Minggu 7 Proses Plastik

RI 1321
Proses Manufaktur
Polimer dan Proses Pengolahan
Polimer (Proses Plastik)
Laboratorium Sistem Manufaktur

Jurusan Teknik Industri ITS
2005
Jurusan Teknik Industri FTI - ITS
Polymer and Polymer Processing
RI 1321 - Proses Manufaktur - Minggu 7 2

Keunggulan Proses Plastik

 Proses pembentukan plastik memungkinkan untuk geometri
yang sangat beragam
 Umumnya dibentuk menggunakan cetakan sehingga
langsung menghasilkan bentuk akhir produk (tidak perlu
proses lanjutan)
 Energi (panas) yang dibutuhkan untuk pembentukan plastik
lebih rendah daripada logam
 Karena temperatur proses pembentukkan rendah dan
jumlah mesin yang dibutuhkan hanya mesin molding, alat
penanganan material lebih sederhana dan sedikit
 Pada umumnya tidak memerlukan proses pengecetan atau
pelapisan permukaan

Polymer, Resin, and Plastics

 A polymer is any substance made up of many of
repeating units, building blocks, called mers.
 When in form ready for further working, they are
called resins.
 Polymers are seldom used in their neat form,
most often compounded with various additives.
The resulting material is usually referred to as a
plastic.
 Frequently, polymers, resins, plastics are used
interchangeably.
Properties and Applications

 Low density, high corrosion resistance,
electrical insulation.
 Ease of manufacturing into complex
shapes.
 Widely used for consumer products.
 Emerging as structural polymers (T<150-
250C).
 Sales of plastics, on a volume basis, has
grown more than double the steel
production in the U.S.
Polymerization Reactions
 Chain polymerization,
also called addition
polymerization, with
the aid of initiators, to
form Paraffin or
Benzene.
 Step reaction, also
called condensation,
dissimilar monomers
joined into short
groups that gradually
grow with by-product
released.

Types of Polymers
Polymer Family Tree
Thermoplastics Thermosets/Elastomers
Will reform when melted Will not reform
Not Cross-Linked Cross-linked

90% of market 10% of market
Polyethylene Epoxy
33% Melamine Formaldehyde
Vinyls Phenolic
16% Polyester (unsaturated)
Polypropylene Polyimide
15% Polyurethane
PMMA Some are thermoplastic as well.
ABS Silicone
Nylon Urea Formaldehyde
Polycarbonate
Saturated Polyester
PEEK
Polyurethane
Some are thermosets as well.
PVC

Basic Concepts
 Molecular weight (MW)
 Degree of polymerization (DP)
 Chain structures
 Crystalline and amorphous polymers
 Glass transition temperature (Tg) and
melting temperature (Tm)
 Mechanical properties

Source of Strength of Polymers

 Primary Bond -
Covalent Bonding
 Secondary Bonds –
 van der Waals PE - mer
 Dipole Bonds
 Hydrogen Bonds

Major Polymer Processes

 Extrusion
 Injection Molding
 Blow Molding
 Thermoforming
 Recycling

Polymer Processes

Extrusion

Extrusion Product Examples

Extrusion Characteristics
 The extrusion machine forms the basis of
nearly all other polymer processes.
 Basically involves melting polymer pellets
and extruding them out through a two
dimensional die.
 Produces long, thin products
 Coating for electrical wire
 Fishing Line
 Tubes, etc.

Injection Molding (See Video)

Injection Molding Product

Examples

Injection Molding Machine Basics

Injection Molding Process Control

 Very similar to die
casting
 Must control heat
transfer and fluid flow
 Do that by controlling
temperature and
pressure

Gas Assist Injection Molding
– Applicable to hollow parts without interior control.

Injection – Compression Molding

Injection Molding of Thermosets

 Plastics “set” when they cool
 Mold temperature will be set to allow full cavity fill, while
increasing production rate
 Thermosets undergo a chemical crosslinking that
produces the solid structure
 Mold temperature will be hotter usually – set to allow
full cavity fill, while accelerating the chemical reaction to
cure.
 Often called “Reaction Injection Molding” (RIM)

Blow Molding Example Products

Blow Molding Processes (See Video)
Extrusion Blow Molding Injection Blow Molding
Stretch Blow Molding

Thermoforming
(a) Vacuum, (b) Pressure, (c) Drape-vacuum,

(d) Plug-assist, (e) Pressure-bubble plug assist
Thermoforming Products

Polymer Recycling
 1998 – Approximately 20% of plastic
waste is recycled (optimistic estimate)
 1998 – Polymers account for
approximately 18% by volume of material
to landfills

Needs vs. Challenges

 Needs for a viable
 Challenges
program:
 10-12 main polymer types
 Stable supply of materials
 Thousands of blends
with reliable collection and
sorting  Additives
 Economical, proven and  Impurities in supply
environmentally sound (labels, glass, dirt, etc)
recycling process
 End use applications for the
recycled material

Recycling of Polymers
• PET (polyethylene • PP (polypropylene)
terphthalate) beverage margarine and yogurt
containers, boil-in food containers, caps for
pouches, processed meat containers, wrapping to
packages replace cellophane
• HDPE (high density • PS (polystyrene) egg
polyethylene) milk bottles, cartons, fast food trays,
detergent bottles, oil bottles, disposable plastic silverware
toys, plastic bags
• Other multi-resin
• PVC (polyvinyl chloride) containers
food wrap, vegetable oil
bottles, blister packaging
• LDPE (low density
polyethylene) shrink-wrap,
plastic bags, garment bags
Processing of Polymer
Composites
What are Composites

• Composites are often
classified by the type of
matrix: polymer, metal or
ceramic
• In addition, composites my
be classified by the type of
embedded material (a.k.a.,
reinforcement) fiber, particle,
whisker, flake, etc.
• Rule of mixtures says that
each constituent contributes
 c  f f  (1  f )  m to the properties of the
composite in proportion to its
volume fraction
Fibers dominate composite properties

Components of Polymer Composites

 Polymer Resin
 Usually a thermoset
 Epoxy
 Bismaleimide
 Polyimide
 Thermoplastics
 Polyester
 Vinylester
 Reinforcing fiber
 Fiberglass
 Graphite (Carbon)

Fabrication of Composites (See

Video)
 Fabrication of polymer-matrix composites
 Open-mold processes
 Pultrusion
 Closed-mold processes (Matched-die molding)
 Metal-matrix composites
 Ceramic-matrix composites

-Mold Processes
 Shaping:
 Male or female mold
 Hand lay-up
 Spry molding
 Tape laying
 Filament winding
 Curing:
 Open air
 Vacuum bag
 High pressure bag
 Heated pressure vessel

t Winding
 Control the orientation
of the fiber using a
relative motion of
rotation and linear
motion
 Example Products:
 Pressure Vessels
 Fishing Poles
 Light Poles

Pultrusion
 Fibers or cloth are
pulled through a
resin bath
 Heated in a die with
a shaped profile
 Cured to shape
 Cut to length

Closed Molding
 Can be done using
Pre-preg or wet layup
 Process:
 Resin impregnated
fibers cut to proper
geometry
 Heated Die sets close
on part
 Part is cured at
temperature
 Die opens and part is
ejected from mold

Resin Transfer Molding (RTM)
Vent Injection Port
Male
Index
mold
half Pin
Gasket
Index
Receptacle
Female Mold Half

Steps of RTM Process

The Resin Transfer
Molding Process:
Pressurized
• Fiber reinforcement is placed in Resin
the mold
• The mold is closed and clamped
Air Air
• Resin is injected into the mold
cavity under pressure
• The resin cures
• The part is removed from the
mold
The RTM Process

Open vs. Closed Molding

 Open Molding  Closed molding – or
 Only one sided mold compression molding
 Limited temperature  Two sided mold – part
control is sandwiched between
 Lower capital cost for two mold halves
molds  Pressure applied
 Improved material
properties (fewer voids)
 Higher Capital cost

Minggu 7 Proses Plastik

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RI 1321

Laboratorium Sistem Manufaktur

Polymer and Polymer Processing

RI 1321 - Proses Manufaktur - Minggu 7 2

Keunggulan Proses Plastik

RI 1321 - Proses Manufaktur - Minggu 7 3

Polymer, Resin, and Plastics

Properties and Applications

RI 1321 - Proses Manufaktur - Minggu 7 6

Not Cross-Linked Cross-linked

RI 1321 - Proses Manufaktur - Minggu 7 7

RI 1321 - Proses Manufaktur - Minggu 7 8

Source of Strength of Polymers

RI 1321 - Proses Manufaktur - Minggu 7 9

Major Polymer Processes

RI 1321 - Proses Manufaktur - Minggu 7 10

RI 1321 - Proses Manufaktur - Minggu 7 11

RI 1321 - Proses Manufaktur - Minggu 7 12

Extrusion Product Examples

RI 1321 - Proses Manufaktur - Minggu 7 13

RI 1321 - Proses Manufaktur - Minggu 7 14

Injection Molding (See Video)

RI 1321 - Proses Manufaktur - Minggu 7 15

Injection Molding Product

RI 1321 - Proses Manufaktur - Minggu 7 16

Injection Molding Machine Basics

RI 1321 - Proses Manufaktur - Minggu 7 17

Injection Molding Process Control

RI 1321 - Proses Manufaktur - Minggu 7 18

Gas Assist Injection Molding

– Applicable to hollow parts without interior control.

RI 1321 - Proses Manufaktur - Minggu 7 19

Injection – Compression Molding

RI 1321 - Proses Manufaktur - Minggu 7 20

Injection Molding of Thermosets

RI 1321 - Proses Manufaktur - Minggu 7 21

Blow Molding Example Products

RI 1321 - Proses Manufaktur - Minggu 7 22

Blow Molding Processes (See Video)

Extrusion Blow Molding Injection Blow Molding

Stretch Blow Molding

(a) Vacuum, (b) Pressure, (c) Drape-vacuum,

RI 1321 - Proses Manufaktur - Minggu 7 25

RI 1321 - Proses Manufaktur - Minggu 7 26

Needs vs. Challenges

RI 1321 - Proses Manufaktur - Minggu 7 27

What are Composites

Fibers dominate composite properties

RI 1321 - Proses Manufaktur - Minggu 7 31

Components of Polymer Composites

RI 1321 - Proses Manufaktur - Minggu 7 32

Fabrication of Composites (See

RI 1321 - Proses Manufaktur - Minggu 7 33

RI 1321 - Proses Manufaktur - Minggu 7 34

RI 1321 - Proses Manufaktur - Minggu 7 35

RI 1321 - Proses Manufaktur - Minggu 7 36

RI 1321 - Proses Manufaktur - Minggu 7 37

Resin Transfer Molding (RTM)

Vent Injection Port

Female Mold Half

RI 1321 - Proses Manufaktur - Minggu 7 38

Steps of RTM Process

RI 1321 - Proses Manufaktur - Minggu 7 39

Open vs. Closed Molding