This book introduces the reader to the concepts of Scientific Molding and Scientific Processing for Injection Molding, geared towards developing a robust, repeatable, and reproducible (3Rs) molding process. It explains the underlying principles of polymer science: the properties that are important to injection molding and their application to molding process development. The effects of polymer morphology, thermal transitions, drying, and rheology on the injection molding process are explained in detail. The development of a robust molding process is broken down into two sections: the Cosmetic Process and the Dimensional Process. Scientific molding procedures to establish a 3R process are provided.

The concept of Design of Experiments (DOEs) for and in injection molding is explained, giving insight into the cosmetic and dimensional process windows. A plan to release qualified molds into production with troubleshooting tips is also provided. Topics that impact a robust process such as the use of regrind, mold cooling, and venting are also described.

Readers will be able to utilize the knowledge gained from the book in their day-to-day operations immediately.

This third edition includes a completely new subchapter covering melt preparation, as well as much additional, revised, and updated material throughout the book. The revisions are deeply informed by the author’s long and ongoing experience as a trainer, resulting in improved ways to conduct a study, perform experiments, or explain a concept.

This definitive book provides a comprehensive account of the full range of dies used for extrusion of plastics and elastomers. The distinctive features of the various types of dies are described in detail. Expert advice on the configuration of dies is given, and the possibilities of computer-aided design, as well as its limitations, are demonstrated. Fundamentals and computational procedures are clearly explained so that no special prior knowledge of the subject is required. The mechanical configuration, handling, and maintenance of extrusion dies are described. Calibration procedures for pipes and profiles are also discussed. This book was written for plastics engineers who need daily support in their practical work in industry and science, as well as for students preparing for their professional life. The 4th edition is brought up to date with several important additions, including coverage of multilayer (>15 layer) dies, melt encapsulation, and simulation tools (rheological/thermal CFD simulations).

This book closes a fundamental gap in the field of mold design. The use of injection molding coatings extends the technical possibilities in the field of plastics production, such as the achievable flow path length, the use of abrasive and corrosive plastics, and the achievable tool life. This possibility of functionalization has so far been somewhat neglected due to a lack of available information on the state of the art and possible applications. This book therefore brings together the available knowledge of various experts in a way that is understandable for engineering students and tool and mold makers.

 

The book covers the individual steps of coating technologies. First, the steel materials that are mainly used for the construction of tools in plastics processing are presented. This is followed by the current status of the various coating technologies. The existing coating technologies are presented and characterized with regard to their suitability for use in tool technology in the plastics processing environment. The third part deals with the characterization of the deposited coatings. On the one hand, the focus is on the characterization of the actual coating, such as chemical composition, coating layout and coating thickness. Secondly, the measurement methods for determining the functional properties of the deposited coatings, such as hardness and wear resistance, thermal properties, thermal conductivity and tribological properties, are presented. Finally, the use of appropriate coatings is illustrated using practical examples from plastics technology.

"Practical Rubber Rheology and Dynamic Properties" provides a unique overview of rubber rheology from a practical perspective. Written by expert authors with many years of experience in the rubber industry, it focuses on applications of rubber rheology testing to solving industrial problems, rubber compound development, predicting changes in processability in the plant, quality assurance, and research and development. However, basic principles are also covered.

Aimed at practitioners in the rubber industry, this book promotes understanding of the material to support efficient production of the high-quality rubber products demanded in today's market. It is also suitable for students and their instructors on rubber courses taught in universities.

From hardware and materials through processing and properties, a broad coverage of blown film extrusion is presented. A primary objective of this book is to ensure a useful balance of theory and practice. The reader will find the answers to why they encounter certain effects in the blown film process so that they are better able to troubleshoot and improve their operations. At the same time, current practices and equipment are emphasized to keep readers up-to-date with the most productive and efficient technology. The companion computer-based learning tool, The Blown Film Extrusion Simulator, is provided to enhance the reader’s understanding. This software was developed specifically to teach blown film extrusion equipment operation and processing principles, and is available for download. Throughout this book, exercises using the simulator are described to complement the methods and principles explained. New in this third edition is a chapter on polymer rheology, with an overview of the rheology of polymer melts and its effect on extruding blown film. Additionally, improvements and corrections have been made throughout the book.