Summer Term 2001
2001 catalog data: Credit (2-4-4) Two Lecture-Hours and Four Laboratory-Hours
Prerequisites: MFGG-370 Engineering Materials
or PHYS-342 Materials Science
A study of how the structure and properties of polymeric materials are affected by processing parameters. Topics include nomenclature and manufacture of polymers, thermoplastics and thermosets, molecular architecture, amorphous and crystalline polymers, molecular weight and distributions, reinforcements and fillers, thermal transition, polymer melt rheology, material characterization and testing, viscoelastic behavior, composites, and environmental aspects of plastics. Major processing methods such as injection molding and extrusion are discussed. Screw and die characteristics, melt mechanism, components of molding machines, optimization of process parameters, and troubleshooting are presented. Other processes such as blow molding, thermoforming, rototational molding, casting, foaming, compression/transfer molding, composites and processes, radiation processes, photo-polymerization-based rapid prototyping, finishing and assembly, and auxiliary equipment are briefly discussed. Laboratory experiences focus on the effects of processing parameters on the stability and mechanical integrity of thermoplastic materials as well as the utilization of modern computer aided engineering in material selection, part/tooling/process design and manufacturing.
Textbook(s): Tim Osswald, Polymer Processing Fundamentals, Hanser, 1998
References: 1. R. C.
Progelhof and J. L. Throne, Polymer Engineering Principles, Hanser, 1993
2. M.L. Berins, Plastics Engineering Handbook of the
Society of Plastics Industry, Chapman
& Hall, 1991
3. A. B. Strong, Plastics: Materials and Processing, Prentice Hall, 2000
Coordinator(s): Gwan Y. Lai, Associate Professor of Manufacturing Engineering
Course learning
objectives:
A student who successfully completes this course will be able to:
1. Identify
and predict polymeric mechanical and physical behaviors based upon molecular
architecture. (Program Outcomes: A, L; MFGG PEOs: 1,2,3,7)
2. Model
the rheological behavior of polymers under elongational, shear, and capillary
flow conditions. (Program Outcomes:
A,E,K,L,N,P,Q; MFGG PEOs: 1,2,3,7)
3. Describe
polymer processing techniques, machine components, and process parameter
optimization. (Program Outcomes:
A,B,E,K,L,P; MFGG PEOs: 1,2,3,7)
4. Apply
rules defining part design and tooling design.
(Program Outcomes: A,C,K,L,N,P,Q; MFGG PEOs: 1,2,3,7)
5. Use
modern computer aided engineering software packages to select proper polymeric
materials and design and optimize polymer processing operations. (Program Outcomes: A,B,C,E,K,L,N,O,P,Q; MFGG
PEOs: 1,2,3,6,7)
6. Describe
operations and environmental aspects of plastics. (Program Outcomes: A,B,E,F,H,K,L,Q; MFGG
PEOs: 1,2,3,4,7)
7. Work
in a team environment on laboratory projects which relate lectures to practical
applications. (Program Outcomes: A,B,C,
D,E,F,G,K,L,N,O,P,Q; MFGG PEOs: 1,2,3,4,5,7)
Prerequisites by
topic:
1. Manufacturing
process capabilities
2. Engineering
graphics skills
3. Differential
equations
4. Mechanics
of solids
5. Computer
programming, word processing and spread sheet graphing
6. Polymer
nomenclature
Topics covered:
1. Polymer
Morphology and Molecular Architecture
2. Polymer
Melt Rheology
3. Material
Selection
4. Extrusion
Process and Troubleshooting
5. Injection
Molding Process and Troubleshooting
6. Other
Polymer Processes: blow molding, thermoforming, rotational molding, casting,
foaming, compression/transfer molding processes, polymer composite materials
and processes, radiation processes, and finishing and assembly
7. Part
and Tooling (Die/Mold) Design
8. Mold
Flow, Cooling, Shrinkage and Warpage, and Structural Analyses
9. Environmental
Aspects of Plastics: Source Reduction, Recycling, Regeneration, Degradation,
Landfills, and Incineration
10. Operations:
Safety and Cleanliness, Resin Handling and Conveying, Plant Layout, Quality
Assurance
11. Final
Learning Experience
Schedule: Two lecture sessions of 60 minutes and two laboratory sessions of 120 minutes per week
Computer usage: 1. Apply computer knowledge to computation of polymer drag flow, pressure flow, leakage flow, and viscosity from experimental data.
2. Use spreadsheet applications to process laboratory data and plot graphs
3. Use statistical programs to perform regression analysis of process experiments.
4. Use commercial computer aided engineering software packages such as MCBase, Prospector, Miniflow, CMOLD or CADPress to select polymeric materials as well as design, simulate, and optimize injection molding and compression molding processes.
Laboratory projects: 1. Investigate
the effects of process parameters on the quality of injection molded parts - I
& II
2. Design and optimize an injection molding process via design of experiments
3. Investigate rheological properties of various polymers via melt indexer, laboratory capillary and on-line process rheometers
4. Investigate thermal properties of polymers
5. Investigate the effects of process parameters on process stream properties and process throughput during extrusion
6. Select polymeric materials via MCBase and Prospector materials data banks
7. Design, simulate, and optimize injection molding and compression molding processes via commercial Miniflow, CMOLD, and/or CADPress software packages.
8. Plastic product development from concept through manufacturing
Relationship to professional component: Three credits of engineering science and one credit of engineering design
Prepared by: Gwan Y. Lai Date: February 22, 2001