Manufacturing Engineering Design

TIE 3220

POLYMER PROCESSING

B.SAREMA (NUST)
AGENDA
 Materials for Polymer Processing
 The processes;
i. Injection Moulding
ii. Compression Moulding
iii. Transfer Moulding
iv. Extrusion
v. Extrusion Blow Moulding
 DFM guidelines for Polymer Processing
Materials for Polymer Processing
 Thermoplastics
 materials, like water and wax, can be repeatedly
softened by heating and hardened by cooling
 Can be crystalline or amorphous
 are formed into parts primarily by injection
moulding, extrusion, and extrusion blow moulding.
Parts include: gears, cams, pistons, rollers, valves, fan
blades, rotors, washing machine agitators, knobs,
handles, camera cases, battery cases, telephone and
flashlight cases, sports helmets, luggage shells,
housings and components for business machines, power
tools, and small appliances.
Materials for Polymer Processing
 Thermosets
 polymeric materials that, similar to an egg,
transform permanently on heating and cannot be
re-melted.
 are formed primarily by compression moulding
and transfer moulding.
 Parts made of thermoset materials can be
subjected to higher temperatures without
creeping, tend to have a harder surface, and are
more rigid than thermoplastics
Parts Include: electrical connections, automotive radiator
parts, computer enclosures,
Injection Moulding
Injection moulding machine

As the geometry of the part becomes complex, so as the

mould and hence costs increase
Injection moulding-complexity

External undercut Internal undercut

 features that will, without  Part is difficult to eject
special provisions, from the core
prevent the part from
being extracted from the
cavity half of the die.
Which ones cost more and why???
Injection Moulding cycle time
Injection moulding cycle time depends
on:
 Complexity
 Wall thickness
Compression Moulding
Transfer moulding
Extrusion
Extrusion blow moulding
DFM guidelines for Polymer Processing
GENERAL RULES OF THUMB
 Smooth flow to fill the cavity evenly

 Rapid cooling and hence solidification to shorten

cycle time
 Uniform cooling to reduce warpage

 Ejection should be accomplished with as

little tooling complexity as possible.
DFM guidelines for Polymer Processing
 In order to follow the rules of thumb designers
must understand;
 mould closure direction
 parting surface. (surface where the two mould meet
when mould closes)
DFM guidelines for Polymer Processing
Parting surface and mould closure direction

External undercut can be created by choice in

the direction of mould closure
DFM guidelines for Polymer Processing
Parting surface and mould closure direction

External undercuts created by location of the

parting plane between the die halves.
DFM guidelines for Polymer Processing
1. Decide the direction of mould closure and the
location of the parting surface
2. Avoid undercuts wherever possible
3. Avoid sharp corners and sudden changes or large
differences in wall thickness ( for flow)
4. Avoid thick walls or heavy sections that slow the
cooling process.
5. Design for uniform thickness
6. Consider multiple gates for complex parts and plan for
fusion lines