Manufacturing Process

(ME 3803)

Dr. Swarnambuj Suman

Assistant Professor
Department of Mechanical Engineering
National Institute of Technology Patna, Patna

Measurements & Instrumentation 1

 MODULE 2

Manufacturing of Plastic Components

Plastics
Plastic
• Plastic is the general common term for a wide range of synthetic or semi synthetic, organic and amorphous
solid materials suitable for the manufacture of industrial products.
• Plastics are typically polymers of high molecular weight, and may contain other substances to improve
performance and/or reduce costs.

Types of Plastics
Plastics can be divided into two major categories:
1. Thermoset or thermosetting plastics.
• Once cooled and hardened, these plastics retain their shapes and cannot return to their original form. They
are hard and durable.
• Thermosets can be used for auto parts, aircraft parts and tires.
• Examples include polyurethanes, polyesters, epoxy resins and phenolic resins.
2. Thermoplastics.
• Less rigid than thermosets, thermoplastics can soften upon heating and return to their original form.
• They are easily molded and extruded into films, fibers and packaging.
• Examples include polyethylene (PE), polypropylene (PP) and polyvinyl chloride (PVC).
Thermoset or Thermosetting Plastics
Classes of Thermosetting Plastics
• Polyurethane Plastics :-
• Polyurethane is the only plastic which can be made in both rigid and flexible foams.
• The flexible polyurethane foam is used in mattresses, carpets, furniture etc.
• The rigid polyurethane foam is used in chair shells, mirror frames and many more.
• Due to the property of high elasticity, some polyurethane plastics are used in decorative and protective coatings.
• The high elasticity makes these polyurethane plastics resistant to a chemical attack.
• Epoxy
• Epoxies are used in numerous ways.
• In combination with glass fibers, it is capable of producing composites that are of high strength and that are heat
resistant.
• This composite is typically used for filament wound rocket motor casings in missiles, in aircraft components, and in
tanks, pipes, tooling jigs, pressure vessels, and fixtures.
• Epoxies are also found in gymnasium floors, industrial equipment, sealants, and protective coatings in appliances.
• Phenolic
• Phenolic plastics are thermosetting resins used in potting compounds, casting resins, and laminating resins.
• They can also be used for electrical purposes and are a popular binder for holding together plies of wood for plywood.
Thermoplastics
Classes of Thermo-Plastics
• Vinyl Plastics
• Vinyl plastics belong to the thermoplastic group.
• Vinyl plastics are the sub-polymers of vinyl derivatives.
• These are used in laminated safety glasses, flexible tubing, molded products etc.
• Polyacrylics Plastics
• Polyacrylics belong to the group of thermoplastics.
• Polyacrylics are transparent and decorative.
• Polyacrylics plastics can be shaped in any form like the windshields for airplane.
• Polyvinyl Chloride
• Polyvinyl Chloride, commonly referred to as PVC or vinyl, was first invented in Germany around 1910.
• It didn't become a useful product in the United States, however, until the late 1920s.
• It became particularly useful during World War II when it was used as a substitute for rubber, which
was in short supply.
• Polyvinyl Chloride is resistant to abrasion and is both weather and chemical resistant.
• Today, it is commonly found in upholstery, wall coverings, flooring, siding, pipe, and even apparel. In
fact, vinyl is perhaps the best known of all plastics.
Thermoplastics
• Polyethylene Terephthalate (PETE)
• PETE is one the most recycled plastic. It finds usage in various bottles like that of soda and cooking oil, etc.
• High Density Polyethylene (HDPE)
• HDPE is generally used in detergent bottles and in milk jugs.
• Low Density Polyethylene (LDPE)
• LDPE finds its usage in dry cleaning bags, food storage containers etc.
• Polypropylene (PP)
• PP is commonly used in bottle caps and drinking straws.
• Polystyrene (PS)
• PS is used in cups, plastic tableware etc.
Some recyclable plastics
Characteristics of Plastics
❑ Mechanical properties
• Mechanical properties refer to displacement or breakage of plastic due to some mechanical change such as applying some
load.
• Mechanical properties are dependent on the temperature, force (load), and the duration of time the load is applied.
• It may also be affected by ultra-violet radiation when used outside.
❑ Thermal properties
• Thermal properties include heat resistance or combustibility.
• Thermoplastic has a larger coefficient of thermal expansion or combustibility and a smaller thermal conductivity or specific
heat than other material such as metals.
❑ Chemical properties
• Chemical resistance, environmental stress crack resistance , or resistance to environmental change are referred as
chemical properties.
• When a plastic contacts chemicals, there is some kind of change. After having a plastic in contacted with chemicals under
no stress for about a week, changes in appearance, weight and size of the plastic are examined. Such changes are
referred to as chemical properties.
❑ Electric properties
• Electric properties are also referred to as electromagnetic properties.
• Electric properties include insulation, conductivity and electro-static charges. Due to their good insulation property, plastics
are often used in electric fields.
• However, plastics do have a defect; they are easily electrified.
❑ Physical properties
• Specific gravity, index of refraction and moisture absorption are called physical properties.
• The specific gravity of the plastic is small, and it varies depending on the character of high polymer , or thermal and
mechanical treatment of the plastic.
Materials for Processing Plastics
Most Plastic resins have to be combined, compounded, or otherwise chemically treated with
processing materials before they are ready for processing.
One of the following additions are usually employed;
1. Plasticizers
2. Fillers
3. Catalyst
4. Initiators
5. Dyes and Pigments
Plasticizers
• Organic Solvents, resins, and even water are used as plasticizers.
• These substances act as internal lubricants improving flow of materials and giving toughness and
flexibility to the material
• Plasticizers are also used to prevent crystallization by keeping the chains separated from one
another.
• The most common plasticizer are, : phthalates, phosphates, carboxylic acid esters, epoxidized fatty
acid esters.
Materials for Processing Plastics
Fillers
• Typical fillers used include wood flour, asbestos fiber, glass fiber, cloth fiber, mica, slate powders
• They may be added in high proportion to many plastics essentially to improve strength, dimensional
stability and heat resistance.
Catalyst
• These are usually added to promote faster and more complete polymerization.
• As such they are also called accelerators and hardeners.
Initiators
• It is used to initiate the reaction, i.e., to allow polymerization to begin
• They stabilize the ends or reaction sites of the molecular chains.
• H2O2 is a common initiator.
Dyes and Pigments
• These are added in many cases, to color the material to different shades
Future of plastic and its application
Advantages of Plastics
Plastics of the following advantages over metals:
1. Plastics are highly flexible as compared to metals. For industries that need designing options, geometry and different kinds of textures, plastics
are going to be the most suited materials.
2. Plastics are cheaper as compared to metals. The manufacturing of plastic parts is budget-friendly.
3. Plastics are highly durable and can last for an indefinitely long period of time. Metals, on the other hand, are much more prone to chemical and
weather susceptibilities.
4. The specific gravity of plastic is much lower making it an extremely lightweight material.
5. Manufacturing of plastic is a faster process as compared to metals.

Applications of Plastics
Plastics are highly durable, lightweight and most importantly can be molded into any form or shape. These properties account for the largest usage of
plastics. Plastics are extremely versatile materials and can be used for a wide variety of purposes. Some usage of plastics are given below:
1. The ability to be moulded makes plastic an ideal packaging material. Plastics in packaging help to keep foods safe and fresh.
2. Being durable and lightweight, plastics have helped in the electronic field. From computers and cell phones to television and microwave, almost all
appliances around us make some use of plastic.
3. Plastics are used to make safety gear like helmets, goggles etc. Plastics are used in the construction industry due to their low maintenance and
high durability.
4. Plastic is strong and lightweight, that is why it is useful in making toys, electrical switches and other household products.
5. Being non-reactive with air and water, plastic is used to store water in plastic bottles and other chemicals in chemical laboratories.
6. Plastic is a poor conductor of electricity and heat. Its insulation property is used for coating the electric wire and to make handles of cooking
utensils and various household products.
Future of plastic and its application
Challenges in Using Plastics
• Plastics are typically made from resources that are non-renewable:
• Although the first materials of plastic came from fibers that were plant-based, most of the items that are
produced now have fossil fuels as their foundation.
• The majority of the pollution discovered in the world’s oceans is plastic:
• Up to 80% of all marine waste comprises plastic. This problem comes from marine and land sources, often
accumulating in large areas of open water where tides come together.
• Plastic pollution can lead to several economic losses:
• Plastic packaging pollution by itself generates an economic loss of approximately $80 billion annually to the global
economy. It makes up approximately 50% of all waste from this industry, and practically every other industry
practices the item in some way.
• Plastic products cannot be infinitely recycled:
• Metals, because of the properties of the material, can be numerous times recycled into a variety of different
products. Plastics don’t bestow that opportunity. People can only recover or reuse it a specific number of times
before it loses its integrity and quality.
• We must spend energy to clean plastics to recycle items:
• Plastics that produce cross-contamination with diverse types formulate unusable products. Before recyclers can
transform the things into new pieces, they also require to have the items cleaned.
Future of plastic and its application
Future of Plastics
As suggested by the futurist Hammond (2007) in his recent publication
• Plastics are already becoming ‘smart’ and will likely serve numerous important roles in future
living, including human tissue or even organ transplants,
• Plastics may act as key materials used in ultra-low-emission lightweight cars and aircraft.
• Plastics may be used as superior insulation for homes that run on photovoltaic technology based
on plastic collectors.
• It may be used as reusable electronic graphic media for books or magazines,
• There are plans to use plastics as smart packaging that monitors food content continuously for
signs of spoilage.
• Polymer based high-efficiency solid-state lighting organic diode technology is also under
development
• As petroleum reserves become more limited, new varieties of plastics are likely to increasingly
be made from renewable biomass.
Plastic Moulding
What is Moulding?
Moulding is a manufacturing process that involves shaping a liquid or malleable raw material by using a
fixed frame; known as either a mould or a matrix.

Common Moulding Processes for Plastics.

• Injection Moulding
• Blow Moulding
• Compression Moulding
• Extrusion Moulding
Injection Moulding
• Injection Moulding Process
It is a manufacturing process used for producing parts or components by injecting molten material into
the mould cavity. Injection molding can be performed with only one of these materials like glass,
plastics, etc. and most commonly, thermoplastic polymers are used.
• Parts of Injection Moulding Machine:
1.Reciprocating Screw
2.Granules
3.Hopper
4.Heater
5.Nozzle
6.Fixed Pattern
7.Mould cavity
8.Moving Pattern
9.Final Product
Injection Moulding
Explanation of Injection Moulding Setup
1. Reciprocating Screw:
The reciprocating screw rotates by means of motor and the reciprocating motion is provided by hydraulic system.
2. Granules:
The thermoplastic granules are to be used in the Injection Moulding Machine to create solid components.
3. Hopper:
By the use of hopper, the plastic granules are to be poured into the Moulding machine.
4. Heater:
It acts as a source of heat for heating the plastic granules to the molten state.
5. Nozzle:
A nozzle of required size is to be placed at the end of heating zone so that, molten material enters from it and acquire the required
shape.
6 and 8. Fixed Pattern and Moving Pattern:
These are the two patterns which are placed side by side so as to form a mould. Among the two patterns, one is the fixed pattern and the
other is the movable pattern.
During Solidification, the molten metal present in between these patterns can stay for some time and after that, the moving pattern
moves aside, and thereby final product is obtained.
7. Mould Cavity:
It is the place where solidification takes place between the fixed pattern and moving pattern and the formation of the component takes
place.
9. Final Product:
Thus the final product will be obtained after cooling.
Injection Moulding
Working Principle of Injection Moulding Machine:
• The reciprocating screw rotates by means of a motor and its reciprocating motion is provided by the hydraulic system.
• The Plastic granules are to be poured into the hopper and they will be pass through the chamber due to the rotation of the
screw.
• The Heater heats the granules to its critical temperature.
• The thermoplastic molten liquid is pressurized (by the hydraulic system) outside the Assembly and allowed to travel through a
nozzle of small diameter[injector] with high velocity and low pressure into the space between the molds.
• The molten charge fills the mould with uniform compaction among the atoms and thereby density is uniform.
• The molten charge is allowed to cool in the mould cavity.
• Any shape and any size of the component can be produced with uniform density.
• Density can be controlled by varying the pressure in the pressure line and thereby production rate is high and wastage is
recyclable.
• The component can be produced any number of times till it achieves the required shape.
Note:
• The thermoplastic molten charge has low viscosity and thereby it can flow easily.
• In the case of thermoset charges, the viscosity is high and thereby it is difficult for it to flow through the nozzle and that's the
reason, thermoplastics are commonly used in Injection Moulding Machine.
Injection Moulding
Injection Moulding
Advantages:
The advantages of Injection Moulding Process are as follows.
• The design flexibility of plastics is very high and it acts as an advantage to the manufacturers to create
various products irrespective of design.
• The scrap is almost zero in this type of machine.
• The color of the products can be managed during the creation of components.
• High production rate.
• Different products can be manufactured by changing dies of mould.
Disadvantages:
The disadvantages of Injection Moulding Process are as follows.
• The machine cost and the tool cost is high.
• The cost for the creation of molds is also higher.
• Larger and complex shapes of the components are difficult to produce with uniform density.
• Difficult to insert metal pieces in the plastic part during the production of the component.
Injection Moulding
Applications:
The applications of Injection Moulding Process are as follows.
• Kitchen Products
• Agriculture Products
• Plastic plates
• Industrial Pump Impeller
• Water Cooler Parts
• Medical Products
Blow Moulding
Blow Moulding is a manufacturing process by which hollow plastic products can be obtained. It is also
used for forming plastic containers, plastic buckets, bottles, or other hollow shapes.

The parts of Blow Moulding process are as follows:

1.The feed from the Extruder
2.Molten Plastic
3.Extruder Head
4.Airtube
5.Parison
6.Mould
7.Air Pressure
8.End Product.
Blow Moulding
Explanation for the Parts of Blow Moulding Setup:
1. The feed from the Extruder:
Extruder is simply a machine which consists of cylinders and barrels where the plastic is to be heated up.
The Feed from the Extruder is given as an input into the Blow Molding Machine.

2. Molten Plastic:
Molten plastic acts as a medium for the creation of plastic hollow components.
3. Extruder Head:
Molten plastic has to be sent to the extruder head so that it can be passed through various other channels.
4. Air tube:
The air tube is used to pressurize the air when the molten plastic enters into the mould cavity and it is about to bulge.
5. Parison:
It is a Tubular shape of hot plastic with a hole at one end through which compressed air can pass.
6. Mould:
Mould cavity consists of patterns where molten plastic is to be deposited and solidification takes place and after solidification, final
product is obtained.
7. Air Pressure:
When the molten plastic enters from the parison into the mould cavity, air pressure is forced into the cavity such that the molten
plastic touches the mould corners and thereafter solidification takes place.
8. End Product:
Finally the end product is obtained after the solidification.
Blow Moulding
Working Principle of Blow Moulding Process:
• The Overview of all the parts of Moulding Machine is shown in the
diagram under Segment A.
• The Feed from the Extruder is given as an input into the Blow
Molding Machine. The feed or the semi-molten plastic it is to be
passed through the extruder head section and thus forming a
parison.
• The parison is a tube-like piece of plastic with a hole at one end
through which compressed air can pass. The parison is to be
passed through the mould.
• The Cope and Drag of mold are to be pressed against each other
and at the same time compressed air is to be passed from the air
tube as shown in segment B.
• By blowing high-pressure air on the soft sheet (parison), it will bend
according to the internal shape of the mold and deposit on the
internal surface of the mould and hence achieve the shape of the
component.
• By the cooling process, the product will regain its hardness.
• This is how you can get the final product in the segment C of the
figure.
• Air pressure required for common products
Water Bottles; P<1 bar
Plastic Buckets; P= 1-2 bar
Large Liquid Containers; P= 2-5 bar
Blow Moulding
Blow Moulding
Advantages
• To produce high thickness plastic parts, high blowing pressure is required.
• Fast production rate.
• Recycling can be done
• Low tool cost in the case of the Blow Moulding process.
Disadvantages
• Difficult to produce Complex geometry of the components with good dimensional accuracy.
• It can be applied only for hollow parts.
• Thick parts cannot be manufactured.
• If the shape of the mold is complex
❖ resulting distribution is non-uniform
❖ compaction of the film is non-uniform
❖ thickness is non-uniform and
❖ dimensional accuracy is low.
Applications
• By this process we can able to make:
• Water Bottles
• Plastic Buckets
• Liquid Containers
• Plastic Cups
• Mugs etc.
Compression Moulding
Compression Moulding is a moulding method in which the moulding material(especially Thermoplastics or
Thermoset plastics) is generally preheated, is placed in a mold cavity and compressed to form different
components.
• Compression Moulding Setup
Compression Moulding
Working Principle
Case 1: For Thermosetting Plastics
• In this Process, the Thermoset liquid is kept in the mould of a required shape and is subjected to the
heating process.
• During heating, the liquid will undergo the following changes i.e.
• liquid gets converted in the form of a gel,
• and by the application of pressure, it turns to solid.
• After that, the Compression load is applied at the gel condition of the liquid so that the shaping of the
component takes place.
• Heating converts the liquid into solid whereas, compression load will give the shape to the component.
Case 2: For Thermoplastics
• The molten charge is kept in the mould of the required shape and subjected to compression followed
by a cooling of the mould.
• Compression gives the shape of the component whereas cooling converts the molten liquid into solid.
• Density and the Strength of the plastic can be controlled by varying the compression load.
• Small and simple shapes of the component can be produced with uniform density.
• Larger and complex shapes of the components are difficult to produce with uniform density.
• Difficult to insert metal pieces in the plastic part during the production of the component.
Compression Moulding
Compression Moulding
Advantages
• It achieves good surface finish.
• The wastage is relatively very small.
• The initial setup cost is low.
• It can be applied to composite thermoplastics with randomly orientated fiber mat, woven fabrics etc.
• It is suitable for manufacturing large and intricate parts.
Disadvantages
• The repetitive nature of the compression molding process leads to wearing of the molds.
• This molding process is not suitable for making complex parts.
• The labor cost is higher in this molding process.
Applications
• Outer envelopes of a washing machine
• Refrigerators
• Automotive Exterior Panels
• Gaskets
• Helmets
• Automobile auto parts etc.
Extrusion Moulding
Introduction
• Extrusion is used for processing most types of thermoplastics and rubbers.
• The extrusion process is a simple process in which molten polymer is forced through a shaped die
using pressure.
• The pressure is generated from the action of screw rotation against barrel wall.

The components of an extruder include:

• Drive
• Screw
• Gearbox and Thrust-bearing
• Feed-hopper
• Barrel
• Breaker Plate
• Die Assembly
Extrusion Moulding
Drive
• It is basically used to provide motion to the screw
Screw
The basic functions of the screw are:
• To transport the polymer from the feed hopper to the extruder outlet.
• To bring about the melting of the polymer.
• To carry out any mixing required during the process.
• To generate a stable and homogeneous supply of polymer melt.
A typical single-stage screw consists of three regions:
(a) The Feed Zone
(b) Compression Zone
(c) Metering (pumping) Zone
Extrusion Moulding
Gearbox and Thrust-bearing
• The gear box is used to provide a range of rpm to the screw.
• The main purpose of using thrust bearing is to sustain load during lateral reciprocating movement of the screw
Feed-hopper
• The feed hopper is used to feed the granular charge into the barrel containing screw
Barrel
• Barrel works as a casing for the screw.
• It also has heating/cooling arrangement for melting the charge
Breaker plate
• A breaker plate is located at the front end of an extruder between screw and die.
• The main purpose of the beaker plate is to support wire mesh filters which screens out dirt or foreign substances
that may have mixed with the polymers.
Die Assembly
• Die is attached to the extruder via an adaptor.
• The adaptor may also be used to change the direction of the flow.
• The geometry (size and shape) and final properties of polymer products are considerably influenced by die
design.
Extrusion Moulding
Extrusion Moulding
Extrusion Moulding
Advantages
• Low production cost of components
• High Production Capacity
• Short lead times to production
• Uniform cross section of parts
• Use of multiple materials are possible in the same part.
Disadvantages
• The setup cost is high
• There is high probability of tool wear
• There is possibility of scaling on the surface of products
Application
• pipe/tubing,
• deck railings
• window frames
• plastic films and sheeting
• thermoplastic coatings
• wire insulation
Plastic Welding
Introduction
• Thermoplastics can easily be welded as can regain their shape after heating.
• Most commonly welded plastics are PVC, polyethylene, acrylics etc.
• They are welded by melting the surface to be joined & allowing them to solidify, as they solidify the
crosslinking of the polymer chains leads to their joining.
Classification of Plastic Welding
• Welding process are classified by the heating method that is used.
• Two general methods are:
• External heating
• Internal heating
❖External heating: It rely on convection & conduction to heat the weld surface.
❖Internal heating: It rely on conversion of mechanical energy into heat through surface friction.
Plastic Welding
Welding By External Heating
They are mainly of two types
• Hot Plate Welding
• Hot Gas Welding
Hot plate welding:
• This process applies heat from a hot plate that is
placed between the plastic surfaces to be bonded.
• The surfaces are pressed and fused together to form
a strong joint.
• Hot plates are made from aluminum alloys.
• Applications of hot plate welding:
❑Polyethylene (PE) pipe welding for gas line
installations.
❑Fuel tank assemblies for the automotive industries.
Plastic Welding
Hot gas welding
• This process utilizes the heat of hot gas
• It is usually air that has been heated by electric
heating elements in the welding gun.
• This is similar to oxy-acetylene welding of metals. The
only difference is that the open flame of oxy-acetylene
welding is replaced by a stream of hot gas.
• Compressed air, nitrogen, hydrogen, oxygen or
carbon dioxide is heated by an electric coil as it
passes through a welding gun
• Applications of hot gas welding:
❑It is used to fabricate pipelines, pond liners, and a
wide variety of vessels.
❑Used to join broken plastics easily.
Plastic Welding
Welding By Internal Heating
They are mainly of two types
• Ultrasonic Welding
• Friction Welding
Ultrasonic welding
• This method uses mechanical vibrations to form the joint.
• The vibrations are of high frequency.
• The parts to be assembled are held together under pressure
between the oscillating horn and an immobile anvil and are
subjected to ultrasonic vibrations of frequency 20 to 40 KHz
at right angles to the contact area.
• Alternating high frequency stresses generate heat at joint
interface to produce a good quality weld.
• Applications :
❑Food packaging,
❑computer components.
Plastic Welding
Friction Welding
• The friction welding of thermoplastic (also called spin welding) is
based on the same principle as that employed for welding of
metals.
• In this process one of the substrates is fixed, while the other is
rotated with a controlled angular velocity.
• Frictional heat causes the polymer to melt
• When the parts are pressed together, a weld is created on cooling.
• Major welding parameters include
➢ rotational speed
➢ friction pressure
➢ forge pressure
➢ weld time
➢ burn off length.
• Applications:
❑Used to make thermoplastic manifolds for the automotive industries