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Polymers
Special Issues
Processing of Polymeric Materials
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Processing of Polymeric Materials

A special issue of Polymers (ISSN 2073-4360). This special issue belongs to the section "Polymer Processing and Engineering".

Deadline for manuscript submissions: closed (25 October 2023) | Viewed by 9070

Special Issue Editor

Dr. Ammar Elsheikh

E-Mail Website
Guest Editor
Production Engineering and Mechanical Design Department, Faculty of Engineering, Tanta University, Tanta 31733, Egypt
Interests: artificial intelligence; energy; desalination; composite materials; welding; machining; friction stir welding; MQL; heat exchangers; nanofluids

Special Issue Information

Dear Colleagues,

Polymeric materials, including polymers and polymer composites, are broadly used in numerous engineering applications such as aerospace, automotive, biomedical, electronics, food packaging and renewable energy. They have remarkable thermal, mechanical, and electrical properties. There are many primary processing techniques of polymeric materials, such as extrusion, thermoforming, blow molding, injection molding, spray-layup, hand-layup, transfer molding, and compression molding. Primary processing techniques produce near-neat shape polymeric products. Therefore, secondary processing techniques such as machining and joining become essential to obtain precise products. This Special Issue aims to shed some light on recent advances, opportunities, and challenges in primary and secondary processing techniques of polymeric materials. Contributions may focus on novel aspects of both processing techniques, modeling of manufacturing processes, and optimization of manufacturing processes using advanced artificial intelligence tools. 

Dr. Ammar Elsheikh
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Polymers is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2700 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • polymeric materials
  • composites
  • primary and secondary processing techniques
  • machining
  • joining

Published Papers (5 papers)

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Research

16 pages, 19767 KiB  
Article
Rotary Friction Welding of Polyetheretherketone Biopolymer Rods Using Variable Rotational Speed
by Chil-Chyuan Kuo, Hua-Xhin Liang, Song-Hua Huang and Shih-Feng Tseng
Polymers 2023, 15(20), 4077; https://doi.org/10.3390/polym15204077 - 13 Oct 2023
Cited by 1 | Viewed by 814
Abstract
Polyetheretherketone (PEEK) is a promising biomaterial due to its excellent mechanical properties. Most PPEK manufacturing methods include additive manufacturing, injection molding, grinding, pulse laser drilling, or incremental sheet forming. Rotary friction welding (RFW) is a promising bonding technique in many industries. However, very [...] Read more.
Polyetheretherketone (PEEK) is a promising biomaterial due to its excellent mechanical properties. Most PPEK manufacturing methods include additive manufacturing, injection molding, grinding, pulse laser drilling, or incremental sheet forming. Rotary friction welding (RFW) is a promising bonding technique in many industries. However, very few studies have focused on the RFW of PEEK. Conventionally, the number of revolutions is fixed during the welding process. Remarkably, the rotary friction welding of PEEK polymer rods using an innovative variable rotational speed is investigated in this study. The average bending strength of the welded part using a three-stage transformation rotational speed was enhanced by about 140% compared with a rotational speed of 1000 rpm. The advantage of computer numerical controlled RFW of PEEK using variable rotational speed is a reduced cycle time of RFW. A reduction in cycle time of about 6% can be obtained using the proposed RFW with a three-stage transformation rotational speed. The innovative approach provides low environmental pollution and high energy efficiency and complies with sustainable development goals. Full article
(This article belongs to the Special Issue Processing of Polymeric Materials)
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15 pages, 5631 KiB  
Communication
Study of the Single-Screw Extrusion Process Using Polylactide
by Mariusz Fabijański
Polymers 2023, 15(19), 3878; https://doi.org/10.3390/polym15193878 - 25 Sep 2023
Viewed by 1351
Abstract
This study presents the extrusion process while using a single-screw extruder and polylactide (PLA). This material belongs to the so-called biodegradable plastics, and is characterized by a higher density compared to typical polymeric materials used to manufacture products in this technology. Various polyethylenes [...] Read more.
This study presents the extrusion process while using a single-screw extruder and polylactide (PLA). This material belongs to the so-called biodegradable plastics, and is characterized by a higher density compared to typical polymeric materials used to manufacture products in this technology. Various polyethylenes and polypropylenes and their derivatives are commonly used. An evaluation of the extrusion process was carried out for various extruder operating parameters. The rotational speed of the screw and the process temperature were changed. For each rotational speed of the screw, the following readings were made: changes in temperature, active power, current intensity, pressure, and mass of extruded plastics each time. Full article
(This article belongs to the Special Issue Processing of Polymeric Materials)
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12 pages, 5051 KiB  
Article
Experimentation and Numerical Modeling of Peak Temperature in the Weld Joint during Rotary Friction Welding of Dissimilar Plastic Rods
by Chil-Chyuan Kuo, Naruboyana Gurumurthy, Hong-Wei Chen and Song-Hua Hunag
Polymers 2023, 15(9), 2124; https://doi.org/10.3390/polym15092124 - 29 Apr 2023
Cited by 9 | Viewed by 1352
Abstract
Rotary friction welding (RFW) could result in lower welding temperature, energy consumption, or environmental effects as compared with fusion welding processes. RFW is a green manufacturing technology with little environmental pollution in the field of joining methods. Thus, RFW is widely employed to [...] Read more.
Rotary friction welding (RFW) could result in lower welding temperature, energy consumption, or environmental effects as compared with fusion welding processes. RFW is a green manufacturing technology with little environmental pollution in the field of joining methods. Thus, RFW is widely employed to manufacture green products. In general, the welding quality of welded parts, such as tensile strength, bending strength, and surface hardness is affected by the peak temperature in the weld joint during the RFW of dissimilar plastic rods. However, hitherto little is known about the domain knowledge of RFW of acrylonitrile butadiene styrene (ABS) and polycarbonate (PC) polymer rods. To prevent random efforts and energy consumption, a green method to predict the peak temperature in the weld joint of dissimilar RFW of ABS and PC rods was proposed. The main objective of this work is to investigate the peak temperature in the weld joint during the RFW using COMSOL multiphysics software for establishing an empirical technical database of RFW of dissimilar polymer rods under different rotational speeds. The main findings include that the peak temperature affecting the mechanical properties of RFW of PC and ABS can be determined by the simulation model proposed in this work. The average error of predicting the peak temperature using COMSOL software for five different rotational speeds is about 15 °C. The mesh element count of 875,688 is the optimal number of meshes for predicting peak temperature in the weld joint. The bending strength of the welded part (y) using peak welding temperature (x) can be predicted by the equation of y = −0.019 x2 + 5.081x − 200.75 with a correlation coefficient of 0.8857. The average shore A surface hardness, impact energy, and bending strength of the welded parts were found to be increased with increasing the rotational speed of RFW. Full article
(This article belongs to the Special Issue Processing of Polymeric Materials)
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16 pages, 2899 KiB  
Article
Predicting Characteristics of Dissimilar Laser Welded Polymeric Joints Using a Multi-Layer Perceptrons Model Coupled with Archimedes Optimizer
by Essam B. Moustafa and Ammar Elsheikh
Polymers 2023, 15(1), 233; https://doi.org/10.3390/polym15010233 - 02 Jan 2023
Cited by 69 | Viewed by 3063
Abstract
This study investigates the application of a coupled multi-layer perceptrons (MLP) model with Archimedes optimizer (AO) to predict characteristics of dissimilar lap joints made of polymethyl methacrylate (PMMA) and polycarbonate (PC). The joints were welded using the laser transmission welding (LTW) technique equipped [...] Read more.
This study investigates the application of a coupled multi-layer perceptrons (MLP) model with Archimedes optimizer (AO) to predict characteristics of dissimilar lap joints made of polymethyl methacrylate (PMMA) and polycarbonate (PC). The joints were welded using the laser transmission welding (LTW) technique equipped with a beam wobbling feature. The inputs of the models were laser power, welding speed, pulse frequency, wobble frequency, and wobble width; whereas, the outputs were seam width and shear strength of the joint. The Archimedes optimizer was employed to obtain the optimal internal parameters of the multi-layer perceptrons. In addition to the Archimedes optimizer, the conventional gradient descent technique, as well as the particle swarm optimizer (PSO), was employed as internal optimizers of the multi-layer perceptrons model. The prediction accuracy of the three models was compared using different error measures. The AO-MLP outperformed the other two models. The computed root mean square errors of the MLP, PSO-MLP, and AO-MLP models are (39.798, 19.909, and 2.283) and (0.153, 0.084, and 0.0321) for shear strength and seam width, respectively. Full article
(This article belongs to the Special Issue Processing of Polymeric Materials)
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17 pages, 10934 KiB  
Article
The Effects of Pin Profile on HDPE Thermomechanical Phenomena during FSW
by Hassanein I. Khalaf, Raheem Al-Sabur, Murat Demiral, Jacek Tomków, Jerzy Łabanowski, Mahmoud E. Abdullah and Hamed Aghajani Derazkola
Polymers 2022, 14(21), 4632; https://doi.org/10.3390/polym14214632 - 31 Oct 2022
Cited by 16 | Viewed by 1661
Abstract
Friction stir welding (FSW) of polymeric materials has recently attracted significant attention. Herein, we present the effect of the tool pin profile on the FSW of high-density polyethylene (HDPE) joints through joint experimental analysis and thermomechanical simulations. For analysis of pin profile effects [...] Read more.
Friction stir welding (FSW) of polymeric materials has recently attracted significant attention. Herein, we present the effect of the tool pin profile on the FSW of high-density polyethylene (HDPE) joints through joint experimental analysis and thermomechanical simulations. For analysis of pin profile effects on the thermomechanical properties of HDPE joints, frustum (FPT), cubic (CPT), and triangular (TPT) pin shapes were selected in this study. This research investigated the heat generation of the parts of the different tools as well as heat flux (internal and surface). The results revealed that the heat generation in pins with more edges (cubic (96 °C) and triangular (94 °C)) was greater than in pins with a smooth shape (frustum (91 °C)). The higher heat generation caused the heat flux on the surface of the HDPE from the cubic pin profile to be greater than for other joints. Due to the properties of HDPE, higher heat generation caused higher material velocity in the stirring zone, where the velocity of the materials in TPT, CPT, and FPT pins were 0.41 m/s, 0.42 m/s, and 0.4 m/s, respectively. The simulation results show sharp-edged pins, such as triangular and cubic, lead to over-stirring action and internal voids formed along the joint line. Furthermore, the simulation results indicated that the size of the stirred zones (SZs) of the FPT, TPT, and CPT samples were 17 mm2, 19 mm2, and 21 mm2, respectively, which is around three times the corresponding values in the HAZ. Full article
(This article belongs to the Special Issue Processing of Polymeric Materials)
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