METE 460 ENGINEERING WITH POLYMERS

 

 

TEXTBOOK : Powell & Housz , Engineering With Polymers, 2nd Edt, Stanley Thornes Pubs., 1998

 

REFERENCE BOOKS :

1.       Osswald & Menges, Materials Science of Polymers for Engineers, Hanser, 1995

2.       McCrum, Bucley, Bucknall , Principals of Polymer Engineering, 2nd Edt.,Oxford, 2000

3.       Ward & Hadley, An Introduction to The Mechanical Properties of Solid Polymers, Wiley, 1993

4.     Williams , Fracture Mechanics of Polymers , Ellis Harwood , 1984

 

 

COURSE CONTENT :

 

1.    POLYMER SCIENCE FOR ENGINEERS (Lecture Notes) (1 week)

      Introduction to Polymers, Types of Polymers, Chemical Structure of Polymers, Names of Polymers

 

2.    STRUCTURE OF POLYMERS (Lecture Notes & Ch-2 ) (1.5 week)

      Linear vs Network Structure, Structure of Thermoplastics, Partial Crystallinity Models

      Molecular Mobility, Molecular Orientation, Structure of Thermosets and Rubbers, Parts of Polymer Structure

 

3.    PROPERTIES AND APPLICATIONS OF POLYMERS (Lecture Notes & Ch-3.3) (1 week)

      An Overview of Thermal, Mechanical, Chemical, Electrical and Optical Properties of Polymers

      Applications of Thermoplastics, Thermosets and Rubbers

 

4.    PROCESSING OF POLYMERS (Lecture Notes & Ch-3.3, 4.1, 4.3, 4.4) (1.5 week)

      Preliminary Steps: Polymerization, Additives and Compounding

      Three Main Steps: Mixing, Shaping and Stabilizing

      Continuous Processes: Extrusion, Calendaring,

      Discrete Processes: Injection Moulding, Reaction Injection Moulding, Compression Moulding, Transfer Moulding, Blow Moulding, Thermoforming, Rotational Moulding, Polymer Casting

 

5.    STIFFNESS OF POLYMERS (Ch-5.1 ) (1 week)

      Elastic Modules of Polymers, Effect of Composition on Modulus,

      Long-term Loading, Stress Relaxation and Creep

 

6.    STRENGTH OF POLYMERS (Ch-6.2.1 , 6.2.2) (2 weeks)

      Short-term Strength, Brittle and Ductile Failure, Effects of Loading Rate and Temperature

      Failure Under Long-term Loading, Constant Loading, Cyclic Fatigue Loading

 

7.    FATIGUE AND FRACTURE OF POLYMERS (Lecture Notes & Ch-6.3) (2 weeks)

      Thermal and Mechanical Fatigue, Factors Influencing Fatigue of Polymers

      Energy and Stress Intensity Approach to Fracture, Fracture Toughness

      Time Dependence of Fracture, Crack Growth Under Constant and Cyclic Load

 

8.    DUCTILE BRITTLE TRANSITION IN POLYMERS (Ch-6.2.3 , 6.3.5) (2 weeks)

      Factors Leading to Ductile-Brittle Transition in Polymers:

      Loading, Stress Concentration, Crack Depth, Thickness, Structure, Compounding, Processing, Environmental Factors, Environmental Stress Cracking

 

9.    INTERACTIONS BETWEEN PROCESSING AND PROPERTIES (Ch-9.2 , 9.3) (1 week)

     Thermal Effects: Residual Stresses, Shrinkage, Dimensional Effects, Inhomogeneity, Crystallization

     Flow Effects: Molecular Orientation, Short Fiber Orientation, Weld Lines, Sharkskin, Die Swell

 

10.DESIGNING WITH POLYMERS (Ch-6.2.4 , Ch-10) (1 week)

     Designing to Avoid Failure in Polymers:

     Stress and Environmental Analyses, Selection of Strength Data and Safety Factor, Design Equation

     Product Design with Polymers

 

 

GRADING :

      Attendance           10 %       (50% attendance is compulsory)

      Midterm exam       30 %

      Term-project         20 %

      Final Exam            40 %

 

 

TERM-PROJECT : A special topic on the use of Engineering Polymers will be assigned for 1-2 students

 

 

PROJECT FORMAT

 

1.      INTRODUCTION TO THE SYSTEM OR COMPONENTS

         Working Principles and Functions of the System or Components

         Acting Loads, Stresses and Operating Environments of the System or Components

 

2.      SELECTION OF ENGINEERING POLYMERS

         Types of Engineering Polymers Used (Thermoplastics, Thermosets, Elastomers, etc.)

         Advantages, Disadvantages, Problems and Comparison with Metallic Materials

 

3.      SELECTION OF POLYMER PROCESSING METHODS

         Primary Shaping Processes Used (Extrusion, Injection, Compression, Transfer Molding, etc.)

         Secondary Processes Used (Heat Treating, Surface Treatment, Joining Methods, etc.)

         Advantages, Disadvantages, Problems and Comparison with Metallic Materials

 

4.      FURTHER CONSIDERSTIONS

         Cost, Safety, Ergonomics, Aesthetics, Recycling and Environmental Issues

         Future Applications, Research and Development

 

 

PROJECT TOPICS

 

1. Automotive Parts 2. Automotive Engine Parts

3. Engine Blocks and Brake Disks  4. Tires and Belts

5. Cars 6. Formula 1 Cars

7. Heavy Vehicles 8. Trains and Railways

9. Bicycles and Motorbikes

 

10. Airframe Structures 11. Aero-engine Parts

12. Airplanes13. Sailplanes

14. Helicopters15. Spacecrafts

16. Missiles and Launches 17. Military Applications

 

18. Ships19. Submarines

20. Racing Yachts 21. Off-Shore Industry

 

22. Civil Engineering Applications    23. Pipes and Pressure Vessels

24. Petro-Chemical Industry  25. Electronics and Electrical Applications

26. Prosthesis and Medical Devices   27. Sporting Goods

 

28. Household Appliances 29. Household White wares

30. Furniture and Sanitary Wares  31. Packaging Industry

32. Textile Industry  33. Dye and Adhesive Industry