Browse Topic: Plastics

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This SAE Recommended Practice is applicable for determining the cold characteristics of flexible plastic materials, as applicable. It consists of three different methods for determining low-temperature properties of materials depending on type of material and end use. The method used shall be as specified by the contractual parties.
Textile and Flexible Plastics Committee
AE-8C2 Terminating Devices and Tooling Committee
A Model Study for Prediction of Performance of Automotive Interior Coatings: Effect of Cross-Link Density and Film Thickness on Resistance to Solvents and Chemicals05-12-02-00073/27/2019
Automotive interior coatings for flexible and rigid substrates represent an important segment within automotive coating space. These coatings are used to protect plastic substrates from mechanical and chemical damage, in addition to providing colour and design aesthetics. These coatings are expected to resist aggressive chemicals, fluids, and stains while maintaining their long-term physical appearance and mechanical integrity. Designing such coatings, therefore, poses significant challenges to the formulators in effectively balancing these properties. Among many factors affecting coating properties, the cross-link density (XLD) and solubility parameter (δ) of coatings are the most predominant factors. In general, the higher the XLD (i.e., more number of cross-links between the polymeric chain per unit volume of coating network), the lower the free volume between polymer chains and the lower the permeability to the diffusion of solvents and chemicals at a given film thickness. Coatings with optimum XLD are desirable as XLD also affects various mechanical properties like flexibility, hardness, and toughness. Coating formulators often use time-consuming trial-and-error studies to determine formulation with optimum XLD. In this study, a range of 2K-polyurethane automotive clear coats with varying XLDs were formulated and applied on widely used automotive plastic substrates at varying dry-film thicknesses (DFT). The XLD of these coatings were determined by equilibrium swelling technique using various solvents and also by dynamic mechanical analysis (DMA). Additionally, these coatings were tested for chemical, physical, and mechanical properties as per standard test protocols. Analysis of the results provided useful insight into the effect of XLD, DFT, and δ on chemical resistance of the coatings. The outcome of this research can be useful for coating formulators, specifiers, and end-users in optimization of formulations, application processes, and trouble shooting.
Mannari, VijayKommineni, Raviteja
CAE Based Head Form Impact Simulations for Development of Vehicle Interiors2019-26-02371/9/2019
The interior components of a passenger vehicle are designed to provide comfort and safety to its occupants. In the event of accident, vehicle interiors are primary source of injuries when occupants interact with them. Vehicle interiors consists of Instrument panel (IP), center console, seats and controls in front of seating position etc. Severity of the injuries depends on the energy dissipating characteristics, profiles, projections of different interior components. These are assessed by ECE R21 and IS12553 head form impact tests. To evaluate the Head form impact performance on Interior components, Computer Aided Engineering (CAE) simulations are extensively used during the vehicle development. In order to predict failure of plastic components and snap joints which might lead to expose sharp edges, it is critical to model plastic material and snap joint. Vehicle interiors are certified for head form impact requirements based on physical testing where dashboard samples from productions tools are used. At this stage of development, if any failure occurs then changes in interior design becomes very expensive and time consuming. To avoid this situation, CAE based failure predictions and injury performance evaluations are done during initial design phase of product development when changes are easily implemented without time and cost penalties. This paper describes the development of vehicle interior using CAE based head form impact simulations and predicting the failures like sharp edges exposure, structural integrity or joint failures. For accurate prediction of these failures in CAE based vehicle interior development, plastic material characterization and snap joint failure characterization are done.
Suryawanshi, YuvrajJoshi, KedarLambate, SachinJadhav, Vilas
This specification covers a cleaner for plastics in the form of a liquid.
AMS J Aircraft Maintenance Chemicals and Materials Committee
ABSTRACT Resin pre-impregnated fiber reinforced plastic components are integral to the advancement of rotorcraft due to their highly customizable configuration, outstanding dynamic properties, and light weight. The complexity of their fabrication introduces numerous manufacturing challenges; chief among these is the internal location of individual plies of material. Industry standard solutions are commensurately complicated and require highly specialized equipment and personnel. In order to mitigate this, the Sikorsky-Boeing SB>1 DEFIANT™ Technology Demonstrator team developed the use of additively manufactured (AM) ply locating templates as a simple, low cost alternative. An AM template eliminates many of the issues associated with industry standard ply location techniques and tools. They are elegantly simple to use while being extremely ergonomic; they are extremely cost effective, and require no capital equipment to support them; and they are flexible and quick to implement.
Dunn, Eric
The Unique Dynamic and Structural Solution of a Finite Element Representation of Full Vehicle Based on the Integrated Implicit/Explicit Approach2018-01-12144/3/2018
This article describes a numerical methodology, based on Finite Element approach, able to simulate, with a unique solution, the dynamic and structural response of a full vehicle running on fatigue reference roads. The current durability process is a multidisciplinary one based on a combination of three different phases: load definition, stress definition, and fatigue life prediction. For Long-Time Histories events, the second phase of this process is necessarily based on a Linear assumption using a Static or Dynamic approach. However, in durability events, some situations can lead the material to work in the plastic range, thus putting on the top the strength aspect of the performances and making these phases not independent and sequential, but strongly interdependent. The goal of the methodology reported in this article is to merge, in a unique numerical simulation, the load and stress definition phases. To this purpose, the solution of a full vehicle model of a commercial van, with a complete Finite Element representation of the body structure, running on fatigue roads, is investigated. This work represents an evolution of current load generation methodology and is able to quantify the impact of Nonlinear effects, such as contact and material plastic behavior, on structural response. A comparison of loads and stresses evaluated with the old approach and the new one is performed.
Duni, EfthimioSignorini, AlbertoPuleo, VincenzoSIAS, AlessandroPiccardi, SimoneMennillo, Serena
The compatibility of key fuel system infrastructure plastics with 39 bio-blendstock fuel candidates was examined using Hansen solubility analysis. Fuel types included multiple alcohols, esters, ethers, ketones, alkenes and one alkane. These compounds were evaluated as neat molecules and as blends with the gasoline surrogate, dodecane, and a mix of dodecane and 10% ethanol (E10D). The plastics included polyphenylene sulfide (PPS), polyethylene terephthalate (PET), polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF), polyoxymethylene (POM), polybutylene terephthalate (PBT), polypropylene (PP), high density polyethylene (HDPE), along with several nylon grades. These materials have been rigorously studied with other fuel types, and their volume change results were found to correspond well with their predicted solubility levels. The compatibility was assessed using Hansen solubility parameters and in many instances peak solubility occurred for blends rather than the neat fuel components. The results showed that good compatibilities can be expected for PPS, PVDF, PET, nylons, acetal, PEI, PVC, HDPE and PBT. PTFE showed potential incompatibilities at low blend concentrations, especially when E10D was used as the base fuel blend. Although, the nylons show good overall compatibility, the results do indicate that mid-range and high alcohol contents may not be suitable for Nylon 6 and Nylon 11 in applications requiring low volume swell. Poor potential compatibility was limited to two plastic types; PETG exposed to mid and high blend levels of the ethers and PP exposed to sabinene and the aromatics. In general, the data showed good compatibility for the majority of the candidate fuels and plastics.
Kass, MichaelWest, Brian H.
EMR with High Reliability for Retrofit of E4100 Riveting Gantry Machines2017-01-20999/19/2017
Electroimpact has retrofitted two E4100 riveting gantry machines and two more are in process. These machines use the EMR (Electromagnetic Riveter) riveting process for the installation of slug rivets. We have improved the skin side EMR to provide fast and reliable results: reliability improved by eliminating a weekly shutdown of the machine. In paper 2015-01-2515 we showed the slug rivet injector using a Synchronized Parallel Gripper that provides good results over multiple rivet diameters. This injector is mounted to the skin side EMR so that the rivet injection can be done at any position of the shuttle table. The EMR is a challenging application for the fingers due to shock and vibration. In previous designs, fingers would occasionally be thrown out of the slots. To provide reliable results we redesigned the fingers retainer to capture the finger in a slotted plastic block which slides along the outside diameter of the driver bearing. The various size fingers are pinned to the block in such a fashion as to allow rotation and clamping on the rivet. The clamping action is provided by opposing wave springs. The design of the fingers and clamping unit are shown in detail. This improvement in the injector (already reported), combined with an improved finger design, has provided unprecedented reliability and rivet rate.
Zieve, Peter B.Gray, TroyWright, Christopher
Two-Component Injection Molding as a Noise Countermeasure for Polycarbonate Glazing2017-01-18176/5/2017
Polycarbonate (PC) glazing as a one-for-one glass replacement offers a 50% weight reduction, but exhibits several dB lower sound transmission loss (STL) in the low frequency range where tire and engine noise are dominant. In the high frequency range where wind noise is dominant, PC glazing offers an STL at least comparable to its glass counterpart, and an STL exceeding glass when this frequency range encompasses the glass coincidence frequency. However, a key value proposition of PC glazing is the opportunity for feature integration afforded by the injection molding process generally used for forming such glazing. Two-component (2K) molding fuses a second shot of plastic material behind, and along the perimeter of, the transparent PC first shot. This second shot can incorporate features and implement functions that require additional components attached or peripheral to a glass version. In effect, a portion of the weight reduction entitlement for PC glazing is transferred to the host vehicle, such that the weight reduction of the glazing itself is less than 50%. Moreover, the second shot tends to stiffen the PC glazing relative to the first shot alone. We show experimentally that these two effects contribute to making the low frequency STL of a 2K PC rear window intermediate between the first shot alone and the comparable glass version. Thus, integration operates as a noise countermeasure for glazing weight reduction. Injection molded PC glazing can also be designed for reduced aerodynamic (high frequency) noise, further improving its noise profile versus glass.
Gasworth, Steven M.Nilajkar, VasudevTerragni, Matteo
Development of GFRTP Crush Box with Consideration of Use Environment and Effect of Fiber Orientation2017-01-04983/28/2017
Regulation of automotive CO2 emissions is becoming increasingly stringent throughout the world in response to global warming. For automakers, this means a focus not only on increasing the fuel economy of powertrains, but also on reducing automotive driving resistance. High expectations are held for thermoplastic fiber-reinforced plastics (FRP) for the realization of automotive weight savings while also offering high levels of productivity and recyclability. Thermoplastic FRP crush boxes display a higher level of energy absorption performance than metal (steel, aluminum, etc.) crush boxes. This will contribute to automotive weight savings and improved package design. In the case of automotive front bumper beam systems, it is necessary to realize stable load characteristics irrespective of the use environment. It is therefore necessary to consider the effects of temperature and thermoplastic resin degradation. The molding process for discontinuous fiber-reinforced FRP produces disordering of the fiber orientation. Research concerning the performance of thermoplastic FRP crush boxes produced findings that assisted in the design of a thermoplastic FRP crush box that would maintain a stable load characteristic in all use environments. It was found that the temperature-dependency of the compression load characteristic of thermoplastic FRP crush boxes in progressive crushing mode in compression tests is low, and that it is necessary to realize an Euler buckling load higher than the progressive crushing load in order to produce a stable crushing mode. This paper discusses a design method for a thermoplastic FRP crush box based on the above-mentioned conditions in order to realize a stable compression load characteristic, with consideration of the use environment and the effect of fiber orientation.
Yabu, TomoyaYasuhara, ShigetoKashiwagi, Masakazu
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