كتاب Rotational Molding Technology

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Rotational Molding Technology

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INTRODUCTION TO ROTATIONAL MOLDING
Introduction
The Process
The Early Days
Materials
Advantages and Disadvantages
General Relationships between Processing Conditions and
Properties
References
ROTATIONAL MOLDING POLYMERS
Introduction
General Characteristics of Polymers
Polymers as Powders and Liquids
Polyethylene Types
Low-Density Polyethylene
Medium-Density Polyethylene
High-Density Polyethylene
Linear Low-Density Polyethylene
Ethylene Vinyl Acetate
Polypropylene
PVC Plastisols, Drysols, and Powdered Flexible Compounds
Nylons
Other Polymers
Polycarbonate
Cellulosics
Acrylics
Styrenics
Liquid Polymers
PVC Plastisols
Polycaprolactam
Polyurethane
Unsaturated Polyester Resin
Silicones
In-Coming Material Evaluation
Melt Index and Melt Flow Index
Sieving
Product Testing Protocols and Relationship to Polymer
Characteristics
Actual Part Testing Protocol
Actual Part Testing Entire Parts
Actual Part Testing Sections
Molded Part Density
Drop Tests
ASTM Tests for Mechanical Properties
Color
Chemical Tests
Environmental Stress Crack Test
Chemical Crosslinking and the Refluxing Hexane Test
Weathering
Odor in Plastics
Fire Retardancy
Desirable Characteristics of a Rotational Molding Resin
References
GRINDING AND COLORING
Introduction
General Issues Relating to Grinding
Particle Size Distribution
Particle Size Analysis
Dry Sieves
Elutriation
Streaming
Sedimentation
Fluidization
Presentation of PSD Data
Particle Shape
Dry Flow
Bulk Density
Packing of Particles
Factors Affecting Powder Quality
Gap Size
Number of Mill Teeth
Grinding Temperature
Grinding Costs
Micropelletizing
Polyvinyl Chloride
Coloring of Plastics for Rotational Molding
Dry Blending
High Speed Mixing (Turbo Blending)
Compounding
Types of Pigments
Aesthetics of Rotationally Molded Parts
Other Types of Additives
References
ROTATIONAL MOLDING MACHINES
Introduction
Types of Rotational Molding Machines
Rock-and-Roll Machines
Clamshell Machines
Vertical Machines
Shuttle Machines
Fixed-Arm Carousel Machine
Independent-Arm Machine
Oil Jacketed Machines
Electrically Heated Machines
Other Types of Machines
Machine Design Considerations
Mold Swing
Mold Speed
Speed Ratio
The Oven
Oven Design
Heat Transfer in Oven
Oven Air Flow Amplification
Cooling
Process Monitors
Internal Air Temperature Measurement in Rotational Molding
Infrared Temperature Sensors
Servicing
Advanced Machine Design
References
MOLD DESIGN
Introduction
Mold Materials
Sheet Steel
Aluminum
Electroformed Nickel
Mechanical and Thermal Characteristics of Mold Materials
Equivalent Mechanical Thickness
Equivalent Static Thermal Thickness
Equivalent Transient Thermal Thickness
Mold Design
Parting Line Design
Butt or Flat
Lap Joint
Tongue-and-Groove
Gaskets
Mold Frame
Clamping
Pry Points
Inserts and Other Mechanical Fastening Methods
Self-tapping Screws
Mechanical Fastening
Postmolded Insert
Molded-in Insert
Threads
Cut-out Areas
Kiss-offs
Molded-in Handles
Temporary Inserts
Calculation of Charge Weight
Methodology
Maximum Part Wall Thickness for a Given Mold
Venting
Simple Estimate for Vent Size
Types of Vent
Is a Vent Necessary?
Mold Surface Finish
Mold Releases
Spray-on Zinc Stearates
Silicones
Disiloxanes
Fluoropolymers
Mold Surfaces to be Coated
Controlled Release
Mold Release Cost
References
PROCESSING
Introduction to Heating
General Anatomy of the Rotational Molding Cycle
General Process Description
Powder Behavior
Characteristics of Powder Flow
Rheology of Powder Flow
Heat Transfer Concepts Applied to Rotational Molding
Heating the Mold
Heating Powder
Transient Heating of an Individual Particle
Heating the Powder Bed
Tack Temperature
Mold Cavity Air Heating Prior to Powder Adhesion to Mold
Surface
Bed Depletion
Particle Coalescence
Densification
Phase Change During Heating
The Role of Pressure and Vacuum
Mathematical Modeling of the Heating Process
Total Oven Cycle Time
Cooling and the Optimum Time for Removal from Oven
Some Comments on Heat Transfer During Cooling
Thermal Profile Inversion
Cooling and Recrystallization
Air Cooling Heat Removal Rate
Water Cooling Heat Removal Rate
Pressurization
Part Removal
Effect of Wall Thickness on Cooling Cycle Time
Overview and Summary of Thermal Aspects of the Rotational
Molding Process
Introduction to Liquid Rotational Molding
Liquid Polymers
Liquid Rotational Molding Process
Liquid Circulating Pool
Cascading Flow
Rimming Flow
Solid Body Rotation
Hydrocyst Formation
Bubble Entrainment
Localized Pooling
Process Controls for Liquid Rotational Molding
Foam Processing
Chemical Blowing Agent Technology
Single Layer vs Multiple Layer Foam Structures
One-Step Process
Two-Step Process
Drop Boxes Inside or Out?
Containerizing Inner Layers
References
MECHANICAL PART DESIGN
Introduction
Design Philosophy
General Design Concepts
Mechanical Design
Three-Point Flexural Beam Loading
Cantilever Beam Loading
Column Bending
Plate Edge Loading
Hollow Beam with Kiss-Off Loading
Creep
Temperature-Dependent Properties
Design Properties of Foams
Uniform Density Foams
Multilayer or Skin-Core Foams
Computer-Aided Engineering in Rotational Molding
CAD/CAM in Rotational Molding
Computer-Aided Stress Analysis
Some General Design Considerations
Uniformity in Wall Thickness
Shrinkage During Cooling
General Shrinkage Guidelines
Effect of Pressurization
Draft Angles and Corner Angles
Warpage Guidelines
Corner Radii The Michelin Man
Right-Angled Corners
Acute-Angled Corners
Parallel Walls
Spacing and Bridging
Internal Threads, External Threads, Inserts, and Holes
Process Effects on Porosity, Impact Strength
Trimming
Surface Decoration
Painting
Hot Stamping
Adhesives
In-Mold Decoration
Postmold Decoration
Internal Chemical Treatment
Troubleshooting and Quality Assurance
Coordinate Measuring Machine
References
APPENDIX A TROUBLESHOOTING GUIDE FOR
ROTATIONAL MOLDING
APPENDIX B CONVERSION TABLE
AUTHOR INDEX
SUBJECT INDEX

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شارك معنا فى حملة فيد وإستفيد

شارك معنا فى المسابقة الهندسية الشهرية

كيفية التسجيل فى منتدى هندسة الإنتاج والتصميم الميكانيكى

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