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Introduction To Plastics Processing CIPET.
Introduction To Plastics Processing CIPET.
Introduction To Plastics Processing CIPET.
PROCESSING
1.0 INTRODUCTION
. Every day newer and newer application are being promoted in all the key sectors
of Indian Economy viz, Automobiles, Agriculture, Aerospace. Building &
Construction, Infrastructure, Telecommunication, IT, Medical & Bio Medical
engineering, Packaging, etc.
This necessitates the need for different types processing methods and machinery to
produce quality plastics products at affordable cost .
Processing Semi-finished
Raw Materials
(Powder/granules) or
Finished Products
In a more technocrate way we may say “Get the Shape and set the Shape”.
Technique to get the shape and Set the shape varies depending on Process and
Material employed.
Principles:
Deformation of a polymer melt (ex) Injection, Extrusion, Blow Moulding etc
Deformation of a polymer in Rubbery state
Ex: Thermoforming
Vacuum Forming
Pressure Forming
Deformation of a Suspension
Ex: PVC Plasticsol Processing / Coating
Deformation of a Solution
Ex : Solvent Casting of CN Film
Deformation of a low melt polymer / monomer
Ex: Acrylic Sheet Casting
Preparation of GR Laminates
Machined Structures
Secondary fabrication operation
1.2 CLASSIFICATION OF PROCESSING METHODS
o Growth Potential
Performance Requirements
Practical Engineering
Approach Approach
Material Selection
Ideal Choice
S. Comp./
Inj. Thermo Blow Roto
N Product Extrusion Transfer
Moulding forming Moulding Moulding
o Moulding
1 Narrow neck - - - 1 - -
container
2 Oil Barrels - - - 1 - 1
Upto (200 ltrs)
3. Tanks (20000 - - - - - 1
ltrs)
4. Films,Profiles, - 1 - - - -
Pipes
5 Housing, Auto 1 - 2 2 2 -
parts
6. Wider Neck 1 - - - - -
parts
7. Hallow - - - - - 1
Containers
1. Best Process 2. Supplementary Process
Parameters that help one to select the right options are
6. Testing and providing quality control, from delivery of the plastics, through
production, to the product
7. Interfacing all these parameters by using logic and experience and / or obtaining a
required update on technology.
1.4 PROCESSABILITY:
Processability means generally the ease or difficulty with which a plastic can be
handled during its fabrication into film, moulded products, pipe, etc.
Almost all processing machines can provide useful products with relative ease, and
certain machines have the capability of manufacturing products to very tight
dimensions and performances. The coordination of plastic and machine facilities
these processes.
PROCESSING METHODS – An Overview:
Depending upon the configuration of the part, economic viability and the part
tolerance, etc the process can be selected.
Machine Operation Terminology
Terminology in the plastics industry regarding the operation of machinery is as follows:
Manual Operation
Each function and the timing of each function is controlled manually by an operator.
Semiautomatic Operation
A machine operating semi automatically will stop after performing a complete cycle of
programmed moulding functions automatically. It will then require an operator to start
another complete cycle manually.
Automatic Operation
A Machine operating automatically will perform a complete cycle of programmed
moulding functions repetitively; it will stop only for a malfunction on the part of the
machine or mould, or when it is manually interrupted.
BLOW MOULDING :
Description :
Limitations:
Generally limited to hollow or tubular parts; some versatile mould shapes, other than
bottles and containers.
BLOW MOULDING
INJECTION MOULDING :
Description :
Limitations:
High initial tool and die costs; not economically practical for small runs.
INJECTION MOULDING
EXTRUSION :
Description :
Widely used for continuous production of film, sheet, tube, and other profiles; also used
in conjunction with blow moulding. Thermoplastic moulding compound is fed from a
hopper to a screw pump where it is heated to plasticate then pumped out through the
shaping orifice (die) to achieve desired cross section. Production lines require input and
takeoff equipment that can be complex. Low tool cost, numerous complex profile shapes
possible, very rapid production rates, can apply coatings or jacketing to core materials
(Such as wire).
Limitations:
Description :
Limitations:
Extremely intricate parts containing undercuts, side draws, small holes, delicate inserts,
etc.; very close tolerances are difficult to produce. Time consuming process.
TRANSFER MOULDING
Description :
Widely used to produce Thermoset products with part complexity. Thermoset moulding
compound is fed into transfer chamber where it is then heated to plasticate; it is then fed
by a plunger through sprues, runners, and gates into a closed mould where it cures; mould
is opened and part ejected. Good dimensional accuracy, rapid production rate, and very
intricate parts can be produced.
Limitations:
High mould cost; high material loss in sprues and runners; size of parts is somewhat
limited.
CALENDERING :
Description :
Limitations:
Limited to sheet materials and very thin films are not possible.
ROTATIONAL MOULDING
Description :
Limitations:
Description :
Limitations:
Limited to parts of simple configuration, high scrap, and limited number of materials
from which to choose.
THERMOFORMING
CASTING
Description :
Liquid plastic which is generally thermoset except for acrylics is poured into a mould
without pressure, cured, and taken from the mould. Cast thermoplastic films are produced
via building up the material (either in solution or hot-melt form) against a highly polished
supporting surface. Low mould cost, capability to form large parts with thick cross
sections, good surface finish, and convenient for low-volume production.
Limitations:
Limited to relatively simple shapes. Most thermoplastics are not suitable for this method.
Except for cast films, method becomes uneconomical at high volume production rates.
CENTRIFUGAL CASTING:
Description :
Reinforcement is placed in mould and is rotated. Resin distributed through pipe;
impregnates reinforcement through centrifugal action. Utilized for round objects,
particularly pipe.
Limitations:
Limited to simple curvatures in single axis rotation. Low production rates.
COATING
Description :
Process methods vary. Both thermoplastics and thermosets widely used in coating of
numerous materials. Roller coating similar to calendaring process. Spread coating
employs blade in front of roller to position resin on material. Coatings also applied via
brushings, spraying, and dipping.
Limitations:
Economics generally depends on close tolerance control.
FILAMENT WINDING :
Description :
Limitations:
Limited to shapes of positive curvature; openings and holes can reduce strength if not
properly designed into moulding operations.
LAMINATING :
Description :
Material, usually in form of reinforcing cloth, paper, foil, metal, wood, glass fibre, Plastic
etc., preimpregnated or coated with thermoset resin (sometimes a thermoplastic) is
moulded under pressure greater than 1000psi (7Mpa) into sheet, rod, tube, or other simple
shapes. Excellent dimensional stability of finished product; very economical in large
production of parts.
Limitations:
High tool and die costs. Limited to simple shapes and cross sections.
MATCHED-DIE MOULDING :
Description :
A variation of the conventional compression moulding, this process employs two metal
moulds possessing a close-fitting, telescoping area to seal in the plastic compound being
moulded and to allow trim of the reinforcement. The mat or preform reinforcement is
positioned in the mould and the mould is closed and heated under pressures of 150 –
400psi (1-3MPa). The mould is then opened and the part is removed after curing.
Limitations:
Prevalent high mould and equipment costs. Part often require expensive surface finishing.
SLUSH MOULDING :
Description :
Limitations:
Limited to hollow parts; production rates are very slow; and limited choice of materials
that can be processed.
Effect of polymer properties on Process
Technique
1.6 EFFECT OF POLYMER PROPERTIES ON PROCESS
TECHNIQUE
When processing thermoplastic melts the following factors should be taken into
account in order both to process efficiently and obtain quality products.
Hygroscopic Materials
PMMA, POM upon depredation liberates MMA & formaldehyde respectively - MMA
volatilize and cause bubbles - Formaldehyde gas causes “eye-irritation”.
PVC & POM (acetal) should never be processed one after the other. This may lead to
explosion
Wetting of the polymer melt against the metal wall of processing equipment can
lead to strong adhesion of polymer to metal. Ex: difficulty in removing PVC - Mix
from two roll mill.
PC has a strong adhesion to metal. It can take away the skin of the barrel if not
properly purged
THERMAL PROPERTIES AFFECTING HEATING AND COOLING
In the case of polymer melts the specific heat varies with temperature. For crystalline
polymers such as POM, NYLON etc. latent heat of fusion and sp.heat should be taken in
to account. i.e Total heat content (Enthalpy) =LH of fusion + sp.heat.
PS 200 310
LDPE 200 500
HDPE 260 810
PP 260 670
Because of higher enthalpy PP requires more cooling time than LDPE and PS.
COOLING SHRINKAGE AND COMPRESSIBILITY
When polymers are in molten stage the vibrations of the molecules results in the polymer
chain being pushed apart so that the volume occupied by a given polymer mass is higher
than when the material is solid.
PP 0.905 0.765(210c)
Because polymer melts are compressible moulding shrinkage is much less than the above
fig.
FROZEN-IN ORIENTATION
When polymer melts are being shaped by either injection moulding or Extrusion the
long polymer chains tend to be elongated or uncoiled in the direction of flow.
After shaping, the melt is usually cooled rapidly and there is seldom time for the
oriented molecules to return to a random coiled shape by the process known as
relaxation.
Some orientation is thus “Frozen-in” the product. Such stressed parts are very weak.
Hence annealing is must.
PROCESS SELECTION CRITERIA FOR PLASITC PRODUCTS
Introduction:
With the advent of New Generation Polymers, blends alloys and
composites, over the last decade, the application spectrum of plastics
has been widened.
Today with the result, the plastics have penetrated deeply in all the key
sectors of economy which includes
Automobiles
Telecommunication
Aerospace
Defence
Biomedical
Building & Construction etc
With the availability of host of plastic raw materials and a wide range of
plastic processing methods and technologies, it is a difficult task for the
processor to select a suitable cost effective process for a specific product.
Although in some cases one or more processes may be suitable for producing a
specific plastics product A plastics processor can select a specific process
keeping in mind the key parameters such as cost, quality and cost/performance
balance.
In this presentation, a few selected case - studies were made for the benefit of
plastic processors.
Process Selection Criteria
The following parameters play a key role in selecting the best suited
process to produce a specific product for a specific application.
1. Material Processibility - Limitations
2. Volume of production
3. Size & shape of the product (configuration)
4. Cost to performance balance
5. Quality
Material Processibility Limitations
If a specific material is suitable for a particular application, then material
processibility will decide the specific method of Processing / Production.
Case :1
Product : PET bottle
Process : Blow Moulding
containers, soft drink bottles will have to be produced by Blow moulding only.
Case 2:
Hollow containers such as Tanks (20,000ltrs) will have to be produced by
Case: 1
Product : 200 litres
chemical container
Material : HDPE
Process : 1. Blow
Moulding 2. Roto
Moulding
Sl. Parameter Blow Moulding Roto Moulding
No.
1. Accumulator Three arm
Specific Process
Blow Moulding rotomoulding
2. Volume of Production High Low
3. Initial investment on
High Moderate
plant & machine
4. Performance Good Good
5. Cost/performance Best good
If medium strength and relatively stress free pipes are required with better
optical properties, then centrifugal casting is the best method.
Case: 3
Product : PVC Flexible sheet
Material : Compounded PVC with additives such as plasticizer, stabilizer,
colourants etc.
Process : 1. Calendering 2. Extrusion
Suitable process : Calendering
Reason : Wider width, cost effectiveness
Case: 4
Product : Acrylic sheet
Material : PMMA
Process : 1. Casting 2. Extrusion
Sl. Parameter Casting Extrusion
No.
1. Mechanical Properties Lower Higher
2. Optical properties High Low
3. Initial investment Low High
Stress built-up
Almost stress
4. Stress built-up due to
free
orientation.
Since optical properties are very essential based on cost/performance & quality
casting process is best.
Quality
Mainly due to quality reasons, inspite of higher cost of manufacture, certain products
are produced by a specific process only.
Case:1
PVC - gramaphone records - even today produced by compression moulding.
Reason: Stress-free moulding
Case:2
Product: PP Blown film
Process: Only downward extrusion process should be used instead of upward blown
film process.
Reason:
PP, being a crystalline polymer,in order to get transparency, the film emerging out of
die lips needs to be quenched.The best /economical way of quenching is to dip in
water which is possible only in downward extrusion. So due to quality reason this
process is selected.
Case:3
Product : Plastic float
Material : PP/HIPS
Processes:
1. Roto Moulding
2. Injection Moulding - Two halves and then joining by vibration welding .
Sl. Parameter Roto Moulding Injection Moulding
No. & Welding
1. Initial Investment Moderate High
2. Quality Good Moderate
3. Production rate Low High
4. Low volume / prototype Best -
5. High volume Production - Best