Proses Pembentukan Plastik

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Plastik:
Berasal dari kata Yunani (Greek) plastikos yg
berarti “mudah untuk dicetak dan dibentuk”.

Plastik juga disebut polymer.

Polymer merupakan makro-molekul yg

terdiri dari banyak monomer yang terikat
menjadi suatu rantai molekul yang panjang
melalui proses polimerisasi.

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

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 Proses Pembentukan Plastik
• Proses pembentukan plastik
hampir mirip dgn proses
pembentukan logam (casting,
molded, extruded, joined).
• Plastik lebih mudah dibentuk
bila dibandingkan dengan
logam.
• Plastik bisa dicairkan dalam
temperatur yg jauh lbh rendah
dp logam.
• Penanganan proses lebih mudah
dan memerlukan lbh sedikit
energi.

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 Bahan baku pembentukan
plastik

• Pellet/granules: bahan
plastik ini berbentuk
butiran-butiran.
• Serbuk (powder): bahan
berbentuk serbuk. Pellet/granules
• Pewarna plastik: memberi
warna sesuai dgn yg
diinginkan.
Pewarna Plastik

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 Beberapa jenis plastik:
1. Poly Propylene (PP)
• Polypropylene (PP) is a
thermoplastic polymer, used
in a wide variety of
applications, including
packaging, textile, stationery,
plastic parts, food containers,
woven bags, laboratory
equipment, automotive
components and many more.
Polypropylene is commonly
recycled product

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 Beberapa jenis plastik:
2. Poly Ethylene (PE)
• HDPE (high density PE): is resistant to
many different solvents and has a wide
variety of applications, including:
Containers, Fuel Tanks for vehicles,
Folding tables and chairs, Storage sheds,
Plastic bags, Water supply pipes, bottles -
suitable for use as refillable bottles etc. and
many more.

• LDPE (low density): is widely used for

manufacturing various containers,
dispensing bottles, wash bottles, tubing,
plastic bags for computer components and
various molded laboratory equipment. Its
most common use is in plastic bags.

• PE is thermoplastic polymers.
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 Beberapa jenis plastik:
3. Poly Vinyl Chloride (PVC)
• Poly Vinyl Chloride (PVC): is
the third most widely used
thermoplastic polymer after
polyethylene and
polypropylene. It is used in
clothing and upholstery and
tubing, flooring and electrical
cable insulation. It is also
commonly used in pool toys,
sewerage pipes, Electric wires,
Pipes, Signs boards (sheets),
PVC Ceiling Tiles etc. and many
more.

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 Beberapa jenis plastik:
4. Epoxies, Phenolics, Silicones.
• Epoxies, Phenolics, Silicones adalah jenis
polymer yang masuk kategori
thermosetting plastics.
• Rantai polymer nya jenis cross-linked
structure.
• Memiliki sifat kekerasan, kekuatan,
kekakuan dan dimensional stability yg
lebih baik.
• Memiliki sifat getas (brittle).

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 Polymer Chains

Figure 7.5 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.
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 Amorphous and Crystalline Regions in a Polymer

Effects of Crystallinity:

Polymer become stiffer,

harder, less ductile, more
rubbery, more resistant
to solvents and heat

Figure 7.8 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. 11
 Proses Ekstrusi Plastik
• Bahan baku bisa berbentuk pellet, granules
maupun serbuk.
• Screw mencampur material, menekannya
sepanjang barrel.
• Campuran material akan dipanaskan dan
dicairkan saat melewati barrel (mulai melting
zone).
• Fungsi screw: (1) feeding, (2) melt or
transition, (3) pumping.

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 Extruder Schematic

Figure 19.2 (a) Schematic illustration of a typical screw extruder. (b) Geometry of an
extruder screw. Complex shapes can be extruded with relatively simple and inexpensive dies.
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 Production of Plastic Film and Bags

(b)

Figure 19.5 (a) Schematic illustration of the production of thin film and plastic bags from
tube – first produced by an extruder and then blown by air. (b) A blown-film operation. This
process is well developed, producing inexpensive and very large quantities of plastic film and
shopping bags. Source: Courtesy of Windmoeller & Hoelscher.

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 Melt-Spinning
Process
Figure 19.6 The melt-spinning process
for producing polymer fibers. The fibers
are then used in a variety of
applications, including fabrics and as
reinforcements for composite materials.

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 Injection Molding
• Proses injection molding u/ plastik,
prinsipnya sama dgn hot-chamber die casting
u/ logam.
• Bahan baku berupa pellet atau granulle.
• Tekanan yg diperlukan u/ injection molding
berkisar 70 MPa – 200 MPa (10.000 – 30.000
psi)
• Skema proses bisa dilihat di Fig. 19.7

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 Injection
Molding
Figure 19.7 Schematic
illustration of injection molding
with (a) plunger and (b)
reciprocating rotating screw.

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 Injection Molding Sequence

Figure 19.8 Sequence of operations in the injection molding of a part with a reciprocating
screw. This process is used widely for numerous consumer and commericial products,
such as toys, containers, knobs, and electrical equipment (see Fig. 19.9). 18
 Products Made by Injection Molding

(a) (b)

Figure 19.9 Typical products made by injection molding, including examples of insert
molding. Source: (a) Courtesy of Plainfield Molding, Inc. (b) Courtesy of Rayco Mold and
Mfg. LLC.

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Mold Features for Injection Molding

Figure 19.10 Illustration of mold features for injection molding. (a) Two-plate
mold with important features identified. (b) Four parts showing details and the
volume of material involved. Source: Courtesy of Tooling Molds West. Inc.
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 Types of Molds used in Injection Molding

Figure 19.11 Types of molds used in injection molding: (a) two-plate mold; (b) three-plate
mold; and (c) hot-runner mold.
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 Injection-Molding Machine

Figure 19.14 A 2.2-MN (250-ton) injection molding machine. The tonnage is the
force applied to keep the dies closed during the injection of molten plastic into the
mold cavities and hold it there until the parts are cool and stiff enough to be removed
from the die. Source: Courtesy of Cincinnati Milacron, Plastics Machinery Division.
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 Reaction-Injection Molding Process
• Disebut RIM karena dlm prosesnya resin (bhn
plastik) dicampur dan direaksikan dgn dua
atau lebih ‘reactive fluid’, sehingga terjadi
reaksi kimia secara cepat di dalam cetakan.
• Hasilnya berupa thermoset part.
• Aplikasi proses: pembuatan fender & bumper
u/ otomotif, insulator termal u/ kulkas &
freezers, water skis, stiffeners.
• Skema ada di Fig 19.15 berikut.
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 Reaction-Injection Molding Process

Figure 19.15 Schematic illustration of the reaction-injection molding

process. Typical parts made are automotive-body panels, water skis,
and thermal insulation for refrigerators and freezers.
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 Blow-Molding
Figure 19.16 Schematic illustrations of
(a) the extrusion blow-molding process
for making plastic beverage bottles; (b)
the injection blow-molding process;
and (c) a three-station injection
molding machine for making plastic
bottles.

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 Rotational Molding Process
• Umumnya digunakan u/ produk axy-simetric
besar (misalnya tangki air/tandon air, bucket,
dll).
• Bahan baku berupa serbuk plastik (powder), yg
volume/jumlahnya disesuaikan dgn volume
celah yg ada di dlm mold/cetakan.
• Mold yg sudah berisi serbuk plastik diputar
(dua sumbu putar), diberi campuran zat kimia
dan dipanaskan dlm oven; sehingga campuran
mencair (melt) & terbentuk produk sesuai yg
diinginkan.
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 Rotational
Molding Process

Figure 9.17 The rotational molding

(rotomolding or rotocasting)
process. Trash cans, buckets, and
plastic footballs can be made by
this process.

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 Thermoforming Process

Figure 19.18 Various thermoforming processes for a thermoplastic sheet. These processes
commonly are used in making advertising signs, cookie and candy trays, panels for shower
stall, and packaging.

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 Compression Molding

Figure 19.19 Types of compression molding – a process similar to forging: (a) positive,
(b) semipositive, and (c) flash, which is later trimmed off. (d) Die design for making a
compression-molded part with external undercuts.
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 Transfer Molding

Figure 19.20 Sequence of operations in transfer molding for thermosetting plastics.

This process is suitable particularly for intricate parts with varying wall thickness.

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 Motorcycle Components

Figure 19.23 Reinforced plastic components for a Honda motorcycle. The

parts shown are front and rear forks, rear swing-arm, wheel, and brake disks.
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 Methods of Reinforcing Plastics

Figure 9.2 Schematic illustration of methods of reinforcing plastics (matrix)

with (a) particles, (b) short or long fibers or flakes, and (c) continuous fibers.
The laminate structures shown in (d) can be produced from layers of
continuous fibers or sandwich structures using a foam or honeycomb core
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(see also Fig. 16.50).
 Tapes used in Making
Reinforced Plastic Parts

(b)

Figure 19.24 (a) Manufacturing process for polymer-matrix composite tape. (b) Boron-
epoxy prepreg tape. These tapes are then used in making reinforced plastic parts and
components with high strength-to-weight ratios, particularly important for aircraft and
aerospace applications and sports equipment. Source: (a) Courtesy of T. W. Chou, R. L.
McCullough, and R. B. Pipes. (b) Courtesy of Avco Specialty Materials/Textron.

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 Tape and Tape-Laying System

(a) (b)

Figure 19.25 (a) Single-ply layup of boron-epoxy tape for the horizontal stabilizer for an
F-14 fighter aircraft. (b) A 10-axis computer-numerical-controlled tape-laying system.
This machine is capable of laying up 75- and 150-mm (3- and 6-in.) wide tapes on
contours of up to +/- 30 degrees and at speeds of up to 0.5m/s (1.7 ft/s). Source: (a)
Courtesy of Grumman Aircraft Corporation. (b) Courtesy of The Ingersoll Milling
Machine Company.
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 Production of Fiber-Reinforced Plastic
Sheets

Figure 19.26 Schematic illustration of the manufacturing process for producing fiber-
reinforced plastic sheets. The sheet still is viscous at this stage and later can be shped
into various products. Source: After T. W. Chou, R. L. McCullough, and R. B. Pipes.
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 Vacuum-Bag Forming and Pressure-Bag Forming

Figure 19.27 Schematic illustration of (a) vacuum-bag forming, and (b) pressure-bag forming.
These processes are used in making discrete reinforced plastic parts. Source: After T. H.
Meister.
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 Filament-Winding

(b)

Figure 19.29 (a) Schematic illustration of the filament-winding process; (b) fiberglass being
wound over aluminum liners for slide-raft inflation vessels for the Boeing 767 aircraft. The
products made by this process have high strength-to-weight ratio and also serve as
lightweight pressure vessels. Source: Courtesy of Brunswick Corporation.
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Design Modifications to Minimize Distortion in Plastic
Parts

Figure 19.31 Examples of design modifications to eliminate or minimize distortion in

plastic parts: (a) suggested design changes to minimize distortion; (b) stiffening the
bottoms of thin plastic containers by doming – a technique similar to the process
used to shape the bottoms of aluminum beverage cans; and (c) design change in a
rib to minimize pull-in (sink mark) caused by shrinkage during the cooling of thick
sections in molded parts.
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TERIMAKASIH

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