1 basics osswald
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Engineering of Polymeric MaterialsThe 5 PʼsTim A. Osswald
Polymer Engineering CenterUniversity of Wisconsin-Madison
King Saud University15-17 November 2008
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Topics
The 5 PʼsIntroduction to PolymersPolymer Recognition and DiagnosticsIntroduction to Mixing and Blending
Anisotropy DevelopmentSolidification Shrinkage and WarpageMechanical Behavior of PolymersFailure of Polymers
Simulating Polymer ProcessesProcessing InnovationsMaterials InnovationPolymers from Renewable ResourcesModeling Innovations
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The 5 Pʼs
Polymer
Processing
Product
Performance
Post-consumer Life
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Polymer
Process
Product
Performance
Post-consumer life
HeatingMixingPumpingForming
PelletFilm/FiberComponent/Assembly
ThermalMechanicalEnvironmentalOpticalElectrical
ExtrusionInjectionCompression
MorphologyOrientationDegradation
MoleculeMaterialFiller FiberAdditive
CompatibilityAdhesionRegulation/LegislationCost
RecyclingEnvironmentSustainabilityLegislation
Properties
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Polymer(s)
Process
Performance
Rheological propertiesThermal propertiesMechanical PropertiesFlow
Heat TransferFiber orientationFiber damageDegradationShrinkage/Warpage
AnisotropyMechanical PropertiesStressesFriction Properties
Assembly Injection Molding
ProductAssemblyDesired interactions
Post-Consumer LifeAssembly/DisassemblyChoice of materials
Osswald - Fürth, Germany, Montagespritzgießen (2007)
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Misconceptions and Misunderstandings
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300
200
100
00
5
10
15200
150
100
50
0
1000
10,000
100
Deflectiontemperature °Cunder flexuralload (1.82 MPa)ASTM D 648
Thermalexpansioncoefficient,10-5 m/m °CASTM D 696
Tensilestrength, MPaat 23°CASTM D 638
Flexuralmodulus, MPaat 23°CASTM D 790
HIPS
HIPS
HIPS
HIPSPP
PP
PP
PP
PC PC
PC
PC PVC
PVC
PVC
PVC
Epoxy
Epoxy
Epoxy
EpoxyPhenolic
PhenolicPhenolic
Phenolic
POM
POM
POM
POM
PMMA
PMMA
PMMA
PMMA
PET
PET
PETPET
PA66
PA66
PA66
PA66
HDPE
HDPE
HDPE
HDPELDPE
LDPE
LDPE
LDPEPS
PS
PS
PS
SAN
SAN
SAN
SAN
ABS
ABS
ABS
ABS
PTFE
PTFE
PTFE
PTFE
PI
PI
PI
PI
UP
UPUP
UP
100
10
1000 2.0
1.5
1.0
1.0
10
100
1000
Elongationat break, %at 23°CASTM D 638
IZOD impactstrengthJ/m of notchat 23°CASTM D 256
Specific gravityASTM D 792
HIPS HIPS
HIPS
PP
PP
PP
PC PC
PC
PVC
PVC
PVC
Epoxy
Epoxy
EpoxyPhenolic
Phenolic
Phenolic
POM
POM
POM
PMMA
PMMA
PMMA
PET
PET
PET
PA66
PA66PA66
HDPE
HDPE
HDPE
LDPE
LDPE no break
LDPE
0.5
PS PS
PSSAN
SAN
SAN
ABS
ABS
ABS
PTFE
PTFE
PTFE
PI
PI
PI
UP
UP
UP
20.0
1.5
1.0
HIPSPP
PC
PVC
Epoxy
Phenolic
POM
PMMA
PET
PA66
HDPELDPE0.5 PS
SANABS
PTFE
PI
UP
5.0
10.0
15.0
Market price $/lb(February 2003)
Data useful for comparison between materials
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Standard Testing Methods (ASTM)
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ASTM Designation: D638 - 01Standard Test Methods for Tensile Properties of Plastics
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Polyethylene Straw Experiment
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Straw Test
10% 20%
“Slower” test
“Impact” Test
100% 200% 300%
STRAIN
“Faster” Test
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PMMA100
80
70
60
50
40
30
20
10
0
90
0 1 2 3 4 5 6 7 8Strain, ε (%)
Strain rate = 0.05%/h0.20.5
110 20
50100200500
100020005000
10000
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Plastics Material Properties Data Survey
Conducted at the SPE ANTEC 2002 People attending product design and
failure sessions 300 surveyed, 100 responded (on site)
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Product Development RespondentsWhich of the following properties do you often use during product and process development?
0.00% 10.00% 20.00% 30.00% 40.00% 50.00% 60.00% 70.00% 80.00% 90.00% 100.00%
Tensile strengthMaterial cost
DensityImpact StrengthMelt flow index
Flexural ModulusChemical resistance
Elastic ModulusYield Stress
Viscosity curvesHeat deflection temperature
Fracture StrainThermal Expansion coefficient
Optical propertiesCreep Data
Friction characteristicsDielectric properties
Tensile-creep modulusSecant ModulusShear ModulusPoisson's ratioP-V-T diagram
Dynamic ModulusHeat Conduction
Isochronous q-e curvesIsometric q-relaxation curves
Product Development respondents
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Polymer Material Data Survey (Germany)*Which of the following properties do you often use during product and process development?
* Berlich, Gabriel, Schmachtenberg, Kunststoffe, 2001
0 50 100 150 200 250 300 350
Young's modulus
Tensile Strength
Temperature behavior
Tensile stress at yield
Tensile strain at breakPrice of raw material
Chemical resistance
Flexural modulus
Viscosity
Tensile-creep modulus
Charpy values
Isochrones
Critical strain
P-V-T diagrams
Poisson's ratio
Reduction factors
Deformation energy density
points
Data from Germany
3 Pts – Often 1 Pts – Rarely 0 Pts – Never-1 Pts – Do not Understand Property
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300
200
100
00
5
10
15200
150
100
50
0
1000
10,000
100
Deflectiontemperature °Cunder flexuralload (1.82 MPa)ASTM D 648
Thermalexpansioncoefficient,10-5 m/m °CASTM D 696
Tensilestrength, MPaat 23°CASTM D 638
Flexuralmodulus, MPaat 23°CASTM D 790
HIPS
HIPS
HIPS
HIPSPP
PP
PP
PP
PC PC
PC
PC PVC
PVC
PVC
PVC
Epoxy
Epoxy
Epoxy
EpoxyPhenolic
PhenolicPhenolic
Phenolic
POM
POM
POM
POM
PMMA
PMMA
PMMA
PMMA
PET
PET
PETPET
PA66
PA66
PA66
PA66
HDPE
HDPE
HDPE
HDPELDPE
LDPE
LDPE
LDPEPS
PS
PS
PS
SAN
SAN
SAN
SAN
ABS
ABS
ABS
ABS
PTFE
PTFE
PTFE
PTFE
PI
PI
PI
PI
UP
UPUP
UP
100
10
1000 2.0
1.5
1.0
1.0
10
100
1000
Elongationat break, %at 23°CASTM D 638
IZOD impactstrengthJ/m of notchat 23°CASTM D 256
Specific gravityASTM D 792
HIPS HIPS
HIPS
PP
PP
PP
PC PC
PC
PVC
PVC
PVC
Epoxy
Epoxy
EpoxyPhenolic
Phenolic
Phenolic
POM
POM
POM
PMMA
PMMA
PMMA
PET
PET
PET
PA66
PA66PA66
HDPE
HDPE
HDPE
LDPE
LDPE no break
LDPE
0.5
PS PS
PSSAN
SAN
SAN
ABS
ABS
ABS
PTFE
PTFE
PTFE
PI
PI
PI
UP
UP
UP
20.0
1.5
1.0
HIPSPP
PC
PVC
Epoxy
Phenolic
POM
PMMA
PET
PA66
HDPELDPE0.5 PS
SANABS
PTFE
PI
UP
5.0
10.0
15.0
Market price $/lb(February 2003)
Data useful for comparison between materials
BUT NOT USEFUL FOR DESIGN!!!
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What kind of data should be used for design?
Creep data (Time dependent)