Hanser Publications

This practical introductory guide to injection molding simulation is aimed at both practicing engineers and students. It will help the reader to innovate and improve part design and molding processes, essential for efficient manufacturing.

A user-friendly, case-study-based approach is applied, enhanced by many illustrations in full color. The book is conceptually divided into three parts:

Chapters 1–5 introduce the fundamentals of injection molding, focusing the factors governing molding quality and how molding simulation methodology is developed. As they are essential to molding quality, the rheological, thermodynamic, thermal, mechanical, kinetic properties of plastics are fully elaborated in this part, as well as curing kinetics for thermoset plastics.

Chapters 6–11 introduce CAE verification of design, a valuable tool for both part and mold designers toward avoiding molding problems in the design stage and to solve issues encountered in injection molding. This part covers design guidelines of part, gating, runner, and cooling channel systems. Temperature control in hot runner systems, prediction and control of warpage, and fiber orientation are also discussed.

Chapters 12–17 introduce research and development in innovative molding, illustrating how CAE is applied to advanced molding techniques, including co-/bi-Injection molding, gas-/water-assisted injection molding, foam injection molding, powder injection molding, resin transfer molding, and integrated circuit packaging.

The authors come from the creative simulation team at CoreTech System (Moldex3D), winner of the PPS James L. White Innovation Award 2015. Several CAE case study exercises for execution in the Moldex3D software are included to allow readers to practice what they have learned and test their understanding.

In the 2nd edition, the concept of Cyber-Physical Systems (CPS) in injection molding is introduced. In order to integrate molding simulation and injection machines, the workflow of machine response characterization is illustrated. By taking into account the real-world machine response, users can more accurately reflect the real-world manufacturing conditions in simulations. The optimized processing conditions obtained from the simulation can then be directly applied on the shop floor, bridging the gap between simulation and manufacturing. In addition, a new flow-fiber coupling model, i.e., the informed-isotropic (IISO) viscosity developed by Dr. Favaloro and Prof. Pipes of Purdue University, to simulate the anisotropic flow for fiber-reinforced thermoplastics is introduced. The IISO coupling is available to simulate some peculiar, irregular filling patterns for fiber-reinforced melts at high fiber concentrations: the free surface advances faster along the side cavity walls.

This book unites the two sides of additive manufacturing: 1) the technical aspect of 3D printing of very different materials and 2) the disruptive consequences for value chains between producers, intermediaries, and customers due to modern business models. This is because 3D printing breaks with many existing business models: companies take over functions from their previous suppliers (following the "do-it-yourself" trend), intermediaries lose their livelihood (so-called "disintermediation"), manufacturers move their production to decentralized locations (e.g., retailers, car dealerships, or hospitals, so-called "decentralized production"), and (end) customers become much more intensive "prosumers" than marketing (as creator of this term) could ever imagine.

The business models of many existing companies from very different industries are becoming toxic, i.e., threatening their very existence, as in logistics and warehousing, industry, services, retail, or customer service. Conversely, there are also many opportunities for modern, existence-securing business models, which the book discusses in more detail. In this way, this book not only shows to a broad range of readers the dangers of disruptive 3D printing technology, but also offers solution approaches and procedural models for identifying new economic livelihoods and competitive advantages. Thanks to the collaboration of the two authors, a profound knowledge of already existing references and management models can be drawn upon.

This book offers a unique overview of usage of biomass, biomaterials, and bioproducts, including biopolymers. Included are materials, processes, usage as an energy source, and, in particular, applications. It is intended to educate both professionals and graduate students, who typically must acquire knowledge outside of traditional academic disciplines to gain an appreciation of these systems.

While the growing need for renewable energy can be satisfied from other renewable sources, biomass is our only real source of renewable carbon-based chemicals and fuels. More and more companies are moving toward using these materials, and investing in new technology based on renewable resources to develop their businesses in a sustainable way.

Despite this, few scientists and engineers have been appropriately trained to work in the interdisciplinary field of the biomass economy. Traditional academic disciplines are not well organized to train engineers and scientists to develop new bio-refinery concepts and bio-based products (including bio-based polymers) in industry, nor to develop and integrate pathways to convert biomass into other forms of energy and useful products. The integration of old and new pathways to satisfy global and local markets is the basic skill required to create new biomass processing alternatives. This book is written to fill this gap.

This text- and workbook provides a clearly written, comprehensive introduction to the major topics associated with plastics technology, from basic chemistry and processing methods to the problem of waste and the issue of recycling plastics. 

Guiding questions at the beginning of each lesson help the reader to work through the material in a targeted manner; success checks at the end of each lesson enable the reader to review what he/she has learned. It thus facilitates independent, self-paced learning, meeting the requirements of modern vocational training.

Specialty thermoplastics command a US$3 billion market worldwide. Their use is proliferating in aerospace and transportation, medical applications including implants, electrical and electronics, textiles and general engineering, and the oil and gas industries. This book provides the key details of all specialty thermoplastics in one volume, uncluttered by information on other commodity and engineering plastics. It covers the spectrum of manufacturing methods, major properties, processing, and applications.

The extraordinary resistance of specialty thermoplastics to high temperature, oxidation, hydrolysis, other chemicals, and radiation, as well as outstanding mechanical properties at temperatures from -40 to 300 °C make them attractive materials for challenging applications. R&D scientists will appreciate the coverage here of different polymer structures for specialty plastics and why certain structures are technically and commercially preferred. Plastics engineers and product design engineers are empowered to select the right plastic in the right grade for the desired applications.

Guidance on processing of specialty plastics using injection and compression molding, extrusion, and coating is provided, together with a wealth of details regarding applications, including aspects that are not readily visible, such as touch and feel.

In addition to users in industry and academic research, this work is also applicable as a textbook for special courses on polymer science and engineering for graduate and undergraduate students.

"Energy in Plastics Technology" provides, unlike any other book, the necessary fundamentals for dealing with thermotechnical issues in the processing of plastics, leading to efficient, robust, reliable, economical, and environmentally friendly processes for high-quality products. Included are the following subject areas:

- Thermodynamics (main theorems, treatment of chemical transformations);

- Fluid mechanics including explanation of similarity theory;

- Heat transfer (free and forced convection, steady-state and unsteady-state heat conduction, some aspects of heat transfer by radiation);

- Thermal and caloric state behavior, deformation and flow behavior of plastics (rheology).

The fundamentals provided are applied - in exemplary calculation examples - to problems relevant to practice in the most important processing and forming methods: heating and cooling processes of molds, extrusion, blow molding, injection molding, pressing of thermosets and thermoplastics, calendering, FRP forming, foaming, casting, additive processes, forming processes, welding, coating processes. The focus is on energy consumption in the form of heat and work (economic and ecological aspects) as well as the resulting temperatures (quality aspect).

The book is aimed at engineers and students working in plastics technology as well as technicians and plastics technologists.

For 30 years, "Designing Plastic Parts for Assembly" has been the definitive guide for both seasoned part designers and novices to the field, facilitating cost-effective design decisions and ensuring that the plastic parts and products will stand up under use.

The detailed yet simplified discussion of material selection, manufacturing techniques, and assembly procedures enables the reader to evaluate plastic materials and design plastic parts with confidence. Good joint design and implementation, the geometry and nature of the component parts, the types of load involved, and other fundamental information necessary for a successful outcome are all included. Throughout, the treatment is practice-oriented and focused on everyday problems and situations.

The 10th edition includes an extensive revision of the chapter on welding techniques for plastics, including a new subchapter on hot gas welding. There are also many more minor updates, improvements, and corrections throughout.

"Sustainable Packaging Materials" provides a concise introduction to the principles and practices of packaging sustainability. It addresses the important issues that concern packaging professionals, decision makers, managers, CTOs, legislators, researchers, and students, including the viability and future of recycling, bio- and oxo-degradable materials, and plastics alternatives such as paper, glass, and metal. Also covered are new regulations such as the extended producer responsibility (EPR) laws, their consequences as to what materials are likely to be banned, and whether microplastics should be a concern for packaging companies.

Written by an experienced professor, educator, author, inventor, and entrepreneur, this book offers uniquely clear answers to these challenges, helping readers to identify packaging materials that are likely to be phased out to meet new regulations, and to find alternatives to benefit their research and businesses. They will also be equipped to follow guidelines on the use of various packaging materials to stay ahead of the demands of the industry, and to make informed choices about packaging materials by considering sustainability, performance, and cost. Furthermore, they will be informed of the emerging packaging trends in both academia and industry, and understand the issues associated with microplastic pollution, and the actions recommended to mitigate these challenges.

Polymers reinforced with discontinuous fibers have a wide range of important applications such as in automotive parts and business machines. The fl ow that occurs during processing of these materials creates a complex but repeatable pattern of fi ber orientation, which plays a key role in achieving the desirable mechanical properties these materials can offer.

The primary focus of this unique book is fiber orientation: how to describe it mathematically, how to measure it experimentally, and how to predict it using models available in commercial software. The book also covers the description, measurement, and modeling of fi ber length, another important variable that can be predicted by commercial software. The connection between fi ber orientation and mechanical properties is explained, as is the relationship between fiber orientation and rheological properties in the fl uid state. “Fundamentals of Fiber Orientation” focuses on the models used in current engineering practice, but also discusses topics from current research that could transition to engineering practice soon.

For practicing engineers, this book teaches the fundamentals needed to understand data, set up meaningful simulations, and interpret results. The book provides a thorough, organized overview of the field, and will also be a valuable resource to those undertaking research in this area. Free MATLAB software implementing the models discussed in the book is provided online.