Plastics Process Analysis, Instrumentation, and Control

ISBN-13: 9781119795735 / Angielski / Twarda / 2021 / 416 str.

Johannes Karl Fink

Spis treści

Preface i1 General Aspects 11.1 Subjects of the Book 11.2 Special Issues 21.3 Injection Molding 31.3.1 Cost Estimation in Injection Molding 31.3.2 Cost Prediction Models 41.4 Miniature Molding Processes 61.5 Computer Determination of Weld Lines in Injection Molding 61.6 Extrusion Blow Molding 81.6.1 Rapid Thermal Cycling Molding 81.6.2 Rapid Heat Cycle Molding 81.6.3 Injection Molding: Heating 161.7 Microcellular Injection Molding 221.8 Mold Cooling 231.9 Microcellular Foam Processing System 271.9.1 Gas-Assisted Injection Molding 271.9.2 Water-Assisted Injection Molding 321.10 Molding Machine for Granules 321.11 Foam Curing of Footwear 331.12 Injection Compression Molding 351.13 Hot Press System 351.14 Stamper Mold 381.14.1 Recoding Media 381.14.2 Microscopic Structured Body 391.15 Plastic Waste 421.15.1 Marine Pollution 431.15.2 Human Health Effects 451.15.3 Recycling 45References 572 Process Analysis 652.1 Concepts and Strategies 662.1.1 Chemometrics 672.1.2 Safety Risks 682.1.3 Feedback Procedures 682.2 Linear Systems 682.2.1 Simple First-Order Systems 682.2.2 Fractional Order Systems 692.2.3 Nonlinear Systems and Linearization 692.2.4 Characteristics of Systems 752.2.5 Controllers and Controller Settings 842.3 Twin-Screw Extrusion 91References 923 Examples of Process Analysis 993.1 Greenhouse Gas Balance 993.1.1 Poly(ethylene furandicarboxylate) 993.1.2 Polyester Binder 1003.2 Injection Molding Technology 1013.2.1 Module for CAD Modeling of the Part 1033.2.2 Module forNumerical Simulation of Injection Molding Process 1043.2.3 Module for Calculation of Parameters of Injection Molding and Mold Design Calculation and Selection 1053.2.4 Module for Mold Modeling 1063.2.5 Examples of Testing 1073.2.6 Molding Air Cooling 1083.2.7 Cavity Pressure 1093.2.8 Plastics Extruder Dynamics 1103.2.9 History of Mathematical Modeling 1103.2.10 Current Physical Components Concept 1123.2.11 Process Stages 1123.2.12 Data Envelopment Analysis 1163.2.13 Taguchi Method 1183.2.14 Tait Model 1193.2.15 Phan-Thien-Tanner Model 1213.2.16 Product Quality Prognosis 1213.2.17 Production Predictive Control 1223.2.18 Parameter Optimization for Energy Saving 1233.2.19 Multilayer Control System 1243.2.20 Smoothed Particle Hydrodynamics Method 1253.2.21 Temperature-Dependent Adaptive Control 1263.2.22 Micro-Injection Molding 1283.2.23 Immiscible Polymer Blends 1313.2.24 Resin Injection Molding 1333.2.25 Foam Injection Molding 1373.2.26 Self-Optimizing Injection Molding Process 1383.2.27 Machine Setup 1403.3 Shrinkage in Injection Molding 1463.3.1 Factors that Affect the Shrinkage 1463.3.2 Effect of a Cooling System 1473.3.3 Influence of Molding Conditions on the Shrinkage and Roundness 1483.3.4 Shear Viscosity 1483.3.5 In-Situ Shrinkage Sensor 1493.3.6 Semicrystalline Polymer 1513.3.7 Thermoplastic Elastomers 1513.3.8 Reprocessing of ABS 1533.3.9 Sequential Simplex Algorithm with Automotive Ventiduct Grid 1553.3.10 Taguchi, ANOVA, CAE, and Neural Network Methods 1563.4 Recycling by Extrusion 1663.4.1 Multiple In-Line Extruders 1663.4.2 Mixed Post-Consumer Plastic Waste 1673.4.3 Poly(methyl methacrylate) 1683.4.4 Poly(ethylene terephthalate) 1693.4.5 Poly(lactic acid) 1693.4.6 Expanded Poly(styrene) 1693.5 Batch Washing of Recycled Films 1713.5.1 Recycling of Poly(styrene)Waste 1713.5.2 Textile Finishing 1723.5.3 Removing Scrap from Containers 1733.5.4 Adsorption Isotherms and Desorption Rates 1753.6 Self-Purging Microwave Pyrolysis 1763.7 Purging and Plasticization in Injection Molding 1773.7.1 Automatic Purging 1773.8 Hot Runner Systems 1793.8.1 Hot Runner Mold with Runner Pipe 1803.8.2 Hot Runner System in Plastics Molding Tools 1833.8.3 Manufacturing and Assembling of Hot Runner Systems 1843.9 Blown Film Extrusion and Thickness Control 1853.10 Residence Time Distribution for Biomass Pyrolysis 1863.11 Reactive Extrusion 187References 1874 Process Instrumentation 2014.1 In-Mold Measurement 2014.2 Temperature 2024.2.1 Soft Actuator 2024.2.2 Thermocouples 2024.2.3 Resistance Temperature Detectors 2064.2.4 Thin Film Miniature Temperature Sensors 2144.2.5 Neural Networks 2144.3 Position Transducers 2154.3.1 Rotary Position Transducer 2154.3.2 Linear Variable Differential Transformers 2164.3.3 Optical Encoders 2184.3.4 Thickness Gauges 2184.4 Composition of Matter 2224.4.1 IR Interferometer for Multilayer Film 2224.4.2 X-Ray Diffraction 2254.4.3 Ion Mobility-Mass Spectrometry 2264.4.4 Test for Ice Adhesion Strength 2264.4.5 Piezoelectric Coaxial Filament Sensors 2284.4.6 Instrumentation for Impact Testing 2284.4.7 Treatment of Titanium Surfaces 2294.4.8 Spatial Differentiation of Sub-Micrometer Domains 2304.5 Medical Issues 2314.5.1 Endoscopic Plastic Surgical Procedures 2314.5.2 Medical Catheters 2314.5.3 Multichannel Plastic Joint 2374.5.4 Transluminal Endoscopic Surgery 2384.5.5 Wire-Actuated Universal-Joint Wrists 2384.5.6 Musculoskeletal Disorders 239References 2405 Actuators and Final Control Elements 2455.1 Servo Valves 2455.1.1 Nozzle Assembly for a Servo Valve 2455.2 Servo Motors 2485.2.1 Hydraulic System 2485.2.2 Functionally Graded Materials 2485.3 Solenoid Valves 2515.3.1 Design Verification Methodology 2515.3.2 Small Solenoid Valve 2525.3.3 High-Speed Solenoid Valve 2525.3.4 Numerical Simulation 2525.4 Heaters 2535.4.1 Conduction Heaters 2535.4.2 Radiant Heaters 2555.4.3 Heater Controls 2555.5 Drive Motors and Motor Speed Control for Extrusion 2565.5.1 Single-Drive Motor 2565.5.2 Linear Induction Motor 2565.5.3 Motor Power Consumption in Single-Screw Extrusion 2575.5.4 Dual Motor Multi-Head 3D Printer 258References 2586 Analysis of Melt Processing Systems 2616.1 Process Parameter Determination of Plastic Injection Molding 2616.1.1 Case-Based Reasoning Method 2616.1.2 Knowledge-Based Reasoning Method 2646.1.3 Rule-Based Reasoning Method 2656.1.4 Fuzzy Reasoning Method 2666.2 Process Parameter Determination of Plastic Injection Molding of LCDs 2676.3 Processing History 2676.3.1 Flow Defects 2676.3.2 Biocomposites 2696.3.3 3D Printing 2716.3.4 Semiconducting Polymer Blends 2726.3.5 Van Gurp-Palmen Plot 2726.3.6 Nanocrystal Composites 2736.3.7 Melt-Mastication 2746.3.8 Crystal Nucleation in Nanocomposites 2756.4 Shear History 2766.5 Extrusion Product Control 2786.5.1 Branched Structures 2786.5.2 Big Area Additive Manufacturing 2796.5.3 Single-Screw Extrusion Control 2806.5.4 Blown Film 2846.5.5 Chill Roll Cast Film 2856.5.6 Sheet 2926.5.7 Profiles 2946.5.8 Pipe and Tubing 2976.5.9 Automatic Screen Changers 3036.6 Extrusion Blow Molding Parison Control 3066.7 Injection Molding 3106.7.1 Ram Velocity Control 3106.7.2 Pressure Control 3136.7.3 Gas-Assisted Control 3196.7.4 System Diagnostics 3226.7.5 Statistical Process and Quality Control 3286.8 Thermoforming 3296.8.1 Twin Sheet Thermoforming 3296.8.2 Rotary Thermoforming 3306.8.3 Process Model for Thermoforming 3316.9 Rotomolding 3326.9.1 Polymer Compositions for Rotomolding 3346.10 Compounders 3486.10.1 History of Compounding 3486.10.2 Types of Compounders 3486.10.3 Special Applications 350References 3527 Auxiliary Equipment 3637.1 Crammer Feeder 3637.1.1 Crammer Feeder for Extruder 3637.1.2 Devulcanization of Scrap Rubber 3637.2 Dryers 3647.2.1 Drying Temperatures 3647.2.2 Moisture Content 3667.2.3 Resin Dryers 3667.2.4 Pellet Dryers 3697.3 Pullers 3797.3.1 Pullers in Extrusion 3797.3.2 Pullers in Injection Molding 3817.4 Chillers 3847.5 Robots 385References 387Index 389Acronyms 389Chemicals 394General Index 399

O autorze

Johannes Karl Fink is Professor of Macromolecular Chemistry at Montanuniversität Leoben, Austria. His industry and academic career spans more than 30 years in the fields of polymers, and his research interests include characterization, flame retardancy, thermodynamics and the degradation of polymers, pyrolysis, and adhesives. Professor Fink has published 20 books on physical chemistry and polymer science with the Wiley-Scrivener imprint, including A Concise Introduction to Additives for Thermoplastic Polymers, The Chemistry of Biobased Polymers, 2nd edition, 3D Industrial Printing with Polymers, The Chemistry of Environmental Engineering and Flame Retardants.