Donald G. Baird, Dimitris I. Collias

Polymer Processing (eBook, PDF)

Principles and Design

• Format: PDF

Produktbeschreibung

Fundamental concepts coupled with practical, step-by-step guidance With its emphasis on core principles, this text equips readers with the skills and knowledge to design the many processes needed to safely and successfully manufacture thermoplastic parts. The first half of the text sets forth the general theory and concepts underlying polymer processing, such as the viscoelastic response of polymeric fluids and diffusion and mass transfer. Next, the text explores specific practical aspects of polymer processing, including mixing, extrusion dies, and post-die processing. By addressing a broad range of design issues and methods, the authors demonstrate how to solve most common processing problems. This Second Edition of the highly acclaimed Polymer Processing has been thoroughly updated to reflect current polymer processing issues and practices. New areas of coverage include: * Micro-injection molding to produce objects weighing a fraction of a gram, such as miniature gears and biomedical devices * New chapter dedicated to the recycling of thermoplastics and the processing of renewable polymers * Life-cycle assessment, a systematic method for determining whether recycling is appropriate and which form of recycling is optimal * Rheology of polymers containing fibers Chapters feature problem sets, enabling readers to assess and reinforce their knowledge as they progress through the text. There are also special design problems throughout the text that reflect real-world polymer processing issues. A companion website features numerical subroutines as well as guidance for using MATLAB¯®, IMSL¯®, and Excel to solve the sample problems from the text. By providing both underlying theory and practical step-by-step guidance, Polymer Processing is recommended for students in chemical, mechanical, materials, and polymer engineering.

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Produktdetails

• Verlag: John Wiley & Sons
• Seitenzahl: 416
• Erscheinungstermin: 3. März 2014
• Englisch
• ISBN-13: 9781118354711
• Artikelnr.: 40615774

Autorenporträt

DONALD G. BAIRD, PhD, is the Alexander F. Giacco and Harry C. Wyatt Professor of Chemical Engineering at Virginia Tech. His research centers on the use of fundamental non-Newtonian fluid mechanics to develop improved processing operations for polymers and polymer composites. Among his many honors, the Society of Plastics Engineers has awarded him the International Award, the International Award for Research, and the International Award for Education. A holder of seven patents, Dr. Baird has published some 300 refereed publications. DIMITRIS I. COLLIAS, PhD, is with the corporate R&D department of the Procter & Gamble Co. in Cincinnati, Ohio. He earned his PhD degree from Princeton University. With twenty years of industry experience in polymers, polymer processing, packaging, paper, and activated carbon, his current research focuses on developing renewable materials and processes for key products in the company's portfolio. Dr. Collias holds fifty-four issued U.S. patents and is inventor or co-inventor in more than thirty U.S. patent applications.

Inhaltsangabe

Preface xi Preface to the First Edition xiii Acknowledgments xv 1 Importance of Process Design 1 1.1 Classification of Polymer Processes
1 1.2 Film Blowing: Case Study
5 1.3 Basics of Polymer Process Design
7 2 Isothermal Flow of Purely Viscous Non-Newtonian Fluids 9 Design Problem I Design of a Blow Molding Die
9 2.1 Viscous Behavior of Polymer Melts
10 2.2 One-Dimensional Isothermal Flows
13 2.2.1 Flow Through an Annular Die
14 2.2.2 Flow in a Wire Coating Die
17 2.3 Equations of Change for Isothermal Systems
19 2.4 Useful Approximations
26 2.5 Solution to Design Problem I
27 2.5.1 Lubrication Approximation Solution
27 2.5.2 Computer Solution
29 3 Viscoelastic Response of Polymeric Fluids and Fiber Suspensions 37 Design Problem II Design of a Parison Die for a Viscoelastic Fluid
37 3.1 Material Functions for Viscoelastic Fluids
38 3.1.1 Kinematics
38 3.1.2 Stress Tensor Components
39 3.1.3 Material Functions for Shear Flow
40 3.1.4 Shear-Free Flow Material Functions
43 3.2 Nonlinear Constitutive Equations
44 3.2.1 Description of Several Models
44 3.2.2 Fiber Suspensions
52 3.3 Rheometry
55 3.3.1 Shear Flow Measurements
56 3.3.2 Shear-Free Flow Measurements
58 3.4 Useful Relations for Material Functions
60 3.4.1 Effect of Molecular Weight
60 3.4.2 Relations Between Linear Viscoelastic Properties and Viscometric Functions
61 3.4.3 Branching
61 3.5 Rheological Measurements and Polymer Processability
62 3.6 Solution to Design Problem II
64 4 Diffusion and Mass Transfer 73 Design Problem III Design of a Dry-Spinning System
73 4.1 Mass Transfer Fundamentals
74 4.1.1 Definitions of Concentrations and Velocities
74 4.1.2 Fluxes and Their Relationships
76 4.1.3 Fick's First Law of Diffusion
76 4.1.4 Microscopic Material Balance
78 4.1.5 Similarity with Heat Transfer: Simple Applications
80 4.2 Diffusivity
Solubility
and Permeability in Polymer Systems
84 4.2.1 Diffusivity and Solubility of Simple Gases
84 4.2.2 Permeability of Simple Gases and Permachor
87 4.2.3 Moisture Sorption and Diffusion
90 4.2.4 Permeation of Higher-Activity Permeants
90 4.2.5 Polymer-Polymer Diffusion
93 4.2.6 Measurement Techniques and Their Mathematics
94 4.3 Non-Fickian Transport
95 4.4 Mass Transfer Coefficients
96 4.4.1 Definitions
96 4.4.2 Analogies Between Heat and Mass Transfer
97 4.5 Solution to Design Problem III
99 5 Nonisothermal Aspects of Polymer Processing 111 Design Problem IV Casting of Polypropylene Film
111 5.1 Temperature Effects on Rheological Properties
111 5.2 The Energy Equation
113 5.2.1 Shell Energy Balances
113 5.2.2 Equation of Thermal Energy
117 5.3 Thermal Transport Properties
120 5.3.1 Homogeneous Polymer Systems
120 5.3.2 Thermal Properties of Composite Systems
123 5.4 Heating and Cooling of Nondeforming Polymeric Materials
124 5.4.1 Transient Heat Conduction in Nondeforming Systems
125 5.4.2 Heat Transfer Coefficients
130 5.4.3 Radiation Heat Transfer
132 5.5 Crystallization
Morphology
and Orientation
135 5.5.1 Crystallization in the Quiescent State
136 5.5.2 Other Factors Affecting Crystallization
142 5.5.3 Polymer Molecular Orientation
143 5.6 Solution to Design Problem IV
145 6 Mixing 153 Design Problem V Design of a Multilayered Extrusion Die
153 6.1 Description of Mixing
154 6.2 Characterization of the State of Mixture
156 6.2.1 Statistical Description of Mixing
157 6.2.2 Scale and Intensity of Segregation
161 6.2.3 Mixing Measurement Techniques
163 6.3 Striation Thickness and Laminar Mixing
164 6.3.1 Striation Thickness Reduction from Geometrical Arguments
164 6.3.2 Striation Thickness Reduction from Kinematical Arguments
169 6.3.3 Laminar Mixing in Simple Geometries
171 6.4 Residence Time and Strain Distributions
174 6.4.1 Residence Time Distribution
174 6.4.2 Strain Distribution
177 6.5 Dispersive Mixing
180 6.5.1 Dispersion of Agglomerates
180 6.5.2 Liquid-Liquid Dispersion
182 6.6 Thermodynamics of Mixing
188 6.7 Chaotic Mixing
189 6.8 Solution to Design Problem V
191 7 Extrusion Dies 201 Design Problem VI Coextrusion Blow Molding Die
201 7.1 Extrudate Nonuniformities
202 7.2 Viscoelastic Phenomena
203 7.2.1 Flow Behavior in Contractions
203 7.2.2 Extrusion Instabilities
203 7.2.3 Die Swell
207 7.3 Sheet and Film Dies
212 7.4 Annular Dies
216 7.4.1 Center-Fed Annular Dies
216 7.4.2 Side-Fed and Spiral Mandrel Dies
217 7.4.3 Wire Coating Dies
217 7.5 Profile Extrusion Dies
220 7.6 Multiple Layer Extrusion
222 7.6.1 General Considerations
222 7.6.2 Design Equations
224 7.6.3 Flow Instabilities in Multiple Layer Flow
227 7.7 Solution to Design Problem VI
228 8 Extruders 235 Design Problem VII Design of a Devolatilization Section for a Single-Screw Extruder
235 8.1 Description of Extruders
235 8.1.1 Single-Screw Extruders
237 8.1.2 Twin-Screw Extruders
238 8.2 Hopper Design
239 8.3 Plasticating Single-Screw Extruders
242 8.3.1 Solids Transport
242 8.3.2 Delay and Melting Zones
246 8.3.3 Metering Section
250 8.4 Twin-Screw Extruders
253 8.4.1 Self-wiping Corotating Twin-Screw Extruders
253 8.4.2 Intermeshing Counterrotating Extruders
256 8.5 Mixing
Devolatilization
and Reactions in Extruders
258 8.5.1 Mixing
258 8.5.2 Devolatilization in Extruders
262 8.5.3 Reactive Extrusion
264 8.6 Solution to Design Problem VII
265 8.6.1 Dimensional Analysis
265 8.6.2 Diffusion Theory
267 9 Postdie Processing 275 Design Problem VIII Design of a Film Blowing Process for Garbage Bags
275 9.1 Fiber Spinning
276 9.1.1 Isothermal Newtonian Model
278 9.1.2 Nonisothermal Newtonian Model
281 9.1.3 Isothermal Viscoelastic Model
285 9.1.4 High-Speed Spinning and Structure Formation
287 9.1.5 Instabilities in Fiber Spinning
290 9.2 Film Casting and Stretching
293 9.2.1 Film Casting
293 9.2.2 Stability of Film Casting
296 9.2.3 Film Stretching and Properties
297 9.3 Film Blowing
297 9.3.1 Isothermal Newtonian Model
299 9.3.2 Nonisothermal Newtonian Model
302 9.3.3 Nonisothermal Non-Newtonian Model
303 9.3.4 Biaxial Stretching and Mechanical Properties
304 9.3.5 Stability of Film Blowing
304 9.3.6 Scaleup
305 9.4 Solution to Design Problem VIII
305 10 Molding and Forming 311 Design Problem IX Design of a Compression Molding Process
311 10.1 Injection Molding
311 10.1.1 General Aspects of Injection Molding
311 10.1.2 Simulation of Injection Molding
315 10.1.3 Microinjection Molding
318 10.2 Compression Molding
319 10.2.1 General Aspects of Compression Molding
319 10.2.2 Simulation of Compression Molding
320 10.3 Thermoforming
322 10.3.1 General Aspects of Thermoforming
322 10.3.2 Modeling of Thermoforming
324 10.4 Blow Molding
328 10.4.1 Technological Aspects of Blow Molding
328 10.4.2 Simulation of Blow Molding
330 10.5 Solution to Design Problem IX
332 11 Process Engineering for Recycled and Renewable Polymers 343 11.1 Life-Cycle Assessment
343 11.2 Primary Recycling
348 11.3 Mechanical or Secondary Recycling
351 11.3.1 Rheology of Mixed Systems
352 11.3.2 Filtration
352 11.4 Tertiary or Feedstock Recycling
354 11.5 Renewable Polymers and Their Processability
357 11.5.1 Thermal Stability and Processing of Renewable Polymers
358 Problems
362 References
363 Nomenclature 365 Appendix A Rheological Data for Several Polymer Melts 373 Appendix B Physical Properties and Friction Coefficients for Some Common Polymers in the Bulk State 379 Appendix C Thermal Properties of Materials 381 Appendix D Conversion Table 385 Index 387