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Plastics
Rubber
Thermoplastics Elastomers
Fibers
Plastics
Plastics Processing
Plastics Processing
Plastics Processing involves 3 key stages:
1. Heating to liquid state
T > Tm or Tg (amorphous polymers).
2. Forming to required shape under pressure
p up to 108 Pa (1
(1 kbar)
3. Cooling to solidify
Generally quenchedquenched-in nonequilibrium structure
(chain orientation, orientation and fraction of
crystallities, ....)
Polymer processing
THERMOPLASTICS
Extrusion
Injection moulding
Blow Moulding
Rotational Molding
THERMOSET
1.Resin Transfer Moulding
2.Pultrusion
3.SMC / DMC Moulding
4.Compression Moulding
5.GRP Moulding
6.RIM
7.Foam Production
Polymer processing
Extrusion
Polymer processing
Injection Moulding
Common Injection
Moulding
Insert Moulding
Gas Assisted Injection
Moulding
Structural Foam Moulding
Reaction Injection Moulding
Injection Blow Moulding
Polymer processing
Blow Moulding
Injection Blow
Moulding
Extrusion Blow
Moulding
Stretch Blow
Moulding
Polymer processing
Thermo forming
Vacuum Forming
Pressure forming
Thermoforming
Pressure Forming
Vacuum Forming
It involves the automatic draping of a heatheatsoftened plastic sheet over a female or male
mold.
Injection Moulding
Plunger type
The main problem with a straightforward
plunger arrangement was that no melt mixing
or homogenisation could be readily imparted
to the thermoplastic material
Injection Moulding
Reciprocating screw injection moulding unit
Injection Moulding
Injection Moulding Process
1. Screw Plasticating
2. Moulding
Injection Moulding
Material is introduced into the injection
moulding machine via a Hopper
Hopper.. The
injection moulding machine consists of a
heated barrel equipped with a reciprocating
screw (driven by a hydraulic or electric
motor), which feeds the molten polymer
into a temperature controlled split mould
via a channel system of gates and runners
runners..
The screw melts (plasticizes) the polymer,
and also acts as a ram during the injection
phase.. The screw action also provides
phase
additional heating by virtue of the shearing
action on the polymer
polymer..
The polymer is injected into a mould tool
that defines the shape of the molded part
part..
PLASTICATING
Plasticating refers to
conversion of plastic
granuals to flow
flow--able
melt.. It happens inside
melt
the
screw
barrel
assembly
of
the
injection unit in the
Injection
Moulding
Machine..
Machine
PLASTICATING-- How?
PLASTICATING
The plastic granules move inside the screw channel when screw is rotated.
The screw has three sections. FEED ZONE, COMPRESSION ZONE and
METERING ZONE.
Melt is then homogenised in metering zone. At the tip of the screw, nonnonreturn valve is fitted. It allows the melt to flow ahead through this valve
while screw is rotated.
Non return valve does not allow the melt to slip back through it to the
screw channel.
Feed Zone
The Feed zone flights are long and designed to
move the material along the barrel as quickly
as possible. As they move along, the granules
are heated by friction (from the movement of
the screw inside the barrel and from the
movement of the granules themselves) and by
the inside of the barrel against which the
granules are forced by movement of the flight
Compression Zone
In the Compression zone the flights become
shorter and the plastic granules are further
heated and compressed, removing any air
pockets. The plastic is melted by now and
becomes thoroughly mixed or homogenized by
the continuing movement of the screw.
Metering zone
The Metering zone contains the shortest
flights, which are designed to pump the plastic
or melt, through the injection/extrusion die
die..
Screw
INJECTION STROKE
The distance that the screw travels during an
injection stroke, up to 4 * diameter.
INJECTION VOLUME
Theoretically, the injection volume is the
length of the injection stroke multiplied by the
cross sectional area of the screw.
only around 90
90%
% of that Injection Volume gets
injected.
INJECTION SPEED
INJECTION RATE :This is the volume of
melt produced by the screw, expressed in cm3
cm3
per second.
SCREW ROTARY SPEED
CLAMP FORCE
The melt is injected into the mould under very
great pressure, which the mould halves, and any
other components or cores, must be able to resist
in order to maintain their shape and to avoid any
seepage. The larger a component is, the greater
the pressure and so, the greater the Clamp Force
required.
Moulding
Moulding refers to shaping of plastic
melt inside the mould.
Power-tool housing
Telephone handsets
Television Cabinets
Electrical Switches
DVDs
Automotive bumpers
Automotive dash boards
Battery Casings
Syringes
Drug Inhalation Units
Disposable razors
Washing-up bowls
Wheelie binsCrates/
Recycling boxes
Bottle Lids/closures
Insert Moulding
Insert moulding
ABS, PA, PC, GPPS,PP
Structural Foam
Moulding
Automotive Bumper
Dash Panel
EXTRUSION
Introduction
Extrusion: (Greek) push out
Pump supplies a continuous stream of material to a
shaping tool or to some other subsequent shaping
process.
Materials
plastics
metals (Al window frames
spaghetti and other noodles
toothpaste
Extrusion useful for shaping parts with extruder dies
Extrusion is basis for injection molding and blow
molding
Extrusion
Extruder Equipment
Exit zonezone- die
die imparts shape on the material, e.g., rod, tube, sheet, channel
exit material is called extrudate
extrudate swells at end of die due to normal forces from the
polymer flow, called die swell
Cooling zone
water bath or air cooled to lower the temperature below Tg
Auxiliary equipment
puller
rollers for proper thickness
Wind
Wind--up or cut off
Extruder Types
Single screw
Most common
A screw rotates in a cylinder and creates a pumping
action.
Twin Screw
Twin screws have more positive pumping action
than single screws and can be used for higher
output.
Co
Co--Rotating Twin Screw: popular for compounding
Counter
Counter-- rotating Twin Screw Extruders
Extrusion
Principle
Continuously shaping a fluid polymer through an orifice of a suitable
tool (die), and subsequently solidifying into a product.
Equipment
Single screw extruder consists of
Screw, barrel, feed hopper, and die
Plastic Extrusion
Sheet Extrusion
Profile Extrusion
Pipe extrusion
CoCo-extrusion
Blown Film Extrusion
Cast Film Extrusion
Foam Extrusion
Pultrusion
Calendering
1 Drive unit
2 Barrel inlet
3 Temperatue
control
4 Feed hopper
and
dosing
unit
5 Vacuum
venting
6 Barrel
7 Screws
1 Drive unit
EXTRUDER
Extruder
L\D ratioratio5-34
Maximum 20 for elastomers
More than 20 for thermoplastics.
Hopper
Barrel
Screw
Extruder screw
Function
conveying resin through extruder
imparting mechanical energy to melt the polymer
mixing ingredients together
building pressure to push resin through die
Type
Single screw
Twin
Twin--screw
Length/diameter (L/D) ratio: Length of flighted portion of the
Sheet Extrusion
Sheet extrusion is a technique for making
flat plastic sheets from a variety of resins
Sheet Extrusion
Applications
Within the building and construction industries, sheet
extrusion is used for a variety of applications. One of the
main uses of extruded PS sheet is for thermal insulation
materials for walls, roofs, and under floors.
In the automotive industry, sheet is currently used to
produce interior trim, panels, and dashboards.
Foamed polyolefin sheet, both crosscross-linked and nonnoncross--linked, is also used in automotive applications.
cross
There are a number of other applications where
thermoformed sheet plays a significant role. These
include the manufacturing of luggage, refrigerator liners,
and shower units.
Profile/Pipe Extrusion
This process is used to manufacture plastic products with a
continuous crosscross-section such as; drinking straws, plastic Pipes and
profiles.
Blow Moulding
After a cooling period the mould is opened and the final article
is ejected.To speed production several identical moulds may
be fed in cycle by the same extruder unit.
Applications
Rotational Moulding
Rotational moulding is a process
used for producing hollow plastic
products.
Rotational moulding differs from
other processing methods in that the
heating, melting, shaping, and
cooling stages all occur after the
polymer is placed in the mould,
therefore no external pressure is
applied during forming.
Rotational Moulding
This provides the following
advantages:
Economically produced large
products
Minimum design constraints
StressStress-free products
No polymer weld lines
Comparatively low mould costs
Charging Mould
A prepre-determined amount of polymer powder is placed in
the mould. With the powder loaded, the mould is closed, locked and
loaded into the oven. The powder can be prepre-compounded to the desired
colour..
colour
Heating & Fusion
Once inside the oven, the mould is rotated around two axis, tumbling the
powder the process is not a centrifugal one. The speed of rotation is
relatively slow, less than 20 rev/min. The ovens are heated by convection,
conduction and, in some cases, radiation. As the mould becomes hotter
the powder begins to melt and stick to the inner walls of the mould. As the
powder melts, it gradually builds up an even coating over the entire
surface.
Cooling
When the melt has been consolidated to the desired level, the mould is
cooled either by air, water or a combination of both. The polymer solidifies
to the desired shape.
Unloading/Demoulding
Unloading/
Demoulding
When the polymer has cooled sufficiently to retain its shape and be easily
handled, the mould is opened and the product removed. At this point
powder can once again be placed in the mould and the cycle repeated.