CENG 600N: Polymer Processing

(Spring 2007)

Instructor:

Professor Furong Gao Room: 4555 Tel. 7139 Email: kefgao Lu Jinde Email: jinde Room: 7119 Tel: 7146

Injection molding theory and Practice, I.Rubin Good injection molding book, old. Some lecture notes on injection molding will be based on this book. Principles of Polymer Processing, Tadmor & Gogos Very good book on mathematical modeling, it is a bit too mathematical, engineering fundamentals covered in this course will be based on this book. Polymer Processing: Principles and modeling, by Agassant, Avenas, Sergent, & Carreau Chapter 2: Energy & heat transfer processes, and Chapter 3: Flow of molten polymers in various geometry will be adopted from this book. Moldflow Design Principles Good introduction of flow phenomena, some flow analysis will be based on this booklet. Gas-assisted Injection Molding, GE Plastics Good note on gas assisted molding Blow Molding Handbook, Rosato/Rosato Good handbook on blow molding. Plastics Processing: an introduction Michaeli Good introduction book

TA:

Textbook There does not exit a single good text book, lecture notes will be distributed to you (via internet). Major reference books: Polymer Processing, D.H. Morton-Jones, The bookstore has it. Good and simple introduction to all polymer processing techniques. It is too simple for this course. It is used for the course for the processes other than injection and extrusion. Polymer Extrusion, Chris Rauwendaal Very Good book on Extrusion, most lecture notes on extrusion will be based on this book.

Plastics processing related journals & magazines 1. Journal of Polymer Engineering & Science 2. International Polymer Processing 3. Advances in Polymer Technology 4. Plastics Engineering 5. Modern Plastics Encyclopedia 6. Kunststoffe - German Plastics 7. Journal of Injection Molding Technology Marking Schemes Assignments: 25% Mid term: 30% Final Exam: 45% -----------------------------------Total: 100%

Course Contents 1. Introduction of Polymer Processing Processes 2. Relevant eng. fundamentals & polymer properties Review of polymer classifications & its structure Fundamental balances equations (Continuity, Momentum, and Energy Balances) Important thermal properties of polymer Important bulk property Important flow properties and rheology 3. Extrusion Introduction to the hardware aspect Solid conveying zone analysis Plasticating zone analysis Melt conveying zone analysis Die forming Extruder design, and trouble shooting Introduction to twin and multi-screw extruders 4. Injection Molding Introduction to machine hardware aspect Injection molding analysis Modeling of simple flow inside a simple mold Injection mold & design Injection molding flow analysis Injection molding trouble shooting Introduction to non-traditional injection molding processes Powder injection Reaction injection molding
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Course Objectives After the completion of this course, students will have a good understanding of the basic principles and major phenomena encountered in polymer flow and processing. In-depth knowledge of design and analysis of the major polymer processing processes: extrusion & injection molding. Good understanding of other polymer process techniques: bottle and film blowing, calendering, fiber forming, compression molding and transfer molding, etc.

 Gas assisted injection molding 5. Bottle Blow Molding Process Parison design Analysis 6. Introduction to other Polymer processing processes Film blowing Calendering Compression molding Transfer molding etc Lab. Visit and Demonstrations -----------------Polymer Processing (Definition) It is defined as the engineering specialty concerned with operations carried out on polymeric materials or systems to increase their utility Primarily it deals with the conversion of polymeric ram materials into useful finished products. Most use of polymer has been in the areas of low cost and ease of fabrication such as packaging industry. Growth of plastic production

To further growth in using of polymer, the key is to improve, control, and use to the best advantage of the polymer material properties. There are three ways to do this: 1. To produce new polymers of intrinsically greater strength and heat resistance. (Chemistry) 2. To reinforce polymer with other materials such as powders and fibers (ABC etc) 3. To process existing polymers so as to enhance their normal bulk properties such as through
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Human history (in term of using of materials) Stone Age Bronze Age Iron Age Polymer Age

2 million years ago

2500BC

500BC

(Now)
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crystallization, orientation etc. (Polymer processings concern)

C: Processibility 1. Thermoplastic (linear and branched) a material that is solid and posses significant elasticity at low temperature, and can turn into a viscous liquid-like material at a high temperature. The change is reversible. 2. Thermoset: (epoxy resins) a highly cross-linked material cannot be melted or appreciably soften.

Review of polymer classification and structure characteristics. Classification A: Base on nature: 1. biological (nature) Wood, Cotton, 2. non-biological (synthetic) ABS, Rubber, HDPE, B: Polymer Structure 1. Linear (polyethylene, PVC)
R R R R R R

Comparison between thermosets and thermoplastics

Thermoplastics Structure Linear, branched Can be molten or soften

Thermosets Cross-linked Infusible

2. Branched (low density polyethylene)

R R R R R R R R R R R R R

Fusibility

D: Methods of Synthesis 1. Addition:

x CH2-CH2 H-[CH2-CH2]x-H (polyethylene)

3. Cross-linked (vulcanized rubbers)

R R R R R R R R R R R R R R R R R
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2. Condensation
Polymer Reaction

: Graft
HOOC COOH Terephthalic acid

Structure Characteristics of polymer

HO C C OH H2 H2 HO OH Ethylene glycol

HO

OH

OH

H2O

Polymers as a giant molecular have a number of important structural characteristics that determine their processing and end-use mechanical, electrical, thermal, and optical properties. These characteristics are: A: Molecular weight a) Number average

H ......

OH

+H
step growth,

H condensation

H + H2O

Mn=
E: No of monomers used in polymerization 1. Homopolymer: one monomer 2. Copolymer: use two (or more) different monomer types in a single polymer to obtain specific properties. e.g. ethylene-propylene
: Alternating
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n M = N M n
i i i i

b) Weight average

2 niM i = wi M M w= niM i

MW ----> Viscosity ----> Processing hardness ----> Part property

: Random : Block
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B: Molecular weight distribution MW characterizes the average degree of polymerization. It is also important in many instances to know the distribution of the molecular weight in the sample.
Mw low polydispersity high polydispersity

E: Crystallinity While many commercially important polymers exist exclusively in the amorphous state, many other are capable of forming zones (regions, domains) where the random conformation of polymeric chains is replaced by a regular (ordered) conformation reminiscent of that found in regular crystals of lowmolecular weight chemicals.

molecular weight w

C: Degree of Branching Different degree of branching will have different behaviors in a flow situation. [affect the entanglement] D: Degree of cross-linking

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Crystallization is a time-dependent process. A coarse morphology is normally associated with slow cooling and a fine morphology is associated with fast cooling. With the former morphology give a stiffer but more brittle and less transparent materials. Additional notes: Tg, Tm, amorphous and semicrystalline Amorphous are composed of chains that are randomly packed and characterized by a major 2nd order transition: the glass transition. T < Tg; polymer are brittle and glassy solid T > Tg; polymer are rubber-like substance Semi-crystalline materials contain both amorphous regions and crystalline regions. Below the melt temperature, Tm, the amorphous regions behavior likes amorphous material. T > Tm; The material behavior likes melt liquid. F: Orientation Orientation represents the alignment of the polymer molecular. Although usually associated with crystalline structure, orientation can and do occur in amorphous material. If stress is applied, either amorphous polymer or crystalline material will be orientated. It is also possible for orientation to bring about crystallization. This occurs when crystalline polymers have been melted into an amorphous state and oriented.
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Orientation of material has strong effect on the part quality. -------------Polymer Additives A: Stabilizers Classes: Thermal stabilizer UV Stabilizer Anti-oxidants Requirements: Stable and compatible with the resin Non-toxic B: Colorants Colorants such as pigments and dyes that absorb light at specific wavelengths added to polymers to produce desired colors. Requirements: Similar to those of stabilizers C: Reinforcing agents

This category of additives is very board and yet very important in that such additives improve the mechanical properties of the base polymers, mainly strength and stiffness.

D: Fillers The main function of fillers is to reduce the cost of end product.

E: Lubricants Lubricants are very low concentration additives that mix with polymers to facilitate their flow behavior during processing. It can be divided into external and internal lubricants two categories: External lubricant: Incompatible with the polymer at all the temperatures, it migrates to metal-polymer surface to promote effective slippage. Internal lubricant: Compatible at processing temperature, incompatible at use temperature. It, therefore, is used to reduce the chain-to-chainintermolecular force to reduce viscosity.
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Videos: BBC: Technical studies: Plastic Materials (TP1140 P5 1981) BBC: Technical Studies: Manufacturing with Plastics (TP1140 M35 1981)

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