MOULD: ITS THEORIES AND PRINCIPLES TYPES OF EXTRUSION

The mould is an assembly of parts containing with in it an impression into which hot plasticized material  ACCORDING TO THE DIRECTION OF FLOW OF METAL
is injected, and then maintained at certain temperature and pressure, then cooled to get a commercially
acceptable shape. 1. DIRECT EXTRUSION:

WORKING PRINCIPLES In this type of extrusion process, metal is forced to flow in the direction of feed of punch. The punch
moves toward die during extrusion. This process required higher force due to higher friction between
The impression of mould is formed by two mould members: billet and container.

• The cavity of portion of the mould- forms the external shape of the moulding 2. INDIRECT EXTRUSION:

• The core portion of the mould- forms the internal form of the moulding In this process, metal is flow toward opposite direction of plunger movement. The die is fitted at
opposite side of punch movement. In this process, the metal is allowed to flow through annular space
DIFFERENT TYPES OF MOLDING PROCESS between punch and container.

1. INJECTION MOLDING  HYDROSTATIC EXTRUSION

 Injection moulding is a manufacturing process for producing parts by injecting molten This process uses fluid to apply pressure on billet. In this process, the friction is eliminated because the
material into a mould. Injection moulding can be performed with a host of materials billet is neither contact with cylinder wall or plunger. There is a fluid between the billet and plunger. The
mainly including metals, glasses, elastomers, confections, and most commonly plunger applies force on fluid which further applied on billet. Normally vegetable oils are used as Fluid.
thermoplastic and thermosetting polymers. This process accomplished by leakage problem and uncontrolled speed of extrusion.

WORKING PRINCIPLE OF INJECTION MOLDING  ACCORDING TO THE WORKING TEMPERATURE

 The purpose of the injection unit is to melt the raw plastic and guide it into the mold. It 1. HOT EXTRUSION:
consists of the hopper, the barrel, and the reciprocating screw.
If the extrusion process takes place above recrystallization temperature which is about 50-60% of its
 The raw plastic material comes as pellets. In the hopper, the pellets can be mixed with melting temperature, the process is known as hot extrusion.
pigment or other additives.
ADVANTAGES:
 Next, the material is fed into the barrel, which contains the reciprocating screw. Once
enough melted plastic is in front of the screw, the ram plunges forward and injects the • Low force required compare to cold working.
material into the empty cavity of the mold. This whole process happens in continuous
fashion, so filling the mold only takes a few seconds. • Easy to work in hot form.

TYPES OF INJECTION MOLDS • The product is free from stain hardening.

 COLD RUNNER MOULD : In a cold runner mold, the runner is cooled and ejected with DISADVANTAGES:
the part. Every cycle, a part and a runner are produced. The obvious disadvantage of this
system is the waste plastic generated.
• Low surface finish due to scale formation on extruded part.
 HOT RUNNER MOULD : In a hot runner mold, the runner is situated internally in the
mold and kept a temperature above the melting point of the plastic. Runner scrap is • Increase die wear.
reduced or eliminated. The major disadvantages of a hot runner is that it is much more
expensive than a cold runner, it requires costly maintenance, and requires more skill to • High maintenance required.
operate.
2. COLD EXTRUSION:
2. COMPRESSION & TRANSFER MOLDING
If the extrusion process takes place below crystallization temperature or room temperature, the process is
Compression molding is the process of molding in which a preheated polymer is placed into an open, known as cold extrusion. Aluminum cans, cylinder, collapsible tubes etc. are example of this process.
heated mold cavity.
ADVANTAGES:
WORKING PRINCIPLE
• High mechanical properties.
 The charge of plastic material is placed in the lower half of a heated mould cavity.
• High surface finish
 The mold cavity is closed with upper movable half mold and pressure is applied.
• No oxidation at metal surface.
 The pressure is applied along with heat to compress the material, which also increases the
polymerization process. DISADVANTAGES:

 The mould cavity is then opened and the final product is taken out. • High force required.

• Product is accomplished with strain hardening.

TRANSFER MOLDING is a manufacturing process where casting material is forced into a mold. 4. BLOW MOLDING

Working Principle Blow molding is the process of forming a molten tube (referred to as the parison or preform) of
thermoplastic material (polymer or resin) and placing the parison or preform within a mold cavity
 A charge is weighted and inserted into the transfer pot. and inflating the tube with compressed air, to take the shape of the cavity and cool the part before
removing from the mold.
 The transfer pot is heated above the melting temperature of the charge.
5. THERMOFORMING
 A plunger is used to push the liquid charge into the mold cavity.
Thermoforming is a manufacturing process where a plastic sheet is heated to a pliable forming
 The mold cavity is held closed until the resin gets cured. The mold cavity is opened and temperature, formed to a specific shape in a mold, and trimmed to create a usable product.
the molded part can be removed.
6. VACUUM FORMING
3. EXTRUSION
Vacuum forming is a simplified version of thermoforming, where a sheet of plastic is heated to
Extrusion is a process used to create objects of a fixed cross-sectional profile. A material is pushed a forming temperature, stretched onto a single-surface mold, and forced against the mold by
through a die of the desired cross-section. a vacuum.

Working Principle: 7. CALENDARING

Extrusion is a simple compressive metal forming process. In this process, piston or plunger is used to
apply compressive force at work piece. These process can be summarized as follow.
 First billet or ingot (metal work piece of standard size) is produced.
 This billet is heated in hot extrusion or remains at room temperature and placed into a
extrusion press (Extrusion press is like a piston cylinder device in which metal is placed in
cylinder and pushed by a piston. The upper portion of cylinder is fitted with die).
 Now a compressive force is applied to this part by a plunger fitted into the press which
pushes the billet towards die.
A Calender is a series of hard pressure rollers used to finish or smooth a sheet of material such as
paper, textiles, or plastics. Calender rolls are also used to form some types of plastic films and to
apply coatings. Some calender rolls are heated or cooled as needed.
INJECTION MOLDING PROCESS
Injection molding is a manufacturing process for producing parts by injecting material into a mould.
(Metals, Glasses, Elastomers, Confections, Polymers)
MAIN COMPONENTS OF INJECTION MOLDING MACHINE

 The die is small opening of required cross section. This high compressive force allow the (Clamping unit, Injection unit, Drive unit, Mould, Hydraulic system, Control system, Hopper, Heaters,
work metal to flow through die and convert into desire shape. Cooling channels)

 Now the extruded part remove from press and is heat treated for better mechanical INJECTION MOLDING PROCESS
properties.
(Material, Machine, Mould, Manpower

MOST COMMONLY USED MATERIALS

( PVC, ABS (Acrylonitrile Butadiene Styrene), Polypropylene, Polystyrene, HDPE (High density poly
ethylene), LDPE (Low density poly ethylene), Rubber Thermoplastic, Epoxy )
INJECTION MOLDING MACHINE PROCESS
EXAMPLES OF THERMOSETTING PLASTICS
 Material granules are fed into hopper then melted down in barrel which is surrounded by
the heaters.
 Melted material is injected into mould cavity and mold is held under pressure until the
material cools and hardens.
 Once the material hardens, the mold is opened and the component is ejected by runner
plate.
 Injection Molding Machine Process
 A thermosetting plastic is a polymer that irreversibly becomes rigid when heated.
 Once hardened, a thermoset cannot be melted for reshaping.
 EPOXY RESINS - Is a type of thermosetting polymer that is used in manufacture of
adhesives, plastics, paints, coatings, primers and sealers etc. and also as a matrix
component in fiber reinforced plastics.
 POLYESTER- Is a polymer which are composed of several esters and fibers which are
widely used in making plastic bottles, tarpaulins, LCD’s and etc.
 POLYIMIDE - used in printed circuit boards and in body parts of modern aircraft,
aerospace composite structures, as a coating material and for glass reinforced pipes.
 PHENOLIC- are a laminated plastic created by the impregnation of layers of a substrate
with a resin then formed utilizing heat and pressure.

2. THERMOPLASTICS
 And the process can be repeated.
 is a material, usually a plastic polymer, which becomes more soft when heated and hard
MOULD when cooled.

 are the common term used to describe the tool used to produce components in molding.  Thermoplastic materials can be cooled and heated several times without any change in
their chemistry or mechanical properties.
 are constructed from hardened steel, pre- hardened steel, aluminum, beryllium-copper
alloy.

 can be manufactured either by CNC machining or by using electrical discharge machining EXAMPLES OF THERMOPLASTICS:
processes.
POLYETHYLENE
MOULD DESIGN
 is the most common plastic.
 The mould consists of two primary components, the injection mould (A plate) and the
ejector mould (B plate).
 primarily used in packaging; plastic bags, plastic films, geomembranes and for industrial
pipings and films.
MOULD DESIGN CONSIDERATION
 Has two types, HDPE (high density polyethylene) and LDPE (low density polyethylene.
(Shrinkage allowance, Cooling circuit, Ejection gap, Mold polishing, Mold filling, Draft)
POLYPROPYLENE
MANPOWER
 is a thermoplastic polymer similar to polyethylene but slightly harder and more heat
 To set up process resistant.

 To monitor process and troubleshoot  mainly used in plastic moldings, piping systems, car batteries etc.

 To operate machine

INJECTION MOLDING USED FOR : POLYVINYL CHLORIDE (PVC)

PLASTIC INJECTION MOLDING  is a tough, lightweight material that is durable, fairly rigid and versatile, and is resistant to
acids and bases.
 It is a manufacturing process for producing components by injecting polymer material into
a mould. It makes Writing instruments components (pen barrel, cap, bush etc), Computer  mostly used in construction industry such as for vinyl siding, drainpipes, gutters and
Electronics, Automotive Components, Aerospace Components, Electronic Components, roofing sheets.
Toys, etc.
NYLON
RUBBER INJECTION MOLDING
 is a thermoplastic silky material that can be melt-processed into fibers, films, or shapes.
 Injection molds can make many rubber components. It makes valve steam seals, oil seals
for engines, telecommunication items etc.
 Nylon fibers are useful in making fabrics, rope, carpets and musical strings, whereas in
bulk form, nylon is used for mechanical parts including machine screws, gears and power
METAL INJECTION MOLDING tool casings.

 Injection molds can stamp out small to large items. It can stamp out automobile parts from ACRYLONITRILE BUTADIENE STYRENE (ABS)
spark plugs and floor pans to ball bearings.
 is a light-weight material that exhibits high impact resistance and mechanical toughness.
ADVANTAGES OF INJECTION MOLDING
 it is used in many consumer products, such as toys, appliances, and telephones.
 Fast production.
3. ELASTOMERS
 Design flexibility.
 is a type of polymer that displays rubber-like elasticity
 High-output production.
 capable of recovering their original shape after being stretched to great extents
 Multiple materials can be used at the same time.
EXAMPLES OF ELASTOMER
 Can be used to produce very small parts.
POLYURETHANE
DISADVANTAGES OF INJECTION MOLDING
 used in the manufacture of high-resilience foam seating, rigid foam insulation panels,
 High initial tooling and machinery cost. microcellular foam seals and gaskets, durable elastomeric wheels and tires

 Part design restrictions. SILICONE

 Small runs of parts can be costly  used for thermoset polymer matrix composites and as ceramic matrix composite
precursors.
APPLICATIONS OF INJECTION MOLDING
 Widely used as sealants and adhesives
 Injection molding is used to create many things such as Cups, Containers, tools,
Mechanical parts (Including gears). PROCESSING TECHNIQUES IN MANUFACTURING ENGINEERING PLASTICS

 Injection molding is the most common modern method of manufacturing parts. It is ideal  Injection Molding
for producing high volumes of the same object.
 Rotational Molding
ENGINEERING PLASTICS
 CNC Machining
 Engineering Plastics are a group of plastic materials that have better thermal properties
than more widely used commodity plastics.
 Extrusion

 Possess physical properties that enables in prolonged use in structural applications, over a
 Polymer Casting
wide temperature range, under mechanical stress and in difficult chemical and physical
environments

TYPES OF ENGINEERING PLASTICS

1. THERMOSETTING PLASTICS