Unit V – Processing of Plastic components

Plastics
 The Word plastic is from the Greek word plastikos, meaning “capable of being molded
and shaped.”
 Plastics can be formed, machined, cast, and joined into various shapes with relative
ease.
 Minimal additional surface-finishing operations, if any at all, are required; this
characteristic provides an important advantage over metals.
 Plastics are available commercially as film, sheet, plate, rods, and tubing of various
cross-sections.
 Consumer and industrial products made of plastics include food and beverage
containers, packaging, signs, housewares, housings for computers and monitors,
textiles (clothing), medical devices, foams, paints, safety shields, toys, appliances,
lenses, gears, electronic and electrical products, and automobile bodies and
components.
 The earliest polymers were made of natural organic materials from animal and
vegetable products; cellulose is the most common example.
Plastics
 By means of various chemical reactions, cellulose is modified into cellulose acetate,
used in making sheets for packaging and textile fibers such as rayon; cellulose nitrate,
for plastics and explosives; and varnishes.
 The earliest synthetic (manmade) polymer was phenol formaldehyde, a thermoset
developed in 1906 and called Bakelite.
 The development of modern plastics technology began in the 1920s when the raw
materials necessary for making polymers were extracted from coal and petroleum
products.
 Ethylene was the first example of such a raw material; it became the building block for
polyethylene.
 Ethylene is the product of the reaction between acetylene and hydrogen, and acetylene is
the product of the reaction between coke and methane.
 Commercial polymers, such as polypropylene, polyvinyl chloride,
polymethylmethacrylate, polycarbonate, and others, are all made in a similar manner;
these materials are known as synthetic organic polymers.
Classification of plastics
The Structure of Polymers
 The properties of polymers depend largely on the structures of individual polymer
molecules, molecule shape and size, and the arrangement of molecules to form a
polymer structure.
 Polymers are long-chain molecules that are formed by polymerization (that is, by the
linking and cross-linking of different monomers).
 A monomer is the basic building block of a polymer. The word mer (from the Greek
meros, meaning “part” ) indicates the smallest repetitive unit; the use of the term is
similar to that of unit cell in crystal structures of metals.
 The term polymer means “many mers,” generally repeated hundreds or thousands of;
times in a chainlike structure.
 Most monomers are organic materials in which carbon atoms are joined in covalent
bonds with other atoms.
Polymerization
 Monomers can be linked into polymers in repeating units to make longer and larger
molecules by a chemical process called a polymerization reaction.
 The following two methods are used to achieve polymerization.
1. Addition polymerization, and
2. Condensation polymerization.
 In addition polymerization, two or more similar monomers directly react to form
polymers. It is also called chain-growth or chain-reaction polymerization.
 It is called “chain reaction” because of the high rate at which long molecules form
simultaneously, usually within a few seconds.
 This rate is much higher than that in condensation polymerization.
 The condensation polymerization takes two or more dissimilar monomers that react to
form polymers plus the by-product water.
 This process is also known as step-growth or step-reaction polymerization, because the
polymer molecule grows step-by-step until all of one reactant is consumed.
Types of plastics
 The plastics are broadly classified in the following two groups:
 1. Thermosetting plastics, and
 2. Thermoplastic materials.
Thermosetting plastics:
 The thermosetting plastics (also known as heat-setting materials) are those plastics
which are formed into shape under heat (in the temperature range of 127ºC to 177ºC)
and pressure and results in a permanently hard product.
 The heat first softens the resins and when special chemicals are added, it becomes hard
by a chemical change known as polymerization.
 The reheating does not soften them again. The thermosetting plastics are soluble in
alcohol and other organic solvents when they are in thermoplastic stage.
 This property is utilized in making paints and varnishes from plastics.
 These plastics are hard, strong and durable. These are manufactured in a variety of
beautiful colours.
Types of plastics
Thermoplastic materials:
 The thermoplastic materials (also known as cold-setting materials) are those plastics
which do not become hard with the application of heat and pressure and no chemical
change occurs.
 They remain soft at elevated temperatures and become hard on cooling.
 They can be remelted repeatedly by the successive application of heat.
 These plastics are better than thermosetting plastics because they can be used again and
again.
 The scrap obtained from the moulding operations and rejected articles can be shaped
into granules and reused to make first quality products.
 These plastics are used for makings toys and other ordinary purposes.
Types of plastics
Types of Thermosetting Resins: Types of Thermoplastic Resins:
 Phenolic resins  Cellulose derivatives
 Amino resins  Polystyrene
 Furane resins  Polyethylene
 Silicon resins  Polypropylene
 Epoxy resins  Acrylic resins
 Polyester resins  Vinyl resins
 Polyurethanes  Polymides
 Polytetrafluoroethylene (PTFE)
 Polymethyl methyacrylate (PMMA)
 Acrylonitrile-butadiene-styrene (ABS)
General Properties of Plastics
 The following are the general properties of plastics due to which it is widely used in
engineering practice.
1. Lightness in weight. The specific gravity varies from 1 to 2.4.
2. Easy workability. The plastics can be easily casted, moulded, drilled, machined etc.
3. Highly resistant to corrosion.
4. Highly resistant to abrasion.
5. Good thermal and electrical insulators.
6. Good strength and rigidity.
7. Absorbent of vibrations and sound.
8. Good resistant to most of the chemicals.
9. Impermeable to water.
10. Low fabrication cost.
11. Good dimensional stability.
12. Can be made transparent or coloured.
Processing of Thermoplastics
 A wide range of techniques are used in plastic processing depending on the type and
nature of polymer.
 The variety of ways that plastics can be processed or formed also increases their
usefulness.
 Small-to-medium sized parts are made by injection moulding; large sheets can be
formed by vacuum forming.
 Medium-to-large parts can be produced by hand lay-up or spray techniques to
produce.
 Other processes such as blow moulding and rotational moulding provide ways to
make hollow parts.
 Profiles can be produced by extrusion.
 Nearly any shape or size of the parts can be manufactured using one of the
techniques.
 Since a single operation is used to produce the finished plastic components, it is very
important to select the material-process combination.
Extrusion moulding
 Extrusion is a process of manufacturing long products of constant cross-section (rods,
sheets, pipes, films, wire insulation coating) forcing soften polymer through a die with
an opening.
 Polymer material in form of pellets is fed into an extruder through a hopper.
 The material is then conveyed forward by a feeding screw and forced through a die,
converting to continuous polymer product.
 Heating elements, placed over the barrel, soften and melt the polymer. The temperature
of the material is controlled by thermocouples.
Extrusion moulding
 The product going out of the die is cooled by blown air or in water bath.
 Extrusion of polymers (in contrast to extrusion of metals) is continuous process
lasting as long as raw pellets are supplied.
 Extrusion is used mainly for Thermoplastics, but Elastomers and Thermosets are
also may be extruded.
 In this case cross-linking forms during heating and melting of the material in the
extruder.
 The thermoplastic extruded products may be further formed by the Thermoforming
method.
Injection Moulding
Plunger type:
 Injection moulding is not only used for thermoplastics and thermosets but also for
elastomers.
 Majority of the plastic parts are made by injection moulding. Injection moulding is
frequently used for mass-production of relatively small parts.
 In this process, plastic compound in powdered or granular form is placed in a hopper,
heated, plasticised and expelled through a nozzle by a plunger or a screw conveyor.
Injection Moulding
 On the far side of the nozzle, there is a mould cavity which serves to shape the plastic
moulding.
 The heat is supplied by circulating steam or hot oil, in coils that are built into the
cylinder wall or by installing electric heating units.
 A spreader is located at the middle of the cylinder to prevent the formation of thick
sections which are difficult to heat and plasticise as the plastic materials furnish good
insulation against heat.
 By action of the spreader, comparatively thin sections are formed which can be easily
heated and melted.
 Venting of the mould must be made to allow the air present to escape.
 The temperature of the material is around 200-300ºC. This molten material flows out of
the nozzle under a pressure of around 35-140 MPa through the spruce opening in the die,
and into the runners which is terminated in a gate leading to the moulding cavity itself.
 The pressure on the plunger is maintained during the period when the material in the
mould cools and contracts.
Reciprocating screw injection moulding
 Most new injection moulding machines used are screw setup instead of
reciprocating plunger.
 Polymer material in form of pellets is fed into an Injection Molding machine
through a hopper.
 The material is then conveyed forward by a feeding screw and forced into a split
mold, filling its cavity through a feeding system with sprue gate and runners.
Reciprocating screw injection moulding
 Screw of injection molding machine is called reciprocating screw since it not only
rotates but also moves forward and backward according to the steps of the molding
cycle.
 It acts as a ram in the filling step when the molten polymer is injected into the mold
and then it retracts backward in the molding step.
 Heating elements, placed over the barrel, soften and melt the polymer.
 The mold is equipped with a cooling system providing controlled cooling and
solidification of the material.
 The polymer is held in the mold until solidification and then the mold opens and the
part is removed from the mold by ejector pins.
 Injection Molding is highly productive method providing high accuracy and control of
shape of the manufactured parts.
 The method is profitable in mass production of large number of identical parts.
Processing of Thermoset plastics
Compression Molding:
 Compression Molding is a process in which a molding polymer is squeezed into a
preheated mold taking a shape of the mold cavity and performing curing due to heat
and pressure applied to the material.
 The method is used mostly for molding thermosetting resins (thermosets), but some
thermoplastic parts may also be produced by Compression Molding.
 The method uses a split mold mounted in a hydraulic press.
 Compression Molding
 Compression Molding process involves the following
steps:
➢ A pre-weighed amount of a polymer mixed with
additives and fillers (charge) is placed into the lower
half of the mold.
 The charge may be in form of powders, pellets,
putty-like masses or pre-formed blanks.
 The charge is usually preheated prior to placement
into the mold. Preheated polymer becomes softer
resulting in shortening the molding cycle time.
➢ The upper half of the mold moves downwards,
pressing on the polymer charge and forcing it to fill
the mold cavity.
 The mold, equipped with a heating system, provides
curing (cross-linking) of the polymer (if thermoset is
processed).
Compression Molding
➢ The mold is opened and the part is removed from it by means of the ejector pin.
 If thermosetting resin is molded, the mold may be open in hot state – cured thermosets
maintain their shape and dimensions even in hot state.
 If thermoplastic is molded, the mold and the molded part are cooled down before
opening.
 Compression Molding cycle time is about 1-6 min, which is longer than Injection
Molding cycle.
 The method is suitable for molding large flat or moderately curved parts.
 Materials commonly processed by Compression Molding are:
❖ Epoxies (EP)
❖ Urea Formaldehyde (UF)
❖ Melamine Formaldehyde (MF)
❖ Phenolics (PF)
Transfer Molding
 Transfer Molding (Resin Transfer Molding) is a process in which a pre-weighed
amount of a polymer is preheated in a separate chamber (transfer pot) and then forced
into a preheated mold through a sprue, taking a shape of the mold cavity and
performing curing due to heat and pressure applied to the material.
 The method is used primarily for molding thermosetting resins (thermosets), but some
thermoplastic parts may also be produced by Transfer Molding.
 The method uses a split mold and a third plate equipped with a plunger (piston)
mounted in a hydraulic press.
 The method combines features of both Compression Molding and Injection Molding.
 Transfer Molding cycle time is shorter than Compression Molding cycle but longer
than Injection Molding cycle.
 The method is capable to produce more complicated shapes than Compression Molding
but not as complicated as Injection Molding.
 Transfer Molding is suitable for molding with ceramic or metallic inserts which are
placed in the mold cavity. When the heated polymer fills the mold it forms bonding
with the insert surface.
Transfer Molding
 Transfer Molding process involves the following steps:
➢ A pre-weighed amount of a polymer mixed with additives and fillers (charge) is placed
into the transfer pot.
 The charge may be in form of powders, pellets, putty-like masses or pre-formed blanks.
 The charge is heated in the pot where the polymer softens.
Transfer Molding
➢ The plunger, mounted on the top plate, moves downwards, pressing on the polymer
charge and forcing it to fill the mold cavity through the sprue.
 The mold, equipped with a heating system, provides curing (cross-linking) of the
polymer (if thermoset is processed).
➢ The mold is opened and the part is removed from it by means of the ejector pin.
 If thermosetting resin is molded, the mold may be open in hot state – cured
thermosets maintain their shape and dimensions even in hot state.
 If thermoplastic is molded, the mold and the molded part are cooled down before
opening.
➢ The scrap left on the pot bottom, in the sprue and in the channels is removed.
➢ Scrap of thermosetting polymers is not recyclable.
Blow molding
 Blow molding is a manufacturing process that is used to create hollow plastic parts by
inflating a heated plastic tube until it fills a mold and forms the desired shape.
 The raw material in this process is a thermoplastic in the form of small pellets or
granules, which is first melted and formed into a hollow tube, called the parison.
 There are various ways of forming the parison.
 The parison is then clamped between two mold halves and inflated by pressurized air
until it conforms to the inner shape of the mold cavity.
 Lastly, after the part has cooled, the mold halves are separated and the part is ejected.
 Parts made from blow molding are plastic, hollow, and thin-walled, such as bottles and
containers that are available in a variety of shapes and sizes.
 Blow molded parts can be formed from a variety of thermoplastic materials, including
the following:
 Low Density Polyethylene (LDPE), High Density Polyethylene (HDPE), Polyethylene
Terephtalate (PET), Polypropylene (PP), Polyvinyl Chloride (PVC).
Extrusion Blow Molding
 Extrusion Blow Molding involves manufacture
of parison by conventional extrusion method
using a die similar to that used for extrusion
pipes.
 The parison is extruded vertically in downward
direction between two mold halves.
 When the parison reaches the required length the
two mold halves close resulting in pinching the
top of parison end and sealing the blow pin in
the bottom of the parison end.
 Parison is inflated by air blown through the
blow pin, taking a shape conforming that of the
mold cavity. The parison is then cut on the top.
 The mold cools down, its halves open, and the
final part is removed.
Extrusion Blow Molding
Extrusion Blow Molding
Injection Blow Molding
 In Injection Blow Molding method, a parison is produced by injecting a polymer into a
hot injection mold around a blow tube or core rod.
 Then the blow tube together with the parison is removed from the injection mold and
transferred to a blow mold.
 Air is injected under pressure blowing the polymer against the mold walls where it
cools and freezes as with extrusion blow molding.
Injection Blow Molding
 Injection Blow Molding is a more accurate and controllable process as compared to
the Extrusion Blow Molding.
 It allows producing more complicated products from a wider range of polymer
materials.
 However production rate of Injection Blow Molding method is lower than that of
Extrusion Blow Molding.
Stretch Blow molding
• Limited to certain plastic materials, such as PET (Polyethylene Terephthalate).
• The container is stretched radially by the blow air and vertically by a mechanical stretch rod.

Refer Textbook – P.N.Rao

Rotational Moulding
 Rotational moulding, also known as rotomoulding, is a plastics moulding technology
which is ideal for making hollow articles.
 It is a casting technic but unlike most other plastics processes there is no pressure
involved.
 Moulds for the process are relatively inexpensive as they do not have to withstand
pressure and therefore relatively short production runs can be made very economically.
 The plastic material in the form of powder is inserted into the mold. The mold
is heated in an oven and rotated biaxial until the powder has melted.
 The molten powder is adhered to the mold wall and makes a thin layer. The mold is
opened and finished part is removed.
 The mold is rotated at different speeds in order to avoid the accumulation of molten
powder.
 The amount of time required to heat the powder at molten temperature in to the oven is
important. If the oven is heated for long time, powder will degrade and it will affect the
mechanical properties.
 Rotational Moulding
 If the mold is heated short time, the
powder may not be completely melted,
resulting in large bubbles in the powder.
 The formed part must be cooled
through the air so that it solidifies
slowly.
 The formed part will shrink on cooling,
and facilitating easy removal of part.
 The cooling rate must be kept within a
certain range.
 The water cooling should be avoided,
because formed part may shrink and
warped after cooling.
 Material Used
 Thermosets and thermoplastic material
can be used, for example: low density
polyethylene (LDPE), HDPE,
polypropylene, and PVC.
Rotational Moulding
Reaction Injection Moulding
 Reaction Injection Moulding (RIM) is the
process used for moulding thermosetting
materials such as polyurethane and epoxy,
which exist in liquid form before they
polymerise.
 The RIM process begins with polymer
liquids (polyol and isocyanate) stored in
storage tanks that are eventually
dispensed by high-pressure industrial
pumps.
 The polymers are recirculated from the
storage tanks to a multi-stream mix-head
and back to the storage tanks in a
continuous loop.
Reaction Injection Moulding
 The process utilizes low-viscosity liquid polymers.
 These polymers expand and thicken through a variety of
chemical reactions. After the polymers have been injected into
the heated mold they eventually harden.
 The result is polyurethane parts with much lighter weight, and
more intricate designs than those created by ordinary injection
molding.
 Typically, this low-temperature process takes less than a minute
to complete, including time for mixing, curing and demoulding.
 Depending on how the polyurethane RIM system is formulated,
the parts moulded with it can be foam or a solid and they can
vary from flexible to extremely rigid.
 The process was originally developed to mould very large
automobile parts such as bumpers, interior trim panels and
spoilers.
 Reaction Injection Moulding
Advantages
 Large Parts - The properties of the liquid
polyurethane components enable them to fill
molds for very large parts.
 Encapsulation of Inserts - Inserts of many types
can be placed into a mold prior to injection of the
RIM material.
 Thick and Thin Walls - The RIM process offers
you the flexibility to design parts with significant
wall thickness variations.
 Low Cost Tooling Options - The low injection
pressures of the RIM process allow for tooling to
be manufactured quicker, and at lower cost, than
tools used in traditional injection molding, or
structural foam.
Film Blowing
 In the process of film blowing, a continuous tubular film is fabricated of which
diameter varies from few centimeters to many meters.
 The principal polymers used in film blowing are the polyethylene (PE) which has
the variations such as linear low and high density; LDPE, LLDPE, and HDPE
etc.
 Commercially, PE film has a significant demand and therefore over 70% of the
current production is LDPE and LLDPE.
 One of the most impressive type of extrusion is blow film extrusion, a combination of
extrusion and blowing.
 The process begins in an extruder where the plastic material is melted and the tube is
formed.
 The tube is drawn upward when is still hot and soft while the air is provided constantly in
order to expand it through the die.
 Then the material of the tube is going upwards by the air and also cooled.
 During this process there are present several types of rolls which have different functions,
such as guiding, collapsing or pinching.
 Film Blowing
 The roll gives the possibility to provide the foil
in one piece.
 The thickness of the foil depends on the
production speed and the diameter of the
blowned plastic.
 Quite a large number of the foil production is
made by this process.
 The advantages of manufacturing plastic film
by this process includes the regulation of film
thickness and eliminate end effects such as edge
bead trim.
 This process can be used for the manufacture of
co-extruded, multi-layer films for high barrier
applications such as food packaging.
Film Blowing
Calendering
 Calendering is a finishing process applied to
textiles and plastic.
 During calendering rolls of the material are
passed between several pairs of heated
rollers, to give a shiny surface.
 Extruded PVC sheeting is produced in this
manner as well other plastics.
 Calendering is a final process in which heat
and pressure are applied to a fabric by
passing it between heated rollers, imparting
a flat, glossy, smooth surface.
 The molten material is fed to the calender
rolls from a large extruder.
 The major plastic material that is calendered
is PVC.
Calendering
 Owing to the large separating forces developed in the calender gap, the rolls tend to
bend.
 This may result in undesirable thickness variations in the finished product.
 Compensations for roll deflections are provided by using crowned rolls having a
larger diameter in the middle than at the ends.
Thermoforming
 Thermoforming is a plastic manufacturing process in which the thermoplastic sheets
are formed with the application of heat and pressure in a mold.
 The thermoplastic sheet is held horizontally over a mold surface and clamped with a
holding device. The sheet is heated up to predetermined temperature using a heating
element called heater.
 The thermostat is used to maintain the temperature of the heater.
 When the temperature becomes substantially high in the mold, the temperature is
controlled by adjusting the heater and providing the cooling air.
 The thermoplastic sheet softens with the application of heat and is pressed into or
stretched over the mold surface by application of air pressure or by any other means.
 The softened sheet conforms to the mold shape and it is held in place until it cools.
 The mold cavity is opened and the thermoformed part is released.
 Some of the plastic materials require air cooling in order to make those rigid quickly,
because plastic materials have low thermal conductivity.
 The excess material is then trimmed out from the formed part.
 Thermoforming
Vacuum Forming:
 In this process, the vacuum pressure is used to
form the heated thermoplastic sheet into the
desired shape.
 The thermoplastic sheet is placed on the mold
surface and fixed with the help of clamping
unit.
 The sheet is heated until it is softens and
thereafter vacuum needs to be applied quickly.
 A surge tank is used to quickly pull the air out
between the mold cavity and the sheet.
 When the vacuum is created, the sheet
conforms to the shape of the mold cavity.
 The formed part is cooled and then ejected
from the mold cavity.
Thermoforming
Vacuum Forming:
Thermoforming
 Pressure Forming
Thermoforming
 Matched die Forming
Bonding of Thermoplastics
Solvent bonding
 Solvent bonding is a common technique used for joining injection molded
components, especially injection molded components of amorphous
thermoplastics.
 When the components are bonded with this technique, the solvent dissolves the
surfaces of the two components and allows the material to flow together.
 After the solvent evaporates, it leaves a pure material-to-material bond.
 The components can be safely set aside to dry after 40-60s of hold time but full
bond strength will not be achieved for 24 to 48 hours.
 In some cases it may be desirable to heat the assembly in an oven to drive of the
excess solvent.
Bonding of Thermoplastics
Solvent bonding
 Advantages of solvent bonding are good, distributes stress over the bonded
surface areas, can provide bond instead of bosses and the bond could be
hermetic.
 Big disadvantages of solvent bonding are that Binder products cannot be
disassembled, sufficient surface area must be available for proper joining, and
solvent vapors released may be hazardous.
 Adequate ventilation has to always be provided to avoid possible health hazards
posed by the use of solvents.
 It is necessary to avoid direct contact with the solvents.
Bonding of Thermoplastics
Adhesive bonding
 Adhesive bonding is one of the most convenient methods of assembling
thermoplastic parts or metal parts.
 Advantage of adhesive bonding is the possibility of joining of similar or
dissimilar materials.
 Adhesives distribute stresses over the entire bonded surface area and can provide
hermetic seal if needed.
 Other advantages are seen in easiness of application using manual or automatic
equipment, elasticity, low costs, easy of repair etc.
 There are five major families of adhesives, each with a somewhat unique set of
characteristics. (Epoxy adhesives, Urethane adhesives, Acrylic adhesives,
Anaerobic adhesives, Cyanoacrylate adhesives).
 The choice of properly type of adhesive, the cure time, cure temperature,
temperature resistance, application area etc. have to be take in account.
Elastomers
Properties of Elastomers
High Elasticity or Rubbery Elasticity
 Elastomers are materials of a very high molecular weight, generally
composed of one or more monomers polymerised or co-polymerised together
to form a polymer (or copolymer).
 The polymer consists of a very long chain of monomer molecules chemically
bonded together to form a single molecule with a molecular weight of
several million.
 This large molecule, which will consist of several tens of thousands of the
small (monomer) units bound together.
 It has a very large length to diameter ratio (often more than 10,000 to 1) and
does not exist as a straight rod-like structure, but in a form known as a
random coil.
Properties of Elastomers
 Flow under stress is a severe limitation to the industrial utilisation of plain
elastomers.
 It can be overcome by cross-linking. In this process the random coils are tied or
cross-linked to others at intervals randomly along their length.
 This is achieved by reaction with added chemicals assisted by heating to 150 to
200°C.
 The resultant mass still exhibits the characteristic high elongation and modulus
behaviour because lengths of random coil between cross-links can still straighten
under load.
 The extent of elasticity will depend upon the length of random coil between
cross-links.
 Physical Properties
 The physical properties of a rubber compound have a complex dependence
on the cross-link system, cross-link density, and the type and quantity of
filler, but in general can be represented as in figure.

Figure. How an elastomer’s properties vary with filler loading or cross-linking density.