Lecture 4.

2: Processing of Plastics

General Behavior of Polymer Melts:
The research and development in the areas of polymer melts has increased due to its nonlinear
behavior. The rheological behavior of polymer melts depends on the three factors:
(a) Structure of the molecules
(b) Development of a realistic fluid dynamics
(c) Molecular orientation formed during polymerization
The polymer melts are highly viscous liquids, and its viscous flow is often connected with large,
rubberlike elastic deformations. Polymer melts can be elongated without rupture. The viscosity
of polymer melts is much higher than the molecular weight. Polymers have the long chain
molecules with high molecular weights. The molecules are entangled together, increasing its
effective molecular weights. The high viscosity of polymer melts comes from molecular
entanglements. As shear rate increases, the molecules orient more along the flow direction and
the degree of molecular entanglements decreases. Thus, the elasticity increases and the viscosity
decreases with increasing shear rate.

Polymer Melt Viscosity as a Function of Shear Rate
The viscosity of polymer melt at a constant temperature is a function of shear rate. The viscosity
behavior can be understood in terms of molecular mechanism. The viscosity of a polymer melt is
constant and it does not depend on shear rate and at very low shear rate, it follows Newtonian
behavior. Molecular entanglements are constantly dissipated as the molecules slide each other by
flow and are reformed at the same time by the kinetic motions of molecular segments. At very
low shear rates, the rates of dissipation and reformation of entanglement are the same, and the
degree of entanglements remain constant.

Crystallization, Melting, and Glass Transition Phenomena
Crystallization rates are governed by the nucleation and crystal growth. Nucleation becomes
slower at higher temperatures. The melting behavior of semi crystalline polymers is intermediate
between that of crystalline materials (sharp density change at a melting temperature) and that of
a pure amorphous material (slight change in slope of density at the glass-transition temperature).
The melting temperature increases with the rate of heating, thickness of the lamellae, and
depends on the temperature at which the polymer was crystallized. Rigid chains have higher
melting temperatures. Melting involves breaking of the inter-chain bonds, so the glass and
melting temperatures depend on:
Chain stiffness
Size and shape of side groups
Size of molecule
Side branches
Cross-linking

Casting
Casting involves processing plastic material into a required shape. Plastic material is melted and
it is poured in to the mold cavity. The molded part is cooled and solidifies in the mold cavity and
molded part is ejected.

Working Principle
A mixture of plastic material, catalyst, and various additives is heated into oven above the
melting temperature and poured into the mold cavity until the mold is filled. The molten plastic
is gravity filled into the mold cavity. The application of heat accelerates the polymerization
process into the mold cavity and hence it is cured. The molded part is allowed to cool and
solidify, allowing the plastic product to be ejected from the mold cavity. Generally, air cooling is
preferred. A mold release spay is used on the mold surface prior to casting. The process cycle for
casting is very short.
There are two types of mold i.e. rigid and flexible. Rigid mold can be made of metals, plaster,
and epoxy to produce soft and flexible parts or rigid parts. Flexible mold is made of silicone,
latex, and urethane to produce hard plastic parts.

Material Used
Thermosets (such as polyesters, urethanes, phenolics, and epoxy) and thermoplastics (acrylics
and nylons) can be used for casting.

Process Parameters
The main process parameters which affect the casting process are:
Melting temperature of plastic
Pouring temperature
Cooling rates

Applications
It is used to produce variety of toys like designer toys, garage kits, ball-jointed dolls, sheet,
wheels, either individual parts or entire models of objects like trains, aircraft, boat and ships.

Advantages
Low initial investment cost
Dimensional stability
High production rate
Flexible parts can be made

Disadvantages
This is more labor intensive than injection molding
Complex shape cannot be produced