Plastics Engineered Product Design

• A comprehensive book which collates the experience of two well-known US plastic engineers.
• Enables engineers to make informed decisions.
• Includes a unique chronology of the world of plastics.

The use of plastics is increasing year on year, and new uses are being found for plastics in many industries. Designers using plastics need to understand the nature and properties of the materials which they are using so that the products perform to set standards.

This book, written by two very experienced plastics engineers, provides copious information on the materials, fabrication processes, design considerations and plastics performance, thus allowing informed decisions to be made by engineers.

It also includes a useful chronology of the world of plastics, a resource not found elsewhere.

Plastics engineers; mechanical engineers; designers; structural engineers and consultants.

Chapter 1 - OVERVIEW
Introduction Materials of Construction
Thermoplastics
Crystalline & Amorphous Polymers
Liquid Crystalline Polymers
Thermosets
Crosslinked Thermoplastics
Reinforced Plastics
Thermal Expansions
Ductilities
Toughnesses
Tolerances/Shrinkages
Compounds
Prepregs
Sheet Molding Compounds
Bulk Molding Compounds
Commodity & Engineering Plastics
Elastomers/Rubbers

Plastic Behaviors
Morphology/Molecular Structure/Mechanical Property
Densities
Molecular Weights
Molecular Weight Distributions
Viscosities and Melt Flows
Newtonian/non-Newtonian
Melt Index
Rheology & Mechanical Analysis
Viscoelasticities
Processing-to-Performance Interface
Glass Transition Temperatures
Melt Temperatures
Processing and Moisture
Drying Operations

Fabricating Processes
Extrusions
Orientations
Postformings
Coextrusions
Injection Moldings
Coinjections
Gas-Assist Moldings
Micromoldings
Blow Moldings
Complex Consolidated Structural Products
Thermoformings
Foams
Reinforced Plastics
Calenders
Castings
Coatings
Compression Moldings
Reaction Injection Moldings
Rotational Moldings

Variables

FALLO Approach

Chapter 2 - DESIGN OPTIMIZATION
Introduction
Terminology

Engineering Optimization
Design Foundation
Problem/Solution Concept
Design Approach
Model Less Costly
Model Type
Computer Software
Design Analysis Approach

Viscoelasticity
Polymer Structure
Viscoelasticity Behavior
Relaxation/Creep Analysis
Summary

Viscosity

Rheology and Mechanical Properties
Hooke's Law

Static Stress
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 Stress
Dynamic/Static Mechanical Behavior
Energy and Motion Control

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
Overview
Stress-Strain Analysis
Plain Reinforced Plates
Composite Plates
Bending 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

Combined Stresses
Surface Stresses and Deformations

Creep

Fatigue

Reinforcement performance

Chapter 4 - PRODUCT DESIGN
Introduction
Reinforced Plastic
Monocoque Structure

Geometric Shape
Modulus of Elasticity
EI theory

Plate
Folded Plate

Beam

Rib
Plastic
Reinforced/Foamed Plastic

Column
Euler's Formula

Torsion

Sandwich
Design

Gear
Contact Stress

Bearing PV Factor

Grommet

Gasket

Shape
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

Spring
Leaf Spring
Special Spring
Cantilever Spring
Torsional Beam Spring

Hinge

Press Fit

Snap Fit

Tape

Packaging
Permeability
Cushioning

Building
House of the Future
House Top

Transportation
Automobile
Truck
Aircraft
Marine Application
Boat
Underwater Hull

Missile and Rocket

Electrical/Electronic
Shielding Electrical Device
Radome

Medical
Surgical Product
Dental Product
Health Care

Recreation

Appliance

Furniture

Water Filter

Lumber

Metal
Metal Replacement with Plastic
Performance Behavior
Moisture Effect
Long Term vs. Short Term Loading
Stress Concentration
Coefficient of Expansion
Bolt Torque Effect
Impact Barrier
Vehicle Oil Pan
Attachment

Design Limitation and Constraint

Chapter 5 - COMPUTER-AIDED DESIGN
Technology overview

Computers and people

Geometric modeling

Design accuracy and efficiency

Input/output device
Central Process Unit

Software
Programs
Databases/General Information
Supply Chain Software

Finite element analysis
Application
Designing
Graphics
Structural Analysis
Software Analysis

Synthesizing design

CAD special use
Optimization
CAD Prototyping
Rapid Prototyping

CAD standard and translator

Data sharing

Engineered personal computer

CAD editing

CIM changing

Computer-based training

IBM advances computer

Artificial intelligence

Plastic Toys-Smart computer

Computer fevices via DNA

Design via internet

Chapter 6 - PLASTIC PERFORMANCE
Overeview
Influencing Factor

Selecting plastic
Comparison
Worksheet

Temperature
Thermal Property
Thermal Conductivity
Thermal Expansion/Contraction
Hyperenvironment

Flammability
Steel and Plastic
Test
Smoke

Electrical/Electronic

Corrosion resistance

Chemical resistance

Friction

Tolerance
Limit
Processing Effect

Recycled plastic

Engineering data information source
Publication
Thomas Register
Industry Societies
Encyclopedia and Industrial Books
Standards
Engineering Information
Information Broker
Engineering Societies and Associations
Designs
Databases
Websites

Training programs

Chapter 7 - DESIGN RELIABILITY
Testing
Classifying Test
Laboratory

Quality Control
Quality and Reliability
Total Quality Management
Quality and Design

Statistics

Testing, QC, statistics and people

Product failure
Spectrum Loading and Cumulative Damage
Crack Growth and Fracture Mechanics
Fatigue and Stress Concentration
Fatigue Loading and Laboratory Testing
Predicting Long Time Reliability

Meaning of Data

Safety Factor
Safety Factor Example

Chapter 8 - SUMMARY AND CHRONOLOGY Overview
Market Size
Customer
Constraint
Responsibility
Responsibility Commensurate with Ability
Risk
Acceptable Risk
Predicting Performance
Design Verification
Perfection
Ethics

Ergonomic

Costing
Technical Cost Modeling

Engineering and law interface

Plastic material

Design demand

Plastic success

Future

Appendix A ABBREVIATIONS
Appendix B GLOSSARY
Appendix C TRADENAMES
BIBLIOGRAPHY