Polymer Products: Design, Materials And Processing by D. Morton-jonesPolymer Products: Design, Materials And Processing by D. Morton-jones

Polymer Products: Design, Materials And Processing

byD. Morton-jones

Paperback | October 8, 2011

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This book is derived from a recent project sponsored by the Polymer Engineering Directorate of the SERC and carried out at the University of Lancaster under the joint auspices of the Departments of Chemistry and Engineering. The project set out to provide a novel type of teaching material for introducing polymers and their uses to students, especially of engineering. Case studies of real examples of polymers at work are used, so the student or teacher can start with a successful and well-designed product and work backwards to its origins in the market, in design and material selection and in the manufacturing process. The philosophy is that such an approach captures interest right at the start by means of a real example and then retains it because of the relevance of the technical explanation. This after all is what most of us do habitually; we turn to examples to make our point. The hope is that subject matter with a somewhat notorious reputation among engineers, such as aspects of polymer chemistry and the non-linear behaviour of polymers under mechanical loading will be fairly painlessly absorbed through the context of the examples. Each study becomes a separate chapter in the book. The original studies, and hence the present chapters, vary in length because different topics demanded different approaches. No attempt has been made to alter this, or to adopt a standardized format because to have done so would have interfered with the vitality of the original work.
Title:Polymer Products: Design, Materials And ProcessingFormat:PaperbackDimensions:9.25 × 6.1 × 0.07 inPublished:October 8, 2011Publisher:Springer NetherlandsLanguage:English

The following ISBNs are associated with this title:

ISBN - 10:9401083207

ISBN - 13:9789401083201

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Table of Contents

1 PST 1: Injection Moulding and its Materials.- 1.1 Injection moulding.- 1.2 Amorphous and crystalline polymers.- 1.3 Polymers in the rubber state.- 1.4 Environmental stress cracking.- 1.5 Creep in polymers.- 2 Optimizing Injection Moulding Conditions.- 2.1 Introduction.- 2.2 Support bracket.- 2.3 Film spool end.- 2.4 Comment on importance of process.- 2.5 Control features in injection moulding.- 2.6 The case for the programmed machine.- 3 Some Examples of Polymer Selection.- 3.1 Combination nozzle for Electrolux cleaner.- 3.2 Impellor for Flymo hover mower.- 3.3 Flymo mower hood.- 3.4 Motor housing in vacuum cleaner.- 3.5 Moulding conditions.- 3.6 Polymer science aspects: polymers in the rubber state.- 4 Plastics Gears.- 4.1 Introduction.- 4.2 The GEC reduction gear box.- 4.3 Why plastics gears?.- 4.4 Methods for making plastics gears.- 4.5 Design of moulded gears.- 4.6 Materials.- 4.7 Design development of office copier gearbox.- 4.8 Injection moulding of gears.- 4.9 References.- 5 Acetal Clips for Roof Tiles.- 5.1 Introduction.- 5.2 The mark 9 clip.- 5.3 Loading calculations.- 5.4 Production and quality control.- 6 Acetal Spring for Selector Switch.- 6.1 Introduction.- 6.2 Development of the acetal spring.- 6.3 Evaluation and testing.- 6.4 Polymer and processing.- 6.5 Comment on design and polymer properties.- 7 PST 2: Foam Cored Mouldings.- 7.1 Structural foam.- 7.2 Comparison of the sandwich moulding and structural foam processes.- 7.3 The sandwich moulding process.- 7.4 Relative merits of compact moulding.- 8 Structural Foam Trolley Base.- 8.1 Introduction.- 8.2 Design brief.- 8.3 Material and manufacturing process selection.- 8.4 Design procedure.- 8.5 The moulding process.- 8.6 References.- 9 Washing Machine Tank in Glass-coupled Polypropylene Structural Foam.- 9.1 Introduction.- 9.2 Background.- 9.3 Operating conditions of the tank.- 9.4 Materials and process selection.- 9.5 Design features.- 9.6 The mould.- 9.7 The moulding machine.- 9.8 Processing conditions.- 9.9 Secondary operation.- 9.10 Testing.- 10 Sandwich Moulded TV Screen Frame.- 10.1 Synopsis.- 10.2 Design of the moulded TV front.- 10.3 Production details.- 10.4 Tests of finished product.- 10.5 Some other aspects of SM.- 10.6 Sandwich moulded toilet cisterns.- 10.7 UK involvement in SM.- 11 PST 3: Polyurethanes.- 11.1 Introduction.- 11.2 Basic reactions.- 11.3 Materials.- 11.4 Relationships between structure and properties.- 11.5 Polyurethane foam.- 12 Reinforced Reaction Injection Moulding (RRIM).- 12.1 Introduction.- 12.2 Polyurethane systems.- 12.3 Development of short glass-fibre reinforcement.- 12.4 RRIM development.- 12.5 The RRIM process.- 13 Polyurethane Shoe Soles.- 13.1 Introduction.- 13.2 Shoe manufacture - historical.- 13.3 Development of the PU sole.- 13.4 Polyurethane materials.- 13.5 PU shoe soling.- 13.6 Manufacture.- 13.7 Product testing.- 13.8 Design considerations.- 13.9 References.- 14 Printed Gaskets in Hydraulic Control Equipment.- 14.1 Background.- 14.2 The hydraulic control valve.- 14.3 The printed gasket.- 14.4 Polyurethane seal.- 14.5 Selection of materials.- 14.6 Production of the printed gasket.- 14.7 Testing and quality control.- 14.8 Failure in printed gaskets.- 14.9 Development of new specifications.- 14.10 Future Developments.- 15 PST 4: Glass-reinforced Plastics (GRP).- 15.1 Introduction.- 15.2 Reinforcing fibres.- 15.3 Unsaturated polyester resins.- 15.4 The hand lay-up process.- 15.5 Sheet moulding compound (SMC).- 15.6 Disadvantage of SMC Moulding Compared with Hand Lay-up.- 15.7 Stiffness of materials (with reference to GRP).- 15.8 Plastics vehicle bodies.- 16 GRP-Clad Lorry Cab.- 16.1 General description.- 16.2 Design considerations.- 16.3 Materials selection.- 16.4 Production details.- 16.5 Testing.- 16.6 Summary of costs.- 16.7 References.- 17 High Speed Train Cab.- 17.1 Introduction.- 17.2 Design considerations.- 17.3 Materials.- 17.4 Production details.- 18 DMC Vehicle Headlamps.- 18.1 Introduction.- 18.2 Historical.- 18.3 Material selection.- 18.4 Some design aspects.- 18.5 Quality and performance aspects.- 18.6 Technical appendix (Lucas).- 18.7 Manufacture.- 18.8 The test programme.- 19 'Fiberlam' Aircraft Flooring.- 19.1 General description of 'Fiberlam'.- 19.2 Materials.- 19.3 Manufacturing aspects.- 19.4 Some product features.- 19.5 Testing.- 19.6 History of sandwich structures in aircraft flooring.- 19.7 References.- 20 PST 5: Rubbers.- 20.1 Natural and synthetic rubbers.- 20.2 Polychloroprene rubber.- 20.3 Vulcanization.- 21 Rubber-Steel Conveyor Belt.- 21.1 Introduction.- 21.2 Background.- 21.3 The development of steel cord belting.- 21.4 Development of the Selby conveyor.- 21.5 Manufacture.- 21.6 Product testing.- 21.7 Installation.- 21.8 References.- 22 The Blow Moulding Process.- 22.1 Introduction.- 22.2 Blow moulding of large containers.- 22.3 Injection blow moulding.- 23 The Acitainer Blow Moulded Acid Container.- 23.1 Introduction.- 23.2 Design considerations.- 23.3 Material selection.- 23.4 Production details.- 23.5 References.- 24 Chemical Effluent Pipe in HDPE.- 24.1 Introduction.- 24.2 Effluents.- 24.3 Selection of materials.- 24.4 Design factors.- 24.5 Manufacture and assembly.- 24.6 Quality control and testing.- 24.7 Pressure pipe - pressure rating calculation.- 24.8 Static loads in buried pipe.- 24.9 Appendix: Crack Propagation.- 25 Failure of a Polypropylene Vessel.- 25.1 Introduction.- 25.2 The plant.- 25.3 The failure incident.- 25.4 Examination of fractured pipe.- 25.5 Investigation.- 25.6 Fracture calculations.- 25.7 Bubble collapse.- 25.8 Conclusion.- 25.9 Remedial action.- 26 Heat Shrinkable Terminations for Power Cables.- 26.1 Introduction.- 26.2 Heat-shrinkable plastics.- 26.3 Power cables.- 26.4 Termination by traditional methods.- 26.5 Application of heat-shrinkable plastics in MV.- 26.6 Heat-shrinkable plastics in high voltage applications.- 26.7 Stress grading.- 26.8 Non-tracking outer insulation.- 26.9 High voltage non-track material (HVTM).- 26.10 Sealant.- 26.11 The development programme.- 26.12 References.