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Mechanical Properties ,[object Object],[object Object],[object Object],[object Object],[object Object]
Properties and product performance ,[object Object],[object Object],[object Object],[object Object],The successful design of a product depends on the synergy of the  design ,  manufacturing  and  materials
Why look at polymer chemistry, structures and properties ? ,[object Object],[object Object],GOAL =  Product Performance
Plastics –  from chemistry to performance Polymer  Chemistry Material microstructure Material properties Product Performance
Intermolecular Attraction Forces ,[object Object],[object Object],[object Object],[object Object]
‹ #› Bonding Energy & Distance Bond energy Bond length
Intermolecular  Attraction Forces ,[object Object],Intermolecular forces Intermolecular distance, d Intermolecular distance,  d d
Intermolecular Attraction Forces ,[object Object],Intermolecular forces Degree of polymerization, n
Mechanical Properties & M W ,[object Object],Intermolecular forces Molecule length   to molecular weight
Differences in Properties ,[object Object],[object Object],[object Object],[object Object],[object Object],Amorphous ,[object Object],[object Object],[object Object],[object Object],[object Object],Crystalline
Mechanical Properties - stiffness Amorphous stiffness temperature T g T g  – glass transition temperature
Mechanical Properties - stiffness Temperature stiffness Semi crystalline T g T m  – melt temperature T m
Mechanical Properties - stiffness T m T m T g stiffness Temperature Amorphous plastic Semi crystalline plastic
Physical Properties 15%GF Polyester, PBT 1400 nylon 6/6 13%GF Density 0.0509   lb/in ³ 0.0444   lb/in ³ Water Absorption 0.1   % 1.1 % Linear Mold Shrinkage 0.005   in/in 0.006 in/in
Plastic Mechanical Properties
Secondary Bonds ,[object Object],[object Object],[object Object],[object Object],Increasing strength
Intermolecular Attraction Forces ,[object Object],[object Object],[object Object],[object Object]
Elastic Behavior of Solids ,[object Object],[object Object],[object Object],[object Object],[object Object]
Stress/Strain Curve Linear Elastic Material
Types of Forces ,[object Object],F F
Types of Forces ,[object Object],T T
Types of Forces ,[object Object],
Stress Testing ,[object Object],A F L Stress,    = F / A Strain,    =   L / L
Tensile Testing Results Stress vs Strain For plastics the rate of stress applied affects the material’s response
Elastic Behavior of Solids ,[object Object],[object Object],[object Object],[object Object],[object Object]
Solid Materials ,[object Object],[object Object],[object Object],[object Object],[object Object]
Mechanical Response as a function of Time ‹ #› F F F time input  time displacement
Elastic Solid Model ‹ #› F F   k Spring constant or stiffness k
Elastic Solid –  Microstructural Behavior ‹ #› The applied force straightens polymer chain segments F F The polymer chain segments return back to a more disorder and stable configuration when force is removed
Viscous Behavior ,[object Object],[object Object]
Viscous Behavior ,[object Object],[object Object],[object Object],[object Object]
Viscous Behavior ,[object Object],[object Object],[object Object],[object Object]
Cone and Plate cone polymer
Stress and Shear Rate Polymer melt  stationary plate  moving plate  force  Shear stress
Newtonian Fluid ,[object Object],  Slope =    viscosity Example – water  =  shear stress  =  shear rate
Newtonian / NonNewtonian ,[object Object],[object Object],[object Object],  pseudoplastic dilatant
Rheometry Experiments Experiment H  Re-Grind PC Melt Rheology at 550  o F
Effects of Time and Temperature ,[object Object],[object Object]
Elastic Solid –  Microstructural Behavior ,[object Object],[object Object]
Mechanical Response as a function of Time ,[object Object],F time  time input response No recovery
Viscous Fluid Model F F  d  dt C Viscous Damping Constant
force force ,[object Object],[object Object],Heat is generated
The plastic part is subjected to a tensile force The plastic part is increases its length L, when the force is removed it will not spring back – this a permanent deformation The plastic part is increases its length L F F L o  ,  original length F F L new  = L o  +   L L new  = L o  +   L permanent
Mechanical Response as a function of Time ,[object Object],F time  time input response recovery
Viscoelastic Solid Model F   (t) time
Viscoelastic Solid,  Microstructural Behavior Polymer chain segments are stretched by the force, this is the elastic element of the model As the Polymer chain segments are stretched there is friction between these chain segments – this is the viscous damping element When the force is removed, the chains return to the original state – during this motion, there is also friction Heat is generated
General Viscoelastic Model F C E K E C P K E  – elastic stretching of chain segments C E  – friction between chain segments (very small) C P  – friction between complete polymer chains
Maxwell Viscoelastic Model F K E C P K E  – elastic stretching of chain segments C P  – friction between complete polymer chains
Viscoelastic Behavior ,[object Object],[object Object],[object Object],[object Object],[object Object]
Mechanical Response & Intermolecular Forces ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Deborah’s Number ,[object Object],[object Object],[object Object],[object Object]
Effects of Time and  Temperature – Silly Putty ,[object Object],[object Object],[object Object],[object Object]
time Tension in a part Relaxation curves Increasing temps Initial  Tension  t o Length after time t o 1 2 3 3 2 1
l Stress Relaxation
Mechanical Response and Intermolecular Forces ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Mechanical Response and  Intermolecular Forces ,[object Object],[object Object],[object Object]
Mechanical Response  and Intermolecular Forces ,[object Object],[object Object]
Mechanical Response  ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Temperature and Mechanical Response ,[object Object]
Load Rate  & Mechanical Response ,[object Object], Increase of  Strain rate 
Dynamic Mechanical Analysis From TA Instruments
Dynamic Mechanical Analysis
Dynamic Mechanical Analysis From TA Instruments
Dynamic Mechanical Analysis From TA Instruments
Dynamic Mechanical Analysis Viscous elastic response From TA Instruments
Viscous elastic response
Viscous elastic response
Dynamic Mechanical Analysis
Creep ,[object Object],[object Object],[object Object],[object Object],force force Heat Chains flow by each other
From TA Instruments
From TA Instruments
Creep Viscoelastic Model  (t) time Critical time For this load, there  has not been enough time to start the  viscous motion F C E K E Permanent Deformation – creep For this load, the  viscous motion has  started
Creep –  Temperature, Time and Load ,[object Object],[object Object],[object Object]
Creep – time, temp loads
Impact Strength and Toughness ,[object Object],[object Object],[object Object]
Plastic Toughness ,[object Object],crystalline amorphous
Depends on material ability to absorb energy Stress/strain curve Area underneath Stress/strain curve is the measure of impact    strain    stress
Toughness is not Strength ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Degree of Crosslinking & Toughness Tough Strong
Small Additives Get between Polymer chains This increases d and can make the degrade properties Example – excess of colorant can weaken a plastic part
Reinforcements ,[object Object],[object Object],[object Object]
Melt Flow Rate (ASTM  D1238) Given a resin's MFR,will the part fill properly? ,[object Object],[object Object],[object Object],[object Object],[object Object],Len Czuba August 2006
Melt Flow Rate Test Apparatus: Resin
Melt Flow Index # grams of flow per 10 minutes Weighted Plunger Barrel Molten Pellets Extrudate Orifice Heater Band Dynisco LMI 4000 Len Czuba August 2006
Tensile Strength (ASTM  D638) ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Len Czuba August 2006
Tensile Strength (ASTM  D638) ,[object Object],[object Object],[object Object]
Tensile Strength Test Apparatus:
Impact Resistance ASTM D256 Is this a relevant impact test for your device? ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Impact Resistance Test Apparatus: Len Czuba August 2006
Impact Resistance Test Specimen: Len Czuba August 2006
Summary ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Summary ,[object Object],[object Object],[object Object],[object Object],[object Object]
Summary ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
 
Design Example ,[object Object],[object Object],   = Mc   /   I   old
Load and Material Interaction ,[object Object],[object Object],[object Object],[object Object]
Load and Material Interaction Failure probability
Load  ave = 6000,  std dev = 1000 PET  ave = 12000, std dev = 1000 Example -  Material Properties & Loads
Load  ave = 6000, std dev = 2000 PET ave = 12000,  std dev = 1000 Solution 1 - use the same part for another application
Load  ave = 6000, std dev =1000 PET  ave = 12000, std dev 1500 Solution 2 - get cheaper materials
Load  ave = 6000, std dev = 1000 Regrind PET  ave = 9500, std dev = 1200 Solution 3 - get cheaper materials, use regrind
25% regrind 75% virgin Solution 4 - get cheaper materials, use regrind + virgin
Solution 4 - get cheaper materials, use regrind + virgin
Solution 4 - get cheaper materials, use regrind + virgin
Solution 5 - Redesign Part   ,[object Object],[object Object],[object Object]
Solution 5 - Redesign Part   Existing cross section New cross section
 
   = Mc   /   I   new
Possible Solutions ,[object Object],[object Object],[object Object],[object Object],[object Object]
Possible Solutions ,[object Object],[object Object],[object Object],[object Object],[object Object]
Design Summary ,[object Object],[object Object],[object Object]
Design Summary ,[object Object]
Plastics   Mechanical Properties

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