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| موضوع: كتاب Plastic Injection Molding - Volume II - Material selection and product design fundamentals الأحد 15 سبتمبر 2019, 3:33 pm | |
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أخواني في الله أحضرت لكم كتاب Plastic Injection Molding - Volume II - Material selection and product design fundamentals Fundamentals of Injection Molding series By Douglas M. Bryce
و المحتوى كما يلي :
Table of Contents Preface xxiii Chapter 1 – Understanding the Injection Molding Process Evolution of the Process 1 Charting Industry Evolution . 1 Evolution of Screw Concept and Evaluation of Plunger . 2 The Process 3 Categorizing the Parameters . 4 Temperature/Pressure/Time/Distance Horizontal versus Vertical Molding 20 Advantages of Horizontal Molding 20 Advantages of Vertical Molding 21 The Need for Process Controls 22 Part Quality 22 Part Cost 23 Parameter Effects . 23 The Setup Sheet . 24 Controlling Shrinkage 26 The Effects of Temperature Adjustments . 29 The Effects of Pressure Adjustments . 30 Post-mold Shrinkage 30 Minimizing Molded-in Stress . 32 Summary . 33 Questions 34 Chapter 2 – The Language of Plastics Definitions Relating to Materials 37 The Definition of Plastic 37 Polymerization . 37 Basic Molecular Structure/Copolymers/Alloys and Blends Thermoplastics versus Thermosets . 42 Amorphous versus Crystalline . 43 Amorphous Materials/Crystalline Materials/Comparison of Amorphous and Crystalline Molecular Chains Elastomers . 44vi How Plastics are Made . 45 Molecular Weight and Distribution 46 Influence of Time and Temperature . 46 Summary . 47 Questions 48 Chapter 3 – Reinforcements and Fillers Why Reinforcements and Fillers are Used 49 What Are They? . 49 Reinforcements 49 Fiberglass/Organic Fibers/Boron/Carbon-graphite/Ceramics (Metal Oxides)/Metals Fillers 53 Colorants/Plasticizers/Heat Stabilizers/Antioxidants/Flame Retardants/Ultraviolet (UV) Absorbers/Antistatic Agents/ Blowing Agents/Lubricants Summary . 57 Questions 58 Chapter 4 – Comparing Amorphous and Crystalline Materials Identifying the Differences 59 Molecular Structure 59 Crystalline Polymers/Amorphous Polymers/ Crystalline/Amorphous Polymers Process Temperature Requirements (injection unit) . 61 Process Temperature Requirements (mold) . 63 Crystalline/Amorphous/General Differences Based on Crystallization Liquid Crystalline Materials . 66 Summary . 67 Questions 67 Chapter 5 – Basic Material Properties Property Descriptions and Terminology 69 Physical Properties 69 Density/Specific Gravity/Shrinkage Rate/Water Absorption/ Transparency (Opacity)/Modulus (Toughness)/Elasticity/ Plasticity/Ductility/Brittleness/Notch Sensitivity/Lubricity/ Isotropy and Anisotropyvii Mechanical Properties 74 Stress and Strain/Modulus of Elasticity/Poisson’s Ratio/Shear Stress and Shear Strain/Shear Modulus/Direct Shear/ Compressive Strength and Modulus/Flexural Strength and Modulus/Creep/Impact Strength/Fatigue Endurance Thermal Properties . 83 Melting Point/Glass Transition Temperature/Melt Index/ Vicat Softening Point/Heat Deflection (Distortion) Temperature/Coefficient of Linear Thermal Expansion/ Thermal Conductivity/Temperature Index/Flammability Electrical Properties 85 Volume Resistivity/Surface Resistivity/Dielectric Strength/ Dielectric Constant (Permittivity)/Arc Resistance/Comparative Tracking Index (CTI) Environmental Concerns 88 Stress/Exposure Factors/Temperature/Chemicals/Weathering Summary . 92 Questions 93 Chapter 6 – Applications and Properties of Specific Materials Characteristics and Applications . 95 Common Thermoplastics 95 Acrylonitrile-butadiene-styrene (ABS)/Acetal/Acrylic/Acrylicstyrene-acrylonitrile (ASA)/Cellulose/Fluoroplastics/Ionomers/ Liquid Crystal Polymers/Methyl Pentenes/Nylon (Polyamide)/ Polyallomers/Polycarbonates/Polyetheretherketone (PEEK)/ Polyethylene/Polyimides/Polyphenylene Oxide (PPO)/ Polyphenylene Sulfide (PPS)/Polypropylene/Polystyrene/ Polysulfones/Polyvinylchloride (PVC)/Thermoplastic Polyesters (PBT, PET)/Thermoplastic Copolyesters (PCTA, PCTG, PETG)/ Polyarylate (Wholly Aromatic Polyester [ARP])/Thermoplastic Rubbers (TPR) Elastomers . 103 Natural Rubber (NR)/Isoprene Rubber (IR)/Styrene-butadiene Rubber (SBR)/Neoprene (CR)/Nitrile Rubber (NBR)/Butyl Rubber (IIR)/Ethylene Rubber (EPM)/Ethylene Terpolymer Rubber (EDPM)/Hypalon (CSM)/Acrylic Rubber (ABR)/Polysulfide Rubber (T)/Silicones (SI, FSI, PSI, VSI, PVSI)/Urethanes (U)/ Fluoroelastomers (FPM)/Butadiene Rubbers (BR)/Carboxylic (COX)/Epichlorohydrin Rubbers (CO, ECO) Star Diagrams 106viii Structural Foams 106 Summary . 107 Questions 107 Chapter 7 – Determining Injection Molding Costs Is It Worth It? . 135 What Information is Needed? . 135 Material Costs 136 Use of Regrind/Impact of Runner versus Shot Size Labor Costs . 139 Machine Costs . 139 Determining Machine Size/Determining Machine Location/ Calculating Molding Process Costs/Should Operator Cost be Included?/Estimating Setup Charges Tooling Costs . 144 Standard Practice/Amortizing Tool Costs/Maintenance Costs Adding It All Up . 146 Secondary Operations (Including Packaging) . 146 Summary . 147 Questions 148 Chapter 8 – Secondary Operations Defining Secondary Operations 149 When to Consider Secondary Operations 150 When Volumes are Small 150 When Tooling Costs are Excessive . 150 When Time to Build the Mold Jeopardizes Marketing Schedules 150 When a Labor-heavy Environment Exists 151 Assembly Operations . 151 Ultrasonic Welding . 151 Energy Directors/Ease of Welding/Variables that Influence Weldability Hot Gas Welding . 157 Induction (Electromagnetic) Bonding . 158 Spin Welding (Friction Welding) 159 Adhesive Bonding 159 Machining Operations 160 Drilling and Tapping Thermoplastics . 160 Drilling and Tapping Thermosets 164ix Reaming Thermoplastics and Thermosets 164 Turning and Milling Thermoplastics and Thermosets 164 Automated Shape Cutting . 165 Water Jet . 165 Laser . 166 Surface Finishes and Decorating Procedures . 166 Preparation of Surface 166 Flame Treatment/Corona Discharge/Plasma Process/ Acid Etch Applied Finishes . 167 Painting/Plating (Electroplating)/Vacuum Metallizing (Deposition)/Hot Stamping/Pad Printing (Heat Transfer)/ Screen Printing In-process Finishes . 173 Molded-in Color/Molded-in Symbols/Two-color (Two-shot) Molding/Textured Surface/In-mold Overlays Summary . 177 Questions 177 Chapter 9 – Testing and Failure Analysis Distinguishing the Terms . 179 Testing . 179 Electrical Testing . 179 Conditioning Samples/Dielectric Strength/Dielectric Constant/ Volume Resistivity/Surface Resistivity/Arc Resistance Physical Testing 181 Shrinkage Rate/Density/Water Absorption/Moisture Content/ Melt Flow Index Mechanical Testing . 186 Tensile Strength/Compressive Strength/Flexural Strength/ Creep/Impact Thermal Testing 189 Melting Point/Heat Deflection Temperature/Vicat Softening Temperature/Flammability/Limiting Oxygen Index Failure Analysis 195 As a Design Tool 195 Stress . 195 Differential Scanning Calorimeter . 196 Stress/Moisture/Tm and Tg Points/Regrind Percentage/ Crystallinityx Calculating Glass Content 199 Furnace Method/TGA Method Summary . 201 Questions 202 Chapter 10 – The Product Design Session Brainstorming 203 Who Are the Players? . 203 What Takes Place? . 204 What Does the Product Do?/How Will the Product be Made?/ When Should Production Start?/Where Will It be Built?/How Much Should It Cost? Project Chart Samples 209 Product Development/Project Management Process/Process Management/Product Development Time Line Why Projects Fail 216 Uninvolved Users/Undisciplined Management System/ Ineffective Communication/Uncontrolled Changes/ Inappropriate Technology/Poorly Defined Products Summary . 220 Questions 220 Chapter 11 – Determining Product Requirements Defining the Product . 223 Typical Project Example . 224 Phase 0 . 225 Phase 1 . 225 Phase 2 . 225 Phases 3 through 8 226 Determining Actual Requirements . 227 Functional Aspects 227 Color/Fit/Appearance Physical and Mechanical Aspects 231 Mechanical Assembly Methods/Other Assembly Methods Thermal Aspects . 248 Electrical Aspects 249 Flammability Considerations 249 Weather and Exposure Limits 250 Safety and Environmental Issues . 251 Summary . 252 Questions 253xi Chapter 12 – Product Design Considerations Design Guidelines 255 Wall Thickness Recommendations . 255 Uniform Wall Thickness Requirement 257 Knit Lines . 258 Sharp Corners . 259 Sink Marks . 261 Warpage and Bowing . 262 Draft . 264 Ejector Pin Marks and Gate Location Restrictions . 269 Gate Marks 270 Dimensions and Drawing Notes . 271 What the Vendor Needs . 272 Common Design Considerations 276 Product Design Checklist 279 Summary . 281 Questions 283 Chapter 13 – Miscellaneous Determinations Annual Volumes . 285 Material Handling Requirements . 286 Secondary Operations 286 Packaging Requirements . 287 Testing Requirements 288 Summary . 289 Questions 290 Chapter 14 – Selecting a Vendor Overview . 293 List of Requirements . 293 Dedicated Specialty or Full Service? 293 Dedicated Specialty/Full Service What to Look For . 295 Basic Investigation 296 Note Condition of Plant and Equipment/Ask to See Product Samples/Check Delivery Performance/Check Quality Rating/ Investigate Specialty Areas/Determine Equipment Availability/ Examine Bidding Practices Familiarity 297 Normal Tolerance Levels/Materials/Molding Processes/ Equipment Type, Age, and Size/Subcontractingxii Capabilities . 298 Volumes/Tool Design, Build, and Repair/Computerized Operations/Statistical Process Control (SPC) and Other Quality Programs Responsibilities . 299 Qualification Form . 300 Summary . 304 Questions 304 Chapter 15 – Prototype Overview The Value of Prototyping . 307 Form . 307 Fit . 308 Function 308 Appearance . 308 The Prototype Option . 309 Typical Methods and Recommended Quantities . 309 Fabrication 309 Thermoforming 309 Casting 310 Molding . 310 Virtual Prototyping 310 Rapid Prototyping (RP) 310 Stereolithography Apparatus (SLA)/Selective Laser Sintering (SLS)/Laminated Object Manufacturing (LOM)/Ballistic Particle Manufacturing (BPM)/Solid Ground Curing (SGC) Which is Best? 312 Summary . 313 Questions 313 Chapter 16 – A Primer on Molds Description of the Mold 315 The “A” and “B” Plates 315 The Cavity Image . 315 The Injection Half of the Mold . 316 The Sprue Bushing . 317 Runners . 317 Flash . 318 The Ejector Half of the Mold . 318xiii Ejector Pins 318 Ejector Plates . 319 Knockout Rod 319 Mold Design Basics 320 Gate Location 320 Runner Cross-section . 321 Venting Concepts . 321 Typical Tool Life 324 Ownership of the Mold (and Other Tools) . 326 What to Expect from Molds . 326 Summary . 328 Questions 329 Chapter 17 – Understanding Defects Overview . 331 What Causes Defects? 332 Common Defects and Remedies . 333 Black Specks or Streaks 333 Excessive Residence Time in Barrel/Contaminated Raw Material Blisters . 334 Back Pressure Too Low Blush . 334 Mold Temperature Too Low Bowing 334 Clamp Opens Too Quickly/Improper Handling Brittleness 335 Excessive Moisture Bubbles (Voids) 335 Section Thickness Too Great/Excessive Moisture Burn Marks 335 Improper Venting/Excessive Regrind Clear Spots 336 Barrel Temperature Too Low/Inconsistent Cycles Cloudy Appearance . 336 Uneven Packing of Cavity Contamination . 337 Improper Regrind/Poor Housekeeping Cracking . 337 Molded-in Stresses/Insufficient Draft or Polishxiv Crazing . 338 Delamination . 338 Foreign Materials or Additives/Excessive Mold Release Discoloration . 338 Improper Mold Temperature/Contamination Flash . 339 Excessive Injection Pressure/Improper Flow Rate Flow Lines 339 Inadequate Injection Pressure Gloss (Low) 339 Inadequate Injection Pressure/Mold Temperature Too Low Jetting . 340 Improper Gate Design or Location Knit Lines (Weld Lines) 340 Barrel Temperature Too Low Nonfill (Short Shots) . 340 Insufficient Material Feed/Insufficient Venting Shrinkage (Excessive) 341 Mold Temperature Too High/Early Gate Opening Sink Marks . 341 Excessive Rib Thickness Splay (Silver Streaking) . 342 Excessive Moisture Warpage . 342 Inadequate Injection Pressure or Time Troubleshooting Tips 342 Summary . 343 Questions 343 Appendix A – Material Tradenames and Descriptions 345 Appendix B – Common Material Acronyms and Their Meanings . 355 Appendix C – Material Rankings for Various Properties . 359 Answers to Chapter Questions 361 Index INDEX Index Terms Links A acetal 2 6 10 45 86 88 95 110 166 168 229 250 252 257 acetate 96 229 acid etch 167 acrylate(s) 45 butadiene 104 acrylic(s) 6 10 45 86 88 96 111 156 168 229 250 257 rubber 104 -styrene-acrylonitrile (ASA) 96 112 acrylonitrile-butadiene-styrene (ABS) 2 6 10 41 42 44 45 54 55 86 96 106 108 154 156 167 168 175 229 241 248 250 257 287 /polycarbonate 109 adhesive bond(ing) 159 161 alkyd 168Index Terms Links alloys 42 47 American Society for Testing and Materials (ASTM) 103 179 standard #D-1238 12 #D-618 180 #D-149 180 #D-150 180 #D-257 180 #D-495 181 #D-955 182 amorphous 28 43 83 198 materials 4 45 59 62 63 65 69 84 151 molecular chains 43 44 structure 59 60 properties 44 shrinkage 29 “angle pins,” 268 anisotropy 73 antioxidants 55 antistatic agents 56 applied finishes 167 aramid 51 arc resistance 88 assembly 233 methods 231Index Terms Links assembly (Cont.) operations 151 automated shape cutting 165 B Ballistic Particle Manufacturing (BPM) 311 barrel 7 capacity 141 333 rear temperature 24 temperature 29 336 340 342 zone 24 black specks 333 blends 42 47 blisters 334 blowing agents 56 blush 334 boron 51 bowing 262 334 Branson Ultrasonics Corp. 153 brittleness 72 335 bubbles (voids) 335 burn marks 335 butadiene rubbers 105 butyl(s) 45 rubber 104 butyrate 96 97Index Terms Links C Canadian Standards Association (CSA) 277 288 carbon-graphite 52 carboxylic 105 casting 310 cavity(ies) image(s) 13 15 29 315 316 320 323 334 mold 12 176 celluloid 1 2 cellulose 96 acetate 6 10 butyrate 6 10 45 propionate 6 10 45 cellulosics 168 ceramic(s) 52 chemical(s) 89 reaction 89 resistance 13 67 90 solvation 89 chlorosulfonated polyethylene 45 clamp force 140 mechanism 4 pressure 14 140 tonnage 140 141 unit 4 13 clear spots 336Index Terms Links cloudy appearance 336 coefficient of linear thermal expansion (CLTE) 84 color 308 colorability 97 colorant(s) 54 156 174 Comparative Tracking Index (CPI) 88 concurrent engineering 216 contamination 334 337 338 contour 308 controlled pressure molding 176 cooling post-mold 30 31 copolymer(s) 41 42 butadiene-acrylonitrile 104 chlorotrifluoroethylene 105 ethylene-propylene 104 hexafluoropropylene 105 isobutylene-isoprene 104 phenylene ether 106 vinylidene fluoride 105 copolyester elastomers 113 corona discharge 167 cracking 33 337 338 crazing 33 338 creep 82 101 189 resistance 13 67 83 92 187 testing 189Index Terms Links cross-linking 46 crystalline 8 28 43 47 197 materials 5 45 46 59 62 64 69 84 98 151 198 246 250 molecular chains 44 64 structure 59 60 66 properties 44 shrinkage 29 crystalline/amorphous molecular structure 60 61 cushion (pad) 18 cycle time(s) 30 142 143 146 159 318 326 gate-to-gate 21 cylinder 3 heating 4 5 D decorative procedures 166 defects 331 delamination 338 density 69 design considerations 276 destaticizers (see antistatic agents)Index Terms Links dielectric constant (permittivity) 87 properties 249 strength 87 Differential Scanning Calorimeter (DSC) 61 67 83 190 196 discoloration 338 dissipation factor 87 values 88 distance 4 15 ejection 20 holding 17 initial injection 17 mold-closed 16 mold-open 18 19 draft 264 287 allowance and tolerances 299 angle(s) 231 264 337 limitations 275 drilling thermoplastics 160 thermosets 164 ductility 72 E ejector bar 319 320Index Terms Links ejector (Cont.) marks 269 270 272 pin(s) 19 318 319 plates 319 320 rod 320 ejector retainer plate 319 elastic limit 79 elasticity 71 72 elastomeric(s) 159 adhesives 160 elastomers 44 45 103 electrical discharge machine (EDM) 315 electrical properties 85 electromagnetic interference (EMI) 53 elongation 50 67 energy director(s) 152 153 245 247 environmental concerns 88 issues 251 epichlorohydrin rubbers 106 epoxy(ies) 159 168 equipment 297 ethyl cellulose 96 97 ethylene 40 rubber 104 terpolymer rubber 104 exposure factors 88 monomer 41 eyelets 241Index Terms Links F fabrication 309 failure analysis (FA) 179 195 fiberglass 49 50 200 fillers 49 53 54 156 finite element analysis (FEA) 308 flame retardants 55 56 156 treatment 166 287 flammability 85 249 testing 193 194 flash 26 318 339 flow index rating 12 lines 339 rate(s) 141 154 155 339 flowability 67 fluorocarbon(s) 45 160 168 fluoroelastomers 105 fluoroplastics 97 fluorosilicones 45 foaming agent(s) (see blowing agents) “freeze off,” 14 friction welding (see spin welding) 159 G gate 15 28 334 341 design 340Index Terms Links gate (Cont.) location 320 location restrictions 269 sizing 336 witness marks 270 glass content 199 glass transition (Tg) area 63 point 62 63 84 range 153 temperatrure 62 gloss 13 339 H hardness 13 heat deflection temperature (HDT) 50 84 191 248 heat exchanger 11 heat resistance 66 heat stabilizer(s) 55 heater band(s) 2 3 5 7 heating cylinder 7 8 332 334 Hooke’s Law 75 79 hopper 4 8 9 51 337 340 horizontal molding 20 hot gas welding 157 hot stamp(ing) 169 machine 170Index Terms Links hygroscopic 154 335 342 materials 72 250 HypalonTM 104 I induction (electromagnetic) bonding 157 injection cylinder 2 molding costs 135 process 4 15 17 33 pressure 140 141 unit 4 14 in-mold overlay(s) 175 process 176 in-process finishes 173 International Organization for Standardization (ISO) 179 standard 9000 299 #IEC 243-1 180 #IEC 250 180 #IEC 93 180 #IEC 294 182 ionomers 97 isotropy 73Index Terms Links J Jetting 340 John Wesley Hyatt 1 2 Just-in-Time (JIT) 209 K knit lines(s) 258 340 knockout rod 19 319 L labor charges 136 costs 139 Laminated Object Manufacturing (LOM) 311 laser cutters 166 limiting oxygen index (LOI) 194 liquid crystalline materials (plastics) 67 83 living hinge(s) 241 242 low-pressure molding 176 lubricants 56 lubricity 73 M machine costs 139Index Terms Links machine (Cont.) fixed 140 variable 139 man hour rate (MHR) 142 147 rate 136 machining operations 160 maintenance costs 145 material(s) 297 applications 95 costs 136 easy-flow 140 255 339 handling requirements 286 properties 69 mechanical properties 74 melamine 43 melt(ing) flow 84 flow index 84 181 187 index (MI) 12 13 84 151 188 rheometer 12 test 154 185 value 185 point (MP) 5 61 62 83 temperature(s) (Tm) 5 6 23 24 83 151 153 metal inserts 237 methyl pentenes (TPX resins) 98Index Terms Links milling thermoplastics 164 thermosets 164 modulus 71 of elasticity 75 secant 79 shear 79 moisture 196 content 154 181 molded-in color 173 symbols 174 mold(ing) 310 “A” half 11 “A” plates 315 “B” half 11 20 “B” plates 315 process(es) 297 315 process costs 142 release 338 release agents 155 287 temperature 334 338 339 341 molecular weight 13 distribution (MWD) 46 47 monomer(s) 37 47 cements 160 molecule 40Index Terms Links N neoprene 45 104 nitrate 95 nitrile 45 rubber 104 nonfill 340 notch sensitivity 73 nozzle 3 18 34 assembly 7 heater zone 8 tip 7 8 nylon 44 45 54 98 154 250 257 elastomers 117 type (6) 6 10 115 type (6/6) 6 10 229 type (12) 116 O overhead costs fixed 141 variable 141 oxygen index 85 P packaging 147 requirements 275 287Index Terms Links pad printing 172 painting 167 168 287 part cost 23 “nesting,” 288 quality 22 volumes 298 parting agents (see mold release agents) 155 peripheral marking 170 permeability 13 phenolic 43 45 168 257 photopolymer 310 pin-hinge 243 plasma etch 167 process 167 plasticity 72 plasticization 92 plasticizers 54 55 155 plating (electroplating) 168 287 238 plunger 2 device 33 injection 54 -type machine 3 Poisson’s Ratio 79 polyalkylene ether glycol(s) 105 polyallomer(s) 6 10 99 polyamide (nylon) 86 88 polyamide-imide 6 10 45Index Terms Links polyarylate 6 10 45 86 88 102 118 250 polybutadiene 105 polybutylene 6 10 -terephthalate 106 119 polycarbonate(s) 2 6 10 45 86 88 96 99 106 121 140 154 156 167 168 229 241 244 250 257 polychloroprene 104 polychlorotrifluoroethylene (FCTFE) 97 poly-dimethyl siloxanes 105 polyester (PBT) 45 96 102 229 polyester (TP) 86 88 250 257 polyetheretherketone (PEEK) 6 10 45 99 polyetherimide 6 10 45 polyethersulfone 45 polyethylene 6 10 40 41 45 55 56 99 106 156 160 229 chlorosulfonated 104 high-density (HDPE) 122 257 low-density (LDPE) 252 257 terephthalate (PET) 120 polyethylene terephthalate (PET) 45 102 polyfluoroethylene-propylene (PFEP) 97 polyimide(s) 100 polyketone(s) 123Index Terms Links polymer(s) 37 40 44 46 47 49 amorphous 60 crystalline 59 97 liquid crystal 6 10 45 86 88 98 114 250 structure 153 sulfone 126 polymerization 37 41 45 addition-type 45 combination 46 condensation-type 45 polymethylpentene 6 10 polyolefin(s) 99 166 287 polyphenylene oxide (PPO) 6 10 45 86 88 100 106 127 229 250 257 sulfide (PPS) 6 10 45 86 88 100 128 250 polypropylene 6 10 45 86 88 98 106 124 156 160 229 250 257 polystyrene 2 6 10 45 54 101 106 156 257 high-impact 125 polysulfide(s) 45Index Terms Links polysulfone(s) 6 10 86 101 154 229 250 rubber 104 polytetrafluoroethylene (TFE) 97 98 polyurethane(s) 45 106 168 polyvinylchloride (PVC) 6 10 45 54 55 96 101 129 156 163 168 229 257 336 polyvinylidene fluoride 97 pressure 4 back 23 24 clamp(ing) 11 13 14 339 closing 17 ejection 338 hold(ing) 11 13 18 injection 11 23 24 26 30 339 342 process controls 22 design 216 implementation 216 maintenance 216 management 213 214 product cost breakdown 208 design 203 204 255 checklist 279 280 development 209Index Terms Links product (Cont.) time line 216 217 requirements 223 227 project management 213 214 propionate 96 97 proportional limit 75 prototype(ing) 307 rapid (RP) 310 virtual 310 Q quality costs 223 part 22 programs 298 rating 296 R radii 278 reaction injection molding (RIM) 106 recycling 251 symbol 251 regrind 2 136 138 156 198 334 336 338 reinforcement(s) 49 156 fibers 52 materials 51 metal fiber(s) 52 53Index Terms Links resin grade 156 resistivity surface 86 volume 86 249 250 rivets 241 robotic systems 149 roll-on decorating 169 rubber(s) isoprene 103 natural 103 neoprene 104 styrene-butadiene 1 runner(s) 140 317 325 337 341 cross-section 321 322 sizing 336 system(s) 136 137 139 318 versus shot size 138 S safety 251 screen printing 172 173 screw concept 2 injection machine 2 3 54 retention 237 self-tapping 237 secondary operation(s) 146 149 150 286Index Terms Links Selective Laser Sintering (SLS) 311 semicrystalline materials 246 costs 146 setup charges 144 sheet 24 25 sharp corners 278 shear direct s 80 81 strain 80 stress 80 shipment schedules 275 short shots 340 shot size 139 shrinkage 26 28 30 65 229 255 257 279 341 amorphous 29 anisotropic 28 control 29 32 crystalline 29 factors 229 high 28 impact 50 66 isotropic 28 low 28 medium 28 post-mold 30 31Index Terms Links shrinkage (Cont.) rate 26 27 29 69 70 73 74 181 silicone(s) 45 105 sink marks 255 261 341 342 snap-fit 243 251 Society of Manufacturing Engineers (SME) 331 Society of Plastics Engineers (SPE) 2 289 Society of the Plastics Industry (SPI) 2 251 265 Solid Ground Curing (SGC) 312 specific gravity 50 51 67 69 181 spin welding 159 splay 342 sprue bushing 317 volume 138 staking 246 star diagrams 106 Statistical Process Control (SPC) 298 Stereolithography Apparatus (SLA) 310 stiffness 13 151 153 156 strain 74 78 normal 75 shear 79 strength compressive 188 and modulus 81Index Terms Links strength (Cont.) dielectric 87 180 flexural 50 82 187 189 s and modulus 81 impact 83 97 IZOD 189 tensile 13 50 51 66 67 188 ultimate 79 yield 13 79 stress(es) 74 76 78 88 195 196 259 262 337 bending 195 compression 195 259 -crack resistance 13 cracking 92 direct 74 molded-in 32 33 normal 75 shear 74 79 195 259 /strain 71 77 tensile 259 tension 195 twisting 195 structural foams 106 107 styrene 41 229 309 acrylonitrile (SAN) 6 10 130 butadiene 6 10 45Index Terms Links styrene (Cont.) -maleic-anhydride (SMA) 131 subcontracting 298 surface finished 166 T tapping thermoplastics 160 thermosets 164 temperature(s) 4 46 47 88 barrel 29 336 340 342 controller 9 24 glass transition(Tg) 62 83 192 197 heat deflection (HDT) 50 84 191 192 index 85 maximum use 67 melt(ing [Tm]) 5 6 23 24 153 192 197 mold 8 23 24 334 338 339 341 process t requirements 61 63 Vicat softening 13 193 zones 5 tensile modulus 67 testing 179 arc resistance 181 182 ASTM #D-495 181 compressive strength 187Index Terms Links testing (Cont.) ASTM #D-695 187 creep 189 ASTM #D-618 180 ASTM #D-674 189 electrical 179 density 183 ASTM #D-792 183 ISO #1183:1987 183 dielectric constant 180 181 ASTM #D-150 180 ISO #IEC 250 180 dielectric strength 180 ASTM #D-149 180 ISO #IEC 243 180 flammability 193 194 ASTM #UL-94 193 ISO #UL-94 193 flexural strength 188 ASTM #D-790 188 ISO #178:1993 188 impact 189 ASTM #D-256 189 ISO #179 and 180:1993 189 limiting oxygen index (LOI) 194 ASTM #D-2863 194 ISO #589:1984 194 melt flow index 185 ASTM #D-1238 185 255Index Terms Links testing (Cont.) ISO # 1133:1991 185 melting point 189 ASTM #D-3418 190 ISO #3146:1985 190 moisture content (Tomasetti Volatile Indicator [TVI]) 185 requirements 288 shrinkage rate 182 ASTM #D-955 182 ISO #294-4 182 surface resistivity 180 181 ASTM #D-257 180 ISO # IEC 93 180 tensile strength 187 ASTM #D-638 187 ISO #527-1 and 2:1993 187 Vicat softening temperature 193 ASTM #D-1525 193 ISO #306:1987 193 volume resistivity 180 181 ASTM #D-257 180 water absorption 184 ASTM #D-570 184 ISO #62:1980 184 test(s) fatigue endurance 83 impact 83 191 Charpy 83 189Index Terms Links test(s) (Cont.) falling dart 83 IZOD 50 83 189 tensile 83 melt index (ASTM #D-1238) stress/strain (tensile) 77 tetrafluoroethylene 6 10 Texas Plastic Technologies 332 textured surface 174 texture(s) 175 230 231 277 300 309 thermal coefficient of expansion 50 conductivity 85 properties 83 thermoforming 309 thermogravimetric analysis (TGA) 200 201 thermoplastic polyester (PBT) 6 10 (PET) 6 10 thermoplastic(s) 42 43 47 55 163 230 248 255 copolyester(s) 102 polyester(s) 102 polyolefin 132 polyurethane 133 rigid 159 rubbers 103 thermosets 42 43 47 55Index Terms Links time 4 46 clamp 15 cooling 15 initial injection 14 injection 14 injection hold 14 mold-closed 15 tolerance levels 297 tool(ing) 326 approval signoff 274 build t 216 charges 136 145 costs 144 amortizing 145 debug t 216 design t 216 build and repair 298 prototype 285 torque 236 toughness 13 transparency 70 troubleshooting 331 343 tips 342 turning thermoplastics 164 thermosets 164 twisting 33 two-color (two-shot) molding 174 175Index Terms Links U ultrasonic assembly machine 246 energy 152 153 245 welding 151 245 287 ultraviolet light 310 312 absorbers 56 undercuts 279 Underwriters Laboratories (UL) 56 85 193 194 249 273 277 288 289 United Silicone, Inc. 169 172 urea 168 urethane(s) 105 elastomer 6 U.S. Food and Drug Administration (FDA) 277 V vacuum metallizing 168 287 process 169 vendor(s) 293 295 dedicated specialty 293 full-service 293 294 qualification form 300 venting 321 324 325 335 341Index Terms Links vertical molding 20 21 stamping 170 vibration welding 152 Vicat softening point 84 vinyl 252 virgin 138 336 material 2 334 viscosity 66 W wall thickness 255 262 263 278 warpage 33 66 67 262 342 water absorption 70 181 jet cutting 166 weathering 92 work-in-process (WIP) 147 yield point 75
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