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 |  موضوع: كتاب Plastic Part Design for Injection Molding - An Introduction الجمعة 15 مايو 2020, 4:34 am | |
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أخوانى فى الله
أحضرت لكم كتاب
Plastic Part Design for Injection Molding - An Introduction
2nd Edition
Robert A. Malloy
و المحتوى كما يلي :
Contents
Preface VII
Contents IX
1 Introduction . 1
1.1 Thermoplastic Materials 1
1.2 Thermosetting Plastic Materials . 2
1.3 Structure-Property Relationships 3
1.4 Additives for Plastic Materials . 7
1.5 General Characteristics of Plastic Materials . 8
References . 13
2 Manufacturing Considerations for Injection Molded Parts . 15
2.1 Introduction 15
2.2 Mold Filling Considerations 16
2.2.1 Gating Considerations 16
2.2.2 Mold Filling Orientation 21
2.2.3 Mold Filling Pressure Losses . 27
2.2.4 Flow Leaders, Flow Restrictors and Flow Hesitation . 39
2.3 Weld Lines . 48
2.3.1 Introduction . 48
2.3.2 Types of Weld Lines 52
2.3.3 Material Considerations . 55
2.3.4 Improving Weld Performance and Appearance . 58
2.4 Shrinkage and Warpage of Injection Molded Parts . 63
2.4.1 Introduction . 63
2.4.2 Part Wall Thickness Variations . 65
2.4.3 Pressure-Volume-Temperature Behavior of Polymers 69
2.4.4 Linear Mold Shrinkage 72
2.4.5 Anisotropic Shrinkage and Part Distortion/Warpage 76
2.5 Cooling and Solidification 86X Contents
2.6 Part Ejection 89
2.6.1 Introduction . 89
2.6.2 Draft Angles . 90
2.6.3 Effect of Cavity and Core Surface Finish . 95
2.6.4 Esthetic Considerations . 99
2.6.5 Undercuts and Holes . 100
2.6.6 Predicting Part Release Forces 106
2.7 Other Injection Molding Processes 109
2.7.1 Gas Assisted Injection Molding 109
2.7.2 Structural Foam Molding 116
2.7.3 Co-Injection Molding . 122
2.7.4 Injection-Compression Molding 124
References . 126
3 The Design Process and Material Selection . 131
3.1 Introduction 131
3.2 The Plastic Part Design Process . 134
3.3 Test Standards for Design Related Plastic Material Properties 142
3.4 Mechanical Behavior of Plastic Materials . 143
3.4.1 Introduction . 143
3.4.2 Short-Term Stress-Strain Behavior 144
3.4.3 Long Term Mechanical Properties: Creep 152
3.4.4 Long-Term Mechanical Properties: Stress Relaxation 163
3.5 Impact Resistance of Plastic Materials 166
3.6 Fatigue Properties . 170
3.7 Thermal Properties of Plastic Materials . 171
3.7.1 Thermal Mechanical Behavior . 171
3.7.2 Deflection Temperature Under Load and the Vicat Temperature 174
3.7.3 Coefficient of Linear Thermal Expansion 174
3.7.4 Aging at Elevated Temperatures 176
3.7.5 Flammability 177
3.8 Melt Flow Properties . 177
3.9 Sources of Plastic Material Property Data . 179
3.10 Standardized Plastic Material Designations . 183
References . 185Contents XI
4 Structural Design Considerations 187
4.1 Introduction 187
4.2 Design Methodology . 187
4.2.1 Design by Experience . 188
4.2.2 Design by Experimental Approach 188
4.2.3 Design Using an Analytical Approach . 189
4.3 Quantifying the Design Problem 192
4.3.1 Simplification of Part Geometry 193
4.3.2 Stress Concentration 194
4.3.3 Type of Support 197
4.3.4 Loading Conditions 199
4.3.5 Plastic Material Properties . 202
4.3.6 Safety Factors 210
4.4 Beams . 214
4.4.1 Introduction . 214
4.4.2 Properties of a Plane Area (Beam Cross Sections) 216
4.4.3 The Use of Reinforcing Ribs to Improve Stiffness . 223
4.4.4 Moment of Inertia for Non-Homogeneous Materials and
Structures . 231
4.4.5 Sample Beam Analysis 233
4.5 Plates 248
4.5.1 Introduction . 248
4.5.2 Sample Plate Problems 250
4.5.3 Plate Elements with Non-Uniform Wall Sections 258
4.6 Shells/Pressure Vessels 260
4.6.1 Introduction . 260
4.6.2 Thin-Walled Pressure Vessels . 261
4.6.3 Thick-Wall Pressure Vessels 264
4.7 Torsion 265
4.7.1 Introduction . 265
4.7.2 Torsion for Circular Bars 265
4.7.3 Torsion for Non-Circular Bars . 269
4.8 Columns . 272
4.9 Dynamic Loads . 274
4.9.1 Introduction . 274XII Contents
4.9.2 Fatigue Loading 274
4.9.3 Impact Loading 280
References . 283
5 Prototyping and Experimental Stress Analysis 285
5.1 Prototyping Plastic Parts . 285
5.1.1 Introduction . 285
5.1.2 Machined and Fabricated Plastic Prototypes . 287
5.1.3 Some Rapid Prototyping Technologies 290
5.1.4 Simulating a Production Quality Appearance on Prototype Parts . 303
5.1.5 Prototype Part Casting Techniques . 306
5.1.6 Prototype Injection Mold Tooling 311
5.1.7 Low Pressure Structural Foam Prototypes . 322
5.1.8 Coordinate Measuring Machines . 324
5.2 Experimental Stress Analysis 325
5.2.1 Introduction . 325
5.2.2 Brittle Coatings 326
5.2.3 Strain Gages . 327
5.2.4 Solvent/Chemical Testing 333
5.2.5 Photoelastic Testing 335
5.2.6 Optical Strain Measurement Techniques . 337
References . 337
6 Assembly of Injection Molded Plastic Parts . 341
6.1 Introduction . 341
6.2 Press Fit Assemblies . 344
6.2.1 Introduction . 344
6.2.2 Material Considerations . 345
6.2.3 Design of Press Fit Assemblies . 347
6.3 Snap Joint Assemblies 352
6.3.1 Introduction . 352
6.3.2 Types of Snap Joints 353
6.3.3 Molding Cantilever Snaps . 362
6.3.4 Design of Snap Joints . 367
6.4 Mechanical Fasteners 372Contents XIII
6.4.1 Introduction . 372
6.4.2 Screws 374
6.5 Welding of Thermoplastics . 416
6.5.1 Introduction . 416
6.5.2 Ultrasonic Welding . 417
6.5.3 Vibration Welding 436
6.5.4 Spin (Rotational) Welding . 438
6.5.5 Electromagnetic Welding 442
6.5.6 Resistance Welding . 444
6.5.7 Hot Tool Welding 444
6.5.8 Hot Gas Welding . 446
6.5.9 Extrusion Welding 449
6.5.10 Infrared and Laser Welding 449
6.6 Adhesive Bonding . 463
6.6.1 Introduction . 463
6.6.2 Adhesive Theory . 466
6.6.3 Adhesive Selection 474
6.7 Solvent Bonding . 477
References . 478
7 Design for Enhanced Recyclability and Sustainability 483
7.1 Plastic Part Design: Recycling Related Issues 483
7.2 Designing Thermoplastic Products with Enhanced Recyclability . 485
7.2.1 Design for Existing Recycling Infrastructure . 486
7.2.2 Standard Material Identification and Marking Systems 489
7.2.3 Minimize Components and Materials of Construction 491
7.2.4 Multi-Component Product Recycling: Design for Disassembly
(Pre-Granulation) 493
7.2.5 Multi-Component Product Recycling: Design for Easy Separation
(Post-Granulation) . 498
7.2.6 Compatible Materials for Commingled Recycling . 501
7.2.7 Use Thermoplastic Formulations that Exhibit Good Property
Retention . 504
7.2.8 Use General Purpose Thermoplastics — Minimize the Use of
Specialty Additives . 507
7.2.9 Use Recycling Friendly Labels and Attachments 509XIV Contents
7.2.10 Avoid Contaminating Surface Coatings 513
7.2.11 Scrapless Manufacturing Processes . 515
7.3 Design for Enhanced Recyclability Case Studies . 517
7.3.1 Case Study 1: More Recyclable Frozen Juice Concentrate Container . 517
7.3.2 Case Study 2: One Time Use Camera is Returnable for Reuse and
Recycling 518
7.3.3 Case Study 4: Preserve Consumer Products from Recycled
Plastics Returnable for Secondary Recycling . 520
7.4 Using Recycled Thermoplastics for Injection Molded Parts 521
7.4.1 Reuse of Manufacturing Scrap: Regrind Specification and Practices . 522
7.4.2 General Properties of Recycled Thermoplastics Relative to Virgin
Thermoplastics 526
7.4.3 Recycled Thermoplastic Availability, Quality, and Pricing 529
7.4.4 Product Standards and Agency Considerations . 532
References . 533
Conversion constants 535
Subject Index 537
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