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