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Handbook of molded part shrinkage and warpage
Fischer, Jerry M.
اطلاعات کتابشناختی
Handbook of molded part shrinkage and warpage
Author :
Fischer, Jerry M.
Publisher :
Plastics Design Library/William Andrew Pub.,
Pub. Year :
2003
Subjects :
Plastics-- Molding -- Handbooks, manuals, etc.
Call Number :
TP 1150 .F59 2003
جستجو در محتوا
ترتيب
شماره صفحه
امتياز صفحه
فهرست مطالب
Front Matter
(1)
Preface
(3)
Acknowledgments
(5)
Table of Contents
Index
07723_grb.pdf
Table of Contents
Glossary
References and Bibliography
References (cited in text)
Bibliography
General References
Index
07723_toc.pdf
Front Matter
Table of Contents
(6)
1. Introduction to Plastics Processing
2. Shrinkage and Warpage
3. Causes of Molded-Part Variation: Part Design
4. Causes of Molded-Part Variation: Material
5. Causes of Molded-Part Variation: Mold Design 51
6. Causes of Molded-Part Variation: Processing79
7. Factors Affecting Post-Mold Shrinkage and Warpage
8. Controlling Mold and Post-Mold Shrinkage and Warpage
9. Computer-Aided Analysis
10. Case Studies
11. Data
Appendix A: Conversion Factors and Equivalents
Appendix B: Abbreviations, Acronyms, and Material Names
(1)
Glossary
References and Bibliography
(3)
Index
07723_01.pdf
Table of Contents
1. Introduction to Plastics Processing
(11)
1.0 Introduction
(11)
1.1 Interactivity Basics
(11)
1.2 Thermodynamic Principles Governing Injection Molding
(13)
1.2.1 Filling
(14)
1.2.2 Holding
(15)
1.2.3 Cooling
(16)
Index
07723_02.pdf
Table of Contents
2. Shrinkage and Warpage
(18)
2.1 In-Mold Shrinkage
(18)
2.1.1 Determination of Shrinkage
(19)
2.1.2 Molded-in Stress
(20)
2.2 Warpage
(21)
2.2.1 Common Causes of Nonuniform Shrinkage
(22)
2.2.2 Principles of Minimizing Warpage
(23)
2.3 Post-Mold Shrinkage
(25)
Index
07723_03.pdf
Table of Contents
3. Causes of Molded-Part Variation: Part Design
(26)
3.1 Wall Thickness
(26)
3.2 Ribs
(27)
3.3 Bosses
(30)
3.4 Example of Proper Part Design
(30)
3.5 Other Design Considerations
(31)
Index
07723_04.pdf
Table of Contents
4. Causes of Molded-Part Variation: Material
(32)
4.1 Amorphous and Semicrystalline Resins
(32)
4.1.1 Amorphous Polymers
(34)
4.1.2 Semicrystalline Materials
(35)
4.2 Effects of Fillers, Reinforcements, Pigments, Time, and Stress
(38)
4.2.1 Effects of Fillers and Fibers
(38)
4.2.2 Minimizing the Effects of Fiber Reinforcements
(41)
4.2.3 Effects of Pigments
(43)
4.2.4 The Effects of Time and Stress on Dimensional Stability
(45)
4.3 Shrinkage Predictions: Using Pressure-Volume-Temperature (PVT) Relationships
(46)
4.3.1 PVT System Properties 37
(46)
4.3.2 Predicting Mold Shrinkage 43
(52)
4.3.3 Predicting Mold Warpage 46
(55)
4.3.4 Accuracy of Shrinkage Predictions 48
(57)
Index
07723_05.pdf
Table of Contents
5. Causes of Molded-Part Variation: Mold Design
(59)
5.1 Cavity Dimensions and Design Factors
(59)
5.2 Gate Types
(61)
5.2.1 Pin, Pinpoint, Tunnel, and Submarine Gates
(62)
5.2.2 Edge and Straight-Edge Gates
(63)
5.2.3 Fan Gates
(63)
5.2.4 Film, Diaphragm, and Ring Gates
(63)
5.2.5 Tab Gates
(64)
5.2.6 Multiple Gates
(64)
5.3 Gate Location
(65)
5.3.1 Side, End, and Center Gates
(66)
5.3.2 Determining Gate Position
(68)
5.4 Gate Size
(70)
5.5 Gate-Design Systems
(70)
5.6 Runner Design
(71)
5.6.1 Multiple-Cavity Molds
(72)
5.6.2 Ejection
(78)
5.7 Mold-Cooling Design
(78)
5.7.1 Cooling Channels
(78)
5.7.2 Effects of Corners
(82)
5.7.3 Thickness Variations
(83)
5.7.4 Runnerless Molds
(83)
5.7.5 Slides
(83)
5.7.6 Venting
(83)
5.8 Mold Construction Materials
(84)
5.10 Pitfalls to Avoid
(85)
Index
07723_06.pdf
Table of Contents
6. Causes of Molded-Part Variation: Processing
(86)
6.1 Molding Conditions
(86)
6.2 Injection Melt Temperature
(90)
6.3 Injection Rate and Pressure
(90)
6.3.1 Injection Speed
(90)
6.3.2 Injection Pressure
(91)
6.4 Holding Pressure and Time
(92)
6.4.1 Holding Pressure
(92)
6.4.2 Holding-Pressure Time
(94)
6.5 Mold Temperature
(95)
6.5.1 Predicting Mold Temperature Effects
(96)
6.5.2 Relationship Between Mold Temperature and Shrinkage
(97)
6.5.3 Relationship Between Wall Thickness and Shrinkage
(97)
6.6 Demolding Temperature
(98)
6.7 Molded-In Stresses
(99)
6.8 Other Molding Processes
(100)
6.8.1 Lost Core Process
(100)
6.8.2 Gas Assist Processing
(100)
6.8.2.1 Foaming
(101)
6.8.2.2 Shrinkage of Gas-Assisted Processes
(102)
Index
07723_07.pdf
Table of Contents
7. Factors Affecting Post-Mold Shrinkage and Warpage
(103)
7.1 Effects of Temperature on Dimensions
(103)
7.2 Effects of Moisture on Dimensions
(107)
7.3 Creep
(107)
Index
07723_08.pdf
Table of Contents
8. Controlling Mold and Post-Mold Shrinkage and Warpage
(110)
8.1 Finding the Cause
(110)
8.2 Processing Considerations
(111)
8.2.1 Melt Temperatures and Uniformity
(111)
8.2.2 Mold Temperatures and Uniformity
(112)
8.2.3 Filling, Packing, and Holding Pressures
(113)
8.2.4 Filling, Packing, and Holding Times
(113)
8.2.5 Part Temperature at Ejection
(114)
8.2.6 Clamp Tonnage
(114)
8.2.7 Post-Mold Fixturing and Annealing
(114)
8.2.8 Special Problems With Thick Walls and Sink Marks
(114)
8.2.9 Nozzles
(115)
8.2.10 Excessive or Insufficient Shrinkage
(116)
8.2.11 Secondary Machining
(116)
8.2.12 Quality Control
(116)
8.3 Material Considerations
(117)
8.3.1 Filler or Reinforcement Content
(119)
8.3.2 Degree of Liquid Absorption
(119)
8.3.3 Regrind
(119)
8.4 Tooling Considerations 114
(119)
8.4.1 Gate Locations
(119)
8.4.2 Types and Sizes of Gates
(120)
8.4.3 Runner Systems
(120)
8.4.4 Mold-Cooling Layout
(121)
8.4.5 Tool Tolerances
(121)
8.4.6 Draft Angles
(122)
8.4.7 Ejection-System Design
(122)
8.4.8 Elastic Deformation of a Mold
(123)
8.4.9 Mold Wear
(123)
8.4.10 Mold Contamination
(123)
8.4.11 Position Deviations of Movable Mold Components
(124)
8.4.12 Special Issues With Gears
(124)
8.5 Part Geometry
(126)
8.5.1 Overall Part Dimensions
(127)
8.5.2 Wall Thickness
(127)
8.5.3 Shrinkage-Restricting Features
(129)
8.6 Controlling Warpage
(129)
Index
07723_09.pdf
Table of Contents
9. Computer-Aided Analysis
(132)
9.1 Capabilities of CAA
(132)
9.2 Limitations of CAA
(133)
9.3 Selecting a CAA Program
(134)
9.4 Customer Requirements
(136)
9.5 Management Tools
(137)
9.6 Filling Analysis
(138)
9.7 Packing and Holding Simulation
(141)
9.8 Shrinkage/Warpage Simulation
(141)
9.9 Cooling Analysis
(141)
9.10 Costs
(142)
9.11 Conclusions
(143)
Index
07723_10.pdf
Table of Contents
10. Case Studies
(144)
10.1 Unexpected Housing Shrink
(144)
10.2 Changing Materials Triggers Warpage
(145)
10.3 Creep in a Water Heater Stand
(146)
10.4 Oversize Part Injection-Molding Alkyd Thermoset
(146)
10.5 Inadequate Baby Dish Mold
(147)
10.6 Gas Entrapment in Baby Dish Mold
(149)
10.7 Warpage in a Molded Spool
(150)
10.8 Daisy-Wheel Breakage
(152)
10.9 PVC Part-Flashing Problems
(152)
10.10 Polycarbonate Switch Failure
(153)
10.11 Square Poker Chip Tray, Inadequate Shot Size
(154)
10.12 Problem Ejecting Square Poker Chips
(154)
10.13 Military Cup Material "Shrinkage"
(155)
10.14 Core-Deflection Problems
(156)
10.15 Elevator Gib Warpage
(157)
10.16 Sucker-Rod Guide Brittleness
(158)
10.17 Bottle-Cap Thread Distortion
(158)
10.18 Plastic Post Creep
(159)
10.19 Excessive Shrinkage of Glass-Filled Nylon
(159)
10.20 Preventing Warpage in Thin Molded Lids
(160)
Index
07723_11a.pdf
Table of Contents
11. Data
(161)
11.1 Unfilled Materials
(162)
11.2 Effects of Fillers
(163)
11.3 Shrinkage vs Various Parameters
(168)
11.3.1 Shrinkage vs Injection Temperature
(168)
11.3.2 Shrinkage vs Melt Temperature
(169)
11.3.3 Shrinkage vs Mold Temperature
(170)
11.3.4 Shrinkage vs Density (Polyethylene)
(170)
11.3.5 Shrinkage vs Holding Pressure
(171)
11.3.6 Shrinkage vs Thickness
(173)
11.4 Moisture Absorption Curves
11.5 Pressure Volume Temperature (PVT) Curves
(1)
11.6 Shrinkage and Warpage of Molded Disks
(15)
11.7 Angular Warpage
(17)
11.8 General Shrinkage Characteristics for Various Plastics
(22)
11.9 Material-Specific Shrinkage Characteristics
11.9.1 Polybutylene Terephthalate (PBT) (Crastin®) (DuPont)
11.9.2 Polyoxymethylene: Acetal (POM) (Delrin® ) (DuPont)
(2)
11.9.3 Polycarbonate (PC)
(5)
11.9.4 Polyphenylene Sulfide (Fortron®) (PPS)
(6)
11.9.5 Thermoplastic Elastomer Ether Ester Block Copolymer (TEEE) (Hytrel®) (DuPont) .......
(8)
11.9.6 Polypropylene (PP)
(9)
11.9.7 Polyethylene Terephthalate (PET) (Rynite®) (DuPont)
(17)
11.9.8 Polyetherimide (PEI) (Ultem®) (GE Plastics)
(17)
11.9.9 Liquid Crystal Polymer (LCP) (Zenite®) (DuPont)
(18)
11.9.10 Polyamide: Nylon (PA) (Zytel®) (DuPont)
(19)
Index
07723_11b.pdf
Table of Contents
11. Data
11.1 Unfilled Materials
(1)
11.2 Effects of Fillers
(2)
11.3 Shrinkage vs Various Parameters
(7)
11.3.1 Shrinkage vs Injection Temperature
(7)
11.3.2 Shrinkage vs Melt Temperature
(8)
11.3.3 Shrinkage vs Mold Temperature
(9)
11.3.4 Shrinkage vs Density (Polyethylene)
(9)
11.3.5 Shrinkage vs Holding Pressure
(10)
11.3.6 Shrinkage vs Thickness
(12)
11.4 Moisture Absorption Curves
(175)
11.5 Pressure Volume Temperature (PVT) Curves
(176)
11.6 Shrinkage and Warpage of Molded Disks
(190)
11.7 Angular Warpage
(192)
11.8 General Shrinkage Characteristics for Various Plastics
(197)
11.9 Material-Specific Shrinkage Characteristics
11.9.1 Polybutylene Terephthalate (PBT) (Crastin®) (DuPont)
11.9.2 Polyoxymethylene: Acetal (POM) (Delrin® ) (DuPont)
(2)
11.9.3 Polycarbonate (PC)
(5)
11.9.4 Polyphenylene Sulfide (Fortron®) (PPS)
(6)
11.9.5 Thermoplastic Elastomer Ether Ester Block Copolymer (TEEE) (Hytrel®) (DuPont) .......
(8)
11.9.6 Polypropylene (PP)
(9)
11.9.7 Polyethylene Terephthalate (PET) (Rynite®) (DuPont)
(17)
11.9.8 Polyetherimide (PEI) (Ultem®) (GE Plastics)
(17)
11.9.9 Liquid Crystal Polymer (LCP) (Zenite®) (DuPont)
(18)
11.9.10 Polyamide: Nylon (PA) (Zytel®) (DuPont)
(19)
Index
07723_11c.pdf
Table of Contents
11. Data
11.1 Unfilled Materials
(1)
11.2 Effects of Fillers
(2)
11.3 Shrinkage vs Various Parameters
(7)
11.3.1 Shrinkage vs Injection Temperature
(7)
11.3.2 Shrinkage vs Melt Temperature
(8)
11.3.3 Shrinkage vs Mold Temperature
(9)
11.3.4 Shrinkage vs Density (Polyethylene)
(9)
11.3.5 Shrinkage vs Holding Pressure
(10)
11.3.6 Shrinkage vs Thickness
(12)
11.4 Moisture Absorption Curves
11.5 Pressure Volume Temperature (PVT) Curves
(1)
11.6 Shrinkage and Warpage of Molded Disks
(15)
11.7 Angular Warpage
(17)
11.8 General Shrinkage Characteristics for Various Plastics
(22)
11.9 Material-Specific Shrinkage Characteristics
(202)
11.9.1 Polybutylene Terephthalate (PBT) (Crastin®) (DuPont)
(202)
11.9.2 Polyoxymethylene: Acetal (POM) (Delrin® ) (DuPont)
(204)
11.9.3 Polycarbonate (PC)
(207)
11.9.4 Polyphenylene Sulfide (Fortron®) (PPS)
(208)
11.9.5 Thermoplastic Elastomer Ether Ester Block Copolymer (TEEE) (Hytrel®) (DuPont) .......
(210)
11.9.6 Polypropylene (PP)
(211)
11.9.7 Polyethylene Terephthalate (PET) (Rynite®) (DuPont)
(219)
11.9.8 Polyetherimide (PEI) (Ultem®) (GE Plastics)
(219)
11.9.9 Liquid Crystal Polymer (LCP) (Zenite®) (DuPont)
(220)
11.9.10 Polyamide: Nylon (PA) (Zytel®) (DuPont)
(221)
Index
07723_app.pdf
Table of Contents
Appendix A: Conversion Factors and Equivalents
(225)
Appendix B: Abbreviations, Acronyms, and Material Names
(226)
B.1 Abbreviations and Acronyms
(226)
B.2 Material Names
(231)
Index
07723_idx.pdf
Table of Contents
(11)
Index
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
Z
07723_grb.pdf
Table of Contents
Glossary
(235)
References and Bibliography
(238)
References (cited in text)
(238)
Bibliography
(240)
General References
(240)
Index
07723_idx.pdf
Table of Contents
(11)
Index
(241)
A
(241)
B
(241)
C
(242)
D
(245)
E
(246)
F
(247)
G
(248)
H
(249)
I
(251)
J
(251)
K
(251)
L
(251)
M
(252)
N
(254)
O
(255)
P
(256)
Q
(258)
R
(258)
S
(260)
T
(262)
U
(264)
V
(264)
W
(265)
Z
(266)
