CHITKARA UNIVERSITY

CHITKARA SCHOOL OF MECHANICAL ENGINEERING

;KULWINDER SINGH

Classification of Plastics
Thermoplastic Materials
Fluidic when subject to heat, harden when
cooled
Usually rigid

Thermostatic Materials
Fluidic or powder form before processing, cure
permanently when subject to heat or mixed with
catalyst
Rigid or elastic

General Purpose Thermoplastic

Materials
Polyethylene (PE)
Buckets

Polypropylene (PP)
Microwavable food containers, electric kettles

Polystyrene (PS)
CD cases

PolyVinylChloride (PVC)
Sewage pipes, flexible hoists

Engineering Thermoplastic Materials

Polyamides (PA, Nylon)
Rope

Polymethylmethacrylate (PMMA, Acrylic)

Cups

AcrylonitrileButadieneStyrene (ABS)
Product casing

Polycarbonate (PC)
Outdoor screenings, Bullet-proof windows, Electric
kettles

PolyethyleneTerephthalate (PET)
Soft-drink bottles

Thermostatic Materials
Melamine Formaldehyde, Urea Formaldehyde
(MF, UF)
Dishes, lamination

Phenolics (PF)
Ashtrays, Pot handles, plugs and switches

Polyurethane
Shoe heels

Unsaturated Polyester (UP)

Fibre-glass installations

Epoxy (EP)
Glue, filler

Injection Moulding
The injection moulding machine
consists of a heated barrel equipped
with a reciprocating screw (usually
driven by a hydraulic motor), which
feeds the molten polymer into a
temperature controlled split mould via a
channel system of gates and runners.
The screw melts (plasticises) the
polymer, and also acts as a ram during
the injection phase. The screw action
also provides additional heating by
virtue of the shearing action on the
polymer. The pressure of injection is
high, dependant on the material being
processed; it can be up to one
thousand atmospheres.
Animation: Injection Moulding

Injection Moulding

Typical Injection Mould Job-shop

Typical Injection Moulding Plant

Blow Moulding
The process is divided in to three.
The injection blow moulding machine is
based on an extruder barrel and screw
assembly which melts the polymer. The
molten polymer is fed into a manifold
where it is injected through nozzles
into a hollow, heated preform mould.
The preform mould forms the external
shape and is clamped around a
mandrel (the core rod) which forms the
internal shape of the preform.
The preform mould opens and the core
rod is rotated and clamped into the
hollow, chilled blow mould. The core
rod opens and allows compressed air
into the preform, which inflates it to the
finished article shape.
After a cooling period the blow mould
opens and the core rod is rotated to
the ejection position. The finished
article is stripped off the core rod and
leak-tested prior to packing.
Animation: Extrusion Blow Moulding
Animation: Injection Stretch Blow Moulding
Animation: Injection Blow Moulding

Blow Moulding stepwise

Cont

Blow moulding after Injection

Moulding

Rotational Moulding
The Rotational Moulding process is
essentially split into four operations:
A pre-determined amount of polymer
powder is placed in the mould. With
the powder loaded, the mould is
closed, locked and loaded into the
oven.
Once inside the oven, the mould is
rotated around two axis. The ovens are
heated by convection, conduction and,
in some cases, radiation. As the mould
becomes hotter the powder begins to
melt and stick to the inner walls of the
mould.
When the melt has been consolidated
to the desired level, the mould is
cooled either by air, water or a
combination of both.
When the polymer has cooled
sufficiently to retain its shape and be
easily handled, the mould is opened
and the product removed.

Animation: Rotational Moulding

Adapted from: http://www.bpf.co.uk/bpfindustry/process_plastics_rotational_moulding.cfm

Rotational Moulding

MT3 by Ron Arad

Compression Moulding
Compound or blend is placed in
mould and heated under pressure.
When reaction is complete,
product is cooled and ejected.
Animation: Compression Moulding

Plastic Resources

http://www.matweb.com

http://www.materialconnexion.com

Plastic Resources

http://plastics.bayer.com