Plastic Product Material and Process Selection Handbook by Dominick V. Rosato, Donald V. Rosato, Matthew V. Rosato • ISBN: 185617431X • Pub. Date: September 2004 • Publisher: Elsevier Science & Technology Books List of fig u res 1.1 1.2 1.3 1.4 1.5 1.6 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3.1 Overview of the plastic industries from source to products that includes plastics and fabrication processes (courtesy of Plastics FALLO) Highlighting load-time/viscoelasticity of plastics: (1) stress-strain-time in creep and (2) strain- stress-time in stress relaxation Examples of plastics subjected to temperatures Guide on strength to temperature of plastics & steel (courtesy of Plastics FALLO) Temperature-time guides retaining 50% plastic properties (courtesy of Plastics FALLO) FALLO approach includes going from material to fabricated product (courtesy of Plastics FALLO) Example how melt index and density influence PE performances; properties increase in the direction of arrows Examples of plasticized flexible PVC Examples of rigid PVC Guide to fluoroplastic properties Basic compounding of natural rubber With modifications each of these plastics can be moved into literally any position in the pie section meeting different requirements Examples of plastic contraction at low temperatures Guide to clear and opaque plastics Examples of the weatherability of plastics Non-plastic (Newtonian) and plastic (non-Newtonian) melt flow behavior (courtesy of Plastics FALLO) 13 16 16 25 38 50 58 59 74 111 120 124 127 127 145 xx List of figures 3.2 3.3 3.4 3.5 3.6 3.7 3.8 Relationship of viscosity to time at constant temperature Molecular weight distribution influence on melt flow Examples of reinforced plastic directional properties Nomenclature of an injection screw (top) and extrusion screw (courtesy of Spirex Corp.) Nomenclature of an injection barrel (top) and extrusion barrel (courtesy of Spirex Corp.) Assembled screw-barrel plasticator for injection molding (top) and extruding (courtesy of Plastics FALLO) Action of plastic in a screw channel during its rotation in a fixed barrel: (1) highlights the channel where the plastic travels; (2) basic plastic drag action; and (3) example of melting action as the plastic travels through the barrel where areas A and B has the melt occurring from the barrel surface to the forward screw surface, area C has the melt developing from the solid plastic, and area D is solid plastic; and (4) melt model of a single screw (courtesy of Spirex Corp.) 146 147 153 157 157 158 159 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 Schematic of an IM machine Three basic parts of an injection molding machine (courtesy of Plastics FALLO) Schematics of single and two-stage plasticators Simplified plastic flow through a single-stage IMM Example of mold operation controls Plastic residence time Molding area diagram processing window concept Molding volume diagram processing window concept Quality surface as a function of process variables Example of a 3-layer coinjection system (courtesy of Battenfeld of America) Example of mold action during injection-compression (courtesy of Plastic FALLO) Schematic of a ram (plunger) injection molding machine Metal injection molding cycle (courtesy of Phillips Plastics) 192 194 196 196 198 203 205 205 207 209 213 224 225 5.1 5.2 Simplifies example of a single-screw extruder Schematic identifies the different components in an extruder (courtesy of Welex Inc.) 227 232 List of figures xxi 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14 5.15 5.16 5.17 5.18 5.19 5.20 5.21 5.22 5.23 Blown film control Sheet line control Assembled blown film line (courtesy of Battcnfelt Gloucester) Blown film line schematic with more details Schematic of flat film chilled roll-processing line Example neck-in and beading that occurs between die orifice and chill roll Simplified water quenched film line Schematic of sheet line processing plastic Coextruded (two-layer) sheet line Schematic of a three-roll sheet cooling stack Introduction to downstream pipe/tube line equipment (a) Example of an inexpensive plate die. (b) Examples of precision dies to produce close tolerance profiles Coating extruder line highlights the hot melt contacting the substrate just prior to entry into the nip of the pressure-chill rolls Example of a wire coating extrusion line Example in using a gear pump to produce fibers (left) and example in using an extruder and gear pump to produce fibers Schematic of a basic three layered cocxtrusion sheet or film system Example of upward extruded blown film process for b i axi ally o ri e n tin g film Example of two-step tenter process Few examples of many different postformed shapes and cuts with some showing dies Examples and performances of compounding equipment Schematic of compounding PVC 235 236 245 246 248 249 250 250 251 251 253 256 259 261 265 268 272 273 276 280 280 6.1 6.2 6.3 6.4 Examples of extrusion, injection, and stretch blow molding techniques Example of a 3-layer coextrusion parison blow mold head with die profiling (left) and example of a 5-layer coextrusion parison blow mold head with die profiling (courtesy of Graham Machinery Group) Schematic of extrusion blow molding a single parison Simplified view of a heart shaped parison die head (left) and grooved core parison die head 283 285 289 291 xxii List of figures 6.5 Examples ofparison wall thickness control by axial movement of the mandrel 6.6 Example of rectangular parison shapes where (1) dic opening had a uniform thickness resulting in weak corners and (2) die opening designed to meet the thickness requirements required 6.7 Introduction to a continuous extruded blow molding system with its accumulator dic head 6.8 Schematics of vertical wheel machine in a production line (courtesy of Graham Machinery Group) 6.9 Three station injection blow molding system 6.10 Schematic of injection blow mold with a solid handle (left) and simple handles (ring, strap, etc.) can be molded with blow molded bottles 6.11 Example of stretched injection blow molding using a rod (left) and example of stretched injection blow molding by gripping and stretching the preform 6.12 Examples of different shaped sequential extrusion blow molding products 6.13 Example of a suction extrusion blow molding process fabricating 3-D products (courtesy of SIG Plastics International) 6.14 Examples of 3-D extrusion blow molded products in their mold cavities (courtesy of SIG Plastics International) 6.15 Example of a 3-part mold to fabricate a complex threaded lid 305 6.16 Examples of water flood cooling blow molding molds 307 292 293 294 295 296 297 299 301 303 304 7.1 Examples of thermoforming methods 309 7.2 (1) In-line high-speed sheet extruder feeding a rotary thcrmoformer and (2) view of the thermoforming drum (courtesy ofWelex/Irwin) Schematic of roll-fed thermoforming line Schematic example of a rotating clockwise three-stage machine View of a rotating clockwise five-stage machine (courtesy of Wilmington Machinery) 7.3 7.4 7.5 313 316 316 316 8.1 8.2 Example of tandem extruder foam sheet line (courtesy of Battcnfeld Gloucester Expandable polystyrene process line starts with precxpanding the PS beads 353 357 List of figures xxiii 8.3 View of PS beads in a perforated mold cavity that are expanding when subjected to steam heat 8.4 Schematic of foam reciprocating injection molding machine for low pressure 8.5 (a) Schematic of gas counterpressure foam injection molding (Cashiers Structural Foam patent). (b) Example of an IMM modified nozzle that handles simultaneously the melt and gas. (c) Microcellular foaming system directing the melt-gas through its shutoff nozzle into the mold cavity 8.6 Liquid (left), froth (center), and spray polyurethane foaming processes 366 8.7 Example of flexible foam density profile 367 358 361 363 9.1 9.2 9.3 9.4 Example of the sheet or film passing through nip rolls to decrease thickness 370 Calender line starting with mixer 371 Examples of the arrangements of rolls in calender lines 372 Example of roll covering 380 10.1 10.2 10.3 10.4 Simplified examples of basic roll coating processes Example of knife spread coating Examples of transfer paper coating line Example of an extrusion coating line 388 388 389 389 11.1 11.2 Example of a liquid injection molding casting process Example of a more accurate mixing of components for liquid injection casting 399 400 12.1 12.2 12.3 12.4 12.5 Example of typical polyurethane RIM processes (courtesy of Bayer) RIM machine with mold in the open position (courtesy of Milacron) Gating and runner systems demonstrating laminar melt flow and uniform flow front (courtesy of Bayer) Example of a dam gate and runner system (courtesy of Bayer) Example of melt flow around obstructions near the vent (courtesy of Bayer) 407 411 413 414 414 13.1 Rotational molding's four basic stations (courtesy of The Queen's University, Belfast) 430 xxiv List of figures 13.2 Rotational rate of the two axes is at 7" 1 for this product (courtesy of Plastics FALLO ) 432 13.3 Example of large tank that is RM 433 14.1 Schematics of compression molding plastic materials. 439 14.2 Examples of flash in a mold: (a) horizontal, (b) vertical, and (c) modified vertical Example of mold types: (a) positive compression mold, (b) flash compression mold, and (c) semipositive compression mold Example of land locations in a split-wedge mold Schematic of transfer molding 14.3 14.4 14.5 442 445 446 454 15.1 15.2 15.3 15.4 15.5 15.6 15.7 15.8 15.9 15.10 Effect of matrix content on strength (F) or elastic moduli (E) of reinforced plastics Properties vs. amount of reinforcement Modulus of different materials can be related to their specific gravities with RPs providing an interesting graph Short to long fibers influence properties of RPs Reinforced plastics, steel, and aluminum tensile properties compared (courtesy of Plastics FALLO) Fiber arrangements and property behavior (courtesy of Plastics FALLO) Layout of reinforcement is designed to meet structural requirements Views of fiber filament wound isotensoid pattern of the reinforcing fibers without plastic (left) and with plastic cured Use is made of vacuum, pressure, or pressure-vacuum in the Marco process Cut away example of a mold used for resin transfer molding 455 455 457 461 467 467 479 483 486 488 17.1 17.2 17.3 17.4 17.5 17.6 Examples of mold layouts, configurations, and actions Sequence of mold operations Examples to simplify mold design and action Example of 3-plate mold Examples of stacked molds Examples of melt flow patterns in a coathanger and T-type die 520 521 522 523 524 530 List of figures xxv 17.7 Examples of melt flow patterns behavior 531 17.8 Flow coefficients calculated at different aspect ratios for various shapes using the same equation Example of the land in an extrusion blow molding die that can have a ratio of 10 to 1 and film or sheet rigid (R) and flexible (F) die lip land Examples of a flat die with its controls Examples of single layer blown film dies include side fed type (left), bottom fed with spiders type (center) and spiral fed type Examples of different pipe die inline and crosshead designs (a) Schematic for determining wire coated draw ratio balance in dies. (b) Schematic for determining wire coated draw down ratio in dies Examples of layer plastics based on four modes of die rotation 17.9 17.I0 17.11 17.12 17.13 17.14 533 535 539 540 541 543 546 18.1 Examples of plant layout with extrusion and injection molding primary and auxiliary equipment 18.2 Example of an extrusion laminator with auxiliary equipment 18.3 Examples of tension control rollers in a film, sheet, or coating line 18.4 Example of roll-change sequence winder (courtesy of Black Clawson) 559 18.5 Guide to slitting extruded film or coating 567 551 551 558 List of ta b les 1.1 1.2 1.3 1.4 1.5 1.6 1.7 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 Examples of major plastic families Thermoplastic thermal properties are compared to aluminum and steel General properties of thermoplastic General properties of thermoset plastic General properties of reinforced thermoplastic General properties of reinforced thermoset plastic Examples of drying different plastics (courtesy of Spirex Corp.) General properties of plastics Example of plastic shrinkage without and with glass fiber Density, melt index, and molecular weight influence PEs performances Examples of polyethylene film properties Property guide for thermoset plastics Elastomer names Elastomers cost to performance guide Guide to elastomer performances where E = Excellent, G - Good, F = Fair, and P = Poor) Example for comparing cost and performance of nylon and die-cast alloys Examples of processes for plastic materials Examples of processes and plastic materials to properties Chemical resistance of plastics (courtesy of Plastics FALLO) Examples of permeability for plastics Examples of transparent plastics 14 18 20 22 24 32 41 43 46 47 102 106 116 117 122 122 123 125 128 129 List of tables xxvii 3.1 3.2 3.3 3.4 3.5 Examples of names of plastic fabricating processes 133 Flow chart in fabricating plastic products (courtesy of Adaptive Instruments Corp.) 138 Examples of thermoplastic processing temperatures for extrusion and injection molding (courtesy of Spirex Corp.) 143 Purging: preheat/soak time (courtesy of Spirex Corp.) 165 Guide to performance of different sensors 171 4.1 Processing window analysis 207 5.1 5.2 5.3 5.4 Example of thermoplastics that are extruded (courtesy of Spirex) Selection guide for barrel heater bands (courtesy of Spirex) Examples of film yields Guide on different information pertaining to different coating methods 229 234 246 258 7.1 Comparison of thermoformer heaters 314 8.1 Examples of rigid plastic foam properties 334 8.2 Examples of physical blowing agent performances 339 8.3 Examples of chemical blowing agents 339 8.4 Properties of 1/4" thick thermoplastic structural foam (20% weight reduction) 344 9.1 Example of comparing calendering and extrusion processes 380 10.1 Examples of coating processes 387 12.1 Comparing processes to mold large, complex products 420 13.1 Comparison of different processes 429 13.2 Examples of RM products 432 14.1 14.2 Example of applications for compression molded thermoset plastics Comparing compression molded properties with other processes 440 441 15.1 Review of a few processes to fabricate RP products 457 [...]... performances Guide to product design vs processing methods 16 .1 Example of a PVC blend formulation 506 17 .1 17.2 17 .3 Examples of the properties of different tool materials SPI Moldmakers Division quotations guide Examples of extrusion dies (courtesy of Extrusion Dies, Inc.) Rapid prototyping processes 514 527 15 .4 15 .5 15 .6 15 .7 15 .8 17 .4 18 .1 18.2 19 .1 459 460 4 61 466 469 493 506 537 549 Examples of... windows, and product stewardship such as dematerialization and multiple life cycles Expectations are higher for plastic materials and processes as well Metals-to -plastic conversions, micro-molded parts, reinforced structural parts, shielded housings, thermoplastic elastomer applications, and parts for harsh environments are malting use of a variety of developed plastics and filler systems Plastics... thermoplastics and thermosct plastics, are of the engineering type Historically, as more competition a n d / o r production occur for certain engineering plastics, their costs go down and they become commodity plastics Half a 3 4 Plastic Product Material and Process Selection Handbook century ago the dividing line costwisc was about $0 .15 /lb; now it is above $1. 00/lb There arc different types of plastics... with Plastics Fallo Table of Contents Ch 1 Introduction 1 Ch 2 Plastic property Ch 3 Fabricating product 13 0 Ch 4 Injection molding 19 2 Ch 5 Extrusion 227 Ch 6 Blow molding 282 Ch 7 Thermoforming 308 Ch 8 Foaming 333 Ch 9 Calendering 369 Ch 10 Coating 382 Ch 11 Casting 394 Ch 12 Reaction injection molding 406 Ch 13 Rotational molding 428 Ch 14 Compression molding 439 Ch 15 Reinforced plastics 455 Ch 16 ... scientific products 4s~ As a matter of fact, many of the technical wonders we take 2 Plastic Product Material and Process Selection Handbook ~ : : : : :: .-.-.: for granted would be impossible without versatile, economical plastics The information in this book reviews the World of Plastics from plastic materials-to-processes that influence product designs that continue to generate the growth of plastics... application and removal of stress 1 Figure 1, 2 Highlighting load-time/viscoelasticity of plastics: (1) stress-strain-time in creep and (2) strain-stress-time in stress relaxation Processing and thermal interface Different plastic characteristics influence processing and properties of plastic products Table 1. 2 reviews these different characteristics that 13 j~ ~ | l jE ~-~~~~ ~ o o ~ ~ ~ ~-"~:~ _ ggggg~~~ l 14 ... measure of viscosity High MI implies low viscosity and low 1 1 12 Plastic Product Material and Process Selection Handbook MI means high viscosity Plastics are shear thinning, which means that their resistance to flow decreases as the shear rate increases This is due to molecular alignments in the direction of flow and disentanglements There is Newtonian and Non-Newtonian viscosity With Ncwtonian viscosity... ~-"~:~ _ ggggg~~~ l 14 Plastic Product Material and Process Selection Handbook ~.) ~.) v~ 'O c- E E E C) ~3 E (13 ~J O_ O ~3 v~ O ~J ~J E O_ -O ~.) m ~.) _E J~ L~ E~_ O E ~J _E F~ !I 1 9 Introduction occur with thermoplastics Important are glass transition temperature (Tg) and melt temperature (Tin) The Tg relates to temperature characteristics of plastics that influence the plastic' s processability It... (Figure 1. 1) Figure 1. 1 Overview of the plastic industries from source to products that includes plastics and fabrication processes (courtesy of Plastics FALLO) There have been a number of paradigm shifts in the plastic business model due to market changes Gone are the days of just buying plastic and fabricating Now industries want these associated with design collaboration, numerical analysis and virtual... atom elements (H) and often also oxygen (O), nitrogen (N), chlorine (C1), fluorine (F), and sulfur (S) Morphology is the study of the physical form or structure of a material (thermoplastics crystallinity or amorphous); the physical molecular structures of a polymer or in turn a plastic As a result of these structures in production of plastics, processing the plastics into products, and product designs, . 559 18 .5 Guide to slitting extruded film or coating 567 5 51 5 51 558 List of ta b les 1. 1 1. 2 1. 3 1. 4 1. 5 1. 6 1. 7 2 .1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2 .10 2 .11 2 .12 2 .13 . of plastics (courtesy of Plastics FALLO) Examples of permeability for plastics Examples of transparent plastics 14 18 20 22 24 32 41 43 46 47 10 2 10 6 11 6 11 7 12 2 12 2 12 3 12 5. Examples of layer plastics based on four modes of die rotation 17 .9 17 .I0 17 .11 17 .12 17 .13 17 .14 533 535 539 540 5 41 543 546 18 .1 Examples of plant layout with extrusion and injection