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| موضوع: كتاب Injection Molding Handbook Third Edition الأربعاء 28 مارس 2012, 1:05 am | |
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أخوانى فى الله أحضرت لكم كتاب Injection Molding Handbook Third Edition EDITED B Y DOMINICK V. ROSATO, P. E. DONALDV. ROSATO, PH.D. MARLENE G. ROSATO, P. E.
ويتناول الموضوعات الأتية :
Contents Preface Chapter 1 The Complete Injection Molding Process Introduction Machine Characteristics Molding Plastics Molding Basics and Overview People and Productivity 6; Plastic Materials 6; Morphology and Performance 9; Melt Flow and Rheology 11;Plasticating 12; Screw Designs 14; Molds 15; Processing 16; Process Controls 18; Control Guides 20; Art of Processing 21; Fine Tuning 21 Automatic 22; Semiautomatic22; Manual 22; Primary 23; Secondary 23 Molding Operations Purchasing and Handling Plastics Processors Training Programs Processor Certifications Plastics Machinery Industry Summary Captive 23; Custom 24; Proprietary 24 Chapter 2 Injection Molding Machines Introduction Reciprocating (Single-Stage) Screw Machines Two-Stage Machines Reciprocating vs. Two-Stage Machines Other Machine Types Machine Operating Systems Hydraulic Operations Injection Hydraulic Accumulator 32 Reservoirs 40; Hydraulic Controls 42: Proportional Valves 42;Servovalves 43: Digital Hydraulic Control 43: Hydraulic Fluids and Influence of Heat 44; Pumps 44; Directional Valves 45; Servo and Proportional Valves 46 Electric Motors 47; Adjustable-Speed Drive Motors 47; Servo Drives 47; Microtechnology Moldings 47;Injection Molding: A Technology in Transition to Electrical Power 48 Electrical Operation Hybrid Operations Clamping Systems Clamping Pressures 60; Hydraulic Clamps 61; Toggle Clamps 62; Hydromechanical Clamps 62; Hydroelectric Clamps 63; Comparison of Clamp Designs 64; Tie-bars 64; Tie-barless Systems 69; Platen Systems 71 Barrel Borescoping 72; Barrel and Feed Unit 72; Barrel Heaters 73;Barrel Cooling 74;Barrel Characteristics 75 Barrels Screw Operations Machine Sizes and Design Variations Rebuilding and Repairs Stripping, Polishing, and Plating 79; Machine Downsizing and Upsizing 79 Machine Lockout 80; Machine Safety 81; Identification of Hazards 82; Safety Built into the Machines 82; Current and Former Installations 88; IMM Safety Checklist 88;Safety Rules for Molding Department 88;American National Standard 92; Safety Standards 92; Plasticator Safety 93; Barrel-Cover Safety 93; Plant Safety 93; Safety Information 93 Designing Facilities Upgrading 93; Clean Room 94; Clean Machines Noise Generation Startup and Shutdown Operations Molding Operation Training Program Safety First Stage: Running an IMM 99;The Sequence in a Cycle 102;Second Stage:Parameter Setting and Starting a Job 105 Factors to Consider 113; Operating the Machine 127; Final Stage: Optimizing Molding Production 128; Specification Information, General 130; Specification Information, Details 131; Productivity and People 134; Training Information 136 Shear-Rate-Sensitive and -Insensitive Materials Molding Guide Guide to IMM Selection Terminology Chapter 3 Plasticizing Introduction Plasticators Plastics Melt Flow 154;Barrel Temperature Override 157 Feed Section 157;Transition Section 161; Metering Section 162 Screw Rotation 163; Soak Phenomena 164; Injection Stroke 165; Injection Pressure Required Screw Design Basics 170; Sequence of Operations 172; Advantages of Screw Plasticizing 173; Length-to-Diameter Ratios 173; Compression Ratios 174;Rotation Speeds 175 Screw Sections Elements of the Plasticating Processes Screw Plasticizing Processing Thermoplastics or Thermoset Plastics Screw Actions Mechanical Requirements 177; Torque 177; Torque vs. Speed 177 Injection Rates Back Pressures Melt Performance Melt Pumping Melt Temperature Temperature Sensitivity 179; Temperature Controls Required 179; Barrel Heating 180;Cooling Melt Performance Residence Time Melt Cushions Melt Shear Rate Melt Displacement Rate Shot Size Screw-Barrel Bridging Vented Barrels Recovery Rate 182 Overview 182; Basic Operations 184; BarrelVenting Safety 188 Design Basics 189;Design Performance 189; Mixing and Melting Devices 189;Screw Barriers 193; Specialized Screw Designs 196; Screw Tips 197; Influence of Screw Processing Plastics 201; Melt Quality 202; Materials of Construction 204 Screw Designs Screw Outputs Influence of Screw and Barrel Wear on Output Influence of the Material on Wear 205; Screw Wear 205; Production Variations 205; Screw Wear Inspections 207; Output Loss Due to Screw Wear Chapter 4 207; Screw Replacement 207; Screw Wear Protection 208 Purging Patents Influence Screw Designs Terminology Molds to Products Overview Interrelation of Plastic, Process, and Product 221; Molding Process Windows 221; Cycle Times 223; Molding Pressure Required 224; Products Basics of Melt Flow 225; Mold Filling Hesitation 225; Melt Cushioning 225; Mold Filling Monitoring 225; Sink Marks 226 Processing Plastics Mold Descriptions Mold Basics Mold Optimization Mold Types Computer Systems 235 Molds For Thermosets 238; Mold Classifications Cold-Slug Well 243; Melt Orientation 244; Fill Rates 250; Melt Temperature 250; Mold Temperature 250; Packing Pressure 251; Mold Geometry 251; Flash Guide 251 Plastic Melt Behaviors Cavity Melt Flow Molding Variables vs. Performance Shot-To-Shot Variation Cavities Cavity Melt Flow Analyses 254; Cavity Melt Fountain Flow 254 Machine Size 258; Plasticizing Capacity 258; Economics 258; Cavity Draft 259; Cavity Packing 259; Cavity Surface 259 Contact Area at Parting Line 262 Sprues 263; Runner Systems 264; Gates 277; Gate Summary 287 Correcting Mold Filling Imbalances in Geometrically Balanced Runner Systems Isolating Mold Variations in Multicavity Molds Ejector Systems 293; Ejector Pin Strength 296; Sprue Pullers 300; Side Actions 300; Angle Pins 301;Cam Blocks 302; Stripper-Plate Ejection 302; Cavity Evaluation Clamping Forces Sprue-Runner-Gate Systems Mold Components External-Positive-Return Systems 302; Cam Actuation 303; Sprue Bushing and Locating Ring 303; Ring and Bar Ejection 303; Top-and-Bottom Ejection 304; Inserts 305; Side Guide Slides 307; Ejector Blades 307 Mold Venting Molds for Thermoset Plastics Mold Construction 313; Cold-Runner Systems 314; Injection-Compression Moldings 314 Overview 314; Design Considerations 315; Basic Principles of Heat Flow 317; Heat Transfer by Heat Pipes 321; Heat Balance of Halves 321; Mold Connection for Fluid 321; Cooling Time 321; Cooling with Melt Pulses 322;Flood Cooling 322; Spiral Cooling 322; Cooling Rates 322; Cooling Temperatures 322; Cooling Flow Meters 323 Mold Cooling Undercuts Mold Shrinkages and Tolerances Ejection of Molded Products Mold Release Agents Mold Materials of Construction Shrinkage vs. Cycle Time 329 Steels 334; Heat Treating 342; Requirements to be Met by Mold Steel 342; Aluminum 343; Beryllium-Copper 343; Kirksite 343; Brass 343 Etching Cavity Surfaces Machining Safety Moldmaker Directory Mold Material Selection Software Fabrication of Components Hobbing 346; Cast Cavities 346; Electroforming 346; Electric-Discharge Machining 346 Tooling Polishing SPI Finish Numbers 348; Hand Benching 349; Direction of Benching 350; Ultrasonic Tools 351; Textured Cavities 351; Patterns of Different Textures 351; Mold Steels 352; Conditions Required for Polishing 352 Nickel 355; Chrome 355; Nitriding and Carburizing 356; Other Plating Treatments 357; Coating Treatments 357; Heat Treatments 358 Overview 359;Manual Cleaning 362;Oven Cleaning 362; Solvent Cleaning 362; Triethylene Glycol Cleaning 363; Postcleaning 363; Salt Bath Cleaning 363; Ultrasonic Solvent Cleaning 363; Fluidized-Bed Cleaning 363; Vacuum Pyrolysis Cleaning 363 Platings, Coatings, and Heat Treatments Cleaning Molds and Machine Parts Chapter 5 Strength Requirements for Molds Stress Level in Steel 364;Pillar Supports 365;Steel and Size of Mold Base 366 Mold Filling 367; Deflection of Mold Side Walls 368 Eyebolt Holes Quick Mold Change Mold Protection Preengineered Molds Standardized Mold Base Assemblies Specialty Mold Components Collapsible and Expandable Core Molds Prototyping Deformation of Mold Automatic Systems 374; Heavy Molds 374 Overview 387; Stereolithography 387; Rapid Tooling 388 Introduction 389; Industry Guide 389; Purchase Order 390;Mold Design 390; Production of Molds Buying Molds Mold Storage Computer-Aided Mold and Product Design Production Control Systems Computer Monitoring of Information Productivity and People Value Analyses Zero Defects Terminology Fundamentals of Designing Products Overview Molding Influences Product Performance Design Optimization Material Optimization Material Characteristics Behavior of Plastics Molding Tolerances Computer Analysis 422 Thermal Stresses 437; Viscoelastic Behavior 437 Tolerances and Designs 443; Tolerance Allowances 443; Tolerances and Shrinkages 444; Tolerances and Warpages 444; Thin-Wall Tolerances 444; Micron Tolerances 444; Tolerance Damage 444; Full Indicator Movements (FIMs) 444; Tolerance Selection 444; Tolerance Stack-Ups 445; Standard Tolerances 445 Tolerance Measurement and Quenching Dimensional Properties Dimensional Tolerances Product Specifications 449; Using Geometric Tolerancing Chapter 6 Design Features That Influence Performance Plastics Memory Residence Time Computerized Knowledge-Based Engineering Orientation Accidental Orientation 453; Orientation and Chemical Properties 453; Orientation and Mechanical Properties 454; Orientation and Optical Properties 454;Orientation Processing Characteristics 454; Orientation and Cost 454 Molecular Orientation: Design of Integral Hinges Interrelation of Material and Process with Design Design Shapes Shapes and Stiffness Stress Relaxation Predicting Performance Choosing Materials and Design Design Concept 458; Engineering Considerations Design Parameters 460; Types of Plastics 460 Designing with Creep Data 463;Allowable Working Stress 465; Creep Behavior Guidelines 466 Stapler 466; Snap-Fits 467; Springs 467 Design Considerations Long-Term Behavior of Plastics: Creep Design Examples Design Approach Example Design Accuracy Risks and the Products Acceptable Risks 472; Acceptable Goals 473; Acceptable Packaging Risks 473; Risk Assessments 473; Fire Risks 473; Risk Management 473; Risk Retention 473 Perfection Cost Modeling Innovative Designs Protect Designs Summary Terminology Molders’ Contributions 476 Molding Materials Overview Definition of Plastics 484; Heat Profiles 488; Costs 489; Behavior of Plastics 490; Checking Materials Received 491 Neat Plastics Polymer Synthesis and Compositions Copolymers Interpenetrating Networks Graftings Polymerization Reactive Polymers Compounds Additives 501; Fillers 502; Reinforcements 502; Summary 502 Alloys and Blends Thermoplastic and Thermoset Plastics Thermoplastics 511; Thermoset Plastics 511; Cross-Linking 512;Cross-Linking Thermoplastics 512;Thermoplastic Vulcanizates (TPVs) 512;Curing 512; Heat Profiles 513 Liquid Crystal Plastics (LCPs) Elastomers, Thermoplastic, and Thermoset Thermoplastic Elastomers 515; Thermoset Elastomers 515; Natural Rubbers 515; Rubber Elasticity 515; Rubber Market 515 Commodity and Engineering Plastics Injection Molding Thermoplastics and Thermosets High Performance Reinforced Moldings Injection Moldings 518; Bulk Molding Compounds (BMCs) 518; Characterizations 519; Directional Properties 521 Newtonian Flow 522; Non-Newtonian Flow 523 Viscosities Viscoelasticities Plastic Structures and Morphology Chemical and Physical Characteristics 524; Crystalline and Amorphous Plastics 524; Catalysts and Metallocenes 526; Plastic Green Strength 527 Average Molecular Weight 527;Molecular Weight Distribution 529; Additives 529; Molecular Weight and Melt Flow 530;Molecular Weight and Aging 530 Flow 531; Viscosity 531; Viscoelasticity 532; Intrinsic Viscosity 533;Shear Rate 533;Laminar and Nonlaminar Melt Flows 535; Melt Flow Analyses 535;Melt Flow Analysis Programs 535;Analyzing Melt Flow Results 536; Melt Flow Defects 536; Hindering Melt Flow with Additives 536; Melt Fractures 536 Molecular Weight ( M W ) Rheology and Melt Flow Cavity Filling Plastic Raw Materials Plastic Advantages and Disadvantages Plastic Properties and Characteristics Weld Line Strengths and Materials Material Selections Colorants 548; Concentrates 549; Barrier Plastics 549 Melt Shear Behaviors 537 ASTM 4000 Standard Guide for Plastic Classifications Thermal Properties and Processability Melt Temperatures 554; Glass Transition Temperatures 555; Dimensional Stabilities 555;Thermal Conductivities and Thermal Insulation 556; Heat Capacities 556; Thermal Diffusivities 556; Coefficients of Thermal Expansion 556; Thermal Stresses 556 Shrinkages Drying Material Handling Annealing Recycling Recycled Plastic Definitions 559; Recycled Plastic Identified 560; Recycled Plastic Properties 560; Recycling Size Reductions 560; Recycling Mixed Plastics 560; Integrated Recycling 560;Recycling Methods and Economic Evaluations 560; Recycling and Lifecycle Analysis 561; Recycling Commingled Plastics 561; Recycling Automatically SortingPlastics 561;Recycling and Common Sense 561; Recycling Limitations 561 Recycling Facts and Myths Warehousing Storage and Condensation 562; Material Storage 562; Silo Storage 562 Processing Different Plastics Polyethylenes Molding Conditions 564; Materials 565; Molding Test Results 565 Molding Conditions 570 Molding Conditions 573; Purging 574; Shutdown and Start-up574;Thermal and Rheological Properties 574; Drying 574; Mechanical Properties 575;Chemical Resistance 575;Weatherability 575; Color 575 Formulations 576;Molding Conditions 576;Screw Design 577; Material Handling Equipment 578; Processing Parameters 579; Problem Solving 579; Splay 579 Molding Conditions 581; Performance Parameters 585; Design Parameters 586; Molding Performance Parameters 591; Mold Release 593; Close Tolerance: Fast Cycles 595; Recycling Plastics 596 Molding Variables and Cause-and-Effect Links 597; Molding Variables and Property Responses 599; Appearance Properties 599; Warping 600; Polypropylenes Copolyesters Polyvinyl Chloride Nylons ABSs (Acrylonitrile-Butadiene-Styrenes) Chapter 7 Mechanical Properties and Molding Variables 601; Izod impact 602; Molding for Electroplating 605; Property Variation with Position Mold Geometry 605; Summary 606 Drying 606; Recycle and Virgin Proportions 607; Processing 608; Hydrolysis 609; Rheology 609; Heat Transfer 609;Residual Stress 610;Annealing Process 613; Hot- and Cold-Runner Molding 614; Material Stuffer 615 Polycarbonates Injection Molding Thermosets Energy Considerations Summary Terminology Process Control Process Control Basics Developing Melt and Flow Control 630; Inspection 630;Computer Process Data Acquisition 630; Control Flow Diagrams 632; Fishbone Diagram Technology 636; Fast Response Controls 638; Control Approaches 639; Process Control Methods 640;Production Monitoring 640;On-Machine Monitoring 641 Overview Temperature Control of Barrel and Melt Electronic Controls Fuzzy Logic Control Process Control Techniques Process Control Approaches What Are the Variables? 652; Why Have Process Control? 654; Control of Which Parameters Can Best Eliminate Variability? 654; What Enables Parameter Controllability? 657; Where Does the Process Controller Go? 661;BasicFeatures a Process Controller Should Have 662; Applications 664; Summary 666 Process Control Problems Cavity Melt Flow Analyses Problem 669;Melt Viscosities versus Fill and Pack 669; Test Methodology 670; Analyzing Results 673;Example Test 673;Using Empirical Test Data to Optimize Fill Rates 674; Melt Vibrations during Filling 675; Stabilizing via Screw Return Time 675 Sensor Requirements 676; Molding Parameters 676; Display of Monitored Molding Parameters Relating Process Control to Product Performances 678; Machine Controls 678; Microprocessor Advantages 679 Functions 680; Rotary and Linear Motion 680 Optimization via PVT 681; PMT Concept 683 Designs 684 Types of Instruments Adaptive Control: PVT and PMT Concepts Controllers Sensor Control Responses Transducers Linear Displacement Transducers 685;Linear Velocity Displacement Transducers 686; Pressure Transducers 686; Transducer Calibrations 686; Transducer Environments 686 Transputer Controllers Temperature Controllers Temperature Variations 688; Melt Temperature Profiles 690; Automatic Tuning 691; Temperature Sensors 691;Fuzzy Logic Controls 692;Fuzzy-PID Controls 692 Temperature Timing and Sequencing Pressure Controls Pressure PID Controls Screw Tips 692; Cavity Fillings 692 PID Tuning: What It Means 693; The Need for Rate Control on High-speed Machines 694 Fuzzy-Pressure Controls Injection Molding Holding Pressures Process Control Fill and Pack Process Control Parameter Variables Injection Molding Boost Cutoff or Two-Stage Control Injection Molding Controller Three-Stage Systems Mold Cavity Pressure Variables Programmed Molding Adaptive Ram Programmers 696 Three-Stage Systems 701 Parting Line Controls 702; Computer Microprocessor Controls 703; Computer Processing Control Automation 703 Molding Thin Walls Control System Reliabilities Operations Optimized Control Tradeoffs Process Control Limitations and Troubleshooting Control 705; Tie-Bar Growth 706; Tie-Bar Elongation 706; Thermal Mold Growth 706; Shot-toShot Variation 706 Intelligent Communications 709; Systematic Intelligent Processing 710 Intelligent Processing Processing Rules Processing and Patience Processing Improvements Control Advantages Automatic Detections Terminology Plantwide Control and Management 713 Chapter 8 Design Features That Influence Product Performance Overview Audits 717; Computer Approaches 717; Design Feature That Influence Performance 718 Plastic Product Failures Design Failure Theory Basic Detractors and Constraints Tolerance and Shrinkage 721;Residual Stress725; Stress Concentration 726; Sink Mark 727 Design Concept Terminology Sharp Corners Uniform Wall Thickness Wall Thickness Tolerance Flow Pattern Parting Lines Gate Size and Location Taper or Draft Angle Weld Lines Vent, Trapped Air, and Ejector Undercuts Blind Holes Bosses Coring Press Fits Internal Plastic Threads External Plastic Threads Molded-In Inserts Screws for Mechanical Assembly Gears Ribs Geometric Structural Reinforcement Snap Joints Integral Hinges Mold Action Meld Lines 740 Chapter 9 Computer Operations Overview Communication Benefits 773; Computerized Databases of Plastics 775; CAD/CAM/CAE Methods 775; Computer-Integrated Manufacturing Benefits of CAD/CAM/CAE for Mold Design Productivity 776; Quality 777; Turnaround Time 778; Resource Utilization 778 Mechanical Design 779; Computer-Aided Engineering 780 Product Designers 783; Mold Designers and Moldmakers 784; Injection Molders 785 Multisections 789;Finite Element Techniques790; Shrinkage and Warpage 791; Benefit Appraisal 795; Moldflow Basic Technology 795 Introduction 796; Fundamentals 799; Mold Cool Analysis 801 Modeling Methods Applied to Part and Mold Design Wire Frame Modeling 824;Surface Modeling 826; Solids Modeling 828 Group Technology 829; Finite Element Modeling 830;Digitizing 831;Layering 832;Groups 833; Patterns 833; Large-Scale Geometry Manipulation 833; Local Coordinates or Construction Planes 834; Model and Drawing Modes and Associativity 834;Verificationof Geometric Relationships 835; Automatic Dimensioning and Automatic Tolerance Analysis 836; Online Calculation Capabilities and Electronic Storage Areas Illustration of Mold Design Process The Manual (Paper) Method 837 The CAD/CAM/CAEMethod Online Databases Basics in CAD/CAM/CAEModeling Mold Flow Analysis Basic Melt Flow Analysis Mold Cooling Computer Capabilities for Part and Mold Design The Database Concept 843; Graphics Databases 844; Defining the Library Database 845 Tolerances and Dimensional Controls Computer Controllers CAD/CAM/CAE and CIM Numerical Control Process Programmable Controller Safety Devices Computer Optical Data Storage Artificial Intelligence Computers and People Computer-Based Training Myths and Facts Capability and Training Computer Software Molding Simulation Programs RAPRA Free Internet Search Engine Software and Database Programs Injection Moldings and Molds 856: Materials 857; Shrinkage 858; Materials and Designs 859; Design Products 860: Engineering 861; Graphics 861; Management 862: General Information 862; Training 862 Plastics,Toys, and Computer Limitations Computers Not Designed for Home Summary Terminology Chapter 10 Auxiliary Equipment and Secondary Operations Introduction Energy Conservation 870; Planning Ahead, Support Systems 871 Hoppers 871; Material Handling, Feeding, and Blending 872; Material Handling Methods 872: Sensors 874 Bulk Density 875; Basic Principles of Pneumatic Conveying 876;Air Movers 883; Pneumatic Venturi Conveying 886; Powder Pumps 886; Piping 888; Hoppers 889; Filters 889; Bulk Storage 891; Blenders 891; Unloading Railcars and Tank Trucks 894 Nonhygroscopic Plastics 895; Hygroscopic Plastics 895;Drying Overview 895;Dryers 896 Overview 904; Heat-Transfer Calculations 905; Requirements Varywith Materials905;Water Recovery 907;General considerations 908;Calculation of the Cooling Load 911;Determining Water Loads 913 Overview Materials Handling Drying Plastics Water Chilling and Recovery Energy-SavingHeat Pump Chillers Granulators Safety 916; Basics 917; Hoppers 917; Cutting Chambers 918; Cutting Chamber Assembly 921; Hard Face Welding 921; Screen Chambers 922; Auger Granulators 922; Granulating and Performance 924 Dewpoints 929; Mold Surface Temperatures 929; Effect of Changein Air Properties930;Air Conditioning and Desiccant Dehumidification 931;DehumidificationSystem 932 Controlled Motions 933; People and PHE 935; DifferentTypes935;Value in Use 937;Detriments 938: Robots Performance 938; Safety Measures 938 Mold Dehumidification Parts-Handling Equipment Chapter 11 Machining Overview 939;Plastic Characteristics 939; Cutting Guidelines 940 Adhesives 941; Solvents 946; Welding Techniques 948; Welding Process Economic Guide 953 Abrasives 953; Carbon Dioxide 953; Cryogenic Deflashing 954; Brass 954; Hot Salts 954; Solvents 954; Ultrasonics 954;Vacuum Pyrolysis 954; Coatings 955 Potential Preparation Problems 955; Pretreatments 959; Removing Mold Release Residues Robot Terms 966 Joining and Assembling Cleaning Tools Finishing and Decorating Terminology Troubleshooting and Maintenance Troubleshooting Introduction Definitions Remote Controls Troubleshooting Approaches Shrinkages and Warpages Weld Lines Troubleshooting Guides Flashes Injection Structural Foams Hot-Runners Hot-Stamp Decorating Paint-Lines Granulator Rotors Auxiliary Equipment Screw Wear Guide Plastic Material and Equipment Variables 970 Defects 972 Finding the Fault 976 Counterflow 979 Inspection Rollers 1010;Diameters 1010;Depths 1011;Concentricity and Straightness 1011;Hardness 1011; Finish and Coating Thickness 1012; Screw Manufacturing Tolerances 1012 Inside Diameters 1012;Straightness and Concentricity 1012; Barrel Hardness 1012;Barrel Specifications 1012 Cleaning the Plasticator Screw 1014;Oil Changes and Oil Leaks 1015; Checking Band Heaters, Thermocouples, and Instruments 1015; Alignment, Level, and Parallelism 1015; Hydraulic, Barrel Inspection Guide Preventive Maintenance Chapter 12 Pneumatic, and Cooling-Water Systems 1015; Hydraulic Hose 1016 Keep the Shop Clean Keep Spare Parts in Stock Return on Investment Maintenance Hydraulic Fluid Maintenance Procedures 1020; Problems and Solutions 1020;Downtime Maintenance 1021:Preventative Maintenance 1021; Services 1022 Safety Maintenance Software Summary Terminology Testing, Inspection, and Quality Control Testing Design and Quality Basic versus Complex Tests Sampling Acceptable Quality Level 1032; Sampling Plan 1032;Sampling Size 1033 Orientation and Weld Lines 1033; Density and Specific Gravity 1035; Morphology: Amorphous and Crystalline Plastics 1036; Molecular Structures 1037 Mechanical Test Equipment 1042; Tensile Test 1042; Deflection Temperature under Load 1045; Creep Data 1045 Characterizing Properties and Tests Mechanical Properties Electrical Tests Thermal Properties Chemical Properties Chromatographic and Thermal Tests Liquid Chromatography 1049; Gel Permeation Chromatography 1049: Gas Chromatography 1050;Ion Chromatography 1050; Thermoanalytical Method 1051; Thermogravimetric Analysis 1051; Differential Scanning Calorimetry 1052; Thermomechanical Analysis 1053;Dynamic Mechanical Analysis 1054; Infrared Spectroscopy 1054: X-Ray Spectroscopy 1055; Nuclear Magnetic Resonance Spectroscopy 1055;Atomic Absorption Spectroscopy 1055;Raman Spectroscopy 1055; Transmission Electron Microscopy 1056; Optical Emission Spectroscopy 1056;Summary of Characterizing Properties 1056 Selected ASTM Tests 1062; Viscoelastic Properties 1079; Rheology, Viscosity, and Flow 1080; Types of Tests Online Viscoelastic Measurements for Plastics Melt Processes 1080 Optical Analysis via Microtoming Thermal Properties Useful Temperature Range 1084;Glass Transition and Melt Temperatures 1084; Thermal Conductivity 1086; Heat Capacity 1086; Coefficient of Linear Thermal Expansion 1086; Temperature Dependence of Mechanical Properties 1089;Diffusion and Transport Properties 1091;Permeability 1091;Migration 1092 Overview of Plastic Properties Melt Tests Melt Flow Tests 1095;Melt Index Test 1095;Melt Index Fractional Tests 1098;Molding Index Tests 1098;Measurements 1098 Types of Scales 1099 Radiography 1099;Ultrasonics 1100;Liquid Penetrants 1100; Acoustics 1100;Photoelastic Stress Analysis 1100;Infrared Systems1101; Vision System Inspections 1101; Computer Image Processors 1102 Temperature Scales Nondestructive Tests Computer Testing Drying Hygroscopic Plastics Laboratory Organizations Worldwide Determining Moisture Content 1103 American Societyfor Testing and Materials 1105; International Organization for Standardization 1105; Underwriters’ Laboratory Classifications International System of Units Inspections Identification of Plastics Estimating Plastic Lifetimes Quality Control Quality Control Defined 1110; Quality Control Variables 1110 No More ABCs 1112; Need for Dependability 1112;Quality Auditing 1112 QC Begins When Plastics Are Received Reliability and Quality Control Failure Analysis Quality Control Methods Quality Control and Quality Assurances Auditing by Variables Analysis Acceptable Quality Levels Quality Optimization Goals Quality System Regulation Image Quality Indicators Total Quality Management Training and People Training and Quality Emerging Trends in Training Training versus Education Economic Significanceof Quality Terminology Cost of Quality 1119 Chapter 13 Statistical Process Control and Quality Control Overview Combining Online SPC and Offline SQC 1127; Improve Quality and Increase Profits1128;Statistical Material Selections: Reliabilities 1128; Statistical Material Selections: Uncertainties That Are Nonstatistical 1129; Statistical Probabilities and Quality Control 1129;Statistics and Commitments 1129;Statistics and Injection Molding 1129 Computers and Statistics 1131; Statistical Tools Online Monitoring of Process Variables Gathering and Analyzing Data Process Control and Process Capability Defect Prevention Understanding Modern Methods of Control Control Charts 1138 Standard Deviations 1142; Frequency Distribution 1143;Control Chart 1145 Standard Deviation versus Range Basic Statistical Concepts Mean Value, Range, and Standard Deviation 1148; Distribution 1149; Process Control Chart 1150;Machine Capability 1150;Process Capability 1150 Importance of Control Charts Practical Example Machine Capability 1153; Process Capability 1153; Control Limits for the Process Control Chart 1154 Production Controls 115.5; SPC Step One: Raw Material 1156; SPC Step Two: Materials Handling 1156; SPC Step Three: Injection Molding 11.56;SPC Implementation: Summary of Experience 1156 How to Succeed with SPC Outlook Terminology A Successful SPC System Chapter 14 Costing, Economics, and Management Overview Machine Sales 1163;Formulas for Business Failures 1164;Managing 1164 Estimating Part Cost 1167; Automation of Data Gathering 1169; Machinery Financing 1169; Energy Savings 1170 Costing Technical Cost Modeling Cost Analysis Methods Material TimesTwo 1171;Material Cost plus Shop Time 1172;Material Cost plus Loaded Shop Time 1172;Quotes 1172 Variable Cost Elements 1173; Fixed Costs 1174; Summary of Fixed and Variable Costs 1177;Process Parameters 1178; Technical Cost Modeling 1178;Summary of Technical Cost Analysis 1179 Technical Cost Analysis Financial Plant Management Cost Management Information Necessary for Product Costing and Cost Control 1182; Reporting from the Production Floor and Management Control Reports 1183 Gathering the Data for Profit Planning and Budgeting 1186;Establishing Profit, Goals, and Sales Forecasts 1186; Developing the Detailed Plans and Budgets 1187;Flexible Budgeting 1187 Order Processing 1188; Inventory Control 1189; Production Scheduling and Control 1189; Scheduling Approaches 1190;Purchasing 1191 Profit Planning and Budgeting Materials Management Terminology Chapter 15 Specialized Injection Molding Processes Introduction Blow Moldings Injection Blow Moldings 1201; Stretched Blow Moldings 1204; Stretched Blow Moldings with Handle 1206;Stretched Blow Molding Operation Specialties 1207;Blow Molding Shrinkages 1209; Troubleshooting 1211; Blow Molding versus Injection Molding 1215 Coinjection Molding Injection Molding Sandwich Structures Gas-Assist Injection Molding Advantages and Disadvantages 1220; Basic Processes and Procedures 1220; Molding Aspects 1223;Shrinkage 1224;Summary Gas Counterflow Molding Melt Counterflow Molding Structural Foam Molding Overview 1225;Performance 1226;Plastic Materials 1226; Characteristics of Foam 1226; Design Analysis 1227; Blowing Agents 1229; Methods of Processing SF with Chemical Blowing Agents 1230; Processing SF with Gas Blowing Agents 1232;Tooling 1234;Start-up for Molding 1234 Injection-Compression Molding (Coining) Multiline Molding Counterflow Molding Oscillatory Molding of Optical Compact Disks Continuous Injection Molding Digital Video Disk Moldings 1238 Velcro Strips 1239;Electrically Insulated Buttons for Coaxial Cables 1242;Railtrack Molding 1243 The Mold 1248;Process Controls 1249 Reaction Injection Molding Liquid Injection Molding Soluble Core Molding Insert Molding Inmolding Two-Color Molding 1253;Decoration 1253;Paint Coating 1254; Back Molding 1254; Two-Shot Molding 1254;Inmold Assemblies 1254;DoubleDaylight Process 1255 Overmolding Compatible Plastics with No Welding Closure Moldings Unscrewing Closures 1256; Conventional Unscrewing Molds 1256; Unscrewing System Moldings 1256; Collapsible and Expandable Core Molds 1257; Split-Cavity Molds 1258; Strippable Thread Molds 1258 Vacuum Molding Tandem Injection Molding Molding Melt Flow Oscillations Ram Injection Molding Golf Ball Moldings Micro Injection Molding Aircraft Canopies Injection Molding Nonplastics Introduction 1266;Metal Injection Molding 1266; Ceramic Injection Molding 1268 Terminology Chapter 16 Injection Molding Competition Introduction Plastic Fabricating Processes Rotational Molding Extrusions Chapter Extrusion Blow Moldings Formings Thermoforming Cold Forming Cold Draw Forming Dip Forming Pressure Forming Rubber Pad Forming Compression-Stretched Moldings Solid-Phase ScraplessForming Solid-Phase Pressure Forming Slip Forming Castings Foam Molding Expandable Plastics Compression Molding Transfer Molding Reinforced Plastics Molds 1291 Expandable Polystyrenes 1294 Laminates 1297 Screw Plunger Transfer Molding 1298 Directional Properties 1301;Processes and Products 1301 Stampable Reinforced Plastics Machining Plastics Processor Competition Legal Matters Accident Reports 1304;Acknowledgments 1304; Chapter 11 Act 1304; Conflicts of Interest 1304;Consumer Product Safety Act 1304; 1305; Defendant 1305; Employee Invention Assignment 1305; Expert Witness 1305; Insurance Risk Retention Act 1305; Invention 1305; Mold Contractional Obligation 1305;Patent 1305;Patentability 1306;Patent Information 1306; Patent Infringement 1306; Patent Pooling with Competitors 1306; Patent Search 1306; Patent Term Extension 1306; Patent Terminology 1306; Plaintiff 1306;Processor, Contract 1307;Product Liability Law 1307; Protection Strategies 1307; Quotations 1307; Right-To-Know 1307; ShopRight 1307; Software and Patents 1307; Tariff 1307; Term 1307;Tort Liability 1308;Trademark 1308;Trade Name 1308;Warranty 1308 17 Summary The Most Important Forming Technique Processing Trends Productivity Machine Aging 1315;Response to Change Process and Material Selections Plastics and Equipment Consumption Machinery Sales Trends in Machinery 1318;Computers and Injection Molding 1320; Interfacing Machine Performance 1320 Molding in an Industrialized Country Compromises Must Frequently Be Made Standard Industrial Classification Plastic Industry Size Energy and Plastics Plastic Data: Theoretical Versus Actual Values Markets Packaging 1325; Velcro for Flexible Packaging 1327; Building and Construction 1327; Lumber 1327;Pallets 1327;Automotive Parts 1329;Printed Circuit Boards and Surface Mounted Technology 1330; U.S. Postal Service 1330; Medical Applications 1330;Toilets and Water Conservation 1330; Bearings 1330; Blow Molding Innovations 1330; Beer Bottles 1331; Collapsible Squeeze Tubes 1331;Asthma Inhalers 1331 Automated Production 1334;Energy Savings 1335 Discipline 1337; Productivity 1338; Experience 1338;Plant Controls 1338 Example 11339;Example 2 1339;Example 3 1340 Myths and Facts 1341; Limited Oil Resources 1342; Limited US. Steel Resources 1342; Plastic Advocates 1342 Statistics: Fact and Fiction 1344;Landfill 1345;Recycling 1345;Incineration 1345;Degradable 1346 Economic Control of Equipment Management and People Analysis of Plastics Affecting Business Strategies Correcting Misperceptions about Plastics Solid Waste Problem and Product Design Solutions Analyze Failures Creativity Innovations and the Markets 1348;Industrial Designers 1348;Da Vinci’s Creativity 1348 Target for Zero Defects 1349 Design Successes Excess Information: So What’s New? Fabricating Employment History Barrel History 1351; Hopper Magnet 1352; Blow Molding 1352; Coca-Cola Bottle 1353; Coor’s Beer Bottle 1353;Recycling History 1353; Squeeze Tube 1353;Zipper 1353;Waste Containers 1354; Shotgun Shells 1354; Water Treatment Profits Plastics, Cradle-to-Grave Future for Injection Molded Plastics Injection Molding in the Forefront Summary Profits and Time 1354 Appendices 1. Abbreviations 2. Conversions 3. Symbols and Signs 4. Web Sites on Plastics References About the Authors Index 1413
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