Professional Documents
Culture Documents
• Extrusion
[hose and tubing, belts, rope and cable
covers, sheeting and films]
• Foaming Techniques
Foam molding offers the possibility of
increasing the size of a part without
increasing weight and reducing the
weight of a part with controlled change
of properties. Chemical foaming involves
mixing a chemical blowing agent with
pellets prior to the pellets being fed into
the feed throat of the molding machine.
• Injection Molding
Most engineering thermoplastic parts
are fabricated by injection molding.
Plastic Products
• Plastics can be shaped into a wide variety
of products:
– Molded parts
– Extruded sections
– Films
– Sheets
– Insulation coatings on electrical wires
– Fibers for textiles
Why Plastic Shaping Processes are
Important
• 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
ISE 316 - Manufacturing
Processes Engineering
Classification of Plastics Shaping
Processes by Product Geometry
• Extruded products with constant cross-section
• Continuous sheets and films
• Continuous filaments (fibers)
• Molded parts which are mostly solid
• Hollow molded parts with relatively thin walls
• Discrete parts made of formed sheets and films
• Castings
• Foamed products
ISE 316 - Manufacturing
Processes Engineering
General Characteristics of Forming and Shaping Processes for Plastics
Process Characteristics
Extrusion Continuous solid, hollow or complex cross sections , high production
rates, low tooling costs, wide tolerances
Injection molding Complex shapes of various sizes, thin walls, very high production
rates, costly tooling, Good dimensional accuracy.
Structural foam Large parts with high stiffness to weight ratio, less expensive tooling
molding than injection molding, low production rates
Blow molding Hollow thin walled parts, bottles of various sizes, high production
rates, relatively low tooling cost
Rotational Large hollow items of simple shape, relatively low tooling costs,
Molding relatively low production rates
Thermo Forming Shallow- Deep cavities, low tooling costs, medium production rates
Compression Parts similar to impression die forging , expensive tooling, medium
molding production rates.
Transfer molding More complex parts than Compression molding, higher production
rates, higher tooling cost. Some scrap loss.
Casting Simple and complex parts can be made with rigid and or flexible low
cost molds, low production rates.
SY B. Tech B Div 11/10/18- 9.00-10.00
101, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 17,
19, 20, 22, 23, 24, 25, 28, 29, 31, 32, 34, 35,
36, 37, 38, 40, 41, 43, 44, 45, 46, 47, 48, 49,
50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61,
62, 63, 64, 65, 66, 67, 68, 71
Additives for Plastics
Fillers
Pigments
Stabilizers
Antistatic Agents
Flame Retardants
Plasticizers
Reinforcements
Catalysts
Polymer Additives
Improve mechanical properties, processing, durability.
• Fillers - Added to improve tensile strength & abrasion
resistance, toughness & decrease cost. Examples: carbon black,
silica gel, wood flour, glass, limestone, talc.
• Plasticizers - Added to reduce the glass transition temperature
Tg below room temperature. Presence of plasticizer transforms
brittle polymer to a ductile one. Commonly added to PVC.
• Stabilizers – Antioxidants, UV protection
• Lubricants - Added to allow easier processing polymer “slides”
through dies easier (sodium stearate).
• Colorants - Dyes and pigments
• Flame Retardants - Substances containing chlorine, fluorine and
boron.
More Additives
Process Parameters
1. The amount of powder
2. Heating temperature and time
3. Rotational speeds
4. Cooling rates
Material used and Applications
• Material Used Thermosets and thermoplastic
material can be used, for example:
• Low density polyethylene (LDPE), high density
polyethylene (HDPE), polypropylene, and polyvinyl
chloride (PVC).
• Applications Additives for weather resistance,
flame retardation can be incorporated.
• Products that can be manufactured include storage
tanks, bins and refuse containers, airplane parts,
road cones, footballs, helmets, and rowing boats.
Advantages and Disadvantages
Advantages :
• Allows complex mold split lines.
• Allows molded threads and mold-in inserts.
• Allows a wide range of surface finishes (textured, smooth,
or polished).
• Very little waste.
• Low residual stresses
• Tooling is less expensive
• Suitable for both low-volume prototypes and high-volume
production runs
Disadvantages :
• Slow production speed.
• It usually takes about one hour to complete the process
• Lower precision
SY B Tech 16/10/2018
101, 2, 3, 4, 5, 6, 7, 8 ,9, 10, 11, 12, 13, 14, 15,
16, 18, 19, 20, 22, 23, 24, 25, 26, 27, 28, 29,
30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 42,
43, 44, 45, 46, 47, 50, 51, 52, 53, 54, 55, 56,
57, 58, 59, 60, 61, 62, 63, 65, 66, 67, 68, 71
Foam Moulding
SE A and B 31/03/2018 9.00- 11.00
SE A SE B
• 1, 29, 39, 49, 53, 55, 56, 58, • 110, 11, 13, 20, 23, 37, 41,
59, 60, 63, 64, 68, 72, 91, 93 44, 50, 51, 54, 60, 61, 62,
64, 66, 68, 72, 75, 79, 80,
82, 83,