CHAPTER 7

Polymers: Structure, General Properties

and Applications

Kalpakjian Schmid
Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 7-1

Range of Mechanical Properties for Various

Engineering Plastics
TABLE 7.1
Material
ABS
ABS, reinforced
Acetal
Acetal, reinforced
Acrylic
Cellulosic
Epoxy
Epoxy, reinforced
Fluorocarbon
Nylon
Nylon, reinforced
Phenolic
Polycarbonate
Polycarbonate, reinforced
Polyester
Polyester, reinforced
Polyethylene
Polypropylene
Polypropylene, reinforced
Polystyrene
Polyvinyl chloride
Kalpakjian Schmid
Manufacturing Engineering and Technology

UTS (MPa)
2855
100
5570
135
4075
1048
35140
701400
748
5583
70210
2870
5570
110
55
110160
740
2035
40100
1483
755

E (GPa)
1.42.8
7.5
1.43.5
10
1.43.5
0.41.4
3.517
2152
0.72
1.42.8
210
2.821
2.53
6
2
8.312
0.11.4
0.71.2
3.56
1.44
0.0144

2001 Prentice-Hall

Elongation
(%)
755

7525

505
1005
101
42
300100
20060
101
20
12510
64
3005
31
100015
50010
42
601
45040

Poissons
ratio ()

0.35

0.350.40

0.460.48
0.320.40

0.38

0.38

0.46

0.35

Page 7-2

Chapter 7 Outline

Figure 7.1 Outline of the topics described in Chapter 7

Kalpakjian Schmid
Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 7-3

Structure of
Polymer
Molecules

Figure 7.2 Basic structure of polymer molecules: (a) ethylene molecule; (b)
polyethylene, a linear chain of many ethylene molecules; molecular structure
of various polymers. These are examples of the basic building blocks for
plastics
Kalpakjian Schmid
Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 7-4

Molecular Weight and Degree of Polymerization

Figure 7.3 Effect of molecular weight
and degree of polymerization on the
strength and viscosity of polymers.

Kalpakjian Schmid
Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 7-5

Polymer Chains
Figure 7.4 Schematic
illustration of polymer chains.
(a) Linear structure-thermoplastics such as
acrylics, nylons, polyethylene,
and polyvinyl chloride have
linear structures. (b) Branched
structure, such as in
polyethylene. (c) Cross-linked
structure--many rubbers or
elastomers have this structure,
and the vulcanization of rubber
produces this structure. (d)
Network structure, which is
basically highly cross-linked-examples are thermosetting
plastics, such as epoxies and
phenolics.

Kalpakjian Schmid
Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 7-6

Polymer Behavior
Figure 7.5 Behavior of polymers as a function of temperature and (a) degree of crystallinity and (b)
cross-linking. The combined elastic and viscous behavior of polymers is known as viscoelasticity.

Kalpakjian Schmid
Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 7-7

Crystallinity
Figure 7.6 Amorphous
and crystalline regions in
a polymer. The crystalline
region (crystallite) has an
orderly arrangement of
molecules. The higher the
crystallinity, the harder,
stiffer, and less ductile the
polymer.

Kalpakjian Schmid
Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 7-8

Specific Volume as a Function of Temperature

Figure 7.7 Specific volume of polymers
as a function of temperature. Amorphous
polymers, such as acrylic and
polycarbonate, have a glass-transition
temperature, Tg, but do not have a specific
melting point, Tm. Partly crystalline
polymers, such as polyethylene and
nylons, contract sharply while passing
through their melting temperatures during
cooling.

Kalpakjian Schmid
Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 7-9

Glass-Transition and Melting Temperatures of

Some Polymers
TABLE 7.2
Material
Nylon 6,6
Polycarbonate
Polyester
Polyethylene
High density
Low density
Polymethylmethacrylate
Polypropylene
Polystyrene
Polytetrafluoroethylene
Polyvinyl chloride
Rubber

Kalpakjian Schmid
Manufacturing Engineering and Technology

Tg (C)
57
150
73

Tm (C)
265
265
265

90
110
105
14
100
90
87
73

137
115

176
239
327
212

2001 Prentice-Hall

Page 7-10

Behavior of Plastics

Figure 7.8 General terminology describing

the behavior of three types of plastics. PTFE
(polytetrafluoroethylene) has Teflon as its
trade name. Source: R. L. E. Brown.

Kalpakjian Schmid
Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 7-11

Temperature Effects

Figure 7.9 Effect of temperature on the stress-strain

curve for cellulose acetate, a thermoplastic. Note the
large drop in strength and the large increase in
ductility with a relatively small increase in
temperature. Source: After T. S. Carswell and H. K.
Nason.

Kalpakjian Schmid
Manufacturing Engineering and Technology

Figure 7.10 Effect of temperature on the impact

strength of various plastics. Small changes in
temperature can have a significant effect on impact
strength. Source: P. C. Powell.
2001 Prentice-Hall

Page 7-12

Elongation
(a)

Kalpakjian Schmid
Manufacturing Engineering and Technology

(b)

2001 Prentice-Hall

Figure 7.11 (a) Loadelongation curve for

polycarbonate, a
thermoplastic. Source: R. P.
Kambour and R. E.
Robertson. (b) High-density
polyethylene tensile-test
specimen, showing uniform
elongation (the long, narrow
region in the specimen).

Page 7-13

General Recommendations for Plastic Products

TABLE 7.3
Design requirement
Mechanical strength
Functional and decorative

Applications
Gears, cams, rollers, valves, fan
blades, impellers, pistons
Handles, knobs, camera and
battery cases, trim moldings, pipe
fittings

Housings and hollow shapes

Power tools, pumps, housings,

sport helmets, telephone cases

Functional and transparent

Lenses, goggles, safety glazing,

signs, food-processing
equipment, laboratory hardware
Gears, wear strips and liners,
bearings, bushings, roller-skate
wheels

Wear resistance

Kalpakjian Schmid
Manufacturing Engineering and Technology

2001 Prentice-Hall

Plastics
Acetal, nylon, phenolic,
polycarbonate
ABS, acrylic, cellulosic,
phenolic, polyethylene,
polypropylene, polystyrene,
polyvinyl chloride
ABS, cellulosic, phenolic,
polycarbonate, polyethylene,
polypropylene, polystyrene
Acrylic, polycarbonate,
polystyrene, polysulfone
Acetal, nylon, phenolic,
polyimide, polyurethane,
ultrahigh molecular weight
polyethylene

Page 7-14

Load-Elongation Curve for Rubber

Figure 7.12 Typical load-elongation

curve for rubbers. The clockwise lop,
indicating the loading and the
unloading paths, displays the hysteresis
loss. Hysteresis gives rubbers the
capacity to dissipate energy, damp
vibraion, and absorb shock loading, as
is necessary in automobile tires and in
vibration dampers placed under
machinery.

Kalpakjian Schmid
Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 7-15