Plastics Engineered Product Design

Chapter 1 - OVERVIEWIntroductionMaterials of ConstructionThermoplastics Crystalline & Amorphous Polymers Liquid Crystalline PolymersThermosets Crosslinked Thermoplastics Reinforced PlasticsThermal Expansions Ductilities Toughnesses Tolerances/Shrinkages Compounds Prepregs Sheet Molding Compounds Bulk Molding Compounds Commodity & Engineering Plastics Elastomers/Rubbers

Plastic BehaviorsMorphology/Molecular Structure/Mechanical PropertyDensitiesMolecular Weights Molecular Weight Distributions Viscosities and Melt FlowsNewtonian/non-Newtonian Melt Index Rheology & Mechanical Analysis Viscoelasticities Processing-to-Performance Interface Glass Transition Temperatures Melt Temperatures Processing and MoistureDrying Operations

Fabricating ProcessesExtrusions Orientations PostformingsCoextrusions Injection MoldingsCoinjections Gas-Assist Moldings MicromoldingsBlow Moldings Complex Consolidated Structural Products Thermoformings Foams Reinforced Plastics CalendersCastings Coatings Compression Moldings Reaction Injection Moldings Rotational Moldings

Variables

FALLO Approach

Chapter 2 - DESIGN OPTIMIZATIONIntroductionTerminology

Engineering OptimizationDesign FoundationProblem/Solution ConceptDesign Approach Model Less Costly Model Type Computer Software Design Analysis Approach

ViscoelasticityPolymer StructureViscoelasticity BehaviorRelaxation/Creep Analysis Summary

Viscosity

Rheology and Mechanical PropertiesHooke's Law

Static StressTensile Stress-Strain Modulus of Elasticity Flexural Stress-Strain Compressive Stress-Strain Shear Stress-Strain Torsion Stress-Strain Direct Load Shear Strength Residual Stress

Dynamic StressDynamic/Static Mechanical Behavior Energy and Motion Control Isolator Torsion Load

Rapid LoadingImpact Impulse Puncture FrictionErosion Hydrostatic Cavitation Rain

High PerformanceReinforced Plastic Orientation of ReinforcementOrientation Terms Basic Design Theory Fiber Strength Theory Fiber Geometry on Strength Stiffness-Viscoelasticity Creep and Stress Relaxation

Conceptual Design ApproachDesign Analysis Pseudo-Elastic MethodTheory of Combined ActionOverview Stress-Strain Analysis Plain Reinforced PlatesComposite PlatesBending of Beams and PlatesStructural SandwichesStiffnessStresses in Sandwich BeamsAxially-Loaded SandwichFilament Wound Shells, Internal Hydrostatic PressureBasic EquationsWeight of FiberMinimum WeightIsotensoid DesignGeodesic-Isotensoid Design

Chapter 3 - DESIGN PARAMETERLoad Determination

Design Analysis ProcessReinforced Plastic Analysis Stress Analysis

Stress-strain BehaviorRigidity (EI)Hysteresis Effect Poisson's Ratio Brittleness Ductile CrazingStress Whitening

Combined StressesSurface Stresses and Deformations

Creep

Fatigue

Reinforcement performance

Chapter 4 - PRODUCT DESIGN IntroductionReinforced PlasticMonocoque Structure

Geometric ShapeModulus of ElasticityEI theory

PlateFolded Plate

Beam

RibPlasticReinforced/Foamed Plastic

ColumnEuler's Formula

Torsion

SandwichDesign

GearContact Stress

BearingPV Factor

Grommet

Gasket

ShapeOverview Filament Wound ShapeNetting Analysis CylinderSphereTankFabricating RP Tank Underground Storage Tank Hopper Rail Car Tank Highway Tank Very Large TankCorrosive Resistant Tank

PipeThermoplastic PipeRP Pipe

SpringLeaf Spring Special Spring Cantilever SpringTorsional Beam Spring

Hinge

Press Fit

Snap Fit

Tape

PackagingPermeability Cushioning

BuildingHouse of the FutureHouse Top

TransportationAutomobileTruck Aircraft Marine Application BoatUnderwater Hull

Missile and Rocket

Electrical/ElectronicShielding Electrical DeviceRadome

MedicalSurgical ProductDental ProductHealth Care

Recreation

Appliance

Furniture

Water Filter

Lumber

MetalMetal Replacement with PlasticPerformance BehaviorMoisture Effect Long Term vs. Short Term Loading Stress ConcentrationCoefficient of Expansion Bolt Torque Effect Impact Barrier Vehicle Oil Pan Attachment

Design Limitation and Constraint

Chapter 5 - COMPUTER-AIDED DESIGNTechnology overview

Computers and people

Geometric modeling

Design accuracy and efficiency

Input/output deviceCentral Process Unit

SoftwareProgramsDatabases/General InformationSupply Chain Software

Finite element analysisApplicationDesigningGraphicsStructural AnalysisSoftware Analysis

Synthesizing design

CAD special useOptimizationCAD PrototypingRapid Prototyping

CAD standard and translator

Data sharing

Engineered personal computer

CAD editing

CIM changing

Computer-based training

IBM advances computer

Artificial intelligence

Plastic Toys-Smart computer

Computer fevices via DNA

Design via internet

Chapter 6 - PLASTIC PERFORMANCE OvereviewInfluencing Factor

Selecting plasticComparison Worksheet

TemperatureThermal PropertyThermal Conductivity Thermal Expansion/ContractionHyperenvironment

FlammabilitySteel and PlasticTestSmoke

Electrical/Electronic

Corrosion resistance

Chemical resistance

Friction

ToleranceLimit Processing Effect

Recycled plastic

Engineering data information sourcePublication Thomas Register Industry SocietiesEncyclopedia and Industrial BooksStandardsEngineering InformationInformation Broker Engineering Societies and AssociationsDesigns DatabasesWebsites

Training programs

Chapter 7 - DESIGN RELIABILITYTestingClassifying Test Laboratory

Quality ControlQuality and Reliability Total Quality ManagementQuality and Design

Statistics

Testing, QC, statistics and people

Product failureSpectrum Loading and Cumulative Damage Crack Growth and Fracture Mechanics Fatigue and Stress Concentration Fatigue Loading and Laboratory Testing Predicting Long Time Reliability

Meaning of Data

Safety FactorSafety Factor Example

Chapter 8 - SUMMARY AND CHRONOLOGYOverview Market SizeCustomerConstraintResponsibility Responsibility Commensurate with Ability RiskAcceptable Risk Predicting PerformanceDesign VerificationPerfectionEthics

Ergonomic

CostingTechnical Cost Modeling

Engineering and law interface

Plastic material

Design demand

Plastic success

Future

Appendix A ABBREVIATIONSAppendix B GLOSSARYAppendix C TRADENAMESBIBLIOGRAPHY