Engineering. Composiies. CRC Press. Taylor & Francis Croup. Boca Raton London New York. CRC Press is an imprint of the

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1 Engineering Design with Polymers and Composiies Second Edition lames G. Gerdeen, PhD, PE Ronald A. L. Rorrer, PhD, PE CRC Press Taylor & Francis Croup Boca Raton London New York CRC Press is an imprint of the Taylor & Francis Croup, an informs business

2 Contents Preface Acknowledgment Authors xiii xv xvii Chapter 1 Introduction Introduction History of Polymers History of Composites Examples of Polymers and Composites in Use Definitions and Classifications Identification of Plastics Raw Materials and Production of Polymers Chemical Structures Glass Transition and Melting Temperatures 21 Homework Problems 25 References 26 Chapter 2 Mechanical Properties of Polymers Introduction Tensile Properties Elongation Elastic Modulus Ultimate Tensile Strength Yield Strength Static Failure Theories Creep Properties Relaxation Properties Dynamic Properties Dynamic Tests Dynamic Modulus and Damping Dynamic Property Data Large Strain Definitions Analysis of Damping Time Hardening Creep Isochronous Creep Curves 51 Homework Problems 51 References 54 v

3 vj Contents Chapter 3 Viscoelastic Behavior of Polymers Mechanical Models Mathematical Models The Maxwell Fluid The Kelvin Solid The Four-Parameter Model The Boltzmann Superposition Principle Advanced Viscoelastic Models The Viscoelastic Correspondence Principle The Time-Temperature Equivalence Principle 71 Homework Problems 74 References 79 Chap ter 4 Creep and Fatigue Failure Creep Failure under Tension Creep Failure under Compression Fatigue of Polymers Notch Sensitivity under Fatigue Creep Buckling of Shells 91 Homework Problems 92 References 93 Chapter 5 Impact Strength and Fracture Toughness Impact Strength Thickness Effects Rate Effects Combined Stiffness and Impact Properties Fracture Toughness Brittle Fracture Ductile Fracture General Theory of Fracture Instability Analysis of the Charpy and Izod Impact Tests Using Fracture Mechanics Analysis of Impact Specimens at the Nanoscale 116 Homework Problems 117 References 119 Chapter 6 Selection of Polymers for Design Applications Introduction Basic Material Properties Performance Parameters Loading Conditions and Geometrical Configurations 122

4 Contents vii 6.5 Availability of Materials 6.6 A Rectangular Beam in Bending 6.7 Weighting-Factor Analysis 6.8 Thermal Gradient through a Beam 6.9 Rating Factors for Various Loading Requirements 6.10 Design Optimization Graphical Solution Computer Solution Microsoft Excel Solver Routine 6.11 Computer Database Design Selection Procedure Example Problem of Impact of a Beam... Homework Problems References Chapter 7 Design Applications of Some 145 Polymers 7.1 Phenolic Resins with Fillers Polycarbonate 7.3 Example Design with PC: Fan Impeller Blade Creep Strain Impact Failure Example Design with PC: Snap/Fit Design Example Design of PVC Pipe Design with Fluorocarbon Resins 156 Homework Problems 158 References Chapter 8 Composite Material Mechanics Introduction Composite Material Nomenclature and Definitions Analysis of Composite Structures Micromechanics of a Unidirectional Fiber-Reinforced Composite Layer (Lamina) Determination of Apparent Longitudinal Young's Modulus Determination ofmajor Poisson's Ratio of Unidirectional Lamina Apparent Transverse Young's Modulus Apparent Shear Modulus Summary of Results from Micromechanics Analysis of Lamina Elastic Moduli Prediction of Tensile Strength in Fiber Direction 177

5 . Notation vjjj Contents Macromechanics of a Unidirectional Fiber- Reinforced Composite Layer of Lamina Stress-Strain Relationships for Isotropic Materials Anisotropic Materials: Contracted Orthotopic Lamina: Hooke's Law in Principal Material Coordinates Stress (Strain) Relationships for Off-Axis Orientation Experimental Determination of Engineering Elastic Constants 190 Homework Problems 194 Bibliography 195 References 195 Chapter 9 Composite Laminate Failure Strength Properties and Failure Theories A Review of Failure Theories for Isotropic Materials Strength and Failure Theories for an Orthotropic Failure by Lamina 199 Fiber Pullout Stiffness oflaminated Composites Sandwich Beam Orthotropic Plate Laminated Plates Thermal Stresses Summary 216 Homework Problems 217 Bibliography 219 References 219 Chapter 10 Polymer Processing Extrusion Manufacture of PVC Pipe by Extrusion Injection Molding Thermoforming Blow Molding Inflation Cooling Phase 236 Homework Problems 241 References 242

6 Contents ix Chapter 11 Adhesion of Polymers and Composites Introduction Fundamentals of Adhesion Wetting and Work of Adhesion Measurement of Adhesion Viscoelasticity ofadhesion Adhesives Common Polymeric Adhesives Polymers as Matrix Materials (In Situ Adhesives) in Polymeric Composites Enhancement of Adhesion in Composites Curing of Adhesives Summary 257 Homework Problems 257 References 258 Chapter 12 Polymer Fusing and Other Assembly Techniques Introduction Heated Tool Welding Ultrasonic Welding Joint Design Staking Friction Welding Linear Vibration and Orbital Welding Spin Welding Laser Welding Hot Gas Resistance Welding Induction Welding Mechanical Fastener Connections Screws Inserts 278 Homework Problems 279 References 279 Chapter 13 Tribology of Polymers and Composites Introduction Contact Mechanics Surface Topography Friction Static and Dynamic Coefficients of Friction Adhesive and Abrasive Friction Wear Archard Wear Law 290

7 , X Contents 13.6 PV Limit Rolling and Sliding Modification of Polymers for Friction and Wear Performance Internal Lubricants Reinforcements Composites Wear of Composites Heat Generation in Sliding Polymer Systems Bulk Surface-Temperature Calculations Flash Temperature Special Considerations Polymer-on-Polymer Sliding Coatings Effect of Surface Topography on Friction and Wear Effect of Environment (Temperature, Humidity, Gases, and Liquids, etc.) on Friction and Wear Friction-Induced Vibration Simulative Laboratory Testing 304 Homework Problems 305 References 305 Chapter 14 Damping and Isolation with Polymers and Composites Introduction Relevance of the Thermomechanical Spectrum Damping Methods of Material Modification (Cross-linking, Mw, Structure) Polymers, and Composites Used in Damping and Isolation Reduced Frequency Nomograph Materials for Damping and Isolation Fundamentals of Vibration Damping and Isolation Dynamics of Vibrating Structures (Continuous 313 and Discrete or Point) Role of Dampers Damping Layers Application of Dampers and Isolators: Discrete Design of Dampers and Isolators for Equipment 320 Homework Problems 323 References 323 Chapter 15 Rapid Prototyping with Polymers Introduction Rapid Product Development, Tooling, and Manufacture 325

8 Contents xl 15.3 RP Techniques RP Materials Materials Used in FDM by Stratasys Materials Used in SLA Materials Used in LOM Materials Used in SLS Applications 334 Homework Problems 339 References 340 Chapter 16 Piezoelectric Polymers Introduction Piezoelectric Strain Behavior Piezoelectric Material Properties Hysteresis Composites 348 Homework Problems 356 Further Reading 357 References 357 Appendix A: Conversion Factors 359 Appendix B: Area Moments of Inertia 361 Appendix C: Beam Reactions and Displacements 363 Appendix D: Laminate MATLAB or Octave Code 367 Appendix E: Sample Input/Output for Laminate Program 377 Appendix F: Composite Materials Properties 383 Appendix G: Thermal and Electrical Properties 385 Index 389

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