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Definition
• Broadly Speaking any Material that shows
the property of Plasticity, i.e. The capacity to
undergo a change in shape under external
pressure and retain the new shape even when
the pressure is withdrawn , is called a Plastic
Material.
• Plastic have found very wide applications in
every major Industry and in manufacturing
of many items of engineering importance.
Plasticity
General Properties
• Plastic are a group of materials which possess many
useful properties which have made them most popular
engineering materials in certain fields, among such
applications following need special mention;
Light Weight
• Plastic are undoubtly the lightest of engineering
materials, their density varies between 1.1 g/cc to 1.6
g/cc compared to 1.75 of magnesium, the lightest metal.
High Resistivity
• To Corrosion and also to electric current makes them ideal
material for insulators.
Low Thermal Conductivity
• Makes them suitable material for use as thermal Insulator.
Magnesium Vs Plastic
General Properties
General Properties
Low Thermal Conductivity
General Properties
Easy Formability
• Many intricate shapes and complicated design can be
given to Plastics with considerable ease and at
economical Cost. Hence, these offer unlimited choice in
product design.
Appealing Color and Finish.
• Plastics are amenable to acquire any desired color
besides taking the desired shape and smooth excellent
surface finish.
Low Cost
• Compared to Similar Products made from other
material, plastics are generally very economical in cost
General Properties
Classification
• All the plastics are Grouped under two main Classes
depending upon their behavior towards heat;
Thermoplastics
• All those varieties of Plastic which becomes soft on
heat, so much so that they can be remolded again
and again are classed as thermoplastics.
• These plastics harden on cooling and soften on heating.
Their hardness is, therefore, a temporary property
subjected to change on heating. Examples; acrylic
plastic, celluloid plastics, polystyrene and asphalt.
Thermoplastics
Manufacturing of Plastics
Thermosetting Plastics
• This Group of Plastics harden on heating and
curing at a particular range of temperature
once ‘cured’ or set they do not become soft by
any further heating.
• Their set and Hardness is, therefore, a permanent
property that does not change on heating again.
They may get destroyed but do not become soft
on reheating. Example are Bakelite, epoxy and
silicones provide the best example of thermosets.
Thermosetting Plastics
Constitution of Plastics
Fillers
• These include a number of materials that are
used in the manufacturing of Plastics with a
view of Increasing their bulk weight without
interfering adversely in their properties.
• Wood pulp, corn, husks, cotton, fibers,
asbestos, micas, clays, leads and zinc oxide,
metal powders and Glass fibers are some
commonly used fillers. These material impart
useful properties of shock resistance and
strength against fracturing to plastics.
Fillers
Manufacturing of Plastics
Plasticizers
• These are substances which are added to
obtain improvement in Certain Properties in
which the resin may be lacking. Such
Properties like Shock resistance, toughness
flexibility and non inflammability can be
greatly improved by addition of plasticizers to
resins.
• Plasticizers are essential constituents of
thermoplastics. In those the thermosets, they are
seldom Used.
Plasticizers
Manufacturing of Plastics
Pigments
• Pigments are added to the plastic at the time of
manufacture to impart them a desired color.
Zinc Oxide, Barites and other metallic
pigments may be used improper proportions. It
is essential that the type of pigment selected
should be durable and inert towards plastic
resin.
• Besides the above material certain other
substances may also be required in the
manufacturing of some varieties of plastics.
Pigments
Fabrication of Plastics
• Casting and moulding are two main processes commonly used to
fabricate end product from plastic resins. The selection of method
depend upon the type of plastic resin being used and the design of the
end product.
Casting
• In this method, desired objected are made by
• (i) Heating the resins to their melting points to make hot liquid melt from
them;
• (ii) Pouring the liquid into the moulds of desired shape and design;
• (iii) Curing the product in the mould itself for a definite time.
• The curing may require much time ranging from few hours to few weeks, it
is expensive method but the product obtained are quite strong & hard.
Fabrication of Plastics
Moulding
• It is very common method in plastic
Industry. It involves shaping the material
under high pressure or temperature or both
factor operating simultaneously.
Compression Moulding
• This is the most prevalent moulding
method. In this the plastic is pressed into the
mould in a heated state. Thus both pressure
and temperature are required.
Compression Moulding
Moulding
Injection Moulding
• In this method, the plastic material is first
heated in a chamber. When it is sufficient
hot, it is then forced into the mould through
a duct under requisite pressure. It is
common Process for Producing shapes of
thermoplastic materials.
Injection Moulding
Moulding
Transfer Moulding
• It is special type of Moulding process
applicable only to thermosetting plastics. It
Combines principles of Both the Compressive &
Injection Moulding
• The material is first heated in a heating
chamber. It is then forced into a mould which
is kept hot. In the mould, the plastic is pressed
hard till it confirms to the final shape of the
product. The Product is Cured under Pressure
and in a hot State.
Transfer Moulding
Moulding
Extrusion
• This is an exclusive Process for
thermoplastic and is similar to injection
moulding in principle. Hot Material is
excluded through a die of required shape.
Thus there is a die in place of a mould in the
extrusion process. Plastic Conducts, rods,,
bars, tubes, and Sheet material is obtained by
extrusion.
Extrusion
Moulding
Cold Moulding
• In this process, shapes are obtained by
applying pressure on the selected type of resin.
The Product However may be Cured by
baking in an Oven. The Process has Limited
Application and is used in phenol-
formaldehyde resins
Cold Moulding
Moulding
Calendaring
• It is a process of converting thermo plastic
Material into thin sheet of desired thickness
A heated mixture of the resin and Plasticizer
is Passed through, a series of heated rolls The
Gap between the two rolls give the thickness to
the Sheet.
Calendaring
Moulding
Laminating
• This is a process of Obtaining plastic
impregnated laminates of Wood, Clothes,
Glass, fibers and Paper.
• Exact technique will differ from material to
material Commonly the material to be
laminated is first soaked in the desired plastic
resin Liquid.
• It is then Squeezed through a set of rolls and
dried. The Product is then cured under controlled
conditions of temperature & Pressure.
Laminating
Specific Properties
• Plastics form a big group of resins showing a wide
range of properties. Their Properties depend on
grade, the method of Manufacturing, the resin and
other fillers and additives such as Plasticizers etc.
used along with the resin in their manufacture. Most of
the properties of Plastic are however Characterized
with,
• Excellent Corrosion Resistance
• Excellent Electrical Resistance
• Good Tensile Strength
• Amenability to Variety of Colors
Uses of Plastics
• Plastic offers some definite advantage over all the
other materials both in cost and in Quality in the
competitive market. A few advantage of plastic are:
• Excellent Combination Of Mechanical &
Electrical Properties.
• Easy fabrication into most intricate design
• Uniform finish and color adaptability
• Much lower Cost
Uses of Plastics
Uses of Plastics
• Corrosion resistance
• Low electrical and thermal conductivity, insulator
• Easily formed into complex shapes, can be
formed, casted and joined.
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