7.1;6.7.1 Acetal Homopolymer Belleville Spring Washer Analysis;412
9.7.2;6.7.2 Belleville Spring Washer Loading Rate;415
9.7.3;6.7.3 Belleville Spring Washer Long-Term Loading Characteristics;415
10;7 Thermoplastic Pressure Vessel Design;416
10.1;7.1 Thermoplastic Thin-Walled Pressure Vessels;416
10.2;7.2 Thin-Walled Cylinder Basic Principles;417
10.3;7.3 Thick-Walled Pressure Vessels;419
10.3.1;7.3.1 Lame’s Equation for Thick-Walled Cylinders;419
10.3.2;7.3.2 Maximum Stresses with Internal and External Pressures;421
10.3.3;7.3.3 Maximum Stresses for Internal Pressure Only;421
10.4;7.4 Designing Cylinders for Cost Reduction;423
10.5;7.5 Thermoplastic Pressure Vessels Design Guidelines;423
10.5.1;7.5.1 Preliminary Pressure Vessel Design;423
10.6;7.6 Testing Prototype Thermoplastic Pressure Vessels;425
10.6.1;7.6.1 Redesign and Retesting the Pressure Vessels;425
10.7;7.7 Pressure Vessel Regulations;425
10.7.1;7.7.1 ASME Pressure Vessel Code;426
11;8 Thermoplastic Assembly Methods;428
11.1;8.1 Introduction;428
11.2;8.2 Cold Heading Method;428
11.2.1;8.2.1 Cold Heading Procedure and Equipment;429
11.3;8.3 Electro Fusion Fitting System;431
11.3.1;8.3.1 The SEF-System;432
11.4;8.4 Hot Plate Welding Method;433
11.4.1;8.4.1 Hot Plate Welding Joint Design;435
11.4.2;8.4.2 Flash or Weld Bead;436
11.5;8.5 Solvent and Adhesive Bonding Methods;436
11.5.1;8.5.1 Solvents Used to Bond Thermoplastic Polymers;437
11.6;8.6 Adhesive Bonding Method;439
11.6.1;8.6.1 Adhesive Families;439
11.6.2;8.6.2 Adhesive Concerns;442
11.6.3;8.6.3 Adhesives Bonding Selection;443
11.6.4;8.6.4 Ultra Violet Curable Adhesives;444
11.6.5;8.6.5 Adhesive Surface Preparation;447
11.6.6;8.6.6 Adhesive Application and Curing Methods;448
11.6.7;8.6.7 Joint Design for Adhesive Bonding;448
11.7;8.7 Metal Fasteners Method;450
11.7.1;8.7.1 Thermoplastic Bosses and Self-Tapping Screws;452
11.7.2;8.7.2 Thread Forming and Thread Cutting Screws;453
11.8;8.8 Press Fitting Method;460
11.8.1;8.8.1 Press Fitting Interference;462
11.8.2;8.8.2 Circular Press Fitting Assembly Method;464
11.9;8.9 Snap Fitting Methods;467
11.9.1;8.9.1 Circular Undercut Snap Fitting Joints;468
11.9.2;8.9.2 Suggestions for Stripping Circular Undercut Snap Fitting;469
11.9.3;8.9.3 Cantilevered Latch Snap Fitting Joint;470
11.9.4;8.9.4 Cantilever Snap Fit Latch Design Guidelines;472
11.9.5;8.9.5 Cantilever Latch Snap Fit Mathematical Model;473
11.9.6;8.9.6 Cantilever Snap Latch Beam Permissible Deflection (?);475
11.9.7;8.9.7 Cantilever Latch Beam Assembly Force (W);476
11.9.8;8.9.8 Design and Material Considerations;477
11.9.9;8.9.9 Uniform Cross Section Cantilever Beam;477
11.9.10;8.9.10 Tapered Cross Section Cantilever Beam;478
11.10;8.10 Electromagnetic Welding Method;481
11.10.1;8.10.1 Electromagnetic Welding Process;482
11.10.2;8.10.2 Electromagnetic Welding Coil Design;483
11.10.3;8.10.3 Electromagnetic Welding Joint Design;486
11.10.4;8.10.4 Available Welding Gasket Shapes and Forms;487
11.11;8.11 Vibration Welding Method;488
11.11.1;8.11.1 High Frequency Vibration Welding;488
11.11.2;8.11.2 Vibration Welding Modes;489
11.11.3;8.11.3 Comparing Vibration Welding to Other Assembly Methods;492
11.11.4;8.11.4 Vibration Welding Equipment;494
11.11.5;8.11.5 Vibration Welding Joint Design;495
11.11.6;8.11.6 Vibration Welding Aligning and Fixturing;496
11.11.7;8.11.7 Vibration Welding Tolerances;497
11.11.8;8.11.8 Vibration Welding Equipment;497
11.12;8.12 Spin Welding Method;499
11.12.1;8.12.1 Applications;499
11.12.2;8.12.2 Basic Spin Welding Equipment;499
11.12.3;8.12.3 Spin Welding Variables;500
11.12.4;8.12.4 Types of Spin Welding Processes;500
11.12.5;8.12.5 Spin Welding Joint Designs;503
11.12.6;8.12.6 Spin Welding Process Suggestions;503
11.13;8.13 Ultrasonic Welding Method;505
11.13.1;8.13.1 Ultrasonic Welding Basic Principles;505
11.13.2;8.13.2 Ultrasonic Welding Basic Components;506
11.13.3;8.13.3 Ultrasonic Welding Equipment;506
11.13.4;8.13.4 Ultrasonic Welding Process Variables;510
11.13.5;8.13.5 Ultrasonic Welding Joint Designs;512
11.13.6;8.13.6 Ultrasonic Welding Energy Director Butt Joint;515
11.13.7;8.13.7 Ultrasonic Welding Method Design Limitations;517
11.13.8;8.13.8 Weldability of Thermoplastic Materials;519
11.13.9;8.13.9 Effects Caused by Thermoplastic Additives on Ultrasonic Welding;520
11.14;8.14 Ultrasonic Insertion;523
11.14.1;8.14.1 Applications;523
11.14.2;8.14.2 Ultrasonic Insertion Configurations;524
11.14.3;8.14.3 Ultrasonic Insertion Product Design;525
11.14.4;8.14.4 Ultrasonic Insertion Equipment Requirements;525
11.14.5;8.14.5 Ultrasonic Insertion Process Guidelines;526
11.15;8.15 Ultrasonic Stud Staking Method;526
11.15.1;8.15.1 Ultrasonic Stud Staking Joint Design;526
11.16;8.16 Ultrasonic Stud Heading Method;529
11.16.1;8.16.1 Thermoplastic Stud Profiles for Ultrasonic Heading;529
11.17;8.17 Ultrasonic Spot Welding Method;532
11.17.1;8.17.1 Hand-Held Ultrasonic Spot Welder;533
12;9 Thermoplastic Effects on Product Design;534
12.1;9.1 Polymer Melt Behavior;534
12.1.1;9.1.1 Thermoplastics Glass Transition Temperature;536
12.2;9.2 General Characteristics of Polymers;536
12.2.1;9.2.1 Critical Properties of Thermoplastics;537
12.3;9.3 Polymer Reinforcements;538
12.3.1;9.3.1 Types of Fiber Reinforcements;539
12.3.2;9.3.2 Isotropic Warpage of Fiber Reinforced Resins;540
12.3.3;9.3.3 Fiber Glass Reinforcement Limitations;540
12.3.4;9.3.4 Injection Molding Process Effects on Fiber Glass Orientation;540
12.3.5;9.3.5 Tensile Stress Effects Caused by Fiber Glass Orientation;541
12.3.6;9.3.6 Flexural Modulus Effects Caused by Fiber Glass Orientation;542
12.4;9.4 Chemical and Environmental Resistance;543
12.4.1;9.4.1 Effects of the Environment;544
12.5;9.5 Types of Degradations;545
12.5.1;9.5.1 Oxidative Degradation;545
12.5.2;9.5.2 Radiation Degradation;545
12.5.3;9.5.3 Photo Oxidation;545
12.5.4;9.5.4 Mechanical Degradation;545
12.5.5;9.5.5 Microbial Degradation;546
12.6;9.6 Moisture Effects on Nylon Molded Parts;546
12.7;9.7 Aqueous Potassium Acetate for Moisture Conditioning Nylon;550
12.8;9.8 Injection Molding Cycles;551
12.9;9.9 Mold Cavity Surface Temperature;552
12.10;9.10 Mold Cavity Temperature Control;553
12.10.1;9.10.1 Mold and Post-Mold Shrinkage;554
12.11;9.11 Process Condition Effects on Mold Shrinkage;556
12.12;9.12 Post-Mold Shrinkage;561
12.13;9.13 Weld Lines;564
13;10 Injection Mold Design;568
13.1;10.1 Classification of Injection Molds;568
13.2;10.2 Effects of Product Design on the Injection Molding Process;569
13.2.1;10.2.1 Uniform Wall Thickness;570
13.2.2;10.2.2 Balance Geometrical Configuration;570
13.2.3;10.2.3 Smooth Internal Sharp Corners;570
13.2.4;10.2.4 Draft Walls;570
13.2.5;10.2.5 Feather Edges;570
13.2.6;10.2.6 Proportional Boss Geometries;571
13.2.7;10.2.7 Gate Type and Location;571
13.2.8;10.2.8 Molded Product Ejection Surface Area;571
13.2.9;10.2.9 Molded Product Tolerances;571
13.2.10;10.2.10 Surface Finish of Molded Product;572
13.3;10.3 Effects of Mold Design on the Injection Molding Process;572
13.3.1;10.3.1 Runner System;572
13.3.2;10.3.2 Mold Cooling System;572
13.3.3;10.3.3 Ejector System;573
13.3.4;10.3.4 Mold Venting;573
13.3.5;10.3.5 Other Mold Devices;573
13.4;10.4 Design Considerations for Injection Molds;573
13.4.1;10.4.1 Preliminary Mold Design;574
13.4.2;10.4.2 Detailed Mold Design;575
13.5;10.5 Types of Steels Required for Injection Molds;576
13.5.1;10.5.1 Major Steel Families;576
13.6;10.6 Steels for Thermoplastic Injection Molds;580
13.6.1;10.6.1 General Steel Selection Procedures;581
13.6.2;10.6.2 Properties and Characteristics of Tool Steels;582
13.6.3;10.6.3 Effects of Alloying Elements on Tool Steel Properties;582
13.6.4;10.6.4 Chemical Composition of Steels Used for Molds;582
13.6.5;10.6.5 Effects of Alloying on Tool Steels;583
13.6.6;10.6.6 Effects of Heat Treatment on Tool Steel Properties;585
13.6.7;10.6.7 Prehardened Tool Steels;587
13.6.8;10.6.8 Carburizing Tool Steels;589
13.6.9;10.6.9 Oil and Air Hardening Tool Steels;590
13.6.10;10.6.10 Stainless Steels;591
13.6.11;10.6.11 Steels Used in Thermoplastic Injection Mold Components;592
13.7;10.7 Mold Cavity Surface Finishing;594
13.7.1;10.7.1 Mold Surface Finishing Process Procedures;596
13.8;10.8 Thermoplastic Injection Mold Bases;601
13.8.1;10.8.1 Standard Mold Base Components;601
13.8.2;10.8.2 Functions of the Mold Base Components;602
13.8.3;10.8.3 Types of Standard Mold Bases;605
13.9;10.9 Types of Thermoplastic Injection Molds;606
13.9.1;10.9.1 Two-Plate Molds;607
13.9.2;10.9.2 Round Mate® Interchangeable Insert Molds;608
13.9.3;10.9.3 Master Unit Die Interchangeable Insert Molds;608
13.9.4;10.9.4 Three-Plate Mold Cold Runner System;609
13.9.5;10.9.5 Vertical Insert Mold for Thermoplastic Encapsulations;610
13.9.6;10.9.6 Hot Runner Molding Systems;611
13.9.7;10.9.7 Hot Runner Mold Temperature Control Systems;612
13.9.8;10.9.8 Hot Runner Mold Gates (Drops);613
13.9.9;10.9.9 Types of Hot Runner Molding Systems;616
13.9.10;10.9.10 Thermoplastic Stack Injection Molds;624
13.9.11;10.9.11 Lost Core Thermoplastic Injection Molds;625
13.10;10.10 Number of Mold Cavities;629
13.10.1;10.10.1 Cavity Number Limitations;629
13.10.2;10.10.2 Number of Mold Cavities Equation;629
13.11;10.11 Mold Parting Line;630
13.11.1;10.11.1 Flat Mold Parting Line;630
13.11.2;10.11.2 Non-Flat Mold Parting Line;631
13.11.3;10.11.3 Balancing of Mold Parting Line Surfaces;633
13.12;10.12 Mold Ejection Systems;633
13.12.1;10.12.1 Ejector Plate Assembly;634
13.12.2;10.12.2 Ejector Plate;634
13.12.3;10.12.3 Retaining Plate;634
13.12.4;10.12.4 Ejector Sleeves;634
13.12.5;10.12.5 Types of Mold Ejection Systems;635
13.13;10.13 Injection Mold Cooling;638
13.13.1;10.13.1 Mold Temperature Control;639
13.13.2;10.13.2 Factors Affecting Mold Cooling;640
13.13.3;10.13.3 Effects Caused by Elevated Mold Temperature;640
13.13.4;10.13.4 Effects Caused by Too Low a Mold Temperature;641
13.13.5;10.13.5 Mold Heat Transfer Methods;641
13.13.6;10.13.6 Mold Cavity Insert Cooling;654
13.14;10.14 Injection Molding Machine Nozzle;662
13.14.1;10.14.1 Mold Cold Runner System;662
13.14.2;10.14.2 Determining the Injection Pressure Needed;676
13.14.3;10.14.3 Cold Runner Flow Tab;677
13.15;10.15 Mold Cavity Gating;678
13.15.1;10.15.1 Types of Mold Cavity Gates;679
13.15.2;10.15.2 Different Types of Hot Runner Gates;686
13.16;10.16 Gate Molding Effects;687
13.17;10.17 Mold Venting Systems;689
13.17.1;10.17.1 Product Design for Venting;690
13.17.2;10.17.2 Venting Characteristics of Thermoplastic Polymers;692
13.17.3;10.17.3 Mold Deposit Problems;692
13.17.4;10.17.4 How to Avoid Venting Problems;693
13.17.5;10.17.5 Planning Mold Venting;694
13.17.6;10.17.6 Mold Venting Process Problems;695
13.17.7;10.17.7 Mold Venting Design;697
13.17.8;10.17.8 Mold Venting Using Sintered Porous Insert Plugs;713
13.17.9;10.17.9 Logic Seal (Negative Coolant Pressure) Mold Venting;714
13.17.10;10.17.10 Mold Cavity Vacuum Venting System;716
13.18;10.18 Mold Cavity Insert Contact Area Strength;721
13.18.1;10.18.1 Cavity Insert Sidewall Strength;722
13.18.2;10.18.2 Methods to Calculate the Strength of Cavity Insert Sidewall;723
13.19;10.19 Mold Layout Case Studies;727
13.20;10.20 Mold Support Pillars;728
13.21;10.21 Tolerances for Thermoplastic Molded Parts;728
13.21.1;10.21.1 Factors Affecting Dimensional Control Tolerances;730
13.22;10.22 General Specifications for Mold Construction for Thermoplastic Injection Molding Resins;732
13.22.1;10.22.1 Mold Design Requirements;732
13.22.2;10.22.2 Mold Drawing Standards;732
13.22.3;10.22.3 Required Types of Tool Steels for Mold Construction;734
13.22.4;10.22.4 Mold Construction Requirements;736
13.23;10.23 Mold Tryout – Debug – Approvals – “MQ1” Requirements;743
13.23.1;10.23.1 Mold Tryout or Evaluation;743
13.23.2;10.23.2 Mold Debug Procedures;743
13.23.3;10.23.3 Approval of Molded Parts and Pre-Production Molding Process;743
13.23.4;10.23.4 Mold Cavity and Core Surface Temperatures;743
13.23.5;10.23.5 “MQ1” Requirements;744
14;11 Performance Testing of Thermoplastics;746
14.1;11.1 Property Data Sheet for Thermoplastics;747
14.2;11.2 Tensile Testing (ASTM D-638);748
14.2.1;11.2.1 Tensile Testing Equipment;748
14.2.2;11.2.2 Tensile Test Specimen;749
14.2.3;11.2.3 Specimen Conditioning;749
14.2.4;11.2.4 Tensile Strength Test Procedures;749
14.2.5;11.2.5 Tensile Modulus and Elongation;750
14.2.6;11.2.6 Molecular Orientation Effects;751
14.2.7;11.2.7 Crosshead Speed Effects;752
14.2.8;11.2.8 Temperature Effects;752
14.2.9;11.2.9 Moisture Absorption Effects;752
14.2.10;11.2.10 Stress-Strain Effects Caused by Creep;753
14.3;11.3 Flexural Testing (ASTM D-790);753
14.3.1;11.3.1 Apparatus;754
14.3.2;11.3.2 Test Procedures and Equations;755
14.3.3;11.3.3 Modulus of Elasticity;756
14.4;11.4 Compressive Strength Testing (ASTM D-695);756
14.4.1;11.4.1 Compressive Testing Apparatus;757
14.4.2;11.4.2 Test Specimens and Conditioning;757
14.4.3;11.4.3 Test Procedures;757
14.4.4;11.4.4 Stress-Strain Tension and Compression Curves;758
14.5;11.5 Shear Strength Testing (ASTM D-732);758
14.5.1;11.5.1 Test Specimen and Apparatus;758
14.5.2;11.5.2 Test Procedures;759
14.5.3;11.5.3 Significance and Limitations;759
14.6;11.6 Surface Hardness Testing;759
14.6.1;11.6.1 Rockwell Hardness Testing (ASTM D-785-60T);760
14.6.2;11.6.2 Barcol Hardness Testing (ASTM D-2583);762
14.6.3;11.6.3 Factors Affecting the Test Results;763
14.7;11.7 Abrasion Resistance Testing (ASTM D-1044);763
14.7.1;11.7.1 Taber Abrasion Testing;764
14.7.2;11.7.2 Theoretical Analysis of Wear;764
14.8;11.8 Coefficient of Friction (ASTM D-1894);765
14.8.1;11.8.1 Coefficient of Friction of Thermoplastic Materials;766
14.8.2;11.8.3 Effects of Lubricants;767
14.9;11.9 Mold Shrinkage Test (ASTM D-955);767
14.9.1;11.9.1 Purpose of the Mold Shrinkage Test;767
14.9.2;11.9.2 Factors Affecting Mold Shrinkage;768
14.9.3;11.9.3 Injection Molding Effects on Shrinkage;768
14.9.4;11.9.4 Requirements for Sampling;768
14.9.5;11.9.5 Test Procedures;769
14.10;11.10 Specific Gravity Testing (ASTM D-792);771
14.10.1;11.10.1 Test Procedures;772
14.11;11.11 Density Gradient Testing (ASTM D-1505);773
14.12;11.12 Water Absorption Testing (ASTM D-570);773
14.12.1;11.12.1 Test Specimen;774
14.12.2;11.12.2 Test Procedure;774
14.13;11.13 Impact Resistance Testing;774
14.13.1;11.13.1 Pendulum Impact Tests;776
14.13.2;11.13.2 Charpy Impact Testing (ASTM D-256);778
14.13.3;11.13.3 Chip Impact Testing;778
14.13.4;11.13.4 Tensile Impact Testing (ASTM D-1822);778
14.13.5;11.13.5 Drop Weight Impact Testing (ASTM D-3029);779
14.13.6;11.13.6 Falling Weight Impact Testing;780
14.13.7;11.13.7 Instrumented Impact Testing;781
14.14;11.14 Creep, Rupture, Relaxation, and Fatigue;784
14.14.1;11.14.1 Tensile Creep Testing;784
14.14.2;11.14.2 Flexural Creep Testing;785
14.14.3;11.14.3 Procedure for Applying Creep Modulus;787
14.15;11.15 Melting Point Test (ASTM D-795);790
14.16;11.16 Vicat Softening Point (ASTM D-1525);790
14.16.1;11.16.1 Melting Point, Glass Transition Temperature;791
14.17;11.17 Brittleness Temperature (ASTM D-746);791
14.17.1;11.17.1 Test Apparatus and Procedures;791
14.18;11.18 UL – Temperature Index;793
14.18.1;11.18.1 Relative Thermal Indices;793
14.18.2;11.18.2 Long Term Thermal Aging Index;795
14.18.3;11.18.3 Creep Modulus/Creep Rupture Tests;796
14.19;11.19 Heat Deflection Temperature (ASTM D-648);797
14.19.1;11.19.1 Apparatus and Test Specimens;797
14.19.2;11.19.2 Test Procedure;798
14.19.3;11.19.3 Test Variables and Limitations;798
14.20;11.20 Soldering Heat Resistance;798
14.21;11.21 Coefficient of Linear Thermal Expansion Testing;799
14.21.1;11.21.1 Test Procedure;800
14.22;11.22 Thermal Conductivity Testing (ASTM C-177);800
14.23;11.23 Melt Flow Testing;802
14.23.1;11.23.1 Moisture Content;803
14.24;11.24 Melt Index Testing (ASTM D-1238);803
14.24.1;11.24.1 Melt Flow Rate;804
14.25;11.25 Capillary Rheometer Melt Viscosity Testing (ASTM D-1703);805
14.25.1;11.25.1 Melt Viscosity vs. Shear Rate Curves;806
14.26;11.26 Electrical Properties Testing;807
14.26.1;11.26.1 Underwriter’s Laboratories (UL) Yellow Cards;808
14.26.2;11.26.2 How to Read and Interpret the “UL Yellow Card”;809
14.26.3;11.26.3 “UL Insulation Systems Recognition”;814
14.27;11.27 Electrical Insulation Properties;815
14.28;11.28 Electrical Resistance Properties;815
14.28.1;11.28.1 Volume Resistivity Testing (ASTM D-257);816
14.28.2;11.28.2 Surface Resistivity Testing (ASTM D-257);817
14.28.3;11.28.3 Dielectric Strength Testing (ASTM D-149);818
14.28.4;11.28.4 Dielectric Constant Testing (ASTM D-150);820
14.28.5;11.28.5 Dissipation Factor Testing (ASTM D-150);823
14.28.6;11.28.6 Arc Resistance Testing (ASTM D-495);824
14.28.7;11.28.7 High Voltage Arc Tracking Rate (UL-746 A);826
14.28.8;11.28.8 Comparative Track Index Testing (ASTM D-3638/UL 746 A).;827
14.29;11.29 Self and Flash Ignition Temperature Testing (ASTM D-1929);828
14.29.1;11.29.1 Test Description;828
14.29.2;11.29.2 High Current Arc Ignition Testing (UL 746A);829
14.29.3;11.29.3 Hot Wire Coil Ignition Testing (UL 746A/ASTM D-3874);830
14.29.4;11.29.4 Hot Mandrel Testing;830
14.29.5;11.29.5 Glow Wire Testing;830
14.30;11.30 Flammability Characteristics of Polymers;832
14.30.1;11.30.1 Inherently Flame Retardant Polymers;833
14.30.2;11.30.2 Less Flame Retardant Polymers;833
14.30.3;11.30.3 Flammable Polymers;833
14.31;11.31 UL 94 Flammability Testing;834
14.31.1;11.31.1 Horizontal Burning Testing, UL 94HB;834
14.31.2;11.31.2 Vertical Burning Testing, UL 94-V0, UL 94-V1, UL 94-V2;835
14.31.3;11.31.3 Vertical Burning Testing, UL 94-5V, UL 94-5VA, UL 94-5VB;836
14.31.4;11.31.4 Factors Affecting UL 94 Flammability Testing;838
14.32;11.32 Limited Oxygen Index Testing (ASTM D-2863);838
14.32.1;11.32.1 Test Procedures;839
14.32.2;11.32.2 Factors Affecting the Test Results;839
14.33;11.33 Smoke Generation Testing;840
14.33.1;11.33.1 Smoke Density Testing (ASTM D-2843);840
14.34;11.34 Weathering Tests for Thermoplastic Materials;841
14.34.1;11.34.1 Weathering Creep Factors (Degradation);841
14.34.2;11.34.2 Ultraviolet (UV) Radiation;842
14.34.3;11.34.3 Temperature;842
14.34.4;11.34.4 Moisture;843
14.34.5;11.34.5 Oxidation;22
14.34.6;11.34.6 Micro-Organisms;843
14.35;11.35 Accelerated Weathering Testing (ASTM G 23);844
14.35.1;11.35.1 Exposure to Fluorescent UV Lamp, Condensation (ASTM G 53);844
14.35.2;11.35.2 Accelerated Weather Testing, Weather-Ometer®;845
14.35.3;11.35.3 Exposure to Carbon Arc Light and Water Testing (ASTM D-1499);846
14.35.4;11.35.4 Exposure to Xenon Arc Light and Water Testing (ASTM D-2565);848
14.35.5;11.35.5 Outdoor Weathering Testing of Thermoplastics (ASTM D-1435);850
14.36;11.36 Fungi Resistance Testing of Thermoplastics (ASTM G 21);851
14.37;11.37 Bacteria Resistance Testing of Thermoplastics (ASTM G 22);852
14.38;11.38 Fungi and Bacteria Outdoor Exposure Resistance Limitations;852
15;12 Thermoplastic Product Cost Analysis;854
15.1;12.1 Injection Molding Process;855
15.2;12.2 Molding Cycle Time;855
15.3;12.3 Material Handling (Regrinds);856
15.4;12.4 Capital Equipment;856
15.5;12.5 Injection Molding Machine Size;856
15.6;12.6 Injection Molding Machine Cost;859
15.7;12.7 Machine Installation and Safety Considerations;860
15.8;12.8 Auxiliary Equipment and Automation;860
15.9;12.9 Mold Cost;861
15.10;12.10 Molded Products Cost Analysis;864
15.10.1;12.10.1 Cost Analysis Basic Method;864
15.10.2;12.10.2 Cost Analysis Graph Method;865
15.10.3;12.10.3 Advanced Cost Analysis Method;866
15.11;12.11 Secondary Molding Operations;871
15.12;12.12 Additional Manufacturing Costs;871
16;Appendix;872
16.1;Acronyms for Polymeric Materials;872
16.2;Common Acronyms;873
16.3;Process Acronyms;874
16.4;Reinforcement and Filler Acronyms;874
16.5;Nomenclature;875
16.6;English and Metric Units Conversion Guide;876
17;Subject Index;878
18;About the Author;892
