MANUFACTURING TECHNOLOGY-I

UNIT-5

PLASTIC FORMATION

M. SUBASH
AP/MECH
Q.1. INJECTION MOULDING IN THERMOPLASTICS:
• Thermo plastics can be processed to their final
shape by moulding and extrusion process.
Injection moulding working principle
• The injection moulding is used to achieve high
speed moulding of thermoplastics.
• The working principle of this process is that the
molten thermoplastic is injected into a mould
under high pressure.
• For achieving high pressure, the plunger system
is used.
Operation
• The thermoplastic which is to be moulded is
loaded into hopper.
• From hopper, it is transferred to a heating section
by a feeding device where the temperature is
raised to 150°C-370°C.
• The thermoplastic melts and transferred to liquid
state.
• It is then forced by an injection ram or plunger
through nozzle and spure in a closed mould
which forms the part.
There are two types of Injection moulding
1. Ram or Plunger type injection moulding:
• the ram or plunger type injection moulding has two
units,
1. Injection unit
2. Moulding unit
• The injection unit is similar to extruder.
• It consists of a barrel that is feed from one end by a
hopper containing a supply of plastic pellets.
• Initially the polymer is filled in a hopper.
• Then , it is fed to the heating section, of the injection
unit where the temperature is about 150°C-370°C.
• In heating section, the polymer is melted and
pressure is increased.
• The function of the torpedo in the heating zone
is to spread the polymer melt into a thin film in
close contact with the heated cylinder walls.
• The heated material is injected by the ram under
pressure.
• So the heated material is forced to fill in the
mould cavity through the nozzle to get the
required shape of the plastics.
PLUNGER TYPE INJECTION MOULD
2. Screw type injection moulding
• There are two units to split and eject the finished
component,
1. Injection unit
2. Moulding unit
• The injection unit has hopper, screw and heating
sections. In clamping section, it has mould.
• In screw type moulding, the pellets are initially
fed in to hopper.
• The resins are pushed along with the heated
reciprocating screw.
• The screw is moved forward to force the plastic
material in to the mould.
• The screw itself move backward and allowing the
accumulation of enough material to fill the
mould.
• The axial motion of the screw provides the filling
action.
• After completion of injection and cooling of
mould, the mould is opened, and the part is
ejected and removed.
SCREW TYPE
ADVANTAGES
• High production capacity and less material loss.
• The cost is low and need less finishing operation.
• Used for making complex threads and thin walled
parts.
• Wide range of shapes
• Accuracy of ±0.025mm can be achieved.
LIMITATIONS
• Equipment of cylinder and die should be Non-
corrosive.
• The reliable temperature control is essential.
APPLICATIONS
• Typical parts such as cups, containers, tool
handles, toys, knobs and plumping fitting can be
produced.
• Electrical and communication components can
be produced.