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Natti S. Rao, Günter Schumacher
Design Formulas for Plastics Engineers
Preface
6
Contents
8
1 Formulas of Rheology
12
1.1 Ideal Solids
12
1.1.1 Hooke's Law
14
1.2 Newtonian Fluids
14
1.3 Formulas for Viscous Shear Flow of Polymer Melts
15
1.3.1 Apparent Shear Rate
16
1.3.2 Entrance Loss
16
1.3.3 True Shear Stress
17
1.3.4 Apparent Viscosity
18
1.3.5 True Shear Rate
18
1.3.6 True Viscosity
19
1.3.7 Empirical Formulas for Apparent Viscosity
19
1.4 Viscoelastic Behavior of Polymers
29
1.4.1 Shear
30
1.4.2 Uniaxial Tension
36
1.4.3 Maxwell Model
40
1.4.4 Practical Formulas for Die Swell and Extensional Flow
42
2 Thermodynamic Properties of Polymers
46
2.1 Specific Volume
46
2.2 Specific Heat
47
2.3 Enthalpy
49
2.4 Thermal Conductivity
51
3 Formulas of Heat Transfer
54
3.1 Steady State Conduction
54
3.1.1 Plane Wall
54
3.1.2 Cylinder
55
3.1.3 Hollow Sphere
56
3.1.4 Sphere
56
3.1.5 Heat Conduction in Composite Walls
57
3.1.6 Overall Heat Transfer through Composite Walls
60
3.2 Transient State Conduction
61
3.2.1 Temperature Distribution in One-Dimensional Solids
62
3.2.2 Thermal Contact Temperature
68
3.3 Heat Conduction with Dissipation
70
3.4 Dimensionless Groups
71
3.4.1 Physical Meaning of Dimensionless Groups
72
3.5 Heat Transfer by Convection
73
3.6 Heat Transfer by Radiation
75
3.7 Dielectric Heating
78
3.8 Fick's Law of Diffusion
80
3.8.1 Permeability
80
3.8.2 Absorption and Desorption
81
4 Designing Plastics Parts
84
4.1 Strength of Polymers
84
4.2 Part Failure
85
4.3 Time-Dependent Deformational Behavior
87
4.3.1 Short-Term Stress-Strain Behavior
87
4.3.2 Long-Term Stress-Strain Behavior
88
5 Formulas for Designing Extrusion and Injection Molding Equipment
92
5.1 Extrusion Dies
92
5.1.1 Calculation of Pressure Drop
92
5.2 Extrusion Screws
116
5.2.1 Solids Conveying
116
5.2.2 Melt Conveying
120
5.2.3 Melting of Solids
129
5.2.4 Temperature Fluctuation of Melt
136
5.2.5 Scale-up of Screw Extruders
137
5.2.6 Mechanical Design of Extrusion Screws
142
5.3 Injection Molding
144
5.3.1 Pressure Drop in Runner
145
5.3.2 Mold Filling
148
5.3.3 Flowability of Injection Molding Resins
150
5.3.4 Cooling of Melt in Mold
153
5.3.5 Design of Cooling Channels
156
5.3.6 Melting in Injection Molding Screws
161
5.3.7 Predicting Flow Length of Spiral Melt Flows
167
A Final Word
174
Index
176
Biography
180
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