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E-raamat: Automotive Plastics and Composites: Materials and Processing

(Professor (retired), Mechanical and Mechatronic Engineering and Sustainable Manufacturing Department, California State University, Chico, CA, USA)
  • Formaat: EPUB+DRM
  • Sari: Plastics Design Library
  • Ilmumisaeg: 23-Jun-2021
  • Kirjastus: William Andrew Publishing
  • Keel: eng
  • ISBN-13: 9780128182406
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Automotive Plastics and Composites: Materials and ProcessingSuurem pilt
  • Formaat: EPUB+DRM
  • Sari: Plastics Design Library
  • Ilmumisaeg: 23-Jun-2021
  • Kirjastus: William Andrew Publishing
  • Keel: eng
  • ISBN-13: 9780128182406
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Automotive Plastics and Composites: Materials and Processing is an essential guide to the use of plastic and polymer composites in automotive applications, whether in the exterior, interior, under-the-hood, or powertrain, with a focus on materials, properties, and processing.

The book begins by introducing plastics and polymers for the automotive industry, discussing polymer materials and structures, mechanical, chemical, and physical properties, rheology, and flow analysis. In the second part of the book, each chapter is dedicated to a category of material, and considers the manufacture, processing, properties, shrinkage, and possible applications, in each case. Two chapters on polymer processing provide detailed information on both closed-mold and open-mold processing. The final chapters explain other key aspects, such as recycling and sustainability, design principles, tooling, and future trends.

This book is an ideal reference for plastics engineers, product designers, technicians, scientists, and R&D professionals who are looking to develop materials, components, or products for automotive applications. The book also intends to guide researchers, scientists, and advanced students in plastics engineering, polymer processing, and materials science and engineering.

  • Analyzes mechanical, chemical, physical, and thermal properties, enabling the reader to select the appropriate material for specific applications
  • Explains polymer processing, with thorough coverage of operations across both closed-mold and open-mold processing
  • Provides systematic coverage of materials, including commodity and engineering thermoplastics, bio-based plastics, thermosets, composites, elastomeric polymers, and 3D-printed plastics
1 Introduction 1(16)
1.1 Introduction
1(1)
1.2 Plastics History
1(1)
1.3 History of Plastics in Automotive Applications
1(12)
1.3.1 Bakelite
3(1)
1.3.2 Automotive Industry Use of Plastics
4(2)
1.3.3 Interior Plastic Parts
6(1)
1.3.4 Exterior Parts
7(2)
1.3.5 Thermosets
9(1)
1.3.6 Thermoplastics
10(1)
1.3.7 Bumper Beams
11(1)
1.3.8 Powertrain Components
12(1)
Homework Questions
13(1)
True and False Questions
13(1)
References
14(1)
Further Reading
15(2)
2 Polymer Materials 17(10)
2.1 Introduction
17(1)
2.2 Carbon-Carbon Orbitals
17(1)
2.3 Functional Groups
17(1)
2.4 Organic Groups
18(1)
2.5 Polymer Classification
19(1)
2.6 Polymer Formation-Addition Polymerization
19(1)
2.7 Polymer Formation-Condensation Polymerization
20(1)
2.8 Mono, Co, and Ter polymers
20(2)
2.9 Thermosets and Cross-Linking
22(1)
2.10 Polyester Polymer
22(1)
2.11 Phenolics Polymer
22(1)
2.12 Isocyanate Groups
23(1)
2.12.1 Silicones
23(1)
Homework Problems
24(1)
True and False Questions
25(2)
3 Microstructures of Polymers 27(12)
3.1 States of Thermoplastic Polymers
27(1)
3.2 Form of Polymers
28(1)
3.3 Glass Transition in Polymers
29(2)
3.4 X-Ray Diffraction
31(1)
3.5 Molecular Weight and Polymer Length
32(4)
3.5.1 Number Average Molecular Weight, Mn
34(1)
3.5.2 Weight Average Molecular Weight, Mw
34(1)
3.5.3 Z-Average molecular weight, Mz
34(1)
3.5.4 Physical and Mechanical Property Implications of MW and MWD
35(1)
3.5.5 Ultrahigh Molecular Weight Polyethylene (UHWMPE)
36(1)
Homework Problems
36(1)
True and False Questions
37(1)
References
37(2)
4 Physical and Mechanical Properties 39(18)
4.1 Mechanical Tests for Automotive Plastics
39(5)
4.2 Impact Strength
44(1)
4.3 Heat Distortion Temperature
44(1)
4.4 Creep
44(2)
4.5 Fatigue
46(1)
4.6 Short Beam Shear Test
46(1)
4.7 Physical Properties
47(6)
4.7.1 Permeability
50(3)
Homework Problems
53(1)
True and False Questions
54(1)
References
55(1)
Further Reading
55(2)
5 Rheology and Plastic Flow 57(14)
5.1 Shear Flow in the Plastic
57(1)
5.2 Viscosity of the Plastic
57(1)
5.3 Shear Rate
58(1)
5.4 Viscoelasticity
59(1)
5.5 Fountain Flow During Injection Molding
60(1)
5.6 Extensional Flow During Blown Film Extrusion
60(1)
5.7 Non-Newtonian Polymers
60(3)
5.8 Viscosity Measurements
63(2)
5.9 Viscosity and Melt Flow Rate
65(1)
5.10 Storage and Loss Moduli for Viscoelasticity Measurements
65(2)
5.11 Molecular Weight and Viscosity Relationship
67(1)
Homework Problems
67(1)
True and False Questions
68(1)
References
69(2)
6 Flow Analysis With Injection Molding 71(12)
6.1 Plastics Flow Analysis for Injection Molding
71(4)
6.2 SolidWorks Design
75(6)
Homework Problems
81(1)
True and False Questions
82(1)
References
82(1)
Further Reading
82(1)
7 Commodity Plastics 83(24)
7.1 Polyolefins Definition
83(1)
7.2 Commodity Plastics Definition
83(1)
7.3 Commodity Plastics
83(7)
7.3.1 Low-Density Poly(ethylene) (LDPE)
86(1)
7.3.2 High-Density Poly(ethene) (HDPE)
86(2)
7.3.3 Linear Low-Density Poly(ethene) (LLDPE)
88(2)
7.3.4 Metallocene Linear Low-Density Poly(ethene) (mLLDPE)
90(1)
7.3.5 Ultrahigh-Molecular-Weight Polyethylene (UHMWPE)
90(1)
7.3.6 Cross-Linkable Polyethylene (XLPE)
90(1)
7.4 Copolymers of Polyethylene
90(1)
7.4.1 Polypropylene (PP)
91(1)
7.5 Polyvinyl Chloride (PVC)
91(2)
7.6 PVC Plasticizers
93(1)
7.7 Polystyrene (PS)
94(3)
7.8 Blends and Alloys
97(1)
7.9 Copolymers
98(1)
7.10 Acrylics
99(1)
7.11 Additives for Plastics
100(3)
Homework Problems
103(1)
True and False Questions
104(1)
References
104(3)
8 Engineering Plastics 107(20)
8.1 Engineering Plastics Definition
107(1)
8.2 Acrylonitrile Butadiene Styrene (ABS)
107(1)
8.3 Acetal (Polyoxymethylene)
108(3)
8.4 Liquid Crystal Polymer (LCP)
111(3)
8.4.1 PBT (Polybutylene Terephthalate)
112(1)
8.4.2 PET (Polyethylene Terephthalate)
113(1)
8.5 Nylon (Polyamide)
114(3)
8.5.1 Polyimide
117(1)
8.6 Polyarylate
117(1)
8.7 Polycarbonate (PC)
118(1)
8.8 Thermoplastic Polyurethane (TPU)
118(5)
8.8.1 Polyether-Ether-Ketone (PEEK)
119(1)
8.8.2 PPS and PPE
120(1)
8.8.3 Polytetrafluoroethylene (PTFE)
121(2)
Homework Problems
123(1)
True and False Questions
124(1)
References
124(1)
Further Reading
125(2)
9 Elastomers and Rubbers 127(22)
9.1 Elastomer and Rubber Definition
127(1)
9.2 Natural Rubber (Isoprene)
127(1)
9.3 Fillers in Natural Rubber
127(1)
9.4 Plastic Elastomers
128(3)
9.5 Polyisoprene
131(1)
9.6 Polybutadiene
131(1)
9.7 Polychloroprene
131(1)
9.8 Butyl Rubber or Polybutylene
131(1)
9.9 Copolymer Elastomers
131(1)
9.10 Acrylonitrile-Butadiene Rubber
132(1)
9.11 EPR and EPDM
133(2)
9.12 Fluoro-Elastomers
135(1)
9.13 Silicones
136(2)
9.14 Vulcanization
138(1)
9.15 Carbon Black
138(3)
9.16 Carbon Black Nomenclature
141(4)
9.16.1 Compound Property Group 2
141(4)
Homework Problems
145(1)
True and False Questions
146(1)
References
147(2)
10 Bio-Based and Biodegradable Plastics 149(26)
10.1 Bio-Based Plastics Definition
149(11)
10.1.1 ASTM D6866
149(1)
10.1.2 Bagasse
149(1)
10.1.3 Polyhydroxyalkanoates (PHA)
150(3)
10.1.4 Polylactic Acid (PLA)
153(2)
10.1.5 Thermoplastic Starch (TPS)
155(3)
10.1.6 Biodegradation Standards
158(1)
10.1.7 Worldwide Biodegradation Standards Agencies
159(1)
10.1.8 Certification
160(1)
10.2 Bio-Based Standard Test Method
160(1)
10.3 United States Bio-Based Standard
161(1)
10.3.1 ASTM D6866-10 Standard Test Methods for Determining the Bio-based Content of Solid, Liquid, and Gaseous Samples Using Radiocarbon Analysis
161(1)
10.4 International Bio-Based Standards
161(1)
10.5 Industrial Compost Environment
161(1)
10.6 United States Biodegradation Standards for Industrial Compost Environment
162(4)
10.6.1 Biodegradation Performance Specification Standard: ASTM D6400. Standard Specification for Compostable Plastics
162(1)
10.6.2 Biodegradation Performance Specification Standard: ASTM D6868-03 Standard Specification for Biodegradable Plastics Used as Coatings on Paper and Other Compostable Substrates
163(1)
10.6.3 Biodegradation Test Method Standard: ASTM D5338. Standard Test Method for Determining Aerobic Biodegradation of Plastic Materials under Controlled Composting Conditions
164(1)
10.6.4 Biodegradation Performance Specification Standard: ASTM D-7081 (Withdrawn). Nonfloating Biodegradable Plastic in the Marine Environment
165(1)
10.7 ASTM Standards for Marine Biodegradation
166(5)
10.7.1 ASTM D7081 (Withdrawn)
167(1)
10.7.2 Biodegradation Test Method Standard: ASTM D6691-09. Standard Test Method for Determining Aerobic Biodegradation of Plastic Materials in the Marine Environment by a Defined Microbial Consortium or Natural Sea Water Inoculum
168(1)
10.7.3 Biodegradation Test Method Standard: ASTM D5526-11. Determining Anaerobic Biodegradation of Plastic Materials Under Accelerated Landfill Conditions
169(1)
10.7.4 Biodegradation Test Method Standard: ASTM D7475. Determining Aerobic Degradation and Anaerobic Biodegradation of Plastic Materials Under Accelerated Landfill Conditions
170(1)
10.7.5 Materials
171(1)
10.7.6 Equipment
171(1)
10.7.7 Home Composting Biodegradation Standards
171(1)
Homework Problems
171(1)
True and False Questions
172(1)
References
173(2)
11 Thermoset Polymers 175(16)
11.1 Automotive Thermoset Polymers
175(1)
11.2 Polyester Resin
175(3)
11.3 Mechanical Properties
178(1)
11.4 Processing of Polyesters
178(1)
11.5 Mechanical Properties
178(1)
11.6 Epoxy
179(1)
11.7 Epoxy Applications
179(1)
11.8 Processing of Epoxies
179(1)
11.9 Polyurethane
179(1)
11.10 Processing of Polyurethane
180(1)
11.11 Polyurethane Automotive Applications
180(1)
11.12 Phenolics
181(1)
11.13 Applications for Phenolics
181(1)
11.14 Processing of Phenolics
182(1)
11.15 Properties of Phenolics
182(1)
11.16 Silicones
183(1)
11.17 Silicone Rubber
184(1)
11.18 Silicone Resin
184(1)
11.19 Chemistry
185(1)
11.20 Dicyclopentadiene
185(1)
11.21 Polyimides
185(1)
11.22 Amino Plastics
186(2)
Homework Problems
188(1)
True and False Questions
188(1)
References
189(1)
Further Reading
190(1)
12 Polymer Composites 191(32)
12.1 Automotive Polymer Composites
191(1)
12.2 Thermoset Polymer Composites
191(1)
12.3 Thermoplastic Polymer Composites
192(3)
12.4 Kevlar Composites
195(1)
12.5 Nanocomposite
195(1)
12.6 Fiber Materials for Composites
195(3)
12.7 Carbon Fiber Manufacturing
198(2)
12.8 Properties of Fibers
200(4)
12.9 Rule of Mixtures
204(2)
12.10 Natural Fibers
206(2)
12.11 Sandwich and Cored Polymer Composite Structures
208(4)
12.12 Polymer PrePreg Composites
212(1)
12.13 Processing of Polymer Composites for Automotive Parts
213(2)
12.14 Aerospace Polymer Composites
215(2)
12.15 Processing of Polymer Composites for Aerospace Parts
217(2)
Homework Problems
219(1)
True and False Questions
220(1)
References
221(1)
Further Reading
222(1)
13 Extrusion 223(18)
13.1 Introduction
223(15)
13.1.1 Coextrusion
229(1)
13.1.2 Blown Film Processing
230(1)
13.1.3 Extrusion Overmolding or Overjacketing
231(1)
13.1.4 Profile Sheet Extrusion
232(1)
13.1.5 Calendering of Plastics Through Extrusion
233(1)
13.1.6 Fiber Extrusion
234(1)
13.1.7 Twin-Screw Extrusion
234(2)
13.1.8 Coextrusion
236(1)
13.1.9 Plant Concepts (Layout and Controllers)
237(1)
Homework Problems
238(1)
True and False Questions
239(1)
References
239(1)
Further Reading
240(1)
14 Injection Molding 241(14)
14.1 Introduction
241(1)
14.2 Injection Molding Process
241(1)
14.3 Ram Injection
241(4)
14.4 Process Control With Injection Molding
245(2)
14.5 Temperature Control of the Plastic
247(1)
14.6 Mold Temperature Control
248(2)
14.7 Machine and Oil Temperatures
250(1)
14.8 Injection Pressure
250(1)
14.9 Time During Injection Molding
251(1)
14.9.1 Distance
252(1)
Homework Questions
252(1)
True and False Questions
253(1)
References
254(1)
Further reading
254(1)
15 Blow Molding 255(10)
15.1 Extrusion Blow Molding
255(1)
15.2 Injection Blow Molding
255(3)
15.3 Stretch Blow Molding
258(1)
15.4 Comparison of Extrusion and Injection Blow Molding Operations
259(2)
15.4.1 Operation and Control
259(2)
Homework Problems
261(1)
True and False Questions
262(1)
References
262(1)
Further Reading
263(2)
16 Compression Molding 265(14)
16.1 Introduction
265(1)
16.2 Materials
265(1)
16.3 Process Overview
265(3)
16.4 BMC-Bulk Molding Compound
268(1)
16.5 GMT: Glass Mat Thermoplastic
269(3)
16.6 Costs With Cycle Time
272(1)
16.7 Process Control with Compression Molding
273(1)
16.8 Temperature Control of the Plastic
274(1)
16.9 Machine and Oil Temperatures
274(1)
16.10 Clamp Pressure
274(1)
16.11 Time During Injection Molding
274(1)
16.11.1 Tooling
274(1)
16.12 Troubleshooting Guide for Compression Molding
275(2)
Homework Problems
277(1)
True and False Questions
278(1)
References
278(1)
17 Recycling and Environmental Aspects 279(22)
17.1 Introduction
279(4)
17.2 Recycled Plastics
283(1)
17.3 Recycling in the United States
283(1)
17.4 Recycling in California
283(1)
17.5 Recycled Plastics Process
284(4)
17.6 End of Life Uses of Plastics
288(1)
17.7 Burning Disposal
289(4)
17.8 Landfill Disposal
293(3)
17.9 Plastics in Automotive End of Life
296(1)
Homework Problems
297(1)
True and False Questions
298(1)
References
299(2)
18 Design Aspects in Automotive Plastics and Composites 301(24)
18.1 Introduction
301(7)
18.2 Design Guidelines
308(10)
18.3 Undercuts
318(1)
18.4 Mold Stack Design
319(1)
18.5 Mold Costs
320(2)
Homework Problems
322(1)
True and False Questions
322(1)
References
323(1)
Further Reading
324(1)
19 Additive Manufacturing in Automotive 325(12)
19.1 Introduction
325(1)
19.2 Plastic 3D Printing
325(5)
19.3 Metal 3D Printing
330(1)
19.4 Laser Sintering
330(2)
19.5 Automotive 3D Printer Projects
332(1)
19.6 The Virtual Foundry
333(1)
Homework Problems
333(1)
True and False Questions
334(1)
References
334(3)
20 Sustainable Car 337(28)
20.1 Sustainable Materials
337(5)
20.1.1 Life Cycle Assessments (LCAs)
337(5)
20.2 LCA for GPPS and PLA
342(5)
20.3 Automotive Sustainable Plastics
347(2)
20.3.1 Exterior Body Panels
348(1)
20.4 Interior Plastic Parts
349(11)
20.4.1 Powertrain Components
354(2)
20.4.2 Transmission Components
356(4)
Homework Problems
360(1)
True and False Questions
361(1)
References
362(1)
Further Reading
363(2)
Appendix A Answers to Questions 365(8)
Index 373
Dr. Joseph P. Greene is a retired professor with 20 years of teaching experience at the Mechanical and Mechatronic Engineering and Sustainable Manufacturing Department of California State University, Chico. Prof. Greene received a PhD in Chemical Engineering in 1993 from the University of Michigan. He began teaching at California State University, Chico, in 1998 after a 14-year career with General Motors Corporation in Detroit, MI. His research interests include plastics materials for automotive applications, bio-based and biodegradable polymers, recycled plastics, composting technology, and anaerobic digestion.
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