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عدد المساهمات : 18984 التقييم : 35458 تاريخ التسجيل : 01/07/2009 الدولة : مصر العمل : مدير منتدى هندسة الإنتاج والتصميم الميكانيكى
| موضوع: كتاب Rotational Molding Technology الأحد 27 أكتوبر 2013, 12:46 am | |
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أخواني في الله أحضرت لكم كتاب Rotational Molding Technology Roy J. Crawford The Queen’s University of Belfast Belfast, Northern Ireland James L. Throne Sherwood Technologies, Inc. Hinckley, Ohio
و المحتوى كما يلي :
Contents Preface . v About the Authors . ix 1. Introduction to Rotational Molding 1 1.0 Introduction . 1 1.1 The Process 2 1.2 The Early Days . 4 1.3 Materials . 6 1.4 Advantages and Disadvantages 9 1.5 General Relationships between Processing Conditions and Properties 11 References . 14 2. Rotational Molding Polymers . 19 2.0 Introduction . 19 2.1 General Characteristics of Polymers 19 2.2 Polymers as Powders and Liquids . 21 2.3 Polyethylene Types 22 2.3.1 Low-Density Polyethylene . 22 2.3.2 Medium-Density Polyethylene . 23 2.3.3 High-Density Polyethylene 24 2.3.4 Linear Low-Density Polyethylene 25 2.3.5 Ethylene Vinyl Acetate 27xii Contents 2.4 Polypropylene . 28 2.5 PVC – Plastisols, Drysols, and Powdered Flexible Compounds 30 2.6 Nylons . 31 2.7 Other Polymers . 33 2.7.1 Polycarbonate . 33 2.7.2 Cellulosics . 34 2.7.3 Acrylics . 35 2.7.4 Styrenics . 35 2.8 Liquid Polymers 36 2.8.1 PVC Plastisols 38 2.8.2 Polycaprolactam . 39 2.8.3 Polyurethane . 41 2.8.4 Unsaturated Polyester Resin . 42 2.8.5 Silicones . 43 2.9 In-Coming Material Evaluation . 43 2.9.1 Melt Index and Melt Flow Index . 44 2.9.2 Sieving 46 2.10 Product Testing Protocols and Relationship to Polymer Characteristics 47 2.10.1 Actual Part Testing – Protocol . 47 2.10.2 Actual Part Testing – Entire Parts . 49 2.10.3 Actual Part Testing – Sections 50 2.10.3.1 Molded Part Density . 51 2.10.3.2 Drop Tests 51 2.10.3.3 ASTM Tests for Mechanical Properties . 54 2.10.3.4 Color . 55 2.10.3.5 Chemical Tests 56 2.10.3.6 Environmental Stress Crack Test . 57Contents xiii 2.10.3.7 Chemical Crosslinking and the Refluxing Hexane Test . 58 2.10.3.8 Weathering . 61 2.10.3.9 Odor in Plastics 62 2.10.3.10 Fire Retardancy 62 2.11 Desirable Characteristics of a Rotational Molding Resin . 64 References . 65 3. Grinding and Coloring 69 3.0 Introduction . 69 3.1 General Issues Relating to Grinding 73 3.2 Particle Size Distribution . 75 3.2.1 Particle Size Analysis 77 3.2.1.1 Dry Sieves 77 3.2.1.2 Elutriation . 78 3.2.1.3 Streaming . 78 3.2.1.4 Sedimentation 78 3.2.1.5 Fluidization . 79 3.2.2 Presentation of PSD Data . 79 3.3 Particle Shape 81 3.4 Dry Flow 83 3.5 Bulk Density 84 3.5.1 Packing of Particles . 85 3.6 Factors Affecting Powder Quality . 88 3.6.1 Gap Size . 89 3.6.2 Number of Mill Teeth . 90 3.6.3 Grinding Temperature . 90 3.7 Grinding Costs 91 3.8 Micropelletizing . 93xiv Contents 3.9 Polyvinyl Chloride . 96 3.10 Coloring of Plastics for Rotational Molding 96 3.10.1 Dry Blending . 97 3.10.2 High Speed Mixing (Turbo Blending) . 99 3.10.3 Compounding 101 3.10.4 Types of Pigments 101 3.10.5 Aesthetics of Rotationally Molded Parts 104 3.10.6 Other Types of Additives . 105 References . 108 4. Rotational Molding Machines 111 4.0 Introduction . 111 4.1 Types of Rotational Molding Machines 112 4.1.1 Rock-and-Roll Machines . 113 4.1.2 Clamshell Machines 115 4.1.3 Vertical Machines 116 4.1.4 Shuttle Machines 116 4.1.5 Fixed-Arm Carousel Machine 117 4.1.6 Independent-Arm Machine 118 4.1.7 Oil Jacketed Machines 119 4.1.8 Electrically Heated Machines 120 4.1.9 Other Types of Machines 121 4.2 Machine Design Considerations 122 4.2.1 Mold Swing . 122 4.2.2 Mold Speed . 125 4.2.3 Speed Ratio 126 4.3 The Oven 127 4.3.1 Oven Design . 129 4.3.2 Heat Transfer in Oven . 131 4.3.3 Oven Air Flow Amplification 135Contents xv 4.4 Cooling 137 4.5 Process Monitors 138 4.5.1 Internal Air Temperature Measurement in Rotational Molding 140 4.5.2 Infrared Temperature Sensors 144 4.6 Servicing . 144 4.7 Advanced Machine Design . 145 References . 147 5. Mold Design . 149 5.0 Introduction . 149 5.1 Mold Materials 151 5.1.1 Sheet Steel . 151 5.1.2 Aluminum 152 5.1.3 Electroformed Nickel . 154 5.2 Mechanical and Thermal Characteristics of Mold Materials . 156 5.2.1 Equivalent Mechanical Thickness . 156 5.2.2 Equivalent Static Thermal Thickness 157 5.2.3 Equivalent Transient Thermal Thickness . 159 5.3 Mold Design 160 5.3.1 Parting Line Design . 161 5.3.1.1 Butt or Flat 161 5.3.1.2 Lap Joint . 162 5.3.1.3 Tongue-and-Groove . 162 5.3.1.4 Gaskets 163 5.3.2 Mold Frame . 165 5.3.3 Clamping . 166 5.3.4 Pry Points . 167xvi Contents 5.3.5 Inserts and Other Mechanical Fastening Methods 168 5.3.5.1 Self-tapping Screws . 168 5.3.5.2 Mechanical Fastening 169 5.3.5.3 Postmolded Insert 169 5.3.5.4 Molded-in Insert . 169 5.3.6 Threads . 171 5.3.7 Cut-out Areas 172 5.3.8 Kiss-offs 172 5.3.9 Molded-in Handles 173 5.3.10 Temporary Inserts . 173 5.4 Calculation of Charge Weight . 174 5.4.1 Methodology . 174 5.4.2 Maximum Part Wall Thickness for a Given Mold 180 5.5 Venting 183 5.5.1 Simple Estimate for Vent Size . 186 5.5.2 Types of Vent 193 5.5.3 Is a Vent Necessary? 195 5.6 Mold Surface Finish 196 5.7 Mold Releases 196 5.7.1 Spray-on Zinc Stearates . 197 5.7.2 Silicones . 197 5.7.3 Disiloxanes . 197 5.7.4 Fluoropolymers . 197 5.7.5 Mold Surfaces to be Coated 198 5.7.6 Controlled Release 199 5.7.7 Mold Release Cost 199 References . 200Contents xvii 6. Processing . 201 6.0 Introduction to Heating . 201 6.1 General Anatomy of the Rotational Molding Cycle 201 6.2 General Process Description 204 6.3 Powder Behavior 205 6.4 Characteristics of Powder Flow 207 6.5 Rheology of Powder Flow 210 6.6 Heat Transfer Concepts Applied to Rotational Molding . 213 6.7 Heating the Mold . 213 6.8 Heating Powder 215 6.8.1 Transient Heating of an Individual Particle 215 6.8.2 Heating the Powder Bed . 217 6.9 Tack Temperature 219 6.10 Mold Cavity Air Heating Prior to Powder Adhesion to Mold Surface . 221 6.11 Bed Depletion . 222 6.12 Particle Coalescence 223 6.13 Densification . 234 6.14 Phase Change During Heating 243 6.15 The Role of Pressure and Vacuum 244 6.16 Mathematical Modeling of the Heating Process 245 6.17 Total Oven Cycle Time . 251 6.18 Cooling and the Optimum Time for Removal from Oven . 259 6.19 Some Comments on Heat Transfer During Cooling 259 6.20 Thermal Profile Inversion 262 6.21 Cooling and Recrystallization 266 6.22 Air Cooling – Heat Removal Rate 274 6.23 Water Cooling – Heat Removal Rate . 275xviii Contents 6.24 Pressurization . 276 6.25 Part Removal 276 6.26 Effect of Wall Thickness on Cooling Cycle Time . 277 6.27 Overview and Summary of Thermal Aspects of the Rotational Molding Process 278 6.28 Introduction to Liquid Rotational Molding . 278 6.29 Liquid Polymers 278 6.30 Liquid Rotational Molding Process . 279 6.30.1 Liquid Circulating Pool 280 6.30.2 Cascading Flow 281 6.30.3 Rimming Flow . 281 6.30.4 Solid Body Rotation . 281 6.30.5 Hydrocyst Formation . 282 6.30.6 Bubble Entrainment . 284 6.30.7 Localized Pooling 285 6.31 Process Controls for Liquid Rotational Molding . 285 6.32 Foam Processing 287 6.32.1 Chemical Blowing Agent Technology 288 6.32.2 Single Layer vs. Multiple Layer Foam Structures . 295 6.32.2.1 One-Step Process 295 6.32.2.2 Two-Step Process 296 6.32.2.3 Drop Boxes – Inside or Out? 297 6.32.2.4 Containerizing Inner Layers . 298 References . 299 7. Mechanical Part Design 307 7.0 Introduction . 307 7.1 Design Philosophy 307 7.2 General Design Concepts 310Contents xix 7.3 Mechanical Design . 314 7.3.1 Three-Point Flexural Beam Loading 315 7.3.2 Cantilever Beam Loading 316 7.3.3 Column Bending 317 7.3.4 Plate Edge Loading . 318 7.3.5 Hollow Beam with Kiss-Off Loading 318 7.3.6 Creep 322 7.3.7 Temperature-Dependent Properties 323 7.4 Design Properties of Foams . 324 7.4.1 Uniform Density Foams . 324 7.4.2 Multilayer or Skin-Core Foams 329 7.5 Computer-Aided Engineering in Rotational Molding 330 7.5.1 CAD/CAM in Rotational Molding . 332 7.5.2 Computer-Aided Stress Analysis . 332 7.6 Some General Design Considerations . 335 7.6.1 Uniformity in Wall Thickness . 336 7.6.2 Shrinkage During Cooling . 337 7.6.3 General Shrinkage Guidelines 339 7.6.4 Effect of Pressurization . 340 7.6.5 Draft Angles and Corner Angles 341 7.6.6 Warpage Guidelines 344 7.6.7 Corner Radii – The Michelin Man 345 7.6.7.1 Right-Angled Corners . 345 7.6.7.2 Acute-Angled Corners 346 7.6.8 Parallel Walls 348 7.6.9 Spacing and Bridging 348 7.6.10 Internal Threads, External Threads, Inserts, and Holes 349 7.7 Process Effects on Porosity, Impact Strength 350 7.8 Trimming . 354xx Contents 7.9 Surface Decoration . 357 7.9.1 Painting . 358 7.9.2 Hot Stamping 358 7.9.3 Adhesives . 358 7.9.4 In-Mold Decoration 359 7.9.5 Postmold Decoration . 359 7.9.6 Internal Chemical Treatment . 359 7.10 Troubleshooting and Quality Assurance 360 7.10.1 Coordinate Measuring Machine . 360 References . 362 Appendices . 367 Appendix A. Troubleshooting Guide for Rotational Molding 367 Appendix B. Conversion Table . 375 Author Index . 379 Index 383379 Straight — Text Citing Italic — Reference Author Index A Andrzejewski, S., 11, 16 Arendt, W.D., 6, 15, 96, 109 Arpaci, V.S., 247, 302 Ashby, M.F., 325, 327, 363 Astarita, T., 210, 211, 300 Astarita, G., 210, 211, 300 Attaran, M.T., 248, 302 B Balmer, R.T., 279, 282, 304, 305 Bawiskar, S., 138, 147 Beall, G.L., vi, 2, 14, 112, 147, 160, 200, 206, 276, 285, 299, 304, 305, 307, 310, 313, 318, 319, 335, 340, 342, 344, 349, 351, 362, 364 Becker, H., 4, 14 Bellehumeur, C.T., 11, 17, 20, 69, 93, 108, 225, 228, 234, 243, 244, 301, 302, 354, 365 Benning, C.J., 28, 59, 60, 65, 68 Bent, A.A., 210, 299 Berins, M.L., 335, 356, 364, 365 Bisaria, M.K., 6, 11, 15, 17 Boenig, H.V., 42, 66 Boersch, E., 1, 14, 96, 104, 109 Bonis, L.J., 225, 300 Bothun, G., 104, 110 Braeunig, D., 6, 15 Brown, R.L., 205, 211, 212, 299 Bruins, P.F., vi, 4, 14, 40, 66, 112, 147 Brydson, J.A., 20, 65, 211, 300 Bucher, J., 4, 14, 367, 374 Burnett, D.S., 333, 335, 363, 364 Burns, M., 332, 363 C Calafut, T., 28, 65 Campbell, C.S., 210, 300 Carrino, L., 104, 110 Carter, B., 4, 14, 113, 147 Cellier, G., 236, 237, 242, 301 Cerro, R.L., 279, 281, 304, 305 Chabot, J.F., 4, 14 Chan, L.S., 6, 16, 69, 108 Chen, C.-H., 146, 148, 201, 214, 247, 248, 299 Cheney, G., 11, 16 Chiou, Y.H., 228, 229, 237, 301 Clark, D.T., 360, 365 Collins, E.A., 38, 65 Copeland, S., 6, 15, 64, 68 Covington, H., 335, 364 Cowan, S.C., 210, 299 Cramez, M.C., 12, 17, 18, 99, 109, 268, 303 Crawford, R.J., vi, 1, 2, 6, 11, 12, 14–18, 69, 85, 90, 94, 99, 100, 108, 109, 112, 120, 138, 140, 142, 146, 147, 148, 186, 200, 201, 207, 214, 238, 240, 248, 268, 299, 302, 303, 318, 319, 323, 348, 349, 350, 352, 353, 354, 362, 364, 365 Crouch, J., 146, 148 Cumberland, D., 85, 109380 Rotational Molding Technology Straight — Text Citing Italic — Reference D de Bruin, W., 69, 90, 92, 108 Dieber, J.A., 279, 281, 304, 305 Dodge, P., 11, 16 Domininghaus, H., 20, 65, 338, 339, 364 Dority, S., 101, 109, 110 Dusinberre, G.M., 266, 303 D’Uva, S., 287, 306 E Eilers, K., 330, 363 Elias, H.-G., 267, 268, 303 Epstein, P.S., 240, 302 Ezrin, M., 56, 67, 307, 362 F Fahnler, F., 39, 66 Fawcett, J., 332, 363 Fayed, M.E., 219, 300 Feast, W.J., 360, 365 Fenner, R.T., 333, 363 Findley, W.N., 323, 362 Flannery, B.P., 333, 363 Fogler, H.S., 239, 302 Foy, D., 101, 110 Frenkel, Ya.I , 225, 300 Frisch, K.C., 59, 67, 291, 306 G Gachter, R., 63, 68 Gebhart, B., 333, 363 Gianchandani, J., 6, 16, 279, 282, 283, 304, 305 Gibson, L.J., 325, 327, 363 Goddard, J.D., 239, 302 Gogos, G., 142, 148, 240, 250, 251, 273, 274, 303 Goodman, M.A., 210, 299 Goodman, T.R., 249, 302 Gotoh, K., 81, 108 Graham, B., 6, 15, 58, 64, 68 H Han, C.D., 239, 302 Hang, C.C., 6, 16, 69, 108 Harkin-Jones, E.M.A., 6, 16, 38, 39, 40, 41, 42, 65, 66, 69, 108, 279, 282, 283, 284, 303, 304, 305 Hartnett, J.P., 250, 261, 303 Hausner, H.H., 225, 300 Hentrich, R., 154, 200 Hickey, H.F., 40, 66 Higashitani, K., 81, 108 Howard, H.R., 11, 16, 101, 109, 110 Huebner, K.H., 333, 363 I Iwakura, K., 146, 148, 201, 214, 247, 248, 299 J Joesten, L., 6, 16, 64, 68 Johnson, L., 105, 110 Johnson, R.E., 279, 281, 304, 305 Jolly, R.E., 44, 66 K Kampf, G., 44, 56, 66 Keurleker, R., 39, 66 Khemani, K.C., 291, 305 Kinghorn, K.B., 6, 15 Klempner, D., 59, 67, 291, 306 Kobayashi, A., 356, 365 Kontopoulou, M., 6, 11, 15, 17, 64, 68, 234, 238, 240, 241, 243, 244, 301, 302, 354, 365 Kreith, F., 205, 215, 216, 299, 300, 335, 364 Kuczynski, G.C., 225, 300 Kumar, S., 328, 363 Kurihara, K., 210, 211, 299 L Lai, J.S., 323, 362 Landrock, A.H., 291, 306 Lang, J., 6, 15, 96, 109 Lefas, J.A., 287, 306 Levitskiy, S.P., 231, 238, 301, 302 Lin, S.T., 228, 229, 238, 301 Liniger, E.G., 211, 300 Linoya, K., 81, 108 Lipsteuer, S.J., 93, 109, 287, 306 Liu, F., 287, 306 Liu, G., 287, 306 Liu, S.-J., 228, 229, 238, 301 Liu, X., 250, 273, 274, 303 Lontz, J.F., 225, 300 Lowe, J., 6, 15Author Index 381 Straight — Text Citing Italic — Reference Lui, S.-J., 11, 17 Lun, C.K.K., 210, 299 M Macauley, N., 270, 303 MacKinnon, C., 191, 200 Maier, C., 28, 65 Malkin, B.A., 279, 280, 305 Malloy, R.A., 315, 322, 323, 345, 346, 362–364 Malwitz, N., 291, 305 Mansure, B., 6, 15 Marchal, J.-M., 287, 306 Marion, R.L., 278, 304 Martin, D., 6, 16, 69, 108 Mazur, S., 225, 226, 227, 228, 232, 233, 301 McCarthy, T.J., 360, 365 McClellan, E., 6, 15 McDaid, J., 69, 70, 71, 73, 76, 86, 89, 90, 91, 94, 108 McDonagh, J.M., 6, 15 Mello, J., 335, 364 Mincey, E., 105, 110 Mish, K.D., 335, 364 Mooney, P.J., 1, 14 Morawetz, H., 22, 30, 65 Moroni, G., 104, 110 Muller, B., 6, 15, 101, 102, 110 Muller, H., 63, 68 Murphy, W.R., 270, 303 Muzzio, F.J., 243, 306 N Nagy, T., 100, 109 Nakajima, N., 38, 65 Narkis, M., 25, 65, 218, 225, 226, 227, 228, 232, 233, 235, 236, 301, 347, 348, 364 Neuville, B., 225, 300 Newman, S.J., 236, 301 Nickerson, J.A., 2, 14 Nugent, P.J., 11, 12, 16–18, 140, 147, 186, 200, 201, 214, 273, 274, 299, 303, 350, 352, 353, 354, 365 O Ocone, R., 210, 211, 300 Ogorkiewicz, R.M., 4, 14, 44, 52, 66, 67, 268, 270, 271, 272, 303 Ohta, Y., 146, 148, 201, 214, 247, 248, 299 Okoroafor, M.O., 291, 306 Oliveira, M.J., 12, 17, 18, 99, 109, 268, 303 Olson, L.G., 250, 273, 274, 303 Onaran, K., 323, 362 Onoda, C.Y., 211, 300 Orr, J., 6, 16, 69, 108 Otten, L., 219, 300 P Paiva, M.C., 12, 18 Park, C.P., 59, 67, 291, 306 Park, C.L., 287, 306 Pasham, V.R., 250, 303 Passman, S.L., 210, 300 Peterson, A.C., 315, 362 Petrucelli, F., 6, 15 Pietsch, W., 81, 109 Plesset, M.S., 240, 302 Polini, W., 104, 110 Pop-Iliev, R., 287, 306 Press, W.H., 333, 363 Progelhof, R.C., 20, 22, 23, 44, 45, 50, 53, 62, 63, 65–68, 217, 229, 230, 231, 236, 237, 242, 267, 279, 300, 301, 303, 304, 315, 323, 328, 330, 362, 363 Q R Rabinovitz, E., 6, 16 Ramesh, N.S., 291, 305 Rao, M.A., 81, 108, 201, 205, 214, 299 Rauenzahn, R.M., 210, 211, 300 Rauwendaal, C., 207, 299 Rees, R.L., 6, 15, 76, 108 Rhodes, M., 77, 108 Richards, J.C., 205, 211, 212, 299 Rigbi, Z., 6, 16 Rijksman, B., 287, 306 Roark, R.J., 318, 362 Rohsenow, W.H., 250, 261, 303 Rosenzweig, N., 25, 65, 218, 225, 226, 227, 228, 232, 233, 235, 236, 301, 347, 348, 364 Ruetsch, R.R., 217, 300 Rumpf, H., 205, 299382 Rotational Molding Technology Straight — Text Citing Italic — Reference S Saffert, R., 6, 15 Sarvetnick, H.A., 37, 38, 65, 278, 304 Schmitz, W.E., 4, 14 Schneider, K., 39, 66 Schneider, P.J., 249, 250, 261, 303 Scott, J.A., 12, 17, 142, 147, 148 Shah, V., 44, 51, 54, 57, 61, 62, 66–68 Shinbrot, T., 243, 306 Shinohara, K., 219, 300 Shrastri, R.K., 48, 49, 67 Shulman, Z.P., 231, 238, 301, 302 Shutov, F.A., 289, 291, 293, 305, 306 Silva, C., 100, 109 Sin, K.K., 6, 16, 69, 108 Smit, T., 69, 90, 92, 108 Sneller, J., 287, 306 Sohn, M.-S., 83, 109, 205, 211, 299 Sowa, M.W., 6, 16 Spence, A.G., 12, 17, 89, 100, 109, 138, 142, 146, 147, 148, 207, 238, 240, 299, 302 Spyrakos, C.C., 266, 303, 310, 333, 334, 362, 363 Stanhope, B.E., 6, 15, 96, 109 Stoeckhert, K., 154, 200 Strebel, J., 89, 90, 91, 109 Strong, A.B., 6, 15 Stufft, T.J., 89, 90, 91, 109 Susnjara, K., 355, 365 Swain, R., 102, 110 Syler, R., 242, 302 T Takacs, E., 64, 68, 69, 93, 108, 109, 243, 244, 287, 302, 306, 354, 365 Tanaki, A., 36, 68 Taylor, T.J., 348, 364 Teoh, S.H., 6, 16, 69, 108 Teukolsky, S.A., 333, 363 Throne, J.L., 6, 10, 16, 20, 22, 23, 25, 44, 45, 50, 53, 62, 63, 65–68, 81, 83, 108, 109, 201, 205, 207, 210, 214, 215, 217, 218, 224, 229, 230, 231, 235, 236, 237, 238, 239, 242, 245, 246, 247, 248, 251, 267, 275, 279, 281, 282, 283, 288, 291, 293, 299–305, 308, 315, 323, 327, 328, 323, 330, 331, 340, 341, 347, 348, 356, 362–365 Tordella, J.P., 44, 66 Tredwell, S., 64, 68 Turner, S., 47, 67 Turng, L.-S., 287, 306 U V Vetterling, W.T., 333, 363 Vincent, P.I., 52, 67 Vlachopoulos, J., 6, 11, 15, 17, 64, 68, 69, 93, 108, 109, 225, 228, 234, 238, 240, 241, 243, 244, 287, 301, 302, 306, 354, 365 Voldner, E., 6, 15 W Walls, K.O., 12, 18 Wang, H.P., 287, 306 Ward, D.W., 38, 65 Ward, W.J., 360, 365 Weber, G., 4, 14 Werner, A.C., 37, 38, 65 White, J.L., 100, 109, 138, 147, 148, 201, 214, 247, 248, 299 Wisley, B.G., 6, 16 Wright, M.J., 138, 120, 147 Wright, E.J., 248, 302 Wytkin, A., 120, 147 X Xin, W., 11, 16 Xu, L., 240, 302 Y Yoo, H.J., 239, 302 Young, W.C., 318, 362 Z Zhang, D.Z., 210, 211, 300 Zimmerman, A.B., 4, 14Index Figure entries are suffixed “F” and those with “T” refer to tables. Index terms Links A ABS 9 See also Acrylonitrile-butadiene-styrene Rotational molding grade, discussed 36 Limitations in rotational molding 36 Acrylic 9 See also PMMA, Polymethyl methacrylate Acrylonitrile-butadiene-styrene As thermoplastic 19 Discussed 35 Air temperature, inner cavity, measurement 140 Air solubility in polymer 239 Aluminum casting See also Mold, aluminum, cast Procedure 152 Amorphous, defined 20 ARM, see Association of Rotational Molders Arms Design weight, described 122 Hollow for inert gas injection 146 Hollow for pressuring molds 146 Offset 122 Straight 122384 Index terms Links Arms (Continued) Support of molds 122 122F Swing diameter Described 123 123F 124F 125F Examples of 123 Association of Rotational Molders 12 ASTM D-1238 24 See also Melt index ASTM D-1693 22 See also ESCR; Environmental stress crack test ASTM D-348 26 32 See also Heat distortion temperature ASTM D-2765 27 See also Polyethylene, crosslinked ASTM D-1238 44 ASTM E-11 46 See also Sieve, screen sizes, discussed ASTM D-1921 46 See also Sieve technology ASTM D-1505 51 See also Density gradient column ASTM D-256 53 See also Impact test, pendulum; Impact test, Charpy; Impact test, Izod ASTM D-3029 53 See also Impact test, falling weight ASTM D-790 54 See also Mechanical test, flexural modulus ASTM D-638 64 See also Mechanical test, tensile modulus385 Index terms Links ASTM D-2990 55 See also Mechanical test, creep ASTM D-671 55 See also Mechanical test, flexural fatigue ASTM D-1693 58 See also Environmental stress crack test, notched strip ASTM D-1435 61 See also Weathering, accelerated tests ASTM D-3801 63 See also Fire retardancy, standard match test ASTM D-2863 63 See also Fire retardancy, oxygen index ASTM E-11 75T See also Sieve ASTM D-1921 76 See also Particle size distribution ASTM D-1895 84 84F See also Powder flow, test method ATM D-1895 46 See also Sieve technology, bulk density; Sieve technology, pourability Attrition 69 See also Pulverization, described B Baffles See also Molds In mold design 136 136F Bridging, considerations for 311 Brittle fracture, impact test 51386 Index terms Links Brittle temperature for several polymers 52 Bubbles 15 Bulk density Grinding factors affecting 89 Powder Fluidized 88T Measurement 84F 88 Poured 88 88T Tamped 88 88T Vibrated 88 88T C CAB, see Cellulose acetate butyrate CAP, see Cellulose acetate propionate Carousel machine Fixed arm 117 118F Independent arm 118 119F Cellulose acetate butyrate, discussed 34 Cellulose acetate propionate, discussed 34 Cellulosic 9 21 Discussed 34 General properties, discussion 35 Centrifugal casting 7 15 Charge weight, calculation of 174 For cylinder 175 175F For rectangle 176 176F 177F For various shapes 177 179T Chemical resistance, post-applied 359387 Index terms Links Chemical test Crazing 57 Haze formation 56 Plasticization 56 Solvation 56 Solvent migration 56 Stress-cracking 57 Chocolate 7 Clamshell machine Discussed 115 115F Oven design 116 Coalescence 26 As sintering 26 Effect of particle size distribution on 87 Color CIE standard 56 Compounding 96 101 Dry blending 96 Concentration level effect 99F High speed mixing 97 Low-intensity 97 Low-intensity, equipment 97 Tumbling 96 97 Turbo-blending 97 Effect of blending technique on dispersion of 100F Effect of blending technique on mechanical properties 101 Factors that affect 55 Methods of, discussed 96 Rotational molding factors that affect 56 XYZ diagram 56388 Index terms Links Cooling Air 137 274 Cycle time for Discussion 259 Mathematical model 260 262 Wall thickness effect on 277 Discussed 137 Effect on shrinkage/warpage 137 Effect of water quench on 275 Experimental and theoretical comparison of 273 274F Part release from mold during 203F 204 Pressurized mold 276 Recrystallization during 203F 204 Recrystallization effects during 266 Recrystallization effects during, modeling Temperature measurements during 202F 203F Thermal inversion Described 262 Technical description 262 263F 264F Distributed parameter model 264 Lumped parameter model 266 Water spray/mist 137 Cooling methods, discussed 137 Cooling rate 16 Coordinate measuring machine, discussion 360 Cracking, localized, impact test 51 Crazing 57 Creep modulus, see Mechanical test, creep modulus; Mechanical test, creep Crystallinity, defined 20389 Index terms Links D Decoration Adhesives 358 Hot stamping 358 In-mold 359 Methods of, discussion 357 357T Painting 358 Post-mold 359 Design Of molds, see Molds, design of Of parts, see Parts, design of; Parts design Part removal 276 Design, mechanical CAD/CAM in 332 Cantilever beam flexural 316 Column bending 317 Computer-aided stress analysis for 332 Computer-aided stress analysis for; see Finite-element analysis Computer aids for, discussed 330 331F Computer aids in prototyping 332 Greep in 322 Criteria for parts 314 Finite difference analysis for 333 Finite-element analysis for 333 Foams, discussion 324 Skin-core foams Stiffness of 329 I-beam model for 329 330F Polynomial beam model, discussed 330 331F390 Index terms Links Design, mechanical (Continued) Uniform density foams 324 Stiffness of 325 Modulus for 325 Foaming efficiency of 325 326T Tensile strength for 327 Impact characteristics of 327 328T Ductile-brittle characteristics of 327 328F Hollow beam with kiss-off 318 Long-term loading 314 Moderate-term loading 314 Plate bending, edge-on 317 Ribbed plate 319 Short-term loading 314 Temperature-dependency in 323 324T Tensile creep in 323 323F Three-point flexural 315 Demolding, schematic 5 2F Density gradient column 51 Density, polyethylene property changes with 25T Differential Scanning Calorimetry 268 270 271F 272F DIN 6174 56 See also Color, CIE standard DIN 5033 56 See also Color, XYZ diagram Distortion 16 Dry blender Double-cone 97 98F Double-ribbon 97 Vee mixer 97 98F391 Index terms Links Dry blending See also Color Additives in melt-blending 98 Additives in tumble-blending 97 Additives suitable for 97 Effect on mechanical properties 99 Effect on polymer crystalline nucleation 99 Effect on polymer morphology 99 Henschel-type mixer 99 Rotational molding powders 97 Turbo mixing 99 Drying conditions for polymers 34T Ductile failure, impact test 51 Ductile yield, impact test 51 Ductile-brittle transition, impact test 52 52F E Electroformed nickel Procedure 155 See also Molds, electroformed nickel Environmental stress crack resistance, LDPE 50 50F Environmental stress crack test Bent strip 57 57F Constant stress test 58 Defined 57 Notched strip 58 Polyethylene 58 Epoxy 9 As liquid polymer 37 ESCR, see Environmental stress crack test392 Index terms Links Ethylene vinyl acetate Chemical structure 27 Density 28 Environmental stress crack resistance 28 Extent of vinyl acetate 28 Foamability 28 Melt temperature range 28 Shore hardness 28 EVA, see Ethylene vinyl acetate F FDE, see Finite difference analysis FEA, see Finite-element analysis FEP, see Fluoroethylene polymer Finite difference analysis 333 Finite-element analysis 333 Arithmetic for 334 Formalization of 334T Limitations of 335 Fire retardancy Defined 62 Oxygen index 63 63T Standard match test 63 Flexural modulus, see Mechanical test, flexural modulus Fluorocarbon 9 Fluoroethylene polymer, as thermoplastic 19 Foam rotational molding Blowing agent efficiency in 290 Bubble nucleation in 291 Chemical foaming agents for 287 288T 289T393 Index terms Links Foam rotational molding (Continued) Endothermic 288 Exothermic 288 Containerized inner layer in 298 Diffusional bubble growth in 291 Discussed 287 Inertial bubble growth in 291 Limitations of 292 One-step process in 295 Oven conditions for 293 293T Physical foaming agents for 287 Single layer structures in 295 Skin/core structure in 287 Terminal bubble growth in 292 Two-step process in 296 Fracture, brittle, impact test 51 G Glass transition temperature, defined 20 Grinding 69 See also Pulverization, described Ball-mill 69 Costs associated with Discussion 91 Factors 92 Economies of scale 92 Frictional heat 71 Gap size effect on powder quality 89 Hammer-mill 69 Horizontal mill 72 73F394 Index terms Links Grinding (Continued) In-house v. outsourcing 91 Mill tooth number effect on powder quality 90 Parallel plate 69 Particle sieving 71 Powder characteristics 73 Particle size distribution 74 Flow 74 Bulk density 74 LLDPE 74 As related to rotational molding parameters 74 75 Particle shape 75 Process control 72 Process equipment 69F 72F Skill factors involved in 92 Temperature effect on powder quality 90 90F 91F Vertical mill 70 70F H Haze formation 57 HDPE Crystallinity of 20T See also Polyethylene, high-density Heat capacity, of powder 218 Heat transfer Coefficient of For air 274 For water 275 Combustion 129 130T Conduction 213395 Index terms Links Heat transfer (Continued) Defined 127 Convection 213 Defined 127 Coefficient 127 127T Effect of polymer morphology on 243 244F Modes, defined 127 Radiation 213 Defined 127 Thermal lag in mold 214 222 245 To coalescing powder bed 223 To powder 215 To powder bed 217 To powder particle 215 To mold 213 To mold assembly 139 To mold assembly, measurements of 139 139F Transient heat conduction in 216F Transient heat conduction model 247 Types in rotational molding 213 Heating See also Oven; Heat transfer Cycle time of 251 Actual 258T Oven temperature effect on 255T 256 256T 258 Thickness effect on 254 255T 256 256T Direct-gas impingement 113 Discussion of 201 Effect of pressure on powder behavior during 244 Effect of vacuum on powder behavior during 244396 Index terms Links Heating (Continued) Kink temperature during 202 203F 220 253 Mathematical modeling of 245 246F Mold cavity air temperature during 221 Mold energy uptake to polymer uptake ratio 252 Polymer morphology effect on rate of 223 224F Temperature measurements during 201 202F 203F Time to inner cavity temperature, thickness effect on 255 Time to kink temperature, thickness effect on 255 Overall cycle time, thickness effect on 256 257F Henry’s law 239 And foam rotational molding 293 I Igepal 22 23 24 27 28 49 58 Impact, process effects on 350 350F 353F 354F Impact test Charpy 53 Constant velocity puncture 53 Described 51 Failure type 51 Factors affecting 53 Falling weight 53 Bruceton method 53 ARM standard, see Impact test, falling weight, Bruceton method ARM standard, low-temperature, see Impact test, falling weight, Bruceton method Probit method 53397 Index terms Links Impact test (Continued) Staircase method, see Impact test, falling weight, Bruceton method “Up-and-down” method, see Impact test, falling weight, Bruceton method Izod 53 Low-temperature, ARM terms 52 Pendulum 53 Test types 53 Tensile 53 L Latex rubber 7 LDPE See also Polyethylene, low-density Crystallinity of 20T Environmental stress crack resistance, melt index effect 50 50F Liquid polymers 69 Discussed 36 Liquid rotational molding Bubble entrainment in 284 Cascading flow in 280F 281 283F 286F Circulating pool in 280 280F 283F 286F Discussed 278 Flow behavior in 280 280F 283F 286F Hydrocyst formation in 282 282F 284F Ideal fluid for 286 Localized pooling in 285 Polymers used in 278 Process 279398 Index terms Links Liquid rotational molding (Continued) Process controls for 285 Rimming flow in 280F 281 283F 286F Role of reaction in 285 Role of gelation in 285 Solid body rotation in 281 283F 286F Time-dependent viscosity in 279 279F LLDPE See also Polyethylene, linear low-density Crystallinity of 20T M Machines Basic elements of 112 Clamshell 115 115F Cooling design in, see Cooling Compared with competition 111 Electrically-heated molds for 120 120F 121F Fixed-arm carousel 117 118F Limiting factors 118 Heat transfer in, see Heat transfer Home-built 111 Independent-arm carousel 118 119F Advantages of 118 Infrared heated 121 Make-Vs-buy 111 Oil-jacketed molds for 119 Oven design in, see Oven Process control of, see Process control Rock-and-roll 113399 Index terms Links Machines (Continued) Shuttle 116 117F Types of, discussed 112 Vertical 116 116F MDPE, see Polyethylene, medium-density Mechanical Properties 16 Mechanical test Creep, defined 54 Creep modulus 55 Creep rupture 55 Defined 54 Flexural fatigue 55 Flexural modulus 54 Tensile modulus 54 MEKP, see Methyl ethyl ketone peroxide Melt flow index 28 See also Melt index Described 44 Melt index 28 45F 64 HDPE 24 LDPE 22 MDPE 23 Polyethylene property changes with 25T Process effects on 352F Quality control of 43 44 Described 44 Melt index test conditions Nonpolyolefins 44 45T Polyolefins 45T 46T Melt indexer 44 45F400 Index terms Links Melt viscosity 15 43 Melt elastic modulus 64 Melting temperature, defined 20 Methyl ethyl ketone peroxide, catalyst for Unsaturated polyester resin 42 Micropellet 46 See also Polyvinyl chloride Coloring of 95 Comparison with conventional pellet 94 95T Discussed 93 Method of production 93 Processing comparison with powder 94 95T Polyethylene 69 PVC, discussed 96 96T Reason for use 93 Mold charging, schematic 5 2F Mold cooling, schematic 5 2F Mold heating, schematic 5 2F Mold release 103 Cost of 199 Discussed 196 Disiloxanes 197 Early part release with 199 Fluoropolymers 197 Selection criteria for 198 Silicone 197 Spray-on 197 Surfaces coated by 198401 Index terms Links Molds Air flow around deep pockets 136 136F Air flow using baffles 136 136F Air flow using venturi 136 137F Alignment methods for 165 164F Aluminum 150 150F 150T 152 Cast 150 152 154F Welded 152 Machined 152 152F Clamping of 166 166F Commercial 149 Design of Discussion 160 For pressurization 276 Parting line 161 Butt or flat 161 161F Lap joint 162 162F Tongue-and-groove 162 163F Gaskets 163 163F Electroformed nickel 149 150T 154 155F Frames for 165 Heat transfer to 213 J-clamps for 166 168F Manual clamps for 166 Materials for Discussed 149 Properties 150T Nonmetallic 149 Pressure buildup without venting 183 Pressurization for 340402 Index terms Links Molds (Continued) Pressurized 146 Pry points, location for 167 167F Sheet-metal 149 149F 150T 151 Spiders for 165 165F Surfaces coated with mold releases 198 Surface finishes for 196 Thermal behavior of Various types 156 157F 158F 159F Equivalent mechanical thickness 156 157F Equivalent static thermal thickness 157 158F Equivalent transient thermal thickness 159 159F Toggle clamps for 166 167F Use of drop-box in 297 Use of drop-box on 296 297F Venting of, see Venting Moment of area, second, see Moment of inertia Moment of inertia, defined 315 Morphology Changes in PP, due to cooling rate 270T 273 273T Crystallinity level and 267 267T Effects of additives on 272 272T Recrystallization rates and 267 268T 269F 270T N Natural gas combustion 129 130T Nylon 9 As thermoplastic 19 Chemical structure 31 Chemical types 32T403 Index terms Links Nylon (Continued) Crystallinity of 20T 32 Fiber-reinforced 9 Melting temperature 32T Moisture concerns with 310 Rotational molding grades 32 32T Nylon 6, WLF constants for 324T Nylon 12, as liquid polymer 40 O Odor Defined 62 Test Olfactory 62 Gas chromatography 62 Oven time 14 Effect on design parameters 351T Oven temperature 14 Oven Air flow around molds with deep pockets 136 136F Air flow in 136 Design of, discussed 127 129 Efficiency of operation of 130 Heat transfer in 131 Heat transfer in Examples of 133404 Index terms Links P PA-6 See also Nylon: Polycaprolactam As liquid polymer 36 Flexural modulus 32 Heat deflection temperature 32 Melting temperature 32 Part design Acute-angled corners in 346 347F Aesthetics 307 Almost kiss-offs in 312 Appearance effect on 308 Application effect on 308 Assembly constraints effect on 309 Bridging criteria for 311 Cavity depth criteria for 312 Competition effect on 309 Computer-aided technique effect on 310 Concerns of warpage in 311 Control of wall thickness in 312 Coordinate measuring machine use in 360 Corner radius guidelines in 345 345T 347F Cost effect on 309 Criteria 307 Criteria for kiss-off 318 Cycle time effect on 310 Decoration effect on 309 Detents in 312 Dimensional tolerance effect on 31 Draft angles 341 342T405 Index terms Links Part design (Continued) Female molds in 312 Polymer-specific 341 342T Texture 342 342T Environment effect on 308 External threads in 312 349 Fiber-reinforcement in 312 Flat panels in 311 General guidelines for, discussed 310 General considerations for 335 Gussets in 312 Holes in 349 Improving mechanical strength through 312 Insert 349 Criteria for 312 Stresses around 312 Internal threads in 312 349 Kiss-offs in 312 Limitations of 309 Market considerations 307 Material choice effect on 309 Mechanical Criteria for 314 Discussion 307 317 Metal molded-in inserts for 313 Minimum wall thickness in 336 Mold cost effect on 309 Molded-in holes in 312 Mold texture transfer to parts in 312 Nominal wall thickness in 336406 Index terms Links Part design (Continued) Parallel walls in 311 348 Part function effect on 308 Part wall separation for 348 Philosophy 307 Powder flow effect on 310 Pressurization effects on 340 Process effects on Discussion 350 Impact 350 350F Melt index 352F Radius concerns in 312 313 Right-angled corners in 345 Ribs in 311 Rim stiffening in 312 Shrinkage guidelines in 337 Size effect on 309 Surface decoration; see Decoration Wall thickness considerations for 311 Wall thickness in 336 337T Wall thickness limitation effect on 309 Wall thickness range in 337T Warpage guidelines for 344 344T Warpage in 311 Undercuts in 311 312 Particle size distribution 75 Data presentation 79 79F 80T 80F Discussed 74 Dry sieving 77 Elutriation 78407 Index terms Links Particle size distribution (Continued) Fluidization 79 Light scattering 78 79 Measurement 77 Sedimentation 78 Streaming 78 Test method 76 78 Factors affecting 78 Test purpose 77 Particle shape Acicular 81 Discussed 81 Effect on part performance 81 Methods of classification 81 Particle size analyzers 82 Physical methods 82 Shape factor 81 82T Spherical 81 Squared-egg 81 Terms defined 82T Particle size analysis 77 Parting line See also Molds, design of, parting line Butt or flat 161 161F Design of 161 Gaskets 163 163F Lap joint 162 162F Tongue-and-groove 162 163F See also Part design408 Index terms Links Parts Blowhole problems in 183 Cutout areas in 172 Failure Discussed 307 Fracture 307 Creep 307 Crazing 307 Stress cracking 307 Fatigue 307 Adhesive failure 308 Warpage 308 Shrinkage 308 Color change 308 Additive migration 308 Cracking element migration 308 Inserts for 168 Kiss-offs for 172 173F Mechanical fastening of 169 Molded-in handles for 173 Molded-in inserts for 169 170F Molded-in threads for 171 171F Post-molded fasteners for 169 Self-tapping screws for 168 Suck-hole problems in 185 Temporary inserts for 173 Warpage with mold release 199 PC, see Polycarbonate PEEK 9 See also Polyether-ether ketone409 Index terms Links Phenolic 9 As thermoset 19 Crosslinked, discussion 19 Pigments Classes of 101 Classification of 104T Color shift in 103 Discussion of 101 Dry-color blending of 101 Heavy metals, restricted use of 101 Organics 102 Azo-type 102 Polycyclic-type 102 Processing concerns of 102 Fluorescents 103 Plate-out of 103 Special-effect 103 Temperature effect on selection of 101 Pinholes 15 Plaster, molding, properties 154 PMMA, see Polymethyl methacrylate Poly-a-aminoacid, see Nylon Polyacetal 9 See also POM, Polyoxymethylene Polyamide, see Nylon Polybutylene 9 Polycaprolactam Chemical structure 39 Defined 32 Fillers for 41410 Index terms Links Polycaprolactam (Continued) Gellation rate 40 General production method 40 Time-dependent crystallinity 40F Time-dependent viscosity during reaction 39F Polycarbonate 9 As thermoplastic 19 Chemical resistance, discussed 34 Chemical structure 33 Drying for rotational molding, discussed 33 34T Flexural modulus 33 Heat distortion temperature 33 Impact strength, discussed 33 Moisture concerns with 310 WLF constants for 324T Polyester Unsaturated 9 As thermoset 19 Polyether-ether ketone 21 As thermoplastic 19 Polyethylene terephthalate, crystallinity of 20 20T Polyethylene As thermoplastic 19 Branched, see Polyethylene, low-density Chemical structure 22 Crosslinked 9 Advantages 58 Crosslinking agents 27 58 59T Density 27 Discussion 19 27411 Index terms Links Polyethylene (Continued) Environmental stress crack resistance 27 Flexural modulus 27 Gel content 27 Peroxide level 60F Time dependency 60F Test 59 Level, procedure 59 Shore hardness 27 Crystallinity of 20T Early applications 6 High-density Chain configuration 23F Crystalline morphology 24 Crystallinity 24 Defined 24 Density 24 Environmental stress crack resistance 24 Flexural modulus 24 Melt index 24 High-pressure, see Polyethylene,low-density Low-density Chain configuration 23F Crystallinity 22 Defined 22 Density 22 Environmental stress crack resistance 22 Flexural modulus 22 Melt index 22 Shore hardness 22412 Index terms Links Polyethylene (Continued) Low-pressure, see Polyethylene, high-density Linear, see Polyethylene, high-density Linear low-density Chain configuration 23F Crystallinity 27 Density 26 Defined 25 Environmental stress crack resistance 27 Flexural modulus 27 Medium-density Crystallinity 23 Defined 23 Density 23 Environmental stress crack resistance 23 Flexural modulus 23 Melt index 23 Metallocene, discussed 26 Micropellet 69 Odor 15 Powder 69 WLF constants for 324T Polyimide 21 Polymer morphology, discussed 20 Polymethyl methacrylate, chemical structure 35 Polyolefin 7 Polypropylene 9 As thermoplastic 19 Atactic, defined 28 Chemical structure 28413 Index terms Links Polypropylene (Continued) Copolymer Defined 29 Effect on properties 29 29T Crystallinity of 20 20T Fillers in 29 High-temperature stability of 29 Homopolymer, flexural modulus 28 Isotactic, defined 28 Melt flow index 28 Recrystallization of 30 Syndiotactic, defined 28 WLF constants for 324T Polystyrene 9 See also Styrenics As thermoplastic 19 Discussed 35 Impact, discussed 35 WLF constants for 324T Polytetrafluoroethylene, crystallinity of 20 Polyurethane 9 As liquid polymer 37 As thermoset 19 Chemical structure 41 Nature of reaction 42 Time-dependent viscosity during reaction 41 Polyvinyl chloride 21 As thermoplastic 19 Chemical structure 30 Drysol, discussed 30414 Index terms Links Polyvinyl chloride (Continued) Drysol hardness 31 Drysol v. micropellet 96 96T Liquid 6 Micropellet 31 Micropellet characteristics 96 96T Plastisols, discussed 30 Plastisol hardness 30 Plastisol v. micropellet 96 96T Role of plasticizers in 30 Types of additives for 30 Porosity, discussed 242 Powder density Discussed 84 Related to powder flow 85F Powder Coalescence 12 Consolidation 14 Densification 12 Fusion 14 Sintering 15 Size 21 Powder particle characterization, quality control 44 Powder flow Discussed 74 83 Effect of tails on 83 Grinding factors affecting 89 Related to powder density 85F Test method 84415 Index terms Links Powder packing 85 See also Powder flow; Particle shape Bulk density Fluidized 88T Measurement 84F 88 Poured 88 88T Tamped 88 88T Vibrated 88 88T Deviation from ideal packing 86 Equal spheres 85 86F 86T Packing fraction defined 85 Particle size distribution effect 87 Powder quality See also Grinding Discussed 88 Grinding factors effecting 89 Powder Airborne dust generation with 207 Antistatic agents for 105 Avalanche flow of 208 208F 209T 222 Bed behavior during heating 222 Bubble dissolution in coalesced 235F Bulk density of various 206T Carbon black in 106 Coalescence 203 235F Defined 223 Coulomb flowing 207 Temperature effect on 219 Densification in 203 235F Air absorption 238416 Index terms Links Powder (Continued) Rayleigh.s model for 238 Capillary action 236 Defined 236 Network collapse 236 237F 238F Particle size distribution during coalescence 242 Rate of 242 Three mechanisms for 234 Under vacuum 237 Flow aspects of 206 Fluidizing 207 Mathematical modeling Bed 248 Static bed 249 Circulating bed 248 250 Moisture concerns with 310 Neck growth Compared with heating profile 226F Defined 223 Viscous model 225 225F 227F Neck growth rate 226 227T Creep compliance model 232 232F 233F Hertzian 228 Linear viscoelastic 229F 230 231F Newtonian 227F 228 Packing aspects of 205 Polyethylene 69 Polymer elasticity effect on coalescence of 234 Rheology of flowing 210 Rotating cylinder flow of 211 212F417 Index terms Links Powder (Continued) Sintering of, defined 223 Slip flow of 208 208F 209T 222 Steady-state circulation of 207 208F 209T 222 Stearates for 106 UV additives for 106 Viscous flowing 207 Process control Discussed 138 Inner cavity air temperature monitoring for 140 Process cycle Discussion of 201 Steps in 201 204 205T Processing and properties, general considerations 14 Propane combustion 129 130T PS, see Polystyrene; Styrenics PSD 74 77 See also Particle size distribution Pulverization, described 69 P-V-T curves HDPE 338F Polycarbonate 339F Shrinkage and 337 PVC plastisol 9 21 As liquid polymer 36 Effect of heat on molecular characteristics 37F Effect of heat on viscosity 38F Fusion 37F 38 Gellation 37F 38 Method of production 38418 Index terms Links PVC plastisol (Continued) Product types 39 Shore hardness 39 PVC, see Polyvinyl chloride Q Quality assurance, discussion 360 R Rayleigh.s equation Inviscid 238 Newtonian 238 Viscoelastic 239 Recrystallization, part design restrictions for 311 Ribs, design criteria for, discussed 311 Rock-and-roll machine 113 114F 115 Oven design 114F 115 Products made on 113 Rotation Fixed ratio, discussed 125 Major-to-minor axis ratio 125 Speed of, discussed 125 Speed ratio Defined 126 Recommended for various geometries 126T Rotational molding Advantages 10 12 14 Applications 3T Basic process 5 10 Cooling 16419 Index terms Links Rotational molding (Continued) Competition 4 6 10T Defined 4 Degradation 15 Design 8 11 Desirable polymer characteristics 64 Disadvantages 10 14 Heating 15 History 6 Internal surface appearance 15 Markets 4 5F Materials 9 10F Molder consumption 21T Nature of polymer in 69 Polymer use 21T Powder flow 15 Rotational molding process Limitations 145 Advances in 146 Rotocasting, see Rotational molding Rotomolding, see Rotational molding S SAN, see Styrene-acrylonitrile Service station, discussed 144 Shrinkage Discussion 337 Guidelines for 340 Linear 338 340T Volumetric, discussion 338420 Index terms Links Shuttle machine 116 117F Dual carriage 117 117F Sieve technology Bulk density 46 Described 46 Dry sieving 46 Pourability 46 ARM recommendation 46 Sieve See also Powder technology Grinding 71 Dry, types of 77 Elutriation 78 Screen sizes, discussed 46 Shaker sizes 76F Sizes of 75T Sonic sifter 78 Silicone 9 As liquid polymer 37 Chemical structure 43 Method of reaction 43 Sintering 26 See also Coalescence Slip casting, ceramics 7 Slush molding 278 Society of Plastics Engineers Rotational Molding Division 12 Spin casting 7 Stress concentration factor 346F Stress-cracking 57421 Index terms Links Styrene-acrylonitrile, see Styrenics Styrenics, chemical structure 35 Surface treatment Activation methods for 104 Applied graphics as 105 105F Discussed 104 Plasma 104 T Tack temperature Amorphous 219 220T Crystalline 219 220T Defined 219 Related to kink temperature 220 253 253T Temperature measurement Correlation of Bubble dissolution time 142 142F Coalescence time 141 Part release from mold 143 Process step 140 141F Recrystallization time 143 Infrared method 144 Inner cavity air temperature 140 Interpretation 140 141F Mold assembly 139 See also Heat transfer Tensile modulus, see Mechanical test, tensile, modulus Testing protocol Actual part 47 Costs 48 49T422 Index terms Links Testing protocol (Continued) Defined 47 Full-scale 47 Segment 48 Test acceptability criteria 48 Testing Environmental stress crack resistance 50 50F Full-scale 49 Molded density 51 Sections 50 Tg, see Glass transition temperature Thermal lag 214 222 245 See also Heat transfer, to mold Mathematical model of 245 Thermal conductivity, of powder 217 218F Thermal diffusivity 248 Powder 218 Thermoplastics Defined 19 Discussed 6 Thermosets See also Thermosetting polymers Defined 19 Rotational molding advantages 43 Thermosetting polymers, liquids 36 Thermosetting liquids, nature of reaction 36 Thermosetting, discussed 6 Titanium dioxide As opacifier 107 As UV additive 107423 Index terms Links Tm, see Melting temperature Trimming Cutting characteristics 356T Various polymers 356 Discussion 354 Multiaxis 354 356T Troubleshooting Discussion 360 Guidelines, Appendix A U UHMWPE, see Ultrahigh molecular weight, polyethylene ULE-84 tunnel test 62 See also Fire retardancy UL 94 63 See also Fire retardancy, standard match test Ultrahigh molecular weight polyethylene, characteristics 22 Undercuts, design criteria for, discussed 311 Unload/load process station, see Service station Unsaturated polyester resin As liquid polymer 37 Chemical structure 42 Fillers for 42 Processing difficulties with 42 Reaction via MEKP 42 UPE, see Unsaturated polyester resin UV additive Carbon black as 106 Classification of 106 Hindered amine light stabilizers as 106424 Index terms Links UV additive (Continued) Titanium dioxide as 107 V Venting Design guidelines for 186 190F 192F Discussion 183 Disposable 193 Permanent 193 194F Pressure buildup without 183 Requirements for 195 Types of 193 Selection criteria 193 Vacuum without 185 Venturi See also Molds Mold design with 136 137F Vertical machine, discussed 116 116F W Wall thickness Calculation of 174 Maximum allowable 180 181F Warpage 16 Weathering Accelerated tests 61 Acid rain 61 Defined 61 Resistance of polymers 61 Ultraviolet effect 61425 Index terms Links Williams-Landel-Ferry model 323 Constants for 324T WLF equation 323 324T See also Williams-Landel-Ferry model X XLPE, see Polyethylene, crosslinked
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