Tek Pol Usai UTS - 2020

M.
Chalid @DTMM FTUI
TEKNOLOGI POLIMER:
MANUFAKTUR PRODUK JADI POLIMER
Mochamad Chalid
DEPARTEMEN TEKNIK METALURGI DAN MATERIAL
FAKULTAS TEKNIK UNIVERSITAS INDONESIA
M. Chalid @DTMM FTUI
Auto-parts Berbasis Polimer (1)



Introduction
Tahapan Proses Manufaktur Produk Polimer
Post
Shaping
Formulation Shaping
(Forming) (Finishing)
Penambahan dan Proses pembentukan Proses akhir
pencampuran aditif produk (extrusion, penyempurnaan bentuk dan
injection molding, dll) modifikasi produk (finishing,
assembly and decorating)
Plastic Shaping Processes
• Almost unlimited variety of part geometries

• Plastic molding is a net shape process; further
shaping is not needed
• Less energy is required than for metals
because processing temperatures are much
lower
– Handling of product is simplified during
production because of lower temperatures
• Painting or plating is usually not required
Viscosity of Polymer Melts

A fluid property that measures the
resistance to flow – quotient of shear stress to
shear rate within a fluid
• Due to its high molecular weight, a polymer melt
is a thick fluid with high viscosity
• Important because most polymer shaping
processes involve flow through small channels or
die openings
• High flow rates lead to high shear rates and shear
stresses, so significant pressures are required to
process polymers
Viscosity
“Non-Newtonian fluid”
“Shear thinning”
Viscosity as a function of
temperature for selected polymers
at a shear rate of 103 s-1.
• Unlike liquid metals, polymer viscosity depends on shear rate

• Like liquid metals, polymer viscosity is dependent on temperature
• Viscosity decreases with temperature, thus the fluid becomes thinner
at higher temperatures
Viscosity, η
penentu kecepatan putar screw (rpm) → kec. geser
Saat kurva tidak
linier, maka
viskositas/keken-
talan dapat ηa > ηc
didefiisikan
ditentukan
dengan 2 cara: ηc : kemiringan garis pada kec. geser
yang diberikan
1. Perhitungan
ηo : kekentalan pada kec geser sangat rendah,
apparent yang mendekati prilaku Newtonian
viscosity, ηa
2. Perhitungan
ηa : kemiringan garis kedua dari titik asal ke nilai
consistency tegangan geser pada kec. geser yg diberikan
viscosity, ηc
Plastic Shaping Process Types

Forming & Shaping

Processes for MFI dan Proses
Polymers
(TP = Thermoplastics; TS = Thermoset; E = Elastomer)

Extrusion → For Making Continues Products
Challenges:
raw materials
formulation,
machines and
die making
Extrusion
Compression process in which material is forced to
flow through a die orifice to provide long
continuous product whose cross-sectional shape
is determined by the shape of the orifice
• Widely used for thermoplastics and elastomers to
mass produce items such as tubing, pipes, hose,
structural shapes, sheet and film, continuous
filaments, and coated electrical wire
• Carried out as a continuous process; extrudate is
then cut into desired lengths
Extruder Schematic
(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.
Extruder
Components and features of a (single-screw) extruder for plastics & elastomers
Major components: Barrel, Screw

Die - not an extruder component (Special tool that must be fabricated for
particular profile to be produced )
Extruder Screw
• Divided into sections to serve several functions:

– Feed section - feedstock is moved from hopper and
preheated
– Compression section - polymer is transformed into
fluid, air mixed with pellets is extracted from melt,
and material is compressed
– Metering section - melt is homogenized and
sufficient pressure developed to pump it through die
opening
Die End of Extruder

• Progress of polymer melt through • The shape of the die orifice
barrel leads ultimately to the die zone determines the cross-sectional
• Before reaching die, the melt passes shape of the extrudate
through a screen pack - series of wire • Common die profiles and
meshes supported by a stiff plate corresponding extruded shapes:
containing small axial holes – Solid profiles
• Functions of screen pack: – Hollow profiles, such as tubes
– Wire and cable coating
– Filter out contaminants and hard
– Sheet and film
lumps
– Filaments
– Build pressure in metering section – Structural shapes
– Straighten flow of polymer melt – Door and window moldings
and remove its "memory" of – Automobile trim
circular motion from screw – House siding
Viscoelasticity
Viscous and elastic (pseudoplastic) properties
• Possessed by both polymer solids and
polymer melts
• Example: die swell in extrusion, in which the
hot plastic expands when exiting the die
opening
Swell ratio, rs = Dx/Dd

Extrusion Die Geometries
Common extrusion die geometries: (a) coat-hanger die for extruding sheet; (b) round die for producing rods;
(c) dies for producing square cross-sections. Note the nonuniform recovery of the part after it exits the die.
Design Modifications to Minimize Distortion in Plastic Parts
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.
Extrusion Die for Solid Cross Section

Side view cross-section of an extrusion die for solid regular shapes, such as
round stock; (b) front view of die, with profile of extrudate. Die swell is
evident in both views.
Hollow Profiles
• Examples: tubes, pipes, hoses, and other
cross-sections containing holes
• Hollow profiles require mandrel to form the
shape
• Mandrel held in place using a spider
– Polymer melt flows around legs supporting the mandrel to
reunite into a monolithic tube wall
• Mandrel often includes an air channel through
which air is blown to maintain hollow form of
extrudate during hardening
Extrusion Die for Hollow Shapes

Side view cross-section of extrusion die for shaping hollow cross-sections
such as tubes and pipes; Section A-A is a front view cross-section
showing how the mandrel is held in place; Section B-B shows the
tubular cross-section just prior to exiting the die; die swell causes an
enlargement of the diameter.
Plastic Tubes and Pipes Extrusion of

Multilayer Products
Extrusion of tubes. Coextrusion for producing a bottle.

Wire and Cable Coating

• Polymer melt is applied to bare wire as
it is pulled at high speed through a die
– A slight vacuum is drawn between wire and
polymer to promote adhesion of coating
• Wire provides rigidity during cooling -
usually aided by passing coated wire
through a water trough
• Product is wound onto large spools at
speeds up to 50 m/s (10,000 ft/min)
Extrusion Die for Coating Wire

• Polymer melt is applied to
bare wire as it is pulled at
high speed through a die
– A slight vacuum is drawn
between wire and
polymer to promote
adhesion of coating
• Wire provides rigidity during
cooling - usually aided by
passing coated wire through
a water trough
• Product is wound onto large
spools at speeds up to 50
m/s (10,000 ft/min)
Side view cross-section of die for coating of electrical
wire by extrusion.
Slit-Die Extrusion of Sheet and Film
Production of sheet and film

by conventional extrusion,
using a narrow slit as the
die opening
• Slit may be up to 3 m (10
ft) wide and as narrow as
around 0.4 mm (0.015 in)
• A problem is uniformity of
thickness throughout
width of stock, due to
drastic shape change of
polymer melt as it flows
through die
• Edges of film usually must
be trimmed because of One of several die configurations for extruding
thickening at edges
sheet and film.
Extensions for Extrusion Process

Extrusion is generally extended by some processes to obtain an
end-product shape
calendering
blown-film
thermoforming
Blow molding
Calendering
Feedstock is passed through a series of rolls to reduce
thickness to desired gage
• Expensive equipment, high production rates
• Process is noted for good surface finish and high gage
accuracy
• Typical materials: rubber or rubbery thermoplastics
such as plasticized PVC
• Products: PVC floor covering, shower curtains, vinyl Schematic illustration of
table cloths, pool liners, and inflatable boats and toys calendering. Sheets produced by
this process subsequently are
used in thermoforming. The
process also is used in the
production of various elastomer
and rubber products.
Thermoforming
• Thermoforming is a process for forming thermoplastic sheets or films over a mold through
the application of heat and pressure
• a sheet is heated in oven to the sag point above Tg (Glass Temperature).
• Sheet is then removed from the oven, placed over a mold, and forced against the mold
through the application of a vacuum.
• The mold is usually at RT, hence the shape of the plastic becomes set upon contact with the
mold.
• Parts with openings cannot be formed.
• Typical parts: advertising signs, tray cookies, refrigeration liners, packaging, and appliance
housings.
• Molds: Aluminum molds, then the tooling is inexpensive. The holes in molds are usually less
than 0.5mm, in order not to leave any marks on the formed parts.
Various thermoforming processes for a thermoplastic sheet. These processes commonly are used 30 in
making advertising signs, cookie and candy trays, panels for shower stall, and packaging.
Vacuum-Bag Forming and Pressure-Bag Forming
Schematic illustration of (a) vacuum-bag forming, and (b) pressure-bag forming. These
processes are used in making discrete reinforced plastic parts.
Thermoforming
Mold Heater
Cutting System
Pressure Thermoforming Process

Blister packaging
Dash board
Blister packaging
Plastic Products
Based on Thermoforming Process
Boat hulls
Disposable tray
Production of Plastic Film and Bags
(b)
(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.
Blown-Film Extrusion Process

Combines extrusion and
blowing to produce a tube
of thin film
• Process sequence:
– Extrusion of tube
– Tube is drawn upward while still
molten and simultaneously
expanded by air inflated into it
through die
• Air is blown into tube to
maintain uniform film
thickness and tube diameter
Blown-film process for high
production of thin tubular film.
Extrusion-Blow Molding
Products
Blow-
Molding
Modifications
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.
Blow molding
• Extrusion blow molding:
1. a tube is first extruded or injection
moldod, [pairson]
2. Then clamped into a mold cavity
much larger than tube diameter.
3. Finally blown outward to fill the
mold cavity.
4. Blowing is usually done with an air
blast at a pressure of 350-700KPa.
5. The molds close around the tubing,
close off both ends (thereby
breaking the tube into sections), and
then move away as air is injected
into the tabular piece.
6. The part is then cooled and ejected.
• Typical parts: beverage bottles and
hollow containers.
Overall Blown-Film Extrusion Process

Melt-Spinning Process
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.
Filament-Winding
(b)
(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.
Injection Molding → For Making Discontinues Products
(Thermoplastics)
Products
Challenges:
raw materials
formulation,
product
design,
machines and
mold making
Products Made by Injection Molding

Multicomponent injection molding (also called coinjection or sandwich molding):
Car rear lights (different colors).
Insert molding: metallic components such as screws, pins, and strips are placed in
the mold cavity prior to injection and then become an integral part of the molded
product.
(a) (b)
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.
Injection-Molding Machine
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.
Structure of Injection Molding Machine
Diagram of an injection molding machine, reciprocating screw type

(some mechanical details are simplified).
Injection Molding Sequence
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
Bagian Utama Injection Molding

Tahapan Kerja Injection Molding

– Penutupan Cetakan

– Pengisian Cetakan

– Packing, holding, Pendinginan

– Pembukaan Cetakan & Pengeluaran Produk
Ejector pins
Injection Molding Cycle
(2) melt is injected into

cavity.
(1) mold is closed

Injection Molding Cycle
(4) mold opens and part is

ejected.
(3) screw is retracted.

Siklus Kerja Injection Molding

Mold Features for Injection Molding
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.
Injection molding (IM)
• Complex shapes and good
dimensional accuracy.
• 3 basic types of molds:
1.cold runner 2-plate
mold: solidified plastic in
channels that connect
the mold cavity to end of
barrel must be trimmed.
2.cold-runner 3-plate:
runner system is
separated from part
when mold opens.
3.Hot-runner mold: more
expensive, no gates,
runners, or sprues
attached to molded part.
Molten plastic is kept hot
in a heated runner plate.
Shorter cycle times.
Main Parameters in IM & Product Defects
Over molten plastic Flows of molten

from mold plastic form a line
Pmax
Degradation
Warpage Good Quality /Burning
Product
Time
Pmin
Mold not complete in
filling mold (short shot)
Tmin Tmax
Extension for IM: Injection-Stretched Blow Molding

Injection-Stretched Blow Molding
Additional explanation on injection blow molding: (1) parison is injected molded

around a blowing rod; (2) injection mold is opened and parison is transferred to a
blow mold; (3) soft polymer is inflated to conform to the blow mold; and (4) blow
mold is opened and blown product is removed.
Injection-Stretched Blow Molding

Variation of injection blow molding in which blowing rod stretches the soft parison for a
more favorable stressing of polymer than conventional blow molding
• Resulting structure is more rigid, more transparent, and more impact resistant
• Most widely used material is polyethylene terephthalate (PET) which has very low
permeability and is strengthened by stretch blow molding
– Combination of properties makes it ideal as container for carbonated beverages
Stretch blow molding: (1) injection molding of parison; (2) stretching; and (3) blowing.
IM for Thermosets & Rubbers:

Reaction injection molding (RIM)
• a monomer and two or more

reactive fluids are forced at
high speed into a mixing
chamber at a pressure of 10 to
20 MPa and then into the mold
cavity.
• Chemical reactions take place
rapidly in the mold, and the
mold solidifies into a thermoset
part.
• Typical parts: automotive
bumpers and fenders, steering
wheels, and instrument
panels), thermal insulation for
refrigerators and freezers,
water skis.

Reaction injection molding (RIM): Example

Rotational molding
• Thin walled metal mold is made of 2
pieces and is designed to be rotated
about 2 perpendicular axes.
• A pre-measured quantity of
powdered plastic material is placed
inside the worm mold.
• The mold is then heated, while
rotated about the 2 axes.
• This action tumbles the powder
against the mold, where heating
fuses the powder without melting it.
• Complex shapes with wall
thicknesses 0.4mm and tanks with
volumes 80,000 liters produced.
• Typical parts: toys, carrying cases,
footballs, storage tanks.
• In addition to powders, liquid
polymers can be used in rotational
molding-PVC being the most
common material [Slush molding or The rotational molding (rotomolding or rotocasting)
Slush casting]. process. Trash cans, buckets, and plastic footballs can
be made by this process. 66
Rotational molding
compression molding & transfer molding
(a) compression molding and (b) transfer molding.

Compression Molding
• A widely used molding process for thermosetting plastics
• Also used for rubber tires and polymer matrix composite
parts
• Molding compound available in several forms: powders
or pellets, liquid, or preform
• Amount of charge must be precisely controlled to obtain
repeatable consistency in the molded product
Compression molding (CM)
• A pre-shaped charge of material, a
pre-measured volume of powder, or
a viscous mixture of liquid resin and
filler material is placed directly into a
heated mold cavity (200 C).
• Forming is done under pressure from
upper half of die (10-150MPa).
• CM is used mainly with
thermosetting plastics,
thermoplastics and elastomers are
also processed. linking is completed
in the heated die.
• Curing times: 0.5-5min.
• Typical parts: dishes, handles,
container caps, fittings.
• 3 types of compression molds:
1. Flash type: for shallow or flat
parts.
2. positive: for high density parts
3. Semi positive: for quality
production. 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.
Transfer Molding (TM)
• Uncured TS material is placed in a heated transfer pot or chamber.
• After material is heated, it’s injected into heated closed molds. Curing takes
place by crosslinking.
• Typical parts: electrical and electronic components, rubber and silicon
parts.
• TM Suitable for intricate shapes with varying wall thicknesses.
Sequence of operations in transfer molding for thermosetting plastics. This process is 71

suitable particularly for intricate parts with varying wall thickness.
Types of Transfer Molding

(a) Pot transfer molding: (1) charge is loaded into pot, (2) softened polymer is pressed into mold
cavity and cured, and (3) part is ejected.
(b) plunger transfer molding: (1) charge is loaded into pot, (2) softened polymer is pressed into
mold cavity and cured, and (3) part is ejected.
Casting
• Simple, inexpensive but slow.
• Typical parts: gears, bearings, wheels, thick sheets.
• convention casting of TP: a mixture of monomer, catalyst, and various
additives is heated and poured into the mold. Part forms after
polymerization takes place at ambient pressure.
• centrifugal casting
• Potting and encapsulation: casting plastic material around electric
component [transformer]. Potting is done in a housing or case, which is
an integral part of product. In encapsulation, component is coated with
a layer of the solidified plastic.
Schematic illustration of (a) casting, (b) potting, and (c) encapsulation processes for plastics
and electrical assemblies, where the surrounding plastic serves as a dielectric.
Pultrusion
(Composite)
(b)
(a) Schematic illustration of the pultrusion process. (b) Examples of parts made by pultrusion.
The major components of fiberglass ladders (used especially by electricians) are made by this
process. Unlike aluminum ladders, they are available in different colors but are heavier because
of the presence of glass fibers.
Production of Fiber-Reinforced Plastic Sheets

(Composite)
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.
Tapes used in Making

Reinforced Plastic Parts
(Composite)
(b)
(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.
Tape and Tape-Laying System (Composite)
(a) (b)
(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).
Open-Mold Processing (Composite)
Manual methods of processing reinforced

plastics: (a) hand lay-up, and (b) spray lay-
up. Note that, even though the process is
slow, only one mold is required. The figures
show a female mold, but male molds also are
used. These methods also are called open-
mold processing. (c) A boat hull made by
these processes.
Production Characteristics of Molding Methods

Proses: Tahapan Manufaktur Produk Polimer

Post
Shaping
Formulation Shaping
(Forming) (Finishing)
Penambahan dan Proses pembentukan Proses akhir penyempurnaan
pencampuran aditif produk (extrusion, bentuk dan modifikasi produk
injection molding, dll) (machining, assembly and
decorating)
Machining and Finishing

• Deflashing
• Smoothing and Polishing
• Sawing and Cutting
• Filing, Grinding and Sanding
• Routing, Milling and Turning
• Drilling
• Tapping and Threading
• Cleaning
• Annealing
Assembly/Joining of Plastic Parts

• Several processes used to join/assemble plastic parts:
1. Mechanical Fastening/Joining
2. Adhesive Bonding
3. Thermal Welding
4. Solvent Cementing
• Solvent cementing and thermal welding use the resin
in the part itself as the "fastener" to hold the assembly
together.
• Adhesive bonding and mechanical fastening use
another substance as the "fastener."
Joining Techniques for Plastic Products

Solvent cemen- Ultrasonic
ting & dopes
Hot-plate & hot-tool welding
Thermal Hot gas welding
bonding
Liquid solvent,water base, anaerobic
METHODE Adhesive Pasta, mastic

Hol melt
Film
Pressure sensitive
Mechanical fastener : staples,screw, etc
Machine Screws & Bolt

Self-threading Screw
Mechanical
Fasterner Rivet
Spring steel Fastener
Decorating Plastics
• The most widely used decorating processes in the
plastic industry are :
– Painting
– Hot decorating (hot stamping, in-mold decorating,
heat transfer)
– Plating (electroless, electrolytic, vacuum metallizing)
– Printing
– Application of labels, decals, etc.
before to decoration, the surface of the plastic part

must be cleaned of mold release, internal plastics
lubricants, and plasticizers.
POLIMER DAN EKOLOGI

• Apakah saling konflik polimer dan ekologi antara satu sama lain????
- polimer sangat bersahabat dengan lingkungan
- polimer tidak berbahaya terhadap alam, karena tidak mengotori air, tanah & udara
➔ terjadi bias diopini publik, karena tumpukan limbah polimer ➔ REGULASI &
PENDIDIKAN solusinya !!! ➔ perlakuan limbah sbg cara komersial mjd PENTING !!
• Beberapa cara bijak untuk pengurangan jumlah tumpukan limbah:
- Peningkatan life cycle polimer dengan refill (penggunaan berulang)
- Modifikasi disain (a.l. penggunaan jumlah polimer) yg efisien (sesuai kebutuhan).
Perlukah substitusi material polimer(sintetik) dg material alami?? Bagaimana dg sifat-
sifatnya? Mengurangi limbah? Ongkos produksi? Polusi?
Limbah: Dampak Tata Kelola yang Lemah
12/30/2020 | 86
Proses Daur Ulang Plastik: Circular Economy

• Pendaur-ulangan PRIMER:
penggunaan kembali secara
langsung bahan off grade dan
scrap oleh pabrik conventer. 80
% termoplastik termasuk bagian
ini, yg dicampur sebanyaknya
20 – 30 % dengan fresh
material
• Pendaur-ulangan SEKUNDER:
daur ulang plastik berbasis
termoplastik paska konsumsi
yang dikumpulkan, dipisahkan,
dicacah, dibersihkan dan dijual.
• Pendaur-ulangan TERSIER:
Pirolisis (pengubahan rantai
molekul polimer dari semua
jenis polimer) menjadi
monomer, oligomer, zat kimia
atau bahan bakar.
• Recovery Energi –
Incineration: pembakaran
semua jenis polimer untuk
menghasilkan energi sebagai
pembangkit tenaga listrik
Limbah Plastik dan Produk Daur Ulangnya

RECOVERY DAN DAUR ULANG
• Model pendaur-ulangan:primer, sekunder, tersier (perlakukan kimia), recovery energi

• Pendaur-ulangan PRIMER: penggunaan kembali secara langsung bahan off grade dan
scrap oleh pabrik conventer. 80 % termoplastik termasuk bagian ini, yg dicampur
sebanyaknya 20 – 30 % dengan fresh material
• Pendaur-ulangan SEKUNDER: bahan bekas termoplastik dikumpulkan, dibersihkan,
dipisahkan dan digunakan setelah diregrind (dicacah). Kompatibilitas limbah
poliblend/plastik→Teknologi SEPARASI masih krusial !!! Pengumpulan limbah polimer via
outlet (repaying deposit money) ?? Pendifusian dan kompresi limbah dalam cetakan??
RECOVERY DAN DAUR ULANG

• Pendaur-ulangan TERSIER: pengubahan (depolimerisasi) scrap polimer (semua jenis
polimer) via perlakuan kimia mjd produk baru (monomer, oligomer, zat kimia atau bahan
bakar). Pirolisis PMMA mjd monomer murni, Hydrolisis PET dan kondensasi
(repolimerisasi) menjadi nilon dan poliurethane.
• Recovery Energi – Incineration: pembakaran senyawa organik dalam bahan limbah, yang
menghasilkan abu, gas emisi dan panas → pembangkit tenaga listrik. Gas berbahaya ??
• Bio- dan photodegradasi: pendegradasian

polimer secara alami → BIO- atau
PHOTO-DEGRADABLE POLIMER!!!
pencangkokan polimer sintetis dengan
bahan alam → pancing mikroba/enzim
disain molekul polimer sintesis, misal
gugus karbonil → serap uv →
photooksidasi→ terurai; atau gugus
karbok-nil/sil →hidrolisis→terurai
Municipal solid waste in the furnace of a moving grate

incinerator capable of handling 15 metric tons (17 short
tons) of waste per hour. The holes in the grate elements
supplying the primary combustion air are visible.
SYSAV incineration plant in Malmö, Sweden
capable of handling 25 metric tons (28 short tons)
per hour household waste. To the left of the main
stack, a new identical oven line is under
construction (March 2007).

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M.

Chalid @DTMM FTUI

Auto-parts Berbasis Polimer (1)

Auto-parts Berbasis Polimer (2)

Auto-parts Berbasis Polimer (3)

Plastic Shaping Processes

• Almost unlimited variety of part geometries

Viscosity of Polymer Melts

• Unlike liquid metals, polymer viscosity depends on shear rate

Plastic Shaping Process Types

Forming & Shaping

(TP = Thermoplastics; TS = Thermoset; E = Elastomer)

Extrusion → For Making Continues Products

Major components: Barrel, Screw

• Divided into sections to serve several functions:

Die End of Extruder

Swell ratio, rs = Dx/Dd

Extrusion Die Geometries

Design Modifications to Minimize Distortion in Plastic Parts

Examples of design modifications to eliminate or minimize distortion in plastic parts: (a)

Extrusion Die for Solid Cross Section

Extrusion Die for Hollow Shapes

Plastic Tubes and Pipes Extrusion of

Extrusion of tubes. Coextrusion for producing a bottle.

Wire and Cable Coating

Extrusion Die for Coating Wire

Slit-Die Extrusion of Sheet and Film

Production of sheet and film

Extensions for Extrusion Process

Vacuum-Bag Forming and Pressure-Bag Forming

Pressure Thermoforming Process

Production of Plastic Film and Bags

Blown-Film Extrusion Process

Overall Blown-Film Extrusion Process

The melt-spinning process for producing polymer fibers.

Products Made by Injection Molding

Structure of Injection Molding Machine

Diagram of an injection molding machine, reciprocating screw type

Injection Molding Sequence

Sequence of operations in the injection molding of a part

Bagian Utama Injection Molding

Tahapan Kerja Injection Molding

Tahapan Kerja Injection Molding

Tahapan Kerja Injection Molding

Tahapan Kerja Injection Molding

Injection Molding Cycle

(2) melt is injected into

(1) mold is closed

Injection Molding Cycle

(4) mold opens and part is

(3) screw is retracted.

Siklus Kerja Injection Molding

Mold Features for Injection Molding

Main Parameters in IM & Product Defects

Over molten plastic Flows of molten

Extension for IM: Injection-Stretched Blow Molding

Injection-Stretched Blow Molding

Additional explanation on injection blow molding: (1) parison is injected molded

Injection-Stretched Blow Molding

IM for Thermosets & Rubbers:

Reaction injection molding (RIM)

• a monomer and two or more