Handbook of Molded Part Shrinkage and Warpage | by Jerry Fischer | ISBN: 9781884207723. Plastics Processing Principles. Mold Design Techniques. How to Prevent Warpage in Thin Molded Lids. Injection Molding Design. In-Mold Shrinkage. Post-Mold Shrinkage. Mold Construction Materials.
Handbook of Molded Part Shrinkage and Warpage
by Jerry Fischer
ISBN:9781884207723
Examining computer-aided methods of forecasting shrinkage and warpage, this handbook explains why moldings shrink and warp, shows how additives and reinforcements change the picture, sets out the effect of molding process conditions, and more.
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Handbook of Molded Part Shrinkage and Warpage
Preface
Chapter 1 – Introduction to Plastics Processing
1.0: Introduction
1.1: Interactivity Basics
1.2: Thermodynamic Principles Governing Injection Molding
Chapter 2 – Shrinkage and Warpage
2.1: In-Mold Shrinkage
2.2: Warpage
2.3: Post-Mold Shrinkage
Chapter 3 – Causes of Molded-Part Variation—Part Design
3.1: Wall Thickness
3.2: Ribs
3.3: Bosses
3.4: Example of Proper Part Design
3.5: Other Design Considerations
Chapter 4 – Causes of Molded-Part Variation—Material
4.1: Amorphous and Semicrystalline Resins
4.2: Effects of Fillers, Reinforcements, Pigments, Time, and Stress
4.3: Shrinkage Predictions: Using Pressure-Volume-Temperature (PVT) Relationships
Chapter 5 – Causes of Molded-Part Variation—Mold Design
5.1: Cavity Dimensions and Design Factors
5.2: Gate Types
5.3: Gate Location
5.4: Gate Size
5.5: Gate-Design Systems
5.6: Runner Design
5.7: Mold-Cooling Design
5.8: Mold Construction Materials
5.9: Prototype Molding with SLA or Similar Type Molds
5.10: Pitfalls to Avoid
Chapter 6 – Causes of Molded-Part Variation—Processing
6.1: Molding Conditions
6.2: Injection Melt Temperature
6.3: Injection Rate and Pressure
6.4: Holding Pressure and Time
6.5: Mold Temperature
6.6: Demolding Temperature
6.7: Molded-In Stresses
6.8: Other Molding Processes
Chapter 7 – Factors Affecting Post-Mold Shrinkage and Warpage
7.1: Effects of Temperature on Dimensions
7.2: Effects of Moisture on Dimensions
7.3: Creep
Chapter 8 – Controlling Mold and Post-Mold Shrinkage and Warpage
Overview
8.1: Finding the Cause
8.2: Processing Considerations
8.3: Material Considerations
8.4: Tooling Considerations
8.5: Part Geometry
8.6: Controlling Warpage
Chapter 9 – Computer-Aided Analysis
Overview
9.1: Capabilities of CAA
9.2: Limitations of CAA
9.3: Selecting a CAA Program
9.4: Customer Requirements
9.5: Management Tools
9.6: Filling Analysis
9.7: Packing and Holding Simulation
9.8: Shrinkage/Warpage Simulation
9.9: Cooling Analysis
9.10: Costs
9.11: Conclusions
Chapter 10 – Case Studies
Overview
10.1: Unexpected Housing Shrink
10.2: Changing Materials Triggers Warpage
10.3: Creep in a Water Heater Stand
10.4: Oversize Part Injection-Molding Alkyd Thermoset
10.5: Inadequate Baby Dish Mold
10.6: Gas Entrapment in Baby Dish Mold
10.7: Warpage in a Molded Spool
10.8: Daisy-Wheel Breakage
10.9: PVC Part-Flashing Problems
10.10: Polycarbonate Switch Failure
10.11: Square Poker Chip Tray, Inadequate Shot Size
10.12: Problem Ejecting Square Poker Chips
10.13: Military Cup Material “Shrinkage”
10.14: Core-Deflection Problems
10.15: Elevator Gib Warpage
10.16: Sucker-Rod Guide Brittleness
10.17: Bottle-Cap Thread Distortion
10.18: Plastic Post Creep
10.19: Excessive Shrinkage of Glass-Filled Nylon
10.20: Preventing Warpage in Thin Molded Lids
Chapter 11 – Data
Overview
11.1: Unfilled Materials
11.2: Effects of Fillers
11.3: Shrinkage vs Various Parameters
11.4: Moisture Absorption Curves
11.5: Pressure Volume Temperature (PVT) Curves
11.6: Shrinkage and Warpage of Molded Disks
11.7: Angular Warpage
11.8: General Shrinkage Characteristics for Various Plastics
11.9: Material-Specific Shrinkage Characteristics
Appendix A – Conversion Factors and Equivalents
Appendix B – Abbreviations, Acronyms, and Material Names
B.1: Abbreviations and Acronyms
B.2: Material Names
Glossary
References and Bibliography
References (Cited in Text)
Bibliography
General References
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