Polymer Process Engineering PDF
Preview Polymer Process Engineering
POLYMER PROCESS ENGINEERING POLYMER PROCESS ENGINEERING Richard G.Griskey Ph.D.,P.E. Institute Professor (Emer.) Chemistry and Chemical Engineering Stevens Institute of Technology SPRINGER-SCIENCE+BUSINESS MEDIA, B.V. Cover design: Edgar Blakeney Copyright © 1995 Springer Science+Business Media Dordrecht Originally published by Chapman & Hali in 1995 Softcover reprint ofthe hardcover 1st edition 1995 Ali rights reserved. No part ofthis book covered by the copyright herean may be reproduced or used in any tonn or by any means--graphic. electronic. Of mechanical. including photocopying, recording. taping, or infonnation storage and retrieval systems--without the written permission ofthe publisher. 2 3 4 5 6 7 8 9 XXX OI 00 99 98 97 Library ofCongress Cataloging-in-Publication Data Griskey, Richard G. Polymer process engineering / Richard G. Griskey. p. cm. Includes bibliographical references and index. ISBN 978-94-010-4257-4 ISBN 978-94-011-0581-1 (eBook) DOI 10.1007/978-94-011-0581-1 L Polymers. 1. Title. TPI087.G75 1995 94-31630 668.9--dc20 CIP To Dr. Pauline B. Griskey my inspiration, my best friend, and my dear wife CONTENTS Preface viii Chapter 1 Polymer Basics, Structural Characteristics, Characterization 1 Chapter 2 Thermodynamics of Solid, Molten, and Thermally Softened Polymer Systems 48 Chapter 3 Applied Polymer Rheology 105 Chapter 4 Heat Transfer in Polymer Systems 141 Chapter 5 Mass Transfer in Polymer Systems 223 Chapter 6 Chemical Reaction Kinetics in Polymer Systems 249 vi Contents vii Chapter 7 Polymer Processes: Extrusion 278 Chapter 8 Injection-Molding Systems 311 Chapter 9 Blow Molding, Rotational Molding, and Other Molding Operations 349 Chapter 10 Calendering, Thermoforming, and Casting 372 Chapter 11 Fiber-Spinning Processes 393 Chapter 12 Interrelation of Polymer Processing, Polymer Structure, and Polymer Properties 448 Index 475 PREFACE Polymers are ubiquitous and pervasive in industry, science, and technology. These giant molecules have great significance not only in terms of products such as plastics, films, elastomers, fibers, adhesives, and coatings but also less ob viously though none the less importantly in many leading industries (aerospace, electronics, automotive, biomedical, etc.). Well over half the chemists and chem ical engineers who graduate in the United States will at some time work in the polymer industries. If the professionals working with polymers in the other in dustries are taken into account, the overall number swells to a much greater total. It is obvious that knowledge and understanding of polymers is essential for any engineer or scientist whose professional activities involve them with these macromolecules. Not too long ago, formal education relating to polymers was very limited, indeed, almost nonexistent. Speaking from a personal viewpoint, I can recall my first job after completing my Ph.D. The job with E.I. Du Pont de Nemours dealt with polymers, an area in which I had no university training. There were no courses in polymers offered at my alma mater. My experience, incidentally, was the rule and not the exception. Since that time, formal education in polymers has grown to the extent that most universities now offer relevant course work. One important aspect of pol ymers has lagged behind, that of polymer processing. There are probably a number of reasons why this has occurred. One of many is the lack of a suitable textbook. viii Preface ix The present text attempts to deal with this problem by providing a book that starts with first principles and then moves through the semiempirical and em pirical approaches needed in polymer processing. While rigorous, the text is not excessively mathematical or theoretical but rather a blend of quantitative and, when needed, semiquantitative approaches. The readership for the text is seniors and first-year graduate students in engineering and science as well as industrial practitioners. The material in the text is an outgrowth of personal experience in industry, both full-time and as a consultant, and in academe, teaching and doing research. Approaches and treatments used in the text were developed in courses taught at the University of Cincinnati (required courses in interdisciplinary graduate pro gram in materials science); at the Virginia Polytechnic Institute (required courses in the graduate materials engineering science program; and senior chemical en gineering courses); at New Jersey Institute of Technology (required graduate courses in polymer engineering and science); and senior and graduate courses at the University of Denver, at the University of Wisconsin-Milwaukee, and at universities in Poland, Brazil, Australia, and Algeria. Further, the relevance of the text to professional practitioners is clearly dem onstrated in the use of the material in successful short courses taught for the American Institute of Chemical Engineers and the American Society for Me chanical Engineers. A suggested syllabus for a university course would be to start with the first chapter, which gives a concise but thorough grounding in polymer classifica tions, structural characteristics, and methods of-characterization. Next, Chapters 2 through 6 should be covered as an interrelated unit. This set of chapters gives the student required background in the relation of thermodynamics, rheology, heat transfer, mass transfer, and chemical kinetics to polymers. Chapters 7 through 11 treat the polymer-processing operations, such as extrusion and in jection molding. Finally, Chapter 12, which treats the important linkage between processing, polymer structural characteristics, and polymer properties, is an im portant capstone to the text. Over the years, it has been apparent that students profit immensely from worked examples. For this reason, a large number of such relevant solved prob lems have been included. Likewise, illustrations have been used to aid the learn ing process as much as possible. Also included in the text are a large number of problems at the end of Chap ters 2 through 11. These problems are designed to emphasize the practice of polymer processing. Indeed, many of them were taken from industrial situations. Additionally, sets of Mini Projects appear at the end of most of the chapters. These open-ended Mini Projects require more time and effort on the student's part than the problems do. As such, they can be assigned as team or group X Preface efforts. Further, one or two of these could be a term-long project for individual students. In any case, the combination of the problems and projects should further enhance the text's ability to optimize a sound approach to polymer processing. All books are our companions, but textbooks fill a special role in that regard. They not only guide us into new areas of knowledge and understanding but can also motivate us to go beyond what is known to what has to be known. It is my strong wish that the present text will do just that. 1 CHAPTER POLYMER BASICS, STRUCTURAL CHARACTERISTICS, CHARACTERIZATION 1.1 INTRODUCTION Man has marked the epochs of his history by the materials that he has used to progress-the Stone Age, the Bronze Age, the Iron Age. If we were to name our own time, it could truly be called the Polymer Age. Each passing year sees unbelievable surges in the production and use of plastics, fibers, films, adhesives, elastomers, and other polymer products. The plastic industry itself continues to grow at a rapid pace not only in the United States but also worldwide (see Fig. 1-1). What has brought this about? What is the basis for the importance of polymers in our lives? Some Definitions In order to develop a better understanding of the impact of polymers, let us first define a polymer. The word itself comes from two Greek words: poly- mean ing "many" and -mer from meros, meaning "part" or "member." Hence, a polymer is a large molecule built by the repetition of many small repeating units. A polymer can also be characterized as a giant molecule, or macromolecule. As an example of a polymer, take cellulose. A chemical analysis of the sub stance shows that cellulose has an empirical chemical formula of CH 0 (mo 6 16 S lecular weight of 162). Yet, a typical cellulose sample might have a molecular weight of 486,000. This indicates that such a cellulose molecule would be made up of 486,000/162, or 3000, repeating units. This number of repeating units is called the degree of polymerization. 1
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