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This book provides the background needed to understand not only the wide field of polymer processing, but also the emerging technologies associated with the plastics industry in the 21st century. It combines practical engineering concepts with modeling of realistic polymer processes. Divided into three sections, it provides the reader with a solid knowledge base in polymer materials, polymer processing, and modeling."Understanding Polymer Processing" is intended for the person who is entering the plastics manufacturing industry and as a textbook for students taking an introductory course in polymer processing. It also serves as a guide to the practicing engineer when choosing a process, determining important parameters and factors during the early stages of process design, and when optimizing such a process. Practical examples illustrating basic concepts are presented throughout the book.New in the third edition are chapters on data-driven modeling and physics-driven modeling, as well as new sections on manufacturing and dimentional analysis. In addition to a number of other smaller improvements and corrections throughout the book, bonus code downloads are also providided. Contents: Part I: Polymeric MaterialsThis section gives a general introduction to polymers, including mechanical behavior of polymers and melt rheology.Part II: Polymer ProcessingThe major polymer processes are introduced in this section, including extrusion, mixing, injection molding, thermoforming, blow molding, film blowing, and many others.Part III: ModelingThis last section delivers the tools to allow the engineer to solve back-of-the-envelope polymer processing models. It includes dimensional analysis and scaling, transport phenomena in polymer processing, and modeling polymer processes.

This is a practical guide to injection molding based on sound engineering fundamentals. It is an ideal course book for mechanical engineers with limited plastic material and injection molding experience, but is also well applicable to self-study or reference. It starts with an overview of plastic material fundamentals. Each section includes material considerations associated with the injection molding process. For example, the molecular weight section shows that use of lower molecular weight plastics are commonly used for the injection molding to minimize orientation, reduce fill time, improve knit line strength. Then, the basics of the injection molding machine, tooling, auxiliary equipment and molding process are introduced. The machine components and component selection for a given application are next considered in more detail.The process/procedure for establishing optimum process conditions for a "new" mold and material (not run previously by the reader) are next described. Finally, a range of other more specialized injection molding processes that are still of practical importance are covered.From a leading author and educator in the area of injection molding, this book gives engineers and process technicians the knowledge and confidence they need to produce high-quality parts reliably and efficiently.Contents:Chapter 1: Material Considerations for the Injection Molding ProcessChapter 2: "Overview" of the Injection Molding ProcessChapter 3: Injection Molding Machine ComponentsChapter 4: Establishing Injection Molding Process ConditionsChapter 5: "Other" Injection Molding Processes (notes)

This book is for those interested in improving the properties of elastomers. It provides an exhaustive overview of the influence of different types of fillers.Starting with the manufacture and characterization of the fillers, the main factor determining the reinforcement is the rubber-filler interaction, which is discussed in detail and is the parameter part for the reinforcement of elastomers. The filler dispersion and distribution depend on the mixing procedure, the type and content of the filler, the nature of the polymer, and the presence of plasticizer. The rheological behavior and the vulcanizate properties are discussed comprehensively according to their different activity and the aspect ratio of the filler. Examples are given from tire compounds and from technical rubber goods.Advantages of the functionalization of fillers and the polymers are also presented. The importance of wet compounding is shown in dynamic and ultimate properties. In contrast, carbon nanotubes can form hybrid systems with carbon black or silica are suitable for special applications like anisometric orientations, increase of tear energy, and reducing cut growth resistance off the compound. Exfoliated layered silica gives excellent barrier properties.

In plastics technology, a wide variety of computer programs are used for the design and optimization of molded plastic parts and for mold design. These programs calculate the filling process, the holding pressure phase, and the cooling phase of the molded part in the mold. The results include, for example, pressures, temperatures, weld/knit lines, and voids. The shrinkage and warpage behavior of the molded part can also be predicted. Understanding and interpreting these simulation results is not trivial, although they are colorful representations with numerical values. Regardless of whether one has many years of experience as a designer, a mold maker, or an injection molder, or whether one is in training or studying, simulation is becoming increasingly important. For this reason, experts who know how to use these programs correctly are increasingly sought after in the market.This book is intended to expand readers' specialist knowledge in the field of simulation, thereby increasing their ability to recognize and avoid molding errors at an early stage. Readers will also learn to draw the right conclusions from the simulation results and develop their own solutions.

The validation of equipment, processes and methods is a basic requirement that nowadays has to be met in most industries. This handbook deals with the validation of computerized systems in general as well as with analytical method validation. The many detailed practical examples focus on thermal analysis of materials, such as plastics and rubber.The handbook is intended for newcomers interested in the theoretical and regulatory aspects of validation and for thermal analysis practitioners who have to validate their equipment and methods.Contents:Part 1: Validation of Computerized SystemsRecent Changes in Regulations and Regulatory GuidanceInstrument Qualification, Computerized System Validation and Method ValidationRegulatory Requirements for Computerized System ValidationComputerized System ValidationWriting the User Requirements Specification (URS)Auditing the System SupplierInstallation Qualification and Operational Qualification (IQ and OQ)Performance Qualification (PQ) or End User TestingPart 2: Method ValidationMeasurement Errors and Uncertainty of MeasurementValidation of Analytical Procedures and MethodsInterlaboratory Studies in Thermal AnalysisMethod Development Through to SOPPractical ExamplesAppendix 1: 21 CFR Part 11 and EU GMP Annex 11Appendix 2: Basic StatisticsAppendix 3: Standard Test Methods for Thermal Analysis

Measurement uncertainty is an important component of modern materials analysis: it indicates the boundaries within which the test results can be trusted. Such results are necessary for understanding of, for example, material and product tolerances and lifetimes, vital for plastic product reliability and safety.Determination of measurement uncertainty is normally quite laborious, but this book shows how the available interlaboratory test data for plastics can be used to calculate measurement uncertainty much more simply. It contains many interlaboratory test results in the fields of thermoanalysis, molar mass determination, and quantitative analysis of the composition of material, presented in tables and graphical charts, discussed in the text, and elaborated by practical examples.In addition to the evaluation by means of the presented data (top-down approach), the relationship to the bottom-up approach specified in the Guide to the Expression of Uncertainty in Measurement (GUM) is explained based on an example. Further sections deal with sampling, and the issue of whether or not the difference between analytical results is significant.

Single-screw or twin-screw extruder? When the need to produce a homogenous polymer melt occurs in the industrial environment, both product attributes and equipment cost must be evaluated. For many applications both the single and twin-screw extruder will produce the desired homogeneous melt needed to form the product through an extrusion die. Some applications such as dispersive mixing of solids in a polymer matrix are best accomplished in a twin-screw extruder. On the other hand, applications involving chemical reactions, color concentrate distributive mixing, and in line polymer-polymer distributive mixing can be accomplished with either device.However, for the same production rate, twin-screw extruders are generally more expensive than single-screw extruders with a diameter less than 200 mm. Therefore, a thorough understanding is needed for the concepts of solids conveying, melting, and mixing for the two types of extruders to make appropriate process acquisition decisions. This book covers engineering and technology concepts that should aid the practitioner in comparing these two types of extrusion equipment relative to process requirements.