MANUFACTURING

PROCESSES -II
2141908

L.D. COLLEGE OF ENGINEERING

DEPARTMENT OF
MECHANICAL ENGINEERING
Guided By:
Pro. SWATI PATEL
 Plastic, Ceramic and Glass
Processing
MECH. DIV-A SEM-4

1) PADHARIYA MEHUL K. -150280119063

2) PANCHAL ANAND J. -150280119064
3) PANCHAL DARSHAN H. -150280119065
4) PANCHAL PARTH D. -150280119066
5) PANDEY PRATHAM -150280119067
Plastics
processing
Plastics History
Plastic types: Thermosets

General properties: more durable, harder, tough, light.

Typical uses: automobile parts, construction materials.

Examples:

Unsaturated Polyesters: lacquers, varnishes, boat hulls, furniture

Epoxies and Resins: glues, coating of electrical circuits,

composites: fiberglass in helicopter blades, boats, …
Plastic types: Elastomers

General properties: these are thermosets, and have rubber-like properties.

Typical uses: medical masks, gloves, rubber-substitutes

Examples:

Polyurethanes: mattress, cushion, insulation, toys

Silicones: surgical gloves, oxygen masks in medical applications

joint seals
 Plastic types: Thermoplastics

General properties: low melting point, softer, flexible.

Typical uses: bottles, food wrappers, toys, …

Examples:

Polyethylene: packaging, electrical insulation, milk and water bottles, packaging film
Polypropylene: carpet fibers, automotive bumpers, microwave containers, prosthetics
Polyvinyl chloride (PVC): electrical cables cover, credit cards, car instrument panels
Polystyrene: disposable spoons, forks, Styrofoam™
Acrylics (PMMA: polymethyl methacrylate): paints, fake fur, plexiglass
Polyamide (nylon): textiles and fabrics, gears, bushing and washers, bearings
PET (polyethylene terephthalate): bottles for acidic foods like juices, food trays
PTFE (polytetrafluoroethylene): non-stick coating, Gore-Tex™ (raincoats), dental floss
Plastics Processing: Extrusion
Plastics Processing: Blow molding
(a) The hollow piece of heated glass (parison)
is first created by a blow mold
(see text-book Fig 17.25)

3-piece mold

heated glass

(b) The mold is put together

(c) Plunger and hot air push the

glass up

- similar to glass blow-molding -

(d) Hot air blows the glass out towards

the mold surface

(e) Mold comes apart, bottle is removed

Plastics Processing: Thermoforming

Sheet of plastic  Heated (soft)  Molded using a shaped die

Vacuum thermoforming
Plastics Processing: Compression and Transfer Molding

• used mostly for thermosetting polymers

• mold is heated and closed using pressure
• plastic flows to fills the cavity
• flash must be trimmed by finishing

dishes, handles for cooking pots

skis, housing for high-voltage switches
some rubber parts like shoe soles
and even composites such as fiber-reinforced parts
 Plastics Processing: Compression and Transfer Molding

compression molding

transfer molding

(more complex shapes)

Plastics Processing: Injection Molding

- Probably the most common, most important, most economical process

Plastics Processing: Injection Molding

Cycle of operation for injection molding

Injection Molding: geometry of the mold

Basic components:

mold pieces (define the geometry of the part), AND

sprue, gates, runners, vents, ejection pins, cooling system

Injection Molding: designing injection molds

1. molding directions  number of inserts/cams required, if any

2. parting lines
3. parting planes  by extending the parting line outwards
4. gating design  where to locate the gate(s) ?
5. multiple cavity mold  fix relative positions of the multiple parts
6. runners: flow of plastic into the cavity
7. sprue located:
8. functional parts of the mold
- ejection system: to eject the molded part
- systems to eject the solidified runners
- alignment rods: to keep all mold components aligned
 Injection Molding: designing injection molds

cup
1. molding directions  number of inserts/cams required, if any
2. parting lines
3. parting planes  by extending the parting line outwards
4. gating design  where to locate the gate(s) ?
5. multiple cavity mold  fix relative positions of the multiple parts parting line

6. runners: flow of plastic into the cavity

7. sprue located:
gate
8. functional parts of the mold
- ejection system: to eject the molded part parting plane

- systems to eject the solidified runners

- alignment rods: to keep all mold components aligned

nozzle knob

cavity cavity runner

cavity cavity
part ejection
plate

core core core core

(a) (b) (c) (d)
Designing injection molds: mold in action

Nozzle

Nozzle Knob

Runner

Runner
Cavity
Cavity Cavity
Part

Part Part
Stripper
plate
Ceramics
 Taxonomy of Ceramics
Glasses Clay Refractories Abrasives Cements Advanced
products ceramics
-optical -whiteware -bricks for -sandpaper -composites engine
-composite -bricks high T -cutting -structural -rotors
reinforce (furnaces) -polishing -valves
-containers/ -bearings
household
-sensors
• Properties:
-- Tm for glass is moderate, but large for other ceramics.
-- Small toughness, ductility; large moduli & creep resist.
• Applications:
-- High T, wear resistant, novel uses from charge neutrality.
• Fabrication
-- some glasses can be easily formed
-- other ceramics can not be formed or cast.
Shaping of Ceramics
1- First, the raw materials must be ground or crushed down into fine
particles.

2- Next, the particles must be mixed with additives, which include:

binder- to hold particles together
lubricant- to reduce friction and aid in removing from mold
wetting agent- to improve mixing process (commonly water)
plasticizer- to improve ease of forming mixture
agents- control of foaming and sintering
deflocculent- to create uniform mixture by applying like
charges to all particles, causing them to repel
each other

3- Finally, the material must be shaped, dried, and fired.

 Crushing

Crushing is typically done in a ball mill, in either wet or dry conditions.

Wet milling is preferred because it strengthens particle bonds and
limits dust.
For correct sizing, the crushed particles are passed through a
sieve.

• Mixing

Particles are then mixed with one of the additives listed and described on the
previous slide.
 Casting
Slip Casting (Drain Casting)-The crushed particles are first mixed with
water, then are poured into a mold.
Pouring must be done properly to avoid air
pockets.
When some of the water has been absorbed, the
remainder of the mixture is poured out of
the top of the mold.
The top of the part can then be trimmed.
Advantages- inexpensive components
Disadvantages- limited control of dimensions & low production rate

Doctor-Blade Process- Used to produce ceramic sheets thinner than 1.5mm.

Ceramic mixture is forced under a blade to create a film, which is then dried in a
drying chamber (usually attached to the same machine).
Forming and Shaping of Glass
Flat Sheet and Plate Glass
Float Method- Molten glass is floated over
a “bath” of molten tin before it is solidified
in a separate chamber.
No additional finishing is necessary.
Drawing Process- Molten glass is
squeezed through two rolls, then
moves on o two smaller rolls.
Rolling Process- Similar to drawing
process, but patterns are commonly
imprinted from the rolls onto the glass,
leaving a rough finish.

Molten Glass
 Glass Tubing and Rods
Tubing- Molten glass is wrapped around a mandrel and taken out by two rolls.
Air is blown through the mandrel to prevent the tube from collapsing
into itself.
Some machines manufacture 2000 fluorescent light bulbs per minute
using this method.

Rods- Rods are made in exactly the same way,

but without the air blown through
the mandrel.
This allows the glass to collapse and
become solid.
 Discrete glass products

Processes used to make discrete glass objects

• Blowing
• Pressing
• Centrifugal casting
• Sagging
Blowing

• Blowing process: Blown air

expands a hollow gob of
heated glass against the inner
walls of a mold.
• A parting agent (such as oil
or emulsion) is usually used
to prevent the glass from
sticking to the mold.
 Blowing
• Applications:
Hollow and thin-
walled glass items
(bottles, vases, and
flasks)
• Surface finish:
Acceptable for
most applications
 Pressing
• Pressing process: A gob of molten glass is placed
into a mold and pressed by a plunger into a
confined shape.
• Molds may be one piece or split. Solidifying glass
acquires the shape of the mold-plunger cavity.
• Similar to closed-die forging.
 Pressing
• One-piece molds cannot be used in pressing if the plunger
cannot be retracted.
• One-piece molds cannot be used for thin-walled items
• Split molds can accommodate thin-walled products
 Pressing
• Pressing can produce higher dimensional
accuracy than blowing.

Press and blow process

• After a part is pressed, it is blown to further
expand the glass into the mold.
Centrifugal Casting (Spinning)

• Centrifugal casting
process: The centrifugal
force pushes the molten
glass against the wall.
• TV picture tubes and
missile nose cones can be
made with centrifugal
casting.
 Sagging
• Sagging process: A sheet of glass is placed over a mold
and heated. The glass sags by its own weight and takes
the shape of the mold.
• Typical applications include dishes, sunglass lenses,
mirrors for telescopes, and lighting panels.