mr Manufacturing Technology-!

Manufacture of Plastic Components

Pressure
7. How are the organic materials classified?

1) Natural organic
2) Synthetic organic.
2. Give some natural organic materials.

Wood, coal, petroleum and

natural rubber
3. Give some synthetic organic materials.

Plastics, synthetic rubber and

glass.
Figure 5.20 Hoi tool welding

In Figure 5.20 (c), a hot plate

heated by a resistance element is
moved over the films to be joined
and the pressure is applied to
complete the joint.
In Figure 5.20 (d), the heat is
transferred to the area of welding
by the hot platen of a welding
press. The edges of the plastic
are scared and champed in the
press having platens heated by a
resistance element. They are
allowed to stay under pressure
after the workpieces are raised to
the welding temperature.
5.3. TWO MARK QUESTIONS AND ANSWERS
|EES
4. Define degree of polymerization.
A polymer is made up of
linking thousands of monomer.
The degree of polymerization is defined as the
number of monomeric units in a
macromolecule or polymer
molecule.
5. Make a note on polymerization.
A polymer is made up of
linking thousands of monomer.
The process of obtaining large
molecule by linking many
monomers is called polymerization process. It
is achieved by one of the two
processing techniques. They are
as follows:
1. Addition polymerization
2. Condensation polymerization.
^
6. Define co-polymerization process.
The addition of two or more
different monomers in additional
polymerization process is called
co-polymerization process.
7. What is condensation polymerization?
In condensation
poiymerization, two or more
unlike monomers are linked and
there is a repetitive
elimination of smaller molecules
to form a by-product. During
this process, by-product such as
water or ammonia is formed. This
by-product formation is known as
condensation.
[AnitaUniv.Nov y
09,Apr,13&Dec
Manufacturing
>
-/ |
14]
Technology | Manufacture
8* How canofbePlastic
properties of polymers modified?
Components |
The properties of polymers are
modified by the addition of
agents such as ‘additives' and fillers . . 9
9. State the purpose of adding plasticizers. Give some examples ofplasticizers.
To improve the plastic
behaviour of the polymer, the
[Anna Univ. Dec’15] plasticizers are added. The plasticizers
are in the form of liquids with
high boiling point. Examples:
Water, organic solvents and
resins.
10. What are catalysts?
Catalysts are usually added to
promote faster and complete
polymerization. The catalysts
are alsocalled ‘accelerators’and 'hardeners’.
11. State the function of stabilizers.
Stabilizers are added to the plastics
to retard the degradation of
polymers.
 12.
\Mm , and give examples of them.
Define initiators Manufacturing Technology-! j Lubricants
of Plastic Components
6.
«*sa-
The initiators are used to initiate 7. Flame retardants
the reaction i.e. it allows to
begin polymerization. They 8. Solvents
stabilize the end reaction of the 9. Elastomers
molecular chains. 10. Stabilizers.
Example: H2O2 is a common initiator. ■(b) Fillers:
13. What are called elastomers? - •
Additives which are added to 1. Mica
the plastics to enhance their 2. Cloth fibre
elastic properties pre called 3. Asbestos.
16. Discuss the various properties of plastics. [Anna Univ. Noy’09]
elastomers.

14. Describe fillers.

Elongation
(i)

Fillers are used to economize the

(ii) Heat resistance
quantity of polymer required and (iii) Resistance to corrosiori
to. vary the properties to some (iv) Insensitive to tension
extent. The fillers are used to cracks
improve the strength and (v) High rigidity
stability of the plastics. The (vi) High surface hardness
type of fillers used in plastics
is mica and cloth fiber. The mica (vii) High viscosity
and asbestos are used to improve (viii) Short term maximum
the heat resistance capacity of usage temperature
the plastics. (ix) Resistance to shock
15. List out the materials for processing plastics. [Anna XJniv. May’06& Nov’ll] (x) Good durability
Various materials used for (xi) Low density
plastics are as follows: (xii) High strength-to-
weight ratio (xiii)
(a) Additives:
Low humidity
1. Plastic absorption
izers 2. 1

(xiv) Availability of wide

Catalyst variety of colours and
3. Dyes and pigments
transparent
4. Initiators

5. Modifiers
|EES Manufacturing Technology-/ |
General chemical
(xv) corrosion | Manufacture2)of Plastic
Polyethylenes
Components |
resistance 3) Polystyrenes
17. Viscosity is an important property of a polymer melt in plastics shaping processes. 4) Acrylic resins
Upon what parameters does viscosity depend? [Anna Univ. May’16]
5) Vinyls
Viscosity of a polymer melt 6) Polyamide
depends on 7) Methyl methacrylate.
(a) Temperature 22. Classify thermoplastics.
(b) Shear rate 1. Cellulose derivatives
(c) Molecular weight of the 2. Synthetic resins.
polymer affects viscosity. 23. Define poly addition. [Anna Univ. May* 15]
18. Classify the types of plastics. [Anna Univ. Apr’05]
is a process in which many
Polyaddition
1) Thermosetting plastics monomers are bonded together via
2) Thermo plastics. rearrangement of bonds without
the loss of any atom or molecule
19. What are thermosetting plastics?
under specific conditions of
The plastics which are heat, pressure, and/or the
hardened by heat effecting a presence of a catalyst. Some of
non-reversible chemical change the plastics made by using
are called thermosetting plastics. polyaddition include polyethenes,
20. What are the characteristics of thermoplastics? [Anna Univ. May* 06]
polypropylene, PVC, Teflon, Buna
The thermoplastics have rubbers, polyacrylates and
separate long and large size polystyrene.
molecules arranged side by side.
It does not have any cross 24. Give some examples for thermosetting plastics.

linking in their molecular 1) Polyesters

structure. When thermo plastics 2) Silicones
are heated, it becomes very soft 3) Phenolics
and rehardens on cooling. During
heating, the linear bonding links 4) Urea formaldehyde
between molecules breakup and 5) Melamines
molecules are separated. 6) Epoxy resins.
Relinking takes place on cooling
and retains their hardness. -
21. Give some example for thermo plastics.

1) Shellac
 ,
\Mm25. Name two important differences between thermoplastics and thermosetting plastics.
Manufacturing Technology-! j of Plastic Components «*sa-
[Anna Univ. Nov*06 & Nov*12]

S.No. Thermoplastics Thermosetting plastics

1. It is softened by heating. It cannot be softened by this process.

2. It is softer and less strong. It is harder and strong.

3. Structure is made of linear chain Structure is made of cross-linked

molecules. molecules.

, 4. It is produced by addition It is produced by condensation

polymerization process. polymerization process.

5. It cannot be reproduced.

It can be reproduced by heating and cooling.

Plasticity is stable at high temperature.
The temperature increases with increase in
6.
plasticity.

7. It can be remoulded to any shape. It cannot be remoulded.

8. Scrap can be reused. Scrap cannot be reused,

26. Give some additives added to manufacture rubbers.

1. Accelerator
2. Softener
3. Reinforcing agents
4. Fillers
5. Colouring agents. ^
27. Name the various methods of processing thermoplastics. [Anna Univ. Dec*l6]

1. Injection moulding - Plunger

and screw machines
2. Blow moulding
3. Rotational moulding
4. Film blowing
5. Sheet forming process
6. Extrusion process
7. Vacuum forming,
 Manufacturing Technology-1 j Manufacture of Plastic Components EM'
Equipment of cylinder and die
1.
28. What are the two types of injection moulding? , should be non-corrosive.
Ram or plunger type injection
1) 2. The reliable temperature
moulding , controls are essential.
2) Screw type injection
32. What are the applications of injection moulding?
moulding.
29. Why is screw injection moulding machine better than a ram type injection moulding 1. It is used in making parts of

machine? I Anna JJniv. Nov* 09] complex threads.

The screw type injection 2. Intricate shapes such as thin
moulding machine allows much more walled parts can be produced.
precise control over the speed of 3. Typical parts such as cups,
injection and the quality of containers, tool handles,
articles produced than a ram type toys, knobs and plumbing
injection moulding machine. This fittings can be produced.
4. Electrical and communication
machine also allowed material to
be mixed before injection, so components such as telephone
that coloured or recycled plastic receivers can be produced.
33. Name the defects in plastic injection moulding.
could be added to virgin material
and mixed thoroughly before being Flow lines
(i)

injected. Sink marks

(ii)
30. State the advantages of injection moulding. • (iii) Vacuum voids
High production
1. (iv) Surface delaminatipn

capacity and less (v) Weld lines ;

material losses are (V|) Short
possible. x2. The cost shots
is low and it needs less (vii)
finishing operation, Warping
3. It is used for making complex
(viii) Bum
threads and thin walled parts. marks
(ix) Jetting
4. Accuracy of ± 0.025 mm can be
(x) Flash.
achieved. 34. How can be sink marks avoided?
5. Wide range of shapes can be The sink marks can be avoided:
moulded. (i) By increasing the amount of
31. Write down the limitations of injection moulding.
material feed ^
\**m • Manufacturing Technology-1 \ Manufacture of Plastic Components EIBi
(ii) By increasing the cavity to stick to the mould surface
internal pressure due to the speed of injection.
40. Define flash.
(iii) By lowering the cylinder
temperature setting Flash is a moulding defect
which occurs when some molten
(iv) By increasing the plastic escapes from the mould
injection rate cavity .
(v) / By increasing the
41. Explain briefly blow moulding.
injection speed
Blow moulding is a moulding process in
(vi) By lengthening the
which air pressure is used to
injection time. inflate soft plastic into a
35. What are vacuum voids?
mould cavity. In this process, a
-Vacuum voids are pockets of hot extruded tube of plastic
air trapped within or close to called parison is placed between two
the surface of an injection parts of open moulds.
moulded prototype.
36. Define surface delamination. 42. Classify blow moulding.

Surface delamination is a . 1. Injection blow moulding

condition where thin surface 2. Extrusion blow moulding.

layers appear on the part due to 43. Write down the applications of blow moulding.
a contaminant material. 1. It is used in making plastic
37. Mention any two ways to avoid weld lines formation during injection moulding.

(i) By raising the temperature of

bottles and toys.
the mould or molten plastic 2. The hollow containers are
(ii) By increasing the injection produced by this process.
speed
3. The multi-layer blow moulding
38. Define warping.
is used in cosmetics and
Warping (or warpage) is the pharmaceutical industries.
deformation that occurs when
there is uneven shrinkage in the 44. Briefly explain the steps involved in injection blow moulding process.
different parts of the moulded Step 1: The parison is injection
component. moulded around a blowing rod
39. What is jetting?
Step 2: Injection mould is opened and
Jetting refers to a situation parison is transferred to a blow
where the'molten plastic fails
 mould Step 3: Soft polymer is 3.The multiplayer blow moulding
inflated to conform to a blow is used in cosmetics and
mould and Step 4: Blow mould is pharmaceutical industries.
opened and blown product is 48. Differentiate between injection moulding and blow moulding

removed. S.No. Injection moulding

Thermoplastic is injected into a mould.
Blow moulding

Thermoplastic is a sheet / parison that is

45. How is extrusion blow moulding performed? 1.
pushed into a mould by air.
In extrusion blow moulding process, the
starting parison is extrusion 2.
A part thickness is influenced by the mould . A part thickness will differ from place to

moulded rather than injection. In and core relationship. place.

most cases, the process is 3.

90% of die time spent on the job is needed for 50% of the time spent on the job is needed for
organized as a very high production making the mould. making the mould.
operation for making plastic 4.
Minimising the presence of air in the injected As a hollow interior, it requires the air to force
bottles. plastic is a key concern. the plastic to expand.
46. Write down the steps involved in extrusion blow moulding. 5.
When the plastic cools at the end of the The process may end in the first mould or the
The parison is extrusion
Step 1:
moulded around a tube die process, the machine opens and the part
is released.
air may be injected in another section of the
machine.
Step 2: The parison pinches at the
top and seales at the bottom around 6.
Parts tend to be solid plastic parts or Parts tend to be hollow containers such
as bottles.
a metal blow components.'
49. What is the rotational moulding of plastics? [Anna Univ. Novy09]
pin as the two halves of
the mould come together Step 3: In this process, a measured
The tube is inflated -;? quantity of polymer powder is
placed in a thin walled metal
that it takes the shape of mould. The mould is closed and
the mould cavity and Step 4: The it is rotated about two mutually
mould is opened and the perpendicular axes as it is
solidified product is heated.
removed. 50. What is the needfor rotational moulding in manufacturing plastic components?
47. List out the typical products made by blow moulding process. [Anna Univ. Apr’05] ! [Anna Univ. Dec,15J

1. It is used in making plastic The rotational moulding is

bottles and toys. / . . needed to make thin walled
2. The hollow containers are hollow parts.
produced by this process.
\**m • Manufacturing Technology-1 \ Manufacture of Plastic Components EIBi
51. State any four applications of rotational moulding.
1. It is used to produce toys
using PVCLv
2. It is used to make large
containers of polyethylene.
 Manufacturing Technology-1 Manufacture of Plastic Components mm |
3. It is used to make petrol tanks packaging film for frozen
for motorcars from polyethylene
and nylon. products, shrink film for
4. Metallic or plastic inserts are transport packaging, food wrap
moulded by this process.
52. Define film blowing. [Anna Univ. Dec* 16] film, packaging bags and seal
The process in which a packaging film)
continuous tubular film is 3. Laminating film (e.g.
fabricated of which diameter laminating of aluminium or
varies from few centimetres to paper used for packaging for
many metres is called film blowing. example milk or coffee)
53. Describe briefly the principle of film blowing. [Anna Univ. Apr* 10, AprHl& Nov’12l
4. Barrier film (e.g. film made of
Crystalline sharp melting raw materials such as
polymers such as nylon or polyamides and Ethylene-Vinyl
polyethylene terephthalate PET Alcohol Copolymer (EVOH) acting
are very much suited for f lm as an aroma or oxygen barrier
productions by melt casting used for packaging food such as
techniques. Initially, the cold meats and cheese).
heated plastic powder is
extruded by using extrude 55. What is calendaring in processing of plastics? [Anna Univ. Apr* 13]

machines called extruder. In this process is used for sheet

Calendering
extruding process, the thin film making. A calender is a series of
is produced. hard pressure rollers used to
After extruding the thin film, form or smooth a sheet of
it is stretdhed by pulling material such as paper or
rollers through the chilled drum plastic film. In this process,
in the reeling wheel. The thin the plastic compounds composed
film is cooled in the chilled of resin, filler, plasticizer
drum and the rollers are used to and other additives are heated
pull the film from chilled drum. for sometime and passed through
The reeling wheel is used to the heated rollers.
make the film roll. 56. Mention the applications of calendaring.
54. What are the applications of film blowing? 1. It is used for making PVC,
Industry packaging (e.g. shrink tapes, and rainwear with very
1.
film, stretch film, bag film or high production rate.
container liners) 2. It is also used for making
floor tiles and cellulose
2. Consumer^packaging (e.g. acetate sheets.
\**m • Manufacturing Technology-1 \ Manufacture of Plastic Components EIBi
57. Write down the main distinct sections in extrusion process. v^
formed easily.
The screw has three distinct 60. Mention the various methods of thermoforming.

sections. 1. Vacuum forming

1. Feed section connects the
2. Pressure forming
3. Matched die forming.
material from hopper into the 61. What are the advantages of thermoforming?

central region of the barrel. 1. It is extremely adaptive to

2. Melt section in which plastic design requirement.
starts to melt.
3. Pumping section in which 2. It is useful for rapid
additional shearing and melting prototype development.
3. Initial setup cost is low.
occur. 4. Production cost is low.
58. State the applications of screw type extrusion process. 5. There are less thermal stresses
1. It is used to make tubes, than injection moulding and
sheets, films, pipes, ropes and compression moulding.
other profiles. 6. Dimensional stability is good.
62. List down various disadvantages of thermofarming.
2. Complete shapes with constant
cross sections can be extruded 1. Surface finish is poor.
with relatively 2. Parts
: may have non-uniform wall
inexpensive tooling. ^
3. Plastic extruders are also
extensively used to reprocess
the recycled plastic waste or
other raw materials after
cleaning, sorting and/or
blending.
59. Define thermoforming.

Thermoforming is the process in which

the thermoplastic sheets are
formed with the application of
heat and pressure in a mould.
Thin sheet (up to 1.5 mm) and
thick sheet (about 3 mm) can be
[833(1 <-_____________ Manufacture of Plastic Components
1.
Manufacturing Technology-1

3. All parts need Compression moulding

to be trimmed. 2. Transfer moulding.
4. Ribs and bosses 66. What are the different types of compression moulds? [Anna Univ. Nov’13]

cannot be 1. Flash type

moulded easily. 2. Landed positive type
5. Limited number of materials 3. Positive type
can be used. 4. Semi positive type.
6. Very thick plastic sheets 67. What are the applications of compression moulds?

cannot be formed, / 1. It is used to make dishes,

handles, containers, taps and
63. Write down the applications of thermoforming process. _
fittings.
2. Electrical and electronic
1. It is very much useful for components, washing machine
making trays, drink cups and agitators and housings
refrigeration door lines. are .made by this process.
2. It is used for making panels
for shower stalls and
advertising signs.
3. Thin gauge parts made using
thermoforming are primarily
used to package or contain a
food item, disposable cups,
containers, lids, blisters and
clamshells.
64. What is the difference between a positive mould and a negative mould in thermoforming?
[Anna Univ. May’16]
S.No. Positive mould Negative mould

1. A positive mould has a convex shape. Negative moulds have concave cavities.

The heated sheet is draped over the The heated sheet is draped over the
2.
convex form using pressure. concave form using vacuum.

65. What are the processes of thermosetting plastics? /

MSI inside the cavity.
| Manufacture of Plastic Components HBt'l
68. Explain briefly how transfer moulding process is carried out. 2. The viscosity of flow
Transfer moulding is a material is reduced.
modification of compression 3. Uniform thickness of parts
moulding. In this process, the can be obtained.
amount of material is measured 4. Durable and dimensionally
and inserted in a separate
chamber called transfer pot before the stabl^parts can be obtained.
71. Mention the limitations of transfer moulding.
moulding process takes place.
The material is then preheated 1. The scrap rate for transfer
and loaded into a pot. A plunger moulded parts will usually be
is then used to force the higher than compression
material from the pot through moulded parts.
the sprue and runner system into 2. It is more complex than
compression moulding.
the mould cavities. The mould 3. Warpage is more of a problem
remains closed as the material because the flow of transfer
is inserted and opened to materials is softer and
release the part from the shrinks more than compression
runner. The mould walls are grade materials.
heated to a temperature above 72. List down the applications of transfer moulding. [Anna Univ. Nov’l 0]
the melting point of the mould 1. It is used for batch
material. It allows a faster
flow of material through the production.
cavities. 2. Short runs of mould metal
69. List down the points to be considered while designing the transfer mould.
occur during moulding.
1. Flow of materials should be 3. Shape of mould can be
easy. readjusted.
2. Ejecting of mould should be
easy.
3. Heating of all the parts
should be uniform.
70. What are the advantages of transfer moulding? [Anna Univ. Nov* 11]

1. Before completely filling the

plastic in the mould cavity,
little pressure is maintained
inside the mould and it will
create full liquid pressure
73. Classify lamination process.
-1.
joining parts through heating in
High pressure laminates Manufacture of Plastic ComponentsManufacturing Technology-1
order to melt (or eventually
2. Low pressure laminates. soften) and fuse the polymer at
7^. Mention the various stages in lamination process.
th.e interface.
80. Explain briefly how friction bonding takes place in plastics.
Saturation of the base with
1. In friction bonding process,
the resirv lution. one of the substrates is fixed
2. Wet drying
while the other one is rotated
with a controlled angular
3. Size cutting
velocity. When the parts are
4. Pressing. pressed together, the frictional
75. State the uses of reinforced plastics.
heat causes the polymer to melt
Reinforced plastics are used and a weld is created on
for making thin sheets, aircraft cooling.
panels, horns and storage bins.
81. What are the advantages of friction bonding?
76. What are the methods for joining plastics and composites?

1. Mechanical fastening 1. Because the heat is generated

2. Adhesive and solvent bonding at the interface, the
properties of the adjoining
and material are not affected and
3. Welding or fusion bonding. the joint has good mechanical
77. Write down the applications of solvent bonding.
properties.
There are many uses for 2. Due to heat produced directly
solvent bonding in product on the surfaces being joined,
fabrication including the this process has the
sealing of fill and vent tubes advantages of high welding
to airtight products. It is used rate, adaptability to
in manufacturing pipe systems automatic control and
and toys. usability under field
78. List out any four types of adhesives used in adhesive bonding ofplastics.
[Anna Univ. Dec’14] conditions.
(i) Epoxies 82. State the limitations of friction bonding.
(ii) Methyl methacrylates 1. The process can he used only
(iii) Silicone adhesives if at least one of the
(iv) Urethanes. components is cylindrical so
79. Define welding orfusion bonding of plastics. that it can be rotated.
Welding of plastics and their 2. The major limitation of this
composites is the process of process is that the flash is
 formed at the joint. grease and
| Manufacture of Plastic graphite have no
Components HBt'l
Therefore, there is wastage of effect on weld quality.
material. Also, it involves 6. The process is easy to apply
the additional cost in
machining to remove and automate.
this'flash.
83. Mention the applications of friction bonding.

1. This welding process is used

for domestic appliance
components such as a cistern
ball float.
2. It is used to make
thermoplastic manifolds for
the automotive industries.
84. Define ultrasonic welding in plastics.

Ultrasonic welding is a
process in which mechanical
vibrations of high frequency are
used to melt and join plastics.
Typical frequency ranges from 15
to 20 kHz.
85. State the advantages of ultrasonic welding.

1. It is used in mass production

because the welding time are
relatively short. -
2. It is applicable for both
amorphous and semi-crystalline
thermoplastics.
3. It is used to bond dissimilar
materials.
4. A large number of
thermoplastics and a wide
range of thickness can be
welded.
5. Surface contaminants such as
 ManufacturingTechnology-1 //
- 2. Capital cost of equipment is
86. What are the limitations of ultrasonic welding? Manufacture of Plastic ComponentsManufacturing Technology-1 high.
1. Horn size is limited to design 90. What are the applications of vibration bonding?
constraints. 1. Most industrial applications of
2. The process and tools must be vibration welding involve
adapted to the materials to be linear joints that are too long
welded. for ultrasonic welding.
2. The consumer products such as
spectacle frames and type
87. Write down the applications of ultrasonic welding. writer cover are made.
1. Food packaging and computer 3. Industrial applications include
components. filter housings, motor saw
2. Challenging and critical housings, heating valves, air
applications are the standard induction ductirig etc.
91. What is induction bonding?
disposable butane lighter. Induction welding utilizes
88. Mention the advantages of vibration bonding.
inductive heating for melting
1. The parts, of any shape can be down the polymer matrix in the
joined.
joining zone. The components to
2. The quality of joint is better be welded are submitted to an
than the joint obtained using
rotating technique. alternating electromagnetic
3. Weld time for large joint areas field. When there are
ranges from 5-15 seconds in making electrically conductive loops in
vibration welding about four the component, for example
times faster than hot plate carbon fibre reinforcement, eddy
technique. currents are induced. It results
4. Alignment of the finished parts in efficient localized heating
of the plastic laminate.
is consistently good.
89. State the limitations of vibration bonding.

1. Linear vibration welding

requires more complex machinery
than spin welding.
92. Mention the applications of induction bonding.
Induction process is used to make spot, static-jig and scam welds.
93. How does hot gas welding differ from oxy-acetylene welding?

The only difference is that- | Manufacture of Plastic Components

Application Most used plastics HBt'l
the open flame of oxy-acetylene Bearings Acetal, Nylon, PETP,PP

welding is replaced by a stream Bolts & nuts Nylon, PVC,PP

of hot gas. Bushes Nylon, PETP, Acetal, PE
94. Write down any two limitations and applications of hot gas welding.
Electrical insulators' PTFE, Bakelite
Limitations:
Gears Nylon, Acetal, Bakelite
1. It is slow manual process.
2. This process cannot be used in Insulators Acetal, Nylon, PTFE, Bakelite
mass production.
Applications:

1. Hot gas welding is frequently

used to weld vinyl plastics,
polysty-rene and some, other
plastic materials.
2. It is used for fabricating
pipelines, pond liners and a
wide variety of vessels.
95. What is hot tool welding?

In hot tool welding process, a

hot tool transfers the heat to
the plastic workpiece by direct
contact. The four different hot
tool welding processes which are
used to join the plastics
96. Write short notes on the application of plastics. [Anna Univ. Mayy15]

Applications of plastics in
different domains are listed
below:
|ESM . Manufacturing Technology-1 | for producing plastics
5.9. SOLVED QUESTIONS '
| Manufacture of Plastic Components
components.
ma-
[Anna Univ. Nov’12]
Refer chapter 5.4.1.1 in Page
State the purpose of the 5.11.
1.
following in plastics (1)
Plastizers (2) Fillers and (3) 8. Why is screw injection moulding
Stabilizer. machine better than a ram type
[Anna Univ. Dec 7(5]
Refer chapter 5.1.3 in Page injection moulding
5.3. machine? [Anna Univ.Nov’09 & May’10]
2. Discuss the properties of Refer chapter 5.4.1.2 in Page
plastic materials and give their 5.12.
limitations. [Anna Univ. Nov ’09] 9. Explain the application of
Refer chapter 5.1.4 in Page injection moulding. (Anna Univ.Nov’10]
5.4. Refer Page 5.13. v
3. What are the types of plastics?
Refer chapter 5.2 in Page
5.5.
4. Write the difference between
thermoplastics and thermosetting
plastics.
[Anna Univ. Nov ’09 & May 7 5]

Refer chapter 5.2.3 in 5.9.

5. What are the types of moulding
of thermoplastics?
Refer chapter 5.3 in Page
5.10.
6. Explain the principle of
injection moulding process.
[Anna Univ. May ’05, May ’06, Nov ’09, Dec 75& May 76]

Refer chapter 5.4.1 in Page 5.10.

7.Describe briefly the plunger
type injection moulding process
 Explain the various steps
11.
5.22.
required to manufacture a
plastic bottle using blow 15. Explain
moulding the calendering process. [Anna Univ. May’15]
process with neat sketches. [Anna Univ. Refer chapter 5.4.5 in Page
Apr 72]
5.24.
Refer chapter 5.4.2 in Page 16. Briefly explain the following
with sketches:
5.18. 1) Calendering
12. Explain Refer chapter 5.4.8 in Page
the injection blow moulding 5.25.
process. [Anna Univ. May’ 5] 1
2) Blow moulding. [Anna Univ. May’06]

Refer chapter 5.4.3 in Page Refer

5.19. chapter 5.4.2 in
13. Explain briefly with neat Page 5.18. s 17.
sketches two commercially used
methods of blow moulding for Explain the
blowing of plastics bottles and extrusion process.
mention their specific
advantages. Refer chapter 5.3.9 in Page
[Anna Univ. Apr’J3] 5.26.
Refer chapter 5.3.4 in Page Explain with
5.21. 18.

14. What is rotational moulding? neat diagrams the thermoforming

State its advantages and process. State its advantages
limitations.
over other processes. [Anna Univ. Nov’12 &
[Anna Univ. Apr’13]
Dec’14]
Refer chapter 5.4.6 in Page Refer chapter 5.3.10 in Page
5.27.
Discuss any two of the defects
10. 19. Explain how plastic sheets are
that can occur in plastic manufactured by thermo forming
injection moulding. method.
[Anna Univ. May’16\ [Anna Univ. Dec’15]
5.4.1.3 in Page 5.13. Refer chapter 5.3.10 in Page
5,27.
20. Describe any two types of
thermoforming process. [Anna Univ. May’15]
Refer Pages 5.27 & 5.28. | Manufacture of Plastic Components ma-
EEE1 Manufacturing Technology-1
Describe the working principle
21. Manufacture of Plastic Components
of film blowing and thermoforming. moulding.
[Anna Univ.Nov’10]
Explain positive, semi positive
27.
Refer chapter 5.3.7 in Page and flash type compression
moulding.
5.24 for film blowing and
chapter 53.10 in Page 5.27
for thermoforming.
22. Why is the thermoforming a
valuable method for the plastic
manufacturer? Explain the
process with neat sketch. [Anna Univ.
Dec’16]

Refer chapter 5.3.10 in Page 5.27.

23.Sketch and explain the principle
of vacuum forming process for
plastics. [Anna Univ. Nov ’ll]
[Anna Univ. May’06]
Refer chapter 5.3.10 in Page 5.27.
24. Discuss the processing of
thermosetting plastics. [Anna Univ.Nov’09]

Refer chapter 5.4 in Page 530.

25. Describe the compression
moulding process. [Anna Univ. May’06, Nov ’13 & May’16]
Refer chapter 5.4.1 in Page
530. -
26. Describe the following plastic
processing methods with neat
sketches (i) Compression
moulding (ii) Blow moulding. [Anna Univ.
Dec ’16]

Refer chapter 5.4.1in Page

5.30 for compression
moulding and chapter 5.3.2
in Page 5.18 for blow
 Enumerate various methods of
31. (i)
| Manufacture Fusion
bonding
of Plastic Components ma-
bonding thermoplastics. [Anna Univ. Apr ’13 & Dec Refer chapter 5.73 in Page
’15] 5.40.
Refer chapter 5.7 in Page (ii) Vibration welding
5.36. Refer chapter 5.7.23 in Page
32. Describe any one method of 5.43.
bonding thermoplastics. [Anna Univ. May ’05 & (iiij Solvent bonding
May 7 0] Refer chapter 5.7.1.1 in
Refer chapter 5.7.1.2 in Page 5.38.
Page 538. (iv) Induction welding.
/ Refer chapter 5.7.2.4 in
33. Explain briefly the following Page 5.44.
methods of bonding of
thermoplastics: - END of Unit 5-
[Anna Univ. Dec’14]
Refer Page 531.
28. What is transfer moulding? Discuss it advantages and limitations.
[Anna Univ. May ’06, May ’10, Nov ’13, Dec ‘14 & Dec 75]

Refer chapter 5.4.2 in Page 532.

29. What is laminating? Explain the high pressure method of laminating.
[Anna Univ. May’06]

Refer chapter 5.6 in Page 534.

30. Explain the various moulding process for reinforced plastics. [Ann# Univ. Nov ’13]

Refer Page 5.35.