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Although designing machines and dies for plastics processing is routinely done with the help of computer modeling and design programs, the results don't always hold up in industrial application. Therefore, it is essential for the designer to have an understanding of the underlying mathematical concepts and their limitations when working with these programs and/or trying to improve their output. This book presents a summary of the most important formulas and their applications to solve design and processing problems with plastics materials. Numerous practical examples guide the reader step-by-step through the computational routine of designing polymer machinery. The approach is unassuming and very practical to enable every engineer to apply these concepts in their daily work and improve their equipment and stabilize their processes.

Tabla de contenidos provista por Syndetics

• Preface(p. V)
• 1 Formulas of Rheology(p. 1)
• 1.1 Ideal Solids(p. 1)
• 1.1.1 Hooke's Law(p. 3)
• 1.2 Newtonian Fluids(p. 3)
• 1.3 Formulas for Viscous Shear Flow of Polymer Melts(p. 4)
• 1.3.1 Apparent Shear Rate(p. 5)
• 1.3.2 Entrance Loss(p. 5)
• 1.3.3 True Shear Stress(p. 6)
• 1.3.4 Apparent Viscosity(p. 7)
• 1.3.5 True Shear Rate(p. 7)
• 1.3.6 True Viscosity(p. 8)
• 1.3.7 Empirical Formulas for Apparent Viscosity(p. 8)
• 1.3.7.1 Hyperbolic Function of Prandtl and Eyring(p. 8)
• 1.3.7.2 Power Law of Ostwald and de Waele(p. 9)
• 1.3.7.3 Muenstedt's Polynomial(p. 11)
• 1.3.7.4 Carreau's Viscosity Equation [11](p. 14)
• 1.3.7.5 Klein's Viscosity Formula [14](p. 16)
• 1.3.7.6 Effect of Pressure on Viscosity(p. 16)
• 1.3.7.7 Dependence of Viscosity on Molecular Weight(p. 17)
• 1.3.7.8 Viscosity of Two Component Mixtures(p. 18)
• 1.4 Viscoelastic Behavior of Polymers(p. 18)
• 1.4.1 Shear(p. 19)
• 1.4.1.1 Linear Viscoelastic Behavior(p. 19)
• 1.4.1.2 Nonlinear Viscoelastic Behavior(p. 23)
• 1.4.2 Uniaxial Tension(p. 25)
• 1.4.2.1 Linear Viscoelastic Behavior(p. 25)
• 1.4.2.2 Nonlinear Viscoelastic Behavior(p. 28)
• 1.4.3 Maxwell Model(p. 29)
• 1.4.4 Practical Formulas for Die Swell and Extensional Flow(p. 31)
• Extensional Flow(p. 32)
• 2 Thermodynamic Properties of Polymers(p. 35)
• 2.1 Specific Volume(p. 35)
• 2.2 Specific Heat(p. 36)
• 2.3 Enthalpy(p. 38)
• 2.4 Thermal Conductivity(p. 40)
• 3 Formulas of Heat Transfer(p. 43)
• 3.1 Steady State Conduction(p. 43)
• 3.1.1 Plane Wall(p. 43)
• 3.1.2 Cylinder(p. 44)
• 3.1.3 Hollow Sphere(p. 45)
• 3.1.4 Sphere(p. 45)
• 3.1.5 Heat Conduction in Composite Walls(p. 46)
• 3.1.6 Overall Heat Transfer through Composite Walls(p. 49)
• 3.2 Transient State Conduction(p. 50)
• 3.2.1 Temperature Distribution in One-Dimensional Solids(p. 51)
• 3.2.2 Thermal Contact Temperature(p. 57)
• 3.3 Heat Conduction with Dissipation(p. 59)
• 3.4 Dimensionless Groups(p. 60)
• 3.4.1 Physical Meaning of Dimensionless Groups(p. 61)
• 3.5 Heat Transfer by Convection(p. 62)
• 3.6 Heat Transfer by Radiation(p. 64)
• 3.7 Dielectric Heating(p. 67)
• 3.8 Fick's Law of Diffusion(p. 69)
• 3.8.1 Permeability(p. 69)
• 3.8.2 Absorption and Desorption(p. 70)
• 4 Designing Plastics Parts(p. 73)
• 4.1 Strength of Polymers(p. 73)
• 4.2 Part Failure(p. 74)
• 4.3 Time-Dependent Deformational Behavior(p. 76)
• 4.3.1 Short-Term Stress-Strain Behavior(p. 76)
• 4.3.2 Long-Term Stress-Strain Behavior(p. 77)
• 5 Formulas for Designing Extrusion and Injection Molding Equipment(p. 81)
• 5.1 Extrusion Dies(p. 81)
• 5.1.1 Calculation of Pressure Drop(p. 81)
• 5.1.1.1 Effect of Die Geometry on Pressure Drop(p. 81)
• 5.1.1.2 Shear Rate in Die Channels(p. 83)
• 5.1.1.3 General Relation for Pressure Drop in Any Given Channel Geometry(p. 83)
• 5.1.1.4 Examples(p. 84)
• 5.1.1.5 Temperature Rise and Residence Time(p. 94)
• 5.1.1.6 Adapting Die Design to Avoid Melt Fracture(p. 95)
• 5.1.1.7 Designing Screen Packs for Extruders(p. 102)
• 5.2 Extrusion Screws(p. 105)
• 5.2.1 Solids Conveying(p. 105)
• 5.2.2 Melt Conveying(p. 109)
• 5.2.2.1 Correction Factors(p. 111)
• 5.2.2.2 Screw Power(p. 111)
• 5.2.2.3 Heat Transfer between the Melt and the Barrel(p. 114)
• 5.2.2.4 Melt Temperature(p. 115)
• 5.2.2.5 Melt Pressure(p. 116)
• 5.2.3 Melting of Solids(p. 118)
• 5.2.3.1 Thickness of Melt Film(p. 118)
• 5.2.3.2 Melting Rate(p. 121)
• 5.2.3.3 Dimensionless Melting Parameter(p. 121)
• 5.2.3.4 Melting Profile(p. 122)
• 5.2.4 Temperature Fluctuation of Melt(p. 125)
• 5.2.5 Scale-up of Screw Extruders(p. 126)
• 5.2.6 Mechanical Design of Extrusion Screws(p. 131)
• 5.2.6.1 Torsion(p. 131)
• 5.2.6.2 Deflection(p. 131)
• 5.3 Injection Molding(p. 133)
• 5.3.1 Pressure Drop in Runner(p. 134)
• 5.3.2 Mold Filling(p. 137)
• 5.3.2.1 Injection Pressure and Clamp Force(p. 137)
• 5.3.3 Flowability of Injection Molding Resins(p. 139)
• 5.3.4 Cooling of Melt in Mold(p. 142)
• 5.3.4.1 Crystalline Polymers(p. 142)
• 5.3.4.2 Amorphous Polymers(p. 145)
• 5.3.5 Design of Cooling Channels(p. 145)
• 5.3.5.1 Thermal Design(p. 145)
• 5.3.5.2 Mechanical Design(p. 149)
• 5.3.6 Melting in Injection Molding Screws(p. 150)
• 5.3.6.1 Melting by Heat Conduction(p. 150)
• 5.3.6.2 Melting during Screw Rotation(p. 151)
• 5.3.7 Predicting Flow Length of Spiral Melt Flows(p. 156)
• A Final Word(p. 163)
• Index(p. 165)
• Biography(p. 169)