~ PRCAlECT TEAM FEASIBILITY - H STUDY Dimensions structural loads gov'Vlndustry standards service environments, etc Identify specific functions Target quantity cost and production schedule Apply available experience I Manual approach l-.{ COnceptual product layout Apply design creativity Computer approach I r1 Formulate plan' R PRELIMINARY DESIGN ANALYSIS r-y I Dimensions & tolerances Geometric drawings or graphic analYSis Engineering analysiS Solid 4~ Image manipulation r- I Surface c-j Structural Integrity Environment -I Physical integrity Mechanical simulatkm I J -@ Dynamic Finite element modeling J Minimum weight/cost n Ae_c.etc.1 rl OPTIMIZE DESIGN r Mok:Jfdie destgn Material selection I Fabrication analysis J Shrinkage analysis Cycle timeJ I detai.led/individual orthotropic drawings Set up safety factors to meet product functions I Nonstandard parts I Standard parts ~ Provtde -1 I selection -i ~ Material I i ProcesSlequipmentltools _I -1 Produce service per10rmance I I Plant personnel capability I iii rl H ~ 1l Release tooling (mOld/die) for manufacture Set up processing specifications I I rl Equipment I H Material handling I 'iii 15 I j MANUFACTURING~ H Automationtrobotics Plant layout H n ANALYSIS Y '12l § I Safety procedures W Manufacturing processing specifications I I Troubleshooting gUide Testing/quality control Plant personnel capability evaluation f rl OPTIMIZE & DOCUMENT PRODUCTION ~ I I I I Ensure product quality Document good manufacturing practice (GMP) procedure H I I I Preventive maintenance Machine operations H Update plant personnel training I H DevelOp production cost models I Finalize testing & quality conlrol I p od hed I r uct output sc ue ~ ~:~~:ii~: :~=~~: Inventory schedule Y Documentation for management to ensure meeting delivery schedules and profitability I J I PRODUCT RELEASE Ensure meeting all product functions Set up value analysis (VA) I II I Cost analysis rl Matt flow analysis H Tool thermal analysis I - Tool part I -1 Databases andlor available information Process selection After start of production analyze ccmplate design (again) to change design/production/safety factors in order to reduce costs I I DESIGNING WITH PLASTI CS AN D COMPOSITES: A HANDBOOK Donald V Rosato, Ph D David P Di Mattia Industrial and Graphic Designer Dominick V Rosato P.E Rhode Island School of Design ~ SPRINGER SCiENCE+BUSINESS MEDIA, LLC Copyright © 1991 by Springer Science+Business Media New York Originally published by Van Nostrand Reinhold in 1991 Softcover reprint of the hardcover 1st edition 1991 Library of Congress Catalog Number 90-46378 ISBN 978-1-4615-9725-4 ISBN 978-1-4615-9723-0 (eBook) DOl 10.1007/978-1-4615-9723-0 All rights reserved No part of this work covered by the copyright hereon may be reproduced or used in any form by any means-graphic, electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval systems-without written permission of the publisher 16 15 14 13 12 11 10 Library of Congress Cataloging-in-Publication Data Rosato, Donald V Designing with plastics and composites: a handbook by Donald V Rosato, David P Di Mattia, and Dominick V Rosato p cm Includes bibliographical references and index Plastics Engineering design II Rosato, Dominick V III Title TP1122.R67 1991 668.4'9 dc20 I Di Mattia, David P 90-46378 CIP Contents Preface / ix FUNDAMENTALS OF DESIGNING WITH PLASTICS AND COMPOSITES / Design Shape / 49 Success by Design / 51 Computers in Design / 52 Design Procedure / 54 Interrelating Product-Resin-Process Performances / 55 THE STRUCTURE AND BASIC PROPERTIES OF PLASTICS / 61 Plastic Structures and Morphology / 66 Thermal Properties of Plastics / 83 Thermal Conductivity and Thermal Insulation / 87 Heat Capacity / 88 Thermal Diffusivity / 88 The Coefficient of Linear Thermal Expansion / 89 Deflection Temperature Under Load / 94 Decomposition Temperature / 95 Mechanical Properties / 96 Physical Properties / 98 Rheology and Deformation / 107 Interrelating Properties, Plastics,and Processing / 116 Orientation / 11 Shrinkage / 123 PLASTICS: DESIGN CRITERIA / 125 Mechanical Properties / 133 Short-Term Behavior / 135 Long-Term Behavior / 153 Short-Duration Rapid and Impact Loads / 201 Electrical Properties / 223 Friction, Wear, and Hardness Properties / 239 iii iv CONTENTS ENVIRONMENTAL CONDITIONS AFFECTING PLASTICS / 253 Temperature Introduction / 253 Chemical Resistance / 264 Weather Resistance / 272 Sterilization-Irradiation / 274 Permeability and Barrier Resistance 276 Biological and Microbial Degradation / 281 Flammability / 282 The Ocean Environment / 288 The Space Environment / 297 STRUCTURAL DESIGN ANALYSIS / 303 Load-Bearing Products / 303 Loads / 305 Support Conditions / 305 Simplifications and Assumptions / 308 Multiaxial Stresses and Mohr's Circle / 308 Safety Factors / 309 Beam Bending Stresses / 312 Beam Bending and Spring Stresses / 321 Shear Stress and Torsion / 323 Shear Stress and Direct Shear / 325 Pressure Vessels / 325 Externally Loaded RP Pipe / 326 Molded-In Inserts / 340 Press Fits / 342 Snap Fits / 345 Hinges / 349 Thread Strength / 355 Pipe Threads / 358 Gears / 359 Gaskets and Seals / 360 Grommets and Noise / 360 Impact Loads / 361 Thermal Stresses / 362 Structural Foams / 365 Structural Sandwiches / 368 Energy and Motion Control / 371 Failure Analysis / 387 Dimensional Tolerances / 387 Plastics / 388 Processing and Tolerances / 391 Product Specification / 398 Combining Variables / 399 Finite Element Analysis / 399 Cantilevered Snap Fits / 402 Laws and Regulations / 402 CONTENTS v THE PROPERTIES OF PLASTICS / 405 Trade Names / 405 Acrylonitrile-Butadiene-Styrene (ABS) / 406 Acetal / 414 Acrylics / 415 Alkyds / 416 Aminos / 416 Cellulosics / 417 Chlorinated Polyethers / 417 Chlorinated Polyethylene / 418 Cross-Linked Polyethylene (XLPE) / 418 Diallyl Phthalate / 418 Epoxies / 419 Ethylene-Vinyl Acetates 419 Fluoroplastics / 420 Furan / 421 lonomers / 421 Ketones / 422 Liquid Crystal Polymers / 422 Melamines / 423 Nylons (Polyamides) / 423 Parylenes / 425 Phenolics / 426 Phenoxy Resins / 427 Polyallomers / 428 Polyamides / 428 Polyamide-imide / 428 Polyarylates / 430 Polyarylethers / 430 Polyaryletherketone / 430 Polyarylsulfone / 431 Polybenzimidazole / 431 Polybutylenes / 432 Polybutylene Terephthalate / 432 Polycarbonates / 432 Polyesters / 433 Polyetherketone / 436 Polyetheretherketone / 438 Polyetherimide / 439 Polyethersulfone / 440 Polyethylene / 440 Polyethylene Terephthalate / 445 Polyimides / 445 Polymethyl Methacrylate / 445 Polymethylpentene / 446 Polyolefins / 446 Polyphenylene Ether / 446 Polyphenylene Sulfide / 447 vi CONTENTS Polypropylene / 447 Polystyrene / 449 Polysulfones / 449 Polyurethane / 452 Polyvinyl Chloride / 452 Polyvinylidene Fluoride / 455 Silicones / 455 Urea Formaldehydes / 456 Elastomers / 458 Thermoset Elastomers / 467 Thermoplastic Elastomers / 472 Film and Sheeting / 473 Foams / 475 Transparent and Optical Plastics / 491 Reinforced Plastics and Composites / 493 Regrind and Recycling / 524 Guide for Plastics Identification / 525 Computerized Databases / 528 Selection Worksheets / 535 Selecting Materials / 535 Selecting Materials under Dynamic Loading / 540 THE PROCESSING OF PLASTICS / 589 Tolerances and Shrinkages / 596 Model Building / 596 Molds and Dies / 599 Drying Hygroscopic Plastics / 602 Heat History, Residence Time, and Recycling / 602 Process Control / 603 Troubleshooting / 603 Inspection / 606 Injection Molding / 610 Extrusion / 624 Basics of Flow / 630 In-Line Postforming / 641 Blow Molding / 646 Extrusion Blow Molding / 651 Forming / 665 Reinforced Plastics/Composites 670 Other Processes / 687 Selecting Processing / 695 AUXILIARY EQUIPMENT AND SECONDARY OPERATIONS / 711 Material Handling / 713 Parts Handling / 713 Finishing and Decorating / 714 Joining and Assembling / 714 Machining / 727 CONTENTS vii TESTING AND QUALITY CONTROL / 731 Basics versus Complex Tests / Specifications and Standards / Orientation and Weld Lines / Types of Tests / 735 Thermoanalytical Tests / 735 Nondestructive Testing / 746 Computer Testing / 753 Quality Auditing / 753 Reliability and Quality Control Failure Analysis / 754 Selecting Tests / 755 Quality and Control / 755 732 732 734 / 754 10 COMPUTER-AIDED DESIGN / 757 Mold Design / 758 CAD/CAM Modeling / 763 Additional CAD/CAM Features Used in Plastic Part and Mold Design / 773 Process-Analysis Tools / 777 Design Databases / 782 Computer-Integrated Manufacturing / 785 Myths and Facts / 785 Capability and Training / 786 11 DESIGN FEATURES THAT INFLUENCE PERFORMANCE / 789 Basic Detractors and Constraints / 789 Injection Molding / 796 Extrusion / 844 Blow Molding / 847 Thermoforming / 854 Reinforced Plastics and Composites / 856 Rotational Molding / 865 Assembly Methods / 869 Mechanical Loading / 870 12 CONCLUSIONS / 877 Product Diversification / 879 Materials Diversification / 883 Equipment Improvements / 887 The Solid-Waste Problem and Product-Design Solutions / 889 Technical Cost Modeling / 898 Success by Design / 900 Design Considerations / 900 Challenge Requires Creativity / 914 The Future / 915 viii CONTENTS Appendix A General Information Sources / 919 Appendix B Conversions / 921 Appendix C Trade Names / 925 Appendix D Computerized Software and Databases / 929 References / 937 Index / 967 REFERENCES 965 916 Stover, D "Recycling Technology Ready for the '90s." Plastics Machinery & Equipment, pp 35-36, Mar 1990 917 Machlis, S "How to Bring CAD to Life." Design News, pp 54-60, Mar 1990 918 Feldmann, P F "User Experiences with PC-Based CAD/CAE System." Kunststojfe, pp 810, Jan 1990 919 Noller, R "Understanding Tight-Tolerance Design." Plastics Design Forum, pp 61-73, Mar.-Apr 1990 920 Stanley, G., and Welch, C The Molding of an Industry British Plastics Federation, 1983 921 Haut, D "Success by Design." Medical Device & Diagnostic Industry, pp 48-69, Sept 1988 922 Kraus, H Creep Analysis New York: Wiley, 1980 923 Goldfein, S "General Formula for Creep and Rupture Stresses in Plastics." Modern Plastics, Apr 1960 924 Sheridan, T W "Creative Design with Thermoplastic Elastomers." Plastics Design Forum, pp 21-26, Mar.-Apr 1989 925 Janzen, W., and Ehrenstein, G W "Hysteresis Measurements for Characterizing the Cyclic Strain and Stress Sensitivity of Glass Fiber Reinforced PBT." SPE ANTEC, pp 659-63, May 1989 926 Felton, L P "Structural Index Method of Optimum Design." Proceedings, AS ME winter annual meeting, New York, 1974 927 Rogers, J K "Design Meets Manufacturing." Plastics Technology, pp 44-55, Nov 1988 928 Klein, A J "Plastics Materials and Designs: Improving and Saving Lives." Plastics Design Forum, pp 25-37, Nov.-Dec 1988 929 Murray, C J "Design with Lives in Mind." Design News, pp 100-2, Feb 1990 930 Stephenson, G M., and Freiherr, G "Cost-Effectiveness: New Yardstick for Medical Device Evaluation." Medical Device & Diagnostic Industry, pp 71-73, Mar 1990 931 Bregar, B "Architect's Concept Would Clad Buildings in Plastic." Plastics News, p 3, Feb 19, 1990 932 Goldsworthy, B "Composites for Roads and Bridges." Plastics Trends, p 12, Jan.-Feb 1990 933 McConnell, V P "Launch Systems: Advancing Composites into Space." Advanced Composites, pp 32-44, Jan.-Feb 1990 934 Robinson, G M "Tomorrow's Technologies at Your Doorstep." Design News, pp 103-7, Mar 1990 935 Vernyi, B "Composites Prove Worthy; GM Testing Use in Luxury Cars." Plastics News, pp 1,6, Feb 16, 1990 936 Snyder, M "Composites Market Plateaus." Plastics Machinery & Equipment, pp 31-32, Apr 1990 937 "A Glimpse at Future Auto Designs." Design News, pp 23-24, Mar 1990 938 "Composites at Sea." Advanced Composites, pp 38-58, Mar.-Apr 1990 939 Grolik, F W., and Naumann, H G "Reinforced Polypropylene for Motor Vehicle Interior Fittings." Kunststo.IJe, pp 34-38, Dec 1989 940 Rosato, D V "Product Design: Plastic Selection Guide." SPE ANTEC, May 1990 Index Ablation, 154,299 See also Heat shield Abrasion, 239, 244, 415 ABS, 74, 622 Absorption, 273 Accumulator head, 652 Acetal, 321,414, 883 Acetate plastic, 417 Acidproof brick, 421 Acid resistance, 438 Acoustic, 380 Acoustic test, 748 Acrylate elastomer, 470 Acrylic plastic, 272, 415 Acrylonitrile-butadiene-styrene plastic, 406 Actual versus theoretical values, 97 Additive, 63, 77, 287 Additive migration, 277 Adhesive, 362, 432, 714, 869 Adiabatic heat, 201 Advantages See Plastic advantages and disadvantages Aerodynamic shape, 235 Aerospace, 18, 196, 300, 309, 361, 740, 885 Aesthetic, 51, 230, 303, 780 Aging at elevated temperature, 95, 385 Aircraft See Aerospace Air entrapment, 614, 686, 814 Alkyd plastic, 416, 435 Alloy, 72 Aluminized film, 434 Aluminum, I, 127, 246 Alvin depth vehicle, 295 American Society for Testing and Materials, 734, 736 Amino plastic, 416, 423 Amorphous plastic, 66, 166 Anisotropic, 71, 122, 329 See also Directional properties; Cbientation Anti-icing, 235 Antilittering, 402 Aorta tube, 26 Apparent creep modulus See Modulus of elasticity, creep-apparent Appliance, 38, 233, 371, 403, 902 Approach engineering, 46 practical, 46, 763, 888 Aquacycle, 648 Aramid fiber, 82, 196, 241 Area under the stress-strain curve, 141, 208 See also Stress-strain Arrhenius plot, 260 Assembling, 340, 345, 714, 869 Athletic equipment, 436 Autoclave, 274 Autoclave molding, 678 Automobile, 29, 371, 681, 885, 904 Automotive bumper, 154, 220 Auxiliary equipment, 643, 711 Barcol hardness, 105, 245 Barrel,628 Barrier resistance, 276, 328 BASF,534 Bayer, 534 Beam, 312, 321, 366, 521 Beam equation, 146 Bearing, 240, 380, 420, 424 Belleville washer, 402 Bellow structure, 317 Bending modulus See Modulus of elasticity, flexural Biaxial direction, 118 See also Cbientation Bidirectional, 122 Biodegradable, 45, 891 Biological degradation, 273, 281 Birefringence, 99 967 968 INDEX Black box, 297 Bleed out, 418 Blend, 72, 406 Blow molding, 17,318,434,638,646,847 Blown film, 638 Boat See Ship Bolt, 163, 362, 400, 833 Boltzman superposition principle, 167 Bond See Adhesive Boron fiber, 82, 196 Bosses, 342, 790, 823 Bottle, 433, 646, 659, 747, 770 Bottle cap, 832, 841 Bottle, collapsible, 318 Box beam, 319, 368 Brackish water, 883 Brass, 1,246 Brinell hardness, 105 Brittle fracture See Fracture Brittleness, 106, 201 Buckling strength, 328, 371 Building and construction, 18, 273, 283, 371, 684 Bulk molding compound, 39, 416, 418, 494 Bumper See Automotive bumper Buoy, 289 Buoyance, 295 Burn cleanly, 893 Burning, 889 Butadiene plastic, 406 Butyl elastomer, 470 Butyrate plastic, 417 Calendering, 693 Cam, 230 Campus database, 534 Canoe, 10 Cantilever beam, 21, 148, 315 hinge, 350 snap fit, 349, 402 spring, 322 Carbon black, 81, 385 See also Filler Carbon fiber, 196, 241, 885 Casting, 424, 693 Catastrophic failure, 153, 198, 285, 310 Cathode sputtering, 230 Cauchy-Riemann differential equation, 395 Cause-effect relationships, 56 Cavitation erosion, 295 Cellulose acetate butyrate plastic, 417 Cellulose acetate plastic, 417 Cellulose acetate propionate plastic, 417 Cellulose nitrate plastic, 417 Cellulose plastic, 72, 417 Cement, 421 See also Adhesive Center of gravity, 385 Charpy impact test, 212 See also Impact Chemical characteristic, 116 process, 71 reaction, 276 resistance, 264, 417, 561 separation system, 886 Chimney liner, 47 Chlorinated polyether plastic, 417 Chlorinated polyethylene plastic, 418, 470 Chlorinated polyvinyl chloride plastic, 452 Chlorosulfonated polyethylene elastomer, 470 Chrome plate, 412 Circuit board, 233, 623 Classifying plastic, 525 Clearance See Tolerance Coating, 230, 301, 420,475,646 Coefficient of diffusion, 276 of friction, 242, 420 of linear thermal expansion, 89, 337, 362, 388, 798 of torsion, 401 Coextrusion, 18,280,635 Coining, 349, 693 Coinjection molding, 623 Cold forming, 105, 355, 668 Cold work, 351, 794 Collapsible container, 316, 663 Collapsible mechanism, 355 Color, 78, 100, 790 Combustion See Flammability Commodity plastic, 82, 254 See also Engineering Plastic Communication protocol, 711, 888 Comonomer, 71 Compatibilizer, 72 Competition, 592, 762 Composite See Reinforced plastic, definition; Plastic, definition Compound, 72 Compressible melt, 116 Compression molding, 668, 679 Compression modulus See Modulus of elasticity, compression Compression properties, 145, 375, 382 Compressive recovery rate, 145 Compressive strength, 135,474 Compressive yield strength, 207, 400 Compromise, 303 Computer image processor, 753 in design, 52, 776 modeling, 763, 680 program, tolerances, 399 technologies, 53 Computer-aided chemistry, 741 design, 53, 615, 757 design drafting, 53 engineering, 615, 778 manufacturing, 53, 652, 758 testing, 54 Computer-integrated manufacturing, 53, 606, 785 Computerized software and databases, 528 See also Appendix D INDEX 969 Concrete, 1, 152, 328 Conductive plastic, 230, 239 Conservation, 402 Constrains, 789 Construction See Building and construction Conversions See Appendix B Cooking utensil, 420 Cooling stresses See Stresses, cooling Copolyester elastomer, 472 Copolymerization, 204 Copolymer, 71, 406, 414 Copper, Core See Foam; Honeycomb; Sandwich Cored metal casting, 693 Coring, 804, 824 Comer, 799 Corrosion, 241, 264, 372,417,420 Corrugation, 49, 838 Cost, 51, 58, 133,249,276,338,373,524,593, 650, 706, 888, 898 Cost modeling, 702 Crack, 142, 154, 191,221,270,309 Crazing, 142, 159, 270 Creativity, 51, 125, 914 Creep, 114, 155,247,401 guidelines, 179, 189 modeling, 174 modulus, 175 rupture, 156, 158, 167, 273 theory, 182 Creep-gasket, 360 Cross-bond, 65 Cross-head rate See Test rate Cross-link, 64, 97, 282, 416, 440 Crystal clear, 415 Crystalline plastic, 66, 166, 195 Cushioning, 475, 488 Cutting plastic guidelines, 728 Cyclic chemistry, 884 Cyclic load See Fatigue Damping, 154,201,361 Data theoretical, 97 Databases, 528, 758, 773, 782, 929 See also Computer and Appendix D Decay, 161 Decomposition temperature, 95, 284 Decorating, 714, 790 Defect, melt flow See Melt flow defects Deflection, 315, 338, 372, 402, 820 Deflection temperature under load, 94, 258 Deformation, 107, 153, 163,203,381 Degradable, 894 Degradation, 117,213,281 Density, 84, 98, 112 Density reduction, 365 Design allowables, 311 analysis, 46, 48, 126, 129, 696, 789, 910 bending of bar, 184, 521 bolt preload, 400 building-fire, 285 building frame, 282 challenge, 52, 914 compromises, 2, 5, 48, 900 consideration, 789, 898 criteria, 125, 132, 910 cushioning, 488 See also Design, dynamic load databases, 782 See also Databases deficiencies, 754, 789 definition, dynamic load, 371, 540 See also Design, cushioning fail-safe, 194 failure analysis See Failure analysis features, 789 flow diagram, for environment, 385 gears, 359 graphic See Graphic graphic uncertainties, 310 optimization, 1, 789, 780 overdesign, 126 See also FALLO approach parameters, 4, 789, 910 pipe-heavy wall, 189 pipe joint, 339 pipeline on supports, 185 pipe-reinforced plastic, 326 See also Pipe pipe, thin wall, 187 procedures, 48, 54, 696 procedures, flow diagrams, products, 2, 703, 789, 895, 929 pseudo-elastic method, 304 redesign, 3, 5, 903 See also FALLO approach reinforced plastic theory, 495 rib, 835 safety factor, 309, 332 See also Safety factor sandwich structure, 368 screw (for processing plastic), 614, 628 shape, 49 snap fit, 346, 402 spring, 321 structures, 303, 835 success, 789, 917 thermal expansion, 362 tolerance guide, 802, 846 torsional spring, 323 with computers See Computers in design with success, 51, 900 Design concept, 4, 231, 247, 904 blow molding, 659, 847 extrusion, 631, 844 injection molding, 617, 796 intermittent See Intermittent behavior long term See Long-term behavior reinforced plastic, 856 rotational molding, 865 thermoforming, 854 Designer and computer, 52 Designer and regulations, 402 See also Regulations Designer ethics See Ethics 970 INDEX Designer responsibilities See Responsibilities Designing classic approach, 46 dies, 629 fundamentals, 1,910 heat generating products, 902 molds, 393, 758 799, 934 molds with "holes", 819 with creep data 175 with databases, 4, 52, 773, 932 See also Databases with elastomers, 458 with fatigue data, 201 with impact data, 220 with materials, 932 with screw insert, 831 Detractor, 789 Deutsches Instut-Normung, 732 Diallyl isophthlate plastic, 418 Diallyl phthlate plastic, 418 Diaphragm, 420, 841 Dichroism, 99 Die, 391, 591, 599, 629 Die shear rate, 109 Dielectric strength, 229, 282, 420 Differential scanning calorimetry, 737 Diffusion, 276 Digitizing, 775 Dimensional change See Tolerance Dimensional characteristic, 87, 265, 634, 834, 869 Directional properties, 118, 121 333, 700 Disadvantages See Plastic, advantages and disadvantages Dispersion, 100 Disposable labware, 18 Disposal,403 Distortion temperature See Deflection temperature under load Dow Chemical, 470 Downtime, 889 Draft angle, 790, 810 Drain-waste-vent, 412 Drawing See Graphics Droop test, 262 Drug release implant, 45 Drying plastic See Hygroscopic plastic Ductile, 105 Ductile fracture See Fracture Ductile-to-brittle transition temperature, 203 Ductility, 102, 160,220 DuPont, 400, 472 Durometer, 385, 460 Dynamic load, 153, 348, 371,540 Dynamic mechanical analysis, 387, 746 Dynamic mechanical behavior, 153, 590, 872 Dynamic modulus See Modulus of elasticity, dynamic Dynamic sensitivity, 238 Dynatup test, 216 See also Impact Eagle wing, 301 Earthquake, 373 Eastman Chemical, 472 "Ecdel", 472 Ecology, 402 Economic analysis, 877, 897 See also Cost Educational information, 53, 896 See also Training Ejector, 814 Elastic deformation, 107, 220, 387 Elastic limit See Tensile elastic limit Elastic modulus See Modulus of elasticity Elastic turbulence, 114, 154 Elasticity, 102, 112 Elastomer, 61, 70, 233, 301, 371,458, 472, 527 Electric iron, 39 Electric power tool, 38 Electrical, 223, 260, 418, 450 Electromagnetic compatibility, 225 interference, 225 radiation, 235, 282 welding, 727 Electronic, 12, 232, 434, 534 Electronic radiation, 228 Elongation creep, 157 fatigue, 191 impact, 207 tensile, 137, 385 Empathy, 51 Endurance limit, fatigue, 194 Energy absorbed, 372, 590 conservation, 713 consumption, 628 control, 371, 781 dissipation, 195, 196, 540 efficiency, 373 impact, 141 kinetic See Kinetic energy ratio of recovery, 590 to failure, 210 to manufacture, 58 via incineration, 891 See also Incineration Engine, 10, 427, 880 Engineering approach See Approach, engineering equation, 125,304,314 plastic, 82, 234, 366 See also Commodity plastic stress See Stress, engineering Environmental concept house, 25 conditions, 253, 429 enbrittlement, 154 influence, 201, 385 Environmental Protection Administration, 891 Epoxy plastic, 263, 419, 427 Equipment improvements, 887 INDEX 971 Ergonomic, 51 Erosion, 295, 300 Ethics, 52 Ethyl cellulose plastic, 417 Ethylene acrylic elastomer, 471 Ethylene chiorotrifluoroethylene plastic, 421 Ethylene oxide, 274 Ethylene propylene elastomer, 470 Ethylene tetraftuoroethylene plastic, 421 Ethylene vinyl acetate plastic, 419 Euler equation, 371 European market, 530 EVAL Company of America, 276 Exothermic reaction, 474 Expandable polystyrene plastic, 449, 690 Extensometer, 142 Extruded hinge, 355 Extrusion, 610, 624, 642, 844 Extrusion blow molding, 651 Extrusion tandem complex, 888 Fabric, 82, 510, 584 Fabric, three-dimensional See Three-dimensional woven fabric Fabricating See Processing Fact and fiction See Statistics, fact and fiction Factor of ignorance, 55, 309 Factor of safety See Safety factor Facts and myths, 785 Fail-safe, 194 Failure analysis, 387, 754 Falling weight test, 415 See also Impact FALLO approach, 3, 589 Fastener, 340, 364, 400, 723, 870 Fatigue, 153, 190, 249, 385 crack, 197 endurance limit, 194, 588 heat generation, 195 rate dependence, 163, 195 strength, 265, 359 strength versus tensile strength, 193 testing, 191 transparent, 196 Fatigue-reinforced plastic, 191, 195 Fatigue-reinforced plastic film interlayer, 196 Fiber orientation, 118 Fick's law of diffusion, 279 Filament winding, 295, 326, 684 Filler, 63, 77, 287, 727 Fillet, 402, 795 Film, 473, 638, 888 Film orientation See Orientation Financial See Cost Fine tuning, 40 Finish, 38, 714 Finite element analysis, 55, 399, 401 Finite element modeling, 773 Fire, 282, 287, 404, 879 Firefighter, 286, 432 Fire Research Center, 288, 403 Fire Safety, 404 Fire, small and large scale, 285 Fit See Press fit; Snap fit Flame dripping, 287 Flame retardant, 285, 420 Flammability, 9, 282, 422 Flash,524 Flexural modulus See Modulus of elasticity, flexural Flexural properties, 146 Flexural strength, 135, 146 Flotation, 292 Flow, nonlaminar, 108, 114 Flow performance, melt See Melt flow Fluorinated ethylene propylene plastic, 421 Fluorine gas, 276 Fluorocarbon, 472 Fluoroplastic, 39, 358, 420 Fluorosilicone elastomer, 471 Foam, 49, 295,475, 590, 624 Foam reentrant, 887 Foam reservoir molding, 679 Foam, structural See Structural foam Foamed-in-place, 475 Foaming processes, 690 Foldable container, 317 Folded membrane, 232, 317 Forrest Products Laboratory, 122 Forming, 665 Fracture, 153, 197, 221, 387 Fracture mechanics, 196 Fracture resistance, 201, 204 Friction, 239 Frozen stress, 638 Fumes, 286, 431 Fungal deterioration, 282 Furan plastic, 421 Fusible core molding, 693 Future high performance plastic, 36, 97, 133 Garbage, 889 Gardner test, 414 See also Impact Gas injection molding, 624 Gas permeability, 104, 276 Gasket, 360,420 Gasohol, 414 Gasoline storage tank, 265 Gate location, 217, 808 Gauge length, 136 Gear, 40, 240, 359, 398 Gear pump, 628 General purpose polystyrene plastic, 449 Geometry factors, 196, 304, 346, 360, 368, 402, 699, 749, 837 German database, 530 Glass, 276, 293 Glass fiber, 66, 196, 241 Glass transition temperature, 70, 83, 195,431, 638 "Glasshopper," 45 972 INDEX Golf course, 879 Gossamer Albatross airplane, 32 Government groups See Appendix A Grafting, 75 Granulate, 524, 886 Granule, 71, 591 Graphics, 310, 783, 930 See also Appendix D Graphite fiber, 30, 82, 196,241,389,884 Gravitational force, 292 Grommet, 360 Guided load, 306 Hairline crack, 309 See also Crack Hand lay-up molding, 674 Handle, 649, 662 Hardness, 105, 239,244 Haze, 98, 100 Health care, 18 Heat capacity, 84, 88 condition, 201 dissipated, 695 distortion temperature See Deflection temperature under load exchange, 116, 614 generation, fatigue, 195, 359 history, 602 release, 282, 359, 555 shield, 253 See also Ablation test, 260 welding, 727 Heterogeneous, 73, 122 Hevea Brazilienst, 458, 467 High-density polyethylene plastic, 276, 444 High molecular weight HOPE plastic, 444 High pressure laminate, 82 Highway, 372 Hinge, 346,349,841 Hoechst Celanese, 358, 472, 534, 883 Hole-blind, 819 Hollow channel, 319, 666 Homogeneous, 73 Homopolymer, 414 Honeycomb, 31, 49 Hooke's law, 139, 495 Hoop stress, 335, 342, 355 Hopper rail car, 45 Hot air duct, 235 Hull-deep submergence, 293 Humidity, 273, 388 Hydrocarbon plastic, 420 Hydrodynamic force, 292 Hygroscopic plastic, 201, 602 "Hypalon," 470 Hypervelocity impact See Impact, strength Hysteresis effect, 140, 201, 359, 540, 565 "Hytrel," 472 I-beam, 314, 368 Identify plastic, 525, 547 Ignition temperature, 284 Ignorance factor See Factor of ignorance Impact detector, 238 factors influencing, 153, 217 load, 210, 361 rapid load, 153, 201, 205, 209 strength, 96 See also Area under the stressstain curve tensile, 119, 210, 215 Implant, 45 Impregnated, 82 Improvements, 57 Incineration, 58, 889, 892 Indentor, 105 Induction welding, 727 Industrial pollutant, 273 Inert, 422 Infrared spectroscopy, 746 Initial modulus See Modulus of elasticity, initial tangent Injection blow molding, 657, 749 Injection molding, 450, 610, 685, 712, 796, 808 circuitboard, 233 gas, 624 liquid,687 Insert, 340, 719, 797, 825, 854 Inspection, 606 Insulator, 20, 225, 275, 902 Integral hinge See Hinge Intermittent behavior, 74, 130, 164 Interrelating product-resin-process performance, 55 Interrelating properties, plastics, and processing, 116,758 Intuitiveness, 125 Ionic bonding, 421 Ionomer plastic, 421 Ironing clothes, 38 Irradiation, 274 Isochronous graph, 157, 181,256 Isometric graph, 157, 181,256,769 Isoprene rubber, 70 Isostatic, 280 Isothermal heat, 201 Isotropic, 71, 121, 141, 368, 509 See also Orientation Iwd impact, 208,212, 594,797 See also Impact Joining, 841, 714, 869 Joint, 336, 339, 838 "Kelvar," 82 Ketone plastic, 422 Keyboard, 238 Kinetic energy, 210 Kinked molecular chain, 118 Knoop indentor, 105 Labeling, 319, 721 Landfill, 58, 891 Law, 402 Leaching, 891 INDEX 973 Leaf spring, 321 Life cycle, 908 Light scattering, 98 Light transmissability, 99 Linear thennal expansion See Coefficient of linear thennal expansion Liquid crystal polymer, 68, 263,422 Liquid injection molding, 687 Liquid penetrant test, 748 Liquid plastic, 591 Living hinge See Hinge Load analyzed, 305, 335, 565 Load bearing product, 303 Load deflection, 370, 380 Load, dynamic See Dynamic load Load pipe externally, 326 Load relaxation See Relaxation load Loading, impact See Impact, load Loading, intermittent See Intermittent behavior Loading, long-tenn See Long-tenn behavior Loading mode, 130,201,362 Loading short duration, rapid See Impact, rapid load Loading, short-tenn See Short-tenn behavior Loading, static, 153 Locking fastener, 402 Longitudinal stress, 336 Long-tenn behavior, 134, 153, 241, 247 Lord Corporation, 372 Loudspeaker, 361 Low-density polyethylene plastic, 441 Low pressure laminate, 81 Lubricity, 107 "Lubricomb," 239 Luminous transmittance, 98 Luscher and Hoeg equation, 333 Machine conditions, 55 Machine improvements, 590, 887 Machining plastic, 727 Machining plastic guidelines, 594, 728 Magnetic resonance imaging, 882 Manufacturing See Fabrication Manufacturing via computer See Computer-aided manufacturing Markets, 9, 877 Mar resistance, 244 Material handling, 713 Material selection See Plastic selection Materials comparison, 7, 8, 35, 97, 740, 931 Mathematical analytical solution, 48 Mathematical model, 614, 776 Matte finish, 38 Maxwell model, 175 Mechanical behavior, dynamic See Dynamic mechanical behavior blending, 72 damping See Damping interface, 342 loading, 195,488,870 properties, 86, 96, 127, 133, 930 properties, superior, 97 Medical, 45, 228, 882 Melamine fonnaldehyde plastic, 82, 416,423 Melt compressibility See Compressible melt flow, 113, 123,209,591,617,630, 778,782 curve, 397 defects, 113, 618 trends, 116 fracture, 114 index, 110, 440 orientation, 117 See also Orientation pump, 628 shear rate, 107 structure, 115 temperature, 65, 83, 611, 614 viscosity, 653 Melting point, 68, 425 Membrane technology, 232 Memory in plastic, 117 Metal, 153, 203, 342, 368 Metallization, 238, 717 See also Coating Microbial degradation, 281 Microcracking, 272 Microtoming, 750 Microwave oven, 233 Migration, 276 Mining in the sea, 289 "MinIon," 400 Missile, 44, 235, 453 Mixing, 591 Mobay Chemical, 349 Modeling, 596, 763 Modeling cost, 898 Modulus of elasticity, 136, 510 compression, 145 creep, 155, 162 creep-apparent, 161, 175 dynamic, 154, 195, 385 flexural, 146, 835 initial tangent, 139, 304 secant, 140, 304, 349 shear, 149, 369 soil, 330 static, 385 temperature, 108 tension, 119, 139 theoretical, 97 viscoelastic, 175, 209 Modulus of rupture See Aexural strength Mohr's circle, 308 Moisture, 273, 282, 416 Mold, 348, 391, 591,599, 615,758,808,934 Mold action, 841 Mold cooling analysis, 780, 934 Mold quotation guide, 600 Mold, time to produce, 601 Molded-in hinge See Hinge Molded-in insert, 340, 825 Molded-in stresses, 116 Mold operation, 605 974 INDEX Molding area diagram, 609 Molding variables versus performances, 616 Molding volume diagram, 609 Molecular motion and mechanical damping, 154 Molecular orientation, 118 See also Orientation Molecular weight, 109, 281 Molecular weight distribution, 109, 116 Molecule, 66 Molecule, kinked, 118 Molybdenum disulfide, 241 Moment of interia, 49,312,319,332,367,521, 835 Moment of inertia, polar, 324 Monomer, 71, 277 Morphology, 66, 84 Motion control, 371 Motor housing, 690 See also Engine "Mylar," 196 Myths and facts, 785, 889 Natural rubber, 70, 467 Neat plastic, 89, 147, 246 Necking, 136, 158, 203 Neoprene elastomer, 469 Netting die, 636 Newtonian liquid, 109 Nitrate plastic, 417 Nitrile elastomer, 469 Nitrogen, 276 Noise, 360, 371 Nomography, 102 Nonburning, 284 Nonconductive, 228 Noncrystalline plastic See Amorphous plastic Nondestructive testing, 55, 746 Nonlarninar flow See Flow, nonlarninar Nonlinear effect, 130 Non-Newtonian liquid, 109, 630 Nonplastication, 115 Notched, 191,208,212 Notch sensitivity, 106 Nuclear magnetic resonance spectroscopy, 747 Nuclear radiation, 282 Nylon plastic, 38, 119, 289, 400, 423, 873 O-ring seal, 292 Ocean environment, 288 Offset strain See Strain, offset Oil resistance, 385 Olefin plastic See Polyolefin plastic Optical analysis test, 98, 750 Optical plastic, 491 Orientation, 118, 166, 209, 268, 515, 616, 620, 638,658,734,791,797,888 Orthotropic, 122, 510 Oscillatory rheometer, 149 Osmosis, 883 Overdesigned, 126 Oxifluorination, 276 Ozone, 273, 283, 385 Packing, 12, 274, 432, 880 Paper, 82 Parabolic reflector, 239 Parison thickness control, 653 Parting line, 805, 843 Parts handling, 713 Parylene plastic, 425 Pascal See Appendix B Pattern making, 596 Pellet, 591 Perfection, 403 Performance prediction, 55, 97, 125 Performance versus molding variables, 616 Permanent set, 136, 402 "Permasep," 883 Permeability, 277, 424, 732 See also Gas permeability; Vapor permeability Perms, 104 Phenol-formaldehyde plastic, 426 Phenolic plastic, 82, 426 Phenoxy plastic, 427 Photoelastic stress analysis test, 748 Photopolymerization, 599 Physical properties, 98 Piezoelectric, 237 Pinch-off, 654 Pipe, 47,269,326,358,432,644,845 See also Design pipe Pipe orientation See Orientation Pipe thread See Thread Plant overhead, 60 Plastic advantages and disadvantages, 56 and the world, 9, 879 behavior, 209 See also Intermittent behavior; Short-term behavior; Long-term behavior brittle, 209 classification, 525 comparisons, 535 consumption, 405, 591, 877, 916 database See Computerized software and databases; Appendix D definition, 61, 109 development, I diversification, 878 future, 97, 915 geometry, 66 high performance, 97 hygroscopic See Hygroscopic plastic identification guide, 525, 527 intermittent behavior See Intermittent behavior long-term behavior See Long-term behavior misapplications, 754 myths, 785, 889 processing See Processing properties, 6, 61, 129, 276,405, 931 selection, 53, 126, 166, 525, 535 short-term behavior See Short-term behavior structure, 66 thickness, 388 See also Thickness to metal, 358, 368 to metal wear, 246 INDEX 975 to plastic wear, 246 types, 6, 62, 166 volume, 901, 916 with a memory, 117 Plastic Bottle Institute, 896 Plasticity, 102, 591 Plasticizer, 204, 692 Plastics are bad, 785, 889 Poisson's ratio, 141, 151,323,336,510 Poisson's ratio, negative, 887 Polarized light, 99 "Polimotor," 880 Polyallomer plastic, 428 Polyamide plastic, 423, 473 Polyamideimide plastic, 263, 428 Polyanhydride plastic, 45 Polyarylate plastic, 430 Polyarylether plastic, 420 Polyaryletherketone plastic, 420 Polyarylsulfone plastic, 431 Polybenzimidazole plastic, 431 Polyblend, 73, 166 Polybutadiene elastomer, 469 Polybutylene plastic, 432 Polybutylene terephthalate plastic, 433 Polycarbonate plastic, 273, 432 Polyester plastic, 433 Polyester thermoplastic, 433 Polyester thermoset plastic, 435 Polyehter chlorinated plastic, 417 Polyetheretherketone plastic, 263, 422, 438 Polyetherimide plastic, 439 Polyetherketone plastic, 422, 436 Polyetherketoneetherketoneketone plastic, 431 Polyethersulfone plastic, 263, 440 Polyethylene chlorinated plastic, 418 Polyethylene plastic, 289, 440 Polyethylene terephthalate plastic, 433 Polyimide plastic, 445 Polyisoprene elastomer, 467 Polymat database, 530 Polymer See Plastic Polymerization, 599 Polymethylmethacrylate plastic, 415 Polymethylpentene plastic, 446 Polynomial, 872 Polyolefin elastomer, 473 Polyolefin plastic, 421, 440, 446 Polyperfluoroalkoxyethylene plastic, 421 Polyphenylene ether plastic, 446 Polyphenylene sulfide plastic, 239, 447 Polypropylene plastic, 447 Polypyrrole plastic, 239 Polystyrene plastic, 23, 449 Polysulfide elastomer, 471 Polysulfone plastic, 449 Polytetraftuoroethylene plastic, 241, 360, 420 Polyurethane elastomer, 469, 472 Polyurethane plastic, 361, 451, 588 Polyvinyl acetate plastic, 454 Polyvinyl alcohol plastic, 454 Polyvinyl butyral plastic, 454 Polyvinyl chloride plastic, 489, 452 Polyvinylidene chloride plastic, 455 Polyvinylidene fluoride plastic, 238, 421, 455 Postage stamp, 881 Postforming, 641, 670 Postshrinkage, 388 See also shrinkage Powder, 591 Powder coating, 692 Practical approach See Approach, practical Pragmatic approach, 126 Preload, 400 Press fit, 40, 163, 342 Pressure bag molding, 678 Pressure, velocity, 241 Pressure vessel, 325, 883 Printed wiring board, 232 Problem solving, 914 Process analysis tools, 777 Process control, 392, 603, 614, 627, 653 Process selection, 166,591,695 See also Selection Processing, 107, 116, 209, 217,524,589,675, 759, 785, 934 Processing and tolerance, 391, 596, 640 Processing cycle, 595 Processing equipment improvement, 887 Processing guidelines, 2, 682, 703 Processing variables, 55 Product life cycle, 908 Product shape, 129 Product size, 699 Product specification, 398 Productivity, 611, 759,879,903 Professional groups See Appendix A Profile, 475, 647 See also Extrusion Property, theoretical, 97 Propionate plastic, 417 Proportional limit See Tensile proportional limit Protocol, communication, 711, 888 Protocol, fire test, 404 Prototype, 164,341,596,762 Pseudo-elastic method See Design, pseudo-elastic method Publications See Appendix A Pultrusion molding, 683 Pump, 295, 420 Punching, 105 Purging, 615 Pyrolyzing, 885 Quality auditing, 753, 761 Quality control, 591, 731, 754 Quotation, 600 Radiation, 274, 902 Radio frequency interference, 228 Radio frequency welding, 725 Radiography, 746 Radome, 13, 235, 301 976 INDEX Rain erosion, 300 Rapid transit vehicle, 371 Reaction injection molding, 682, 687 Reactive polymer, 76 Reactor, 71 Reciprocating screw, 610 Recovery rate, compression, 145 Recreation, Recycling, 24, 58, 524, 602, 889, 892 Reduced cross section, 136, 158 Reentrant foam, 887 Refractive index, 98 Refrigerator, 42 Regrind See Granulate Regulation, 402, 732, 897 Reinforced plastic, 81, 121, 265,293,299,310, 421,435,493,668,670, 856 definition, 81 493 fatigue testing, 191, 195 film interlayer, 196 hysteresis measurement, 584 pipe, 326 processing, 673, 698 spring, 321 weep, 334 Reinforcement, 63, 77, 501, 673 Relative thermal index, 261 Relaxation load, 114, 153, 164 Reliability control, 754 Residence time, 602 Residual deflection See Deflection Residual monomer, 277 Residual stress, 791, 872 Resin See Plastic, definition Resin-transfer molding, 679 Resource utilization, 762 Responsibilities, 51 Retardation, 140 Reynold's number, 395 Rheology, 107 Rheometer, oscillatory, 149 Ribs, 50, 310,316, 331,790,833 "Riteflex," 472 Rivet, 362 Robots, 888 Rockwell hardness, 245 Rotational molding, 691, 865 Roving, 510 Rubber, 458, 467 See also Elastomer Rupture strain See Strain, rupture Safety factor, 54, 125, 332 See also Design, safety factor Safety factor guidelines, 309 Safety glass, 18 Sailboard, Salt spray test, 273 Sandwich structure, 31, 49, 235, 295, 368 Scrap, 524 Scratch, 244, 415, 491 Screen pack, 627 Screw design, processing plastic See Design, screw Screw thread See Thread Sea environment, 288 Seal, 341, 360 Sealing See Hot sealing Secant modulus See Modulus of elasticity, secant Secondary operations, 711 Selection See Plastic selection; Process selection; Test selection Selection worksheet, 535 Self-extinguishing, 284 Self-latching, 318 Self-tapping screw, 358 Sensor, 239 Sewing machine, 41 S-glass, 196 Shape, 49, 129, 235, 319, 663, 699, 789, 843 Shape factor, 360, 373, 591 Sharkskin, 114 Shear modulus See Modulus of elasticity, shear Shear properties, 149, 382 See also Melt, shear Shear rate, melt See Melt, shear rate Shear strength, 135, 151 Shear strength, direct shear, 150, 325 Shear stress See Stress, shear Shear yield strength, 151 Sheet, 473, 645 Sheet molding compoond, 416, 494 Sheet orientation See Orientation Shielding, 228 Ship, 11,289,371,879 Shock, 371 Shoe, 195,587,769 Shore durometer, 105, 245 Short-term behavior, 135,201,209,241,247, 355 Shot peening, 265 Shot-to-shot variation, 615 Shotgun shell, 881 Shrink allowance, 390, 393,596,607,616,656, 661, 791 Shrinkage, 70, 115, 123, 388, 758, 829, 934 Silicone elastomer, 471 Silicone plastic, 233, 241,455 Simple support load, 306 Sink mark, 624, 798, 804, 836 Sinusoidal deformation, 153 Sketches See Graphics Skin, integral, 49 Skis, Smoke generation, 264, 282, 286 Snap fit, 12,345, 402, 838 Snap switch, 232 S-N curve, 191 Software See Computer; Databases; Appendix D Solar radiation, 272, 297 Sole of shoe See Shoe Solid modeling, 772 Solid-phase forming, 668 Solid waste, 58, 889, 896 INDEX 977 Solubility, 66 Solvent, 429, 714, 869 Sound absorbing, 361 Space communication antenna, 15 Spadoning, 38 Space environment, 297, 371 Spangler Iowa equation, 331 Specific gravity, 98 Specific heat, 285 Specification, 398, 402, 594, 732 Spherical shape, 235 Spin welding, 725 Splay, 366, 624 Spray-up molding, 674 Spray-zinc arc, 230 Spring, 163, 195, 380, 400 See also Design, spring Staking, 325 Stamping, 666, 683, 717 Stamps, 881 Standard,732 Stapler, 321 Static loading, 153 Statistics, 126, 193, 223, 212 Statistics, fact and fiction, 890 Steel, I, 127,247,328 Stereolithography, 598 Sterilization, 274 Stiffness, %, 129, 319, 368, 380, 836 Stiffness factor, 331, 370, 521 Stiffness-to-weight ratio, 310 Storage tank, 265 Strain analysis, 164, 333, 339 compression, 145, 375 creep, 155 damping, 154 dynamic See Dynamic load fatigue, 190 impact See Impact induced load, 305, 336 initial, 158, 385 limit, 304 offset, 137 plastic, 136 rapid, 201, 215 recovery, 164 rupture, 159 shear, 151, 523 tensile, 136, 336 thermal contraction, 333 time dependent, 159 Strain-to-first crack, 334 Strapping, 474, 664 Strength, 91 See also Tensile strength; Compression strength; Flexural strength; Fatigue strength; Shear strength; Buckling strength Strength, regression, 161 Strength-to-weight ratio, 310 Stress, 872 allowable working, 178 amplitude, 191, 197 analysis, 304, 820, 872 beam bending, 312, 315 bending, 146, 359 compression, 147,400 concentration, 217, 794, 799 constant, 201 corrosion, 265, 295 cracking, 156, 270 crazing, 159, 270 creep, 155 damping, 154 deflection See Deflection engineering, 136 fatigue, 190 frozen, 638 harden, 873 history, 153 hoop See Hoop stress impact, 362 imposed, 167,825 longitudinal, 336 multiaxial, 308 nonrecoverable, 136 number of cycles curve, 335 peak,359 relaxation, 114, 118, 162, 360 residual See Residual stress sandwich beam, 369 shear, 110, 149, 323, 325, 355, 387 spring, 321 tensile, 136, 147, 400 thermal See Thermal stress time, creep, 157 true, 136 Whitening, 160, 272 zero, 1% Stress-strain behavior, 136, 147, 157, 181,207 curve/data, 57, 139, 141, 143,273,335,459 impact, 361 polynomial, 872 Stresses-molded-in, 820 Stretching See Orientation Structural foam, 23, 295, 365, 474, 709 Structure, 31, 50, 293, 297, 303, 368, 380, 667, 837 Styrene, 418 Styrene-acrylonitrile plastic, 412, 883 Styrene butadiene elastomer, 468 Styrene copolymer elastomer, 473 Submarine, 289 Success by design, 51 Super polymer, 422 Support condition, 305 Surface finish, 700 Surface modeling, 767 Surfboard, 10 Suspension system, 378, 385 Swelling, 66, 630 978 INDEX Swimming pool, 436 Switch, 232, 416 Symbols, 143 Synergistic effects, 72 Syntactic foam, 295, 475 Tank,44,46, 265, 647, 883 Tape, 639, 643 Taper, 660, 810 Technical cost modeling, 898 "Techturf," 879 Telephone, 412 Temperature, 203,253, 297,903 Temperature, glass transition See Glass transition temperature Temperature index, 95 Temperature range, 92, 428 Tennis, Tensile bridging, 338 elastic limit, 136, 138, 387 elongation See Elongation, tensile hysteresis See Hysteresis, effect impact See Impact, tensile modulus of elasticity See Modulus of elasticity, tensile properties, 136 property symbols, 143 proportional limit, 137 strain See Strain, tensile strength, 36, 135, 138, 2ll, 724 strength, theoretical, 97 strength at break, 138 strength versus fatigue strength, 193 stress See Stress, tensil stress crazing See Crazing yield strength, 137, 400, 402 Tentering frame, 638, 642 Terpolymer, 71 Test assumptions, 308 Test method, 734, 735 acoustic, 380 appliance safety, 403 artificial, 273 chemical, 272 classification, 525 coefficient of linear thermal expansion, 89 compressive properties, 145 creep-rupture properties, 156, 160 deflection temperature under load, 94 density, 98 drop-weight, 361 Dynatup, 215 elastomer, 458 electric, 225, 422 electromagnetic, 228 falling weight, 215 fatigue, 191 flame, 287, 403 flexable culvert, 331 flexural, 146 flow, 417 foundation, 332 friction and wear, 241 Gardner, 215 gas transmission, 279 gasket, 360 glass transition temperature, 83 hardness, 71, 105 heat capacity, 88 heat test, 260 hydrostatic, 334 impact, 209,212, 217 limiting oxygen index, 287 long-term behavior, 153 melt index, llO modulus, 175 pipe deflection, 330 plastic selection, 540 safety factor, 332 shear, 149 specific gravity, 98 spring, 322 stress cracking, 271 temperature index, 95 tensile, 136 tensile impact, 215 test rate, 143 thermal conductivity, 87 thermal diffusivity, 88 thermal insulation, 87 torsion, 152 wall thickness, 747 water absorption, 104, 272 wear See Test method; Friciton; Wear weather, 273 Test rate, 143 Test selection, 755 See also Selection Test simplification, 308, 732 Test specimen cross-section, 136, 735 Testing, 272, 292, 334, 731 high speed, 209 nondestructive See Nondestructive testing short-term, 134 Testing via computer See Computer-aided testing Theoretical versus actual values, 97 Thermal aging, 260 conductivity, 84, 87 contraction, 333, 377 diffusivity, 84, 88 expansion, 84, 90, 362, 377 failure, 196, 201 index, relative, 261 insulation, 84 properties, 83, 903 stress, 90, 297, 362 Thermoanalytical test, 735 Thermodynanrics, 116, 201 Thermoforming, 666, 886 Thermoforming orientation See Orientation Thermogravimetric analysis test, 740 INDEX 979 Thennomechanical analysis test, 744 Thennoplastic, 64, 253, 611 Thennoplastic elastomer, 70, 371,472 Thennoset, 64, 66, 253, 611 Thennoset elastomer, 70, 467 Thickness, 790 Thread strength, 355, 358, 680, 824, 831 Three-dimensional woven fabric, 122 Throwaway aspect, 890 Time dependent loading, 130 Titanium, I Toilet flushing, 883 Tolerance, 387, 398,416,596, 606,629,647, 660,761,791, 802,834,846,855,864,869 Tooling, 596, 701, 758 Torque, 832, 870 Torsion pendulum, 149 Torsion properties, 152, 323, 355, 380, 401 Toughness, 96, 105,203,415,421,432 See also Area under the stress-strain curve Towline, 292 Toxicity, 282, 286,431, 889 Trade association See Appendix A Trade magazine See Appendix A Trade name, 76,405, 533 See also Appendix C Training, 786 See also Educational infonnation Transducer, 237 Transfer molding, 679 Transmission, water vapor, 104 Transparency, 98, 415, 491 Transportation, 18 Trash compactor, 361 Trial-and-error, 399 Troubleshooting, 603 True stress See Stress, true Turf, 879 Turnaround time, 762 Two-shot molding, 623, 719 ''Tyrin,'' 470 Ultrahigh molecular weight polyethylene plastic, 444 Ultrasonic test, 748 Ultrasonic welding, 272, 723 Ultraviolet radiation, 415 Uncertainties See Safety factor Undercut, 348, 816, 843 Underground, 44, 265, 429 Underwater, 288, 293, 330 Underwriters Laboratory, 95, 732, 739 Uniaxial direction, 118 See also Orientation Unidirectional, 122 See also Orientation Unsaturated polyester plastic, 416 Unscrewing, 355 Urea fonnaldehyde plastic, 416, 423,456 Urethane See Polyurethane Utensil, 420 Vacuum bag molding, 677 Vacuum metalization, 230 "Vamac," 471 Vapor barrier, 104 Vapor penneability, 104 Variables combined, 399,495 "Velcro" strip, 622 Vent, 814 Vessel, 325 Vibration, 239, 372 Vibration welding, 725 Vickers, 105 Vinyl dispersion, 692 Viscoelasticity, 107,114, 140, 155, 174,304 Viscosity, 870 Viscous, defonnation, 107, 174 Viscous modulus See Modulus of elasticity, creep-apparent Vision system inspection, 749, 753 Void,217 Void content determination, 686 Volatile, 115 Volume resistivity, 229 Wall thickness, 187, 189, 201, 355, 598, 747, 780, 798, 801 Warpage, 70, 261, 510, 616, 624, 798, 804 Washer, 401 Waste, 883 See also Solid waste economic consideration, 889 public education, 890, 896 regulatory support, 891 Waste-to-energy incineration, 891 Water, 924 Water absorption, 104, 274 Water treatment, 883 Water vapor transmission, 104 Watertight assembly, 233, 292 Wear, 239, 420, 424, 628, 882 Wear, plastic to metal, 246 Wear, plastic to plastic, 246 Weather resistance, 272, 414 Weep, 334 Weight saving, 37, 365, 890 Welding, 336, 362, 723, 869 Weldline, 217, 618, 695, 734, 813 Wetability, 884 Wire frame modeling, 757, 765 Wood, I, 122, 161, 311 Woods Hole vehicle, 295 Wodd without plastic, Wright-Patterson Air Force Laboratories, 122 X-ray spectroscopy test, 747 "Xydar," 263 Yield See Tensile, yield strength; Compressive yield strength Young's modulus See Modulus of elasticity Zero defect, 887 Zinc-arc straying, 230 "Zytel," 873, 882 ~ PRCAlECT TEAM FEASIBILITY - H STUDY Dimensions structural loads gov'Vlndustry standards service environments, etc Identify specific functions Target quantity cost and production schedule Apply available experience I Manual approach l-.{ COnceptual product layout Apply design creativity Computer approach I r1 Formulate plan' R PRELIMINARY DESIGN ANALYSIS r-y I Dimensions & tolerances Geometric drawings or graphic analYSis Engineering analysiS Solid 4~ Image manipulation r- I Surface c-j Structural Integrity Environment -I Physical integrity Mechanical simulatkm I J -@ Dynamic Finite element modeling J Minimum weight/cost n Ae_c.etc.1 rl OPTIMIZE DESIGN r Mok:Jfdie destgn Material selection I Fabrication analysis J Shrinkage analysis Cycle timeJ I detai.led/individual orthotropic drawings Set up safety factors to meet product functions I Nonstandard parts I Standard parts ~ Provtde -1 I selection -i ~ Material I i ProcesSlequipmentltools _I -1 Produce service per10rmance I I Plant personnel capability I iii rl H ~ 1l Release tooling (mOld/die) for manufacture Set up processing specifications I I rl Equipment I H Material handling I 'iii 15 I j MANUFACTURING~ H Automationtrobotics Plant layout H n ANALYSIS Y '12l § I Safety procedures W Manufacturing processing specifications I I Troubleshooting gUide Testing/quality control Plant personnel capability evaluation f rl OPTIMIZE & DOCUMENT PRODUCTION ~ I I I I Ensure product quality Document good manufacturing practice (GMP) procedure H I I I Preventive maintenance Machine operations H Update plant personnel training I H DevelOp production cost models I Finalize testing & quality conlrol I p od hed I r uct output sc ue ~ ~:~~:ii~: :~=~~: Inventory schedule Y Documentation for management to ensure meeting delivery schedules and profitability I J I PRODUCT RELEASE Ensure meeting all product functions Set up value analysis (VA) I II I Cost analysis rl Matt flow analysis H Tool thermal analysis I - Tool part I -1 Databases andlor available information Process selection After start of production analyze ccmplate design (again) to change design/production/safety factors in order to reduce costs I I [...]... the state of the art in designing with plastics Chapter 1 FUNDAMENTALS OF DESIGNING WITH PLASTICS AND COMPOSITES There is a practical, easy approach to designing with plastics and composites (see Figs 1-1 to 1-3) that is basically no different than designing with other materials: steel, aluminum, titanium, copper, brass, wood, concrete, and so forth This book provides useful and necessary information... sailboat; d) inflatable boat, a sailboat, and surfboards c d 11 12 DESIGNING WITH PLASTICS AND COMPOSITES: A HANDBOOK 2 In electronics Most of the electrical equipment and electronic devices we use and enjoy today would not be practical, economical, or occasionally even possible without plastics (see Fig 1-7) 3 In packaging When packaging problems are tough, plastics often are the answersometimes the... plOChe d out 17 PL 18 DESIGNING WITH PLASTICS AND COMPOSITES: A HANDBOOK d Figure 1-8 (Continued) 4 In building and construction This market is the second-largest consumer of plastics, after packaging Durable and easy to install, as well as cost effective, plastics continue to find more and more applications (see Figs 1-9 to 1-15) 5 In health care Health-care professionals depend on plastics for everything...Preface For some time there has been a strong need in the plastic and related industries for a detailed, practical book on designing with plastics and composites (reinforced plastics) This one-source book meets this criterion by clearly explaining all aspects of designing with plastics, as can be seen from the Table of Contents and Index It provides information on what is ahead as well as today's... comprehend plastics' and composites' extreme range of properties, structural responses, product-performance characteristics, part shapes, manufacturing processes, and their influence on product performance, the simplifying of designs, as guides on selecting plastics and processes as well as on how to keep up-todate on important information and understand the econc:>mics of designing with plastics [1-200]... bent, and so on Designing has never been easy in any material, particularly plastics, because there are so many Plastics provide more types than all other materials put together -with about 45 families of plastics, many variations are available (see Figs 1-4 and 1-5) Of the more than fifteen thousand different plastics, only a few hundred are used in large quantities Unfortunately, many designers view plastics. .. fibers Skis are laminated 10 DESIGNING WITH PLASTICS AND COMPOSITES: A HANDBOOK composites selectively reinforced to eliminate flutter at high speeds Similarly sophisticated advanced engineering has been applied to canoes, surfboards and sailboards, outboard engine shrouds, hockey sticks, sails for racing boats, and other equipment (see Fig 1-6) a b Figure 1-6 Examples of plastics in recreation; a) tennis... designed using plastics and composites They will take low to extremely high loads and operate in widely different environments, from highly corrosive ones to those involving electrical insulation They challenge the designer with a combination of often unfamiliar and unique advantages, and limitations By understanding the many different structures and properties as well as the design and fabrication... different products made from plastics They exist in all types of applications-underground, underwater, in the atmosphere, in outer space, in the office, and in the home Although plastics and composites may appear to some observers to be new, because the industry has an unlimited capacity to produce new plastics to meet new performance and processing requirements, plastics and composites have been used... half-century, aeronautics technology has soared, with plastics playing a major role Lightweight durable plastics and composites save on fuel while standing up to forms of stress like creep and fatigue, and different environments (see Figs 1-21 to 1-34) 1.0 - _.C_ "'" - Figure 1-9 An example of the 1940s to 1950s concept of plastics in buildings from The House That Plastics Built [14], 1