Polymer Processing Design

Course No. PPE-308L

5th Semester

Dr. Farhan Saeed

Assistant professor
Department of Polymer and Process Engineering
University of Engineering and Technology,
Lahore.
f.saeed@uet.edu.pk
Contents
Introduction ............................................................................................................................................... 3
Laboratory organization......................................................................................................................... 3
Contacts ................................................................................................................................................... 3
Conduct of students in laboratory ........................................................................................................ 3
Lab locations ........................................................................................................................................... 3
Laboratory reports ................................................................................................................................... 3
Dates for submission ............................................................................................................................. 3
Submitting laboratory reports ............................................................................................................... 4
Structure of laboratory report ............................................................................................................... 4
Data presentation ..................................................................................................................................... 4
Graphs ..................................................................................................................................................... 4
Tables ...................................................................................................................................................... 5
Overall objectives ................................................................................................................................ 5
List of Experiments ................................................................................................................................. 6
1. Vertical Injection Molding .................................................................................................................. 6
2. Polymer Identification ........................................................................................................................ 6
3. Laboratory Scale Internal Mixer ....................................................................................................... 6
4. Extrusion Wire Coating ..................................................................................................................... 6
5. Compression Molding ....................................................................................................................... 6
6. Blown Film Extrusion Line ................................................................................................................ 6
7. Blow Molding ...................................................................................................................................... 7
8. Injection Molding ................................................................................................................................ 7
Introduction
Laboratory organization
You will perform 8 laboratory exercises for this course. All of these experiments will be written
up as a report according to the questionnaires and guidelines provided. These items are each
worth 10% of the total module marks. This booklet contains the scripts for all the of the lab
exercises. You need to have read the relevant script before beginning a laboratory exercise.

You can improve your chance of receiving high marks for a lab exercise by planning ahead.
This will allow you to:

• Prepare tables to record data.

• Plan graphs that need drawing.

• Prepare questions to ask during laboratory session.

Contacts
Dr. Farhan Saeed

Conduct of students in laboratory

• No smoking, eating or drinking in the laboratory for reasons of health and safety.
• Students are responsible for leaving the apparatus in good condition and the bench
should be clean and tidy. At the end of the practical work one student from each
experimental group will report to the Laboratory Technician, who will check and record
that this has been done.
• Appropriate clothing, including laboratory coat, should be worn at all times.

Lab locations
The various laboratory exercises for this semester take place in a range of locations. Make sure
that you know where to go in plenty of time before the labs. The location of each laboratory
exercise is indicated on the top of their scripts.

Laboratory reports
Dates for submission
Laboratory reports must be submitted within 2 weeks of completing a lab class. After
submission time had passed the reports can only be entertained with prior permission from
Departmental Chairman.
Submitting laboratory reports
All laboratory reports are to be submitted in a soft binding. The report can be produced using
any computer based report writing software (Microsoft Word, Google Docs etc.). Hand written
reports are not accepted (Only the appendix section for calculations at the end of report can be
hand written).

Structure of laboratory report

The laboratory report must use a consistent template and formatting. A typical structure of
laboratory report is given below:

1) Abstract (75-120 words – summary of work done and the main findings).
2) Introduction
3) Experimental – refer to the Lab Sheet for experimental and do not reproduce this in
the text
4) Results and discussion – full presentation of data derived (tables or graphs). Attempt
to assess errors and statistical significance, whenever possible. Discussion of results
and interpretation. As a rule you should make sure that the points covered in the
questionnaire are covered in the full report
5) Conclusions
6) References
The laboratory report must contain table and figure captions with proper formatting. Examples of
calculations should be put into an appendix that appears at the end of report. The appendix will
be used to check the calculations.

Data presentation
Graphs
To gain full marks a graph must meet the following criteria:

• The axes are correctly chosen between Linear/log axes.

 The axes range covers data set without leaving large regions with no data.

 The label step size is suitable (e.g. in steps of 10 for a range from 0 to 50).

 Correct SI prefixes are used so that the numbers are in a sensible range.

 The varied parameter is on the x-axis and the measured/calculated quantity is on the y-

axis.

• The axes are labeled correctly with suitable name and correct units.
 • The data points (and accompanying error bars where appropriate) are clear.

• Any trend line or fit to the data is physically meaningful—e.g. no trend lines (unless a

request has been made for one in the questionnaire).

• All the data sets requested have been plotted.

• No unnecessary decorations such as gridlines have been included.

• A suitably descriptive caption is provided—this is compulsory in reports and may be

requested in questionnaires.

Tables
To gain full marks a table must meet the following criteria:

• Headings are clear.

• The units are included.

• SI multipliers are used so that the numbers are in a sensible range.

• The errors associated with average values are presented.

• The data are presented in columns not rows.

• Where appropriate the data have been calculated correctly.

• In a report a suitable descriptive caption is included.

Overall objectives
There are 8 practical’s in the laboratory rotation covering the processing techniques of Blow
molding, Injection molding, recycling extrusion, film extrusion, pipe extrusion, wire coating and
polymer identification. On completion of the practical sessions the student should be able to (for
each technique):

• Describe the operation of the instrument.

• Discuss the underlying principles.
• Understand the data that can be obtained and how it is analyzed
List of Experiments
1. Vertical Injection Molding
To study the working of a vertical injection molding machine
To examine the effects of process variables (cooling rate, clamping pressure and
injection pressure) on dog bone structure weight, dimensions, and machine output

2. Polymer Identification
To examine some commodity plastics and perform several simple tests to identify them

3. Laboratory Scale Internal Mixer

To study the preparation routes involved in the manufacturing of master batches for
commodity thermoplastics on a laboratory scale internal mixer
To examine the effects of process variables (mixing time, mixing temperature, and
mixing speed) on polymer blend formation in a laboratory scale internal mixer

4. Extrusion Wire Coating

To study the working of an extrusion wire coating machine and examine the product
quality of PVC coated copper wires

5. Compression Molding
To utilize compression molding as a tool for facilitating sample preparation
To investigate the effect of cure time and cure temperature on the polymer sheet
weight, thickness distribution and surface characteristics

6. Blown Film Extrusion Line

To get "hands on" experience on the blown film extrusion process and learn how the
extruder works. Also, to learn how processing parameters affect the properties of
thermoplastic polymers
7. Blow Molding
To study the working of a blow molding machine

To examine the effects of process variables on product weight, dimensions, and

machine output
8. Injection Molding
To study the working of an injection molding machine and examine the product quality
of ABS injection molded articles
DEPARTMENT OF POLYMER AND PROCESS ENGINEERING

POLYE-308L POLYMER PROCESSING DESIGN

VERTICAL INJECTION MOLDING

Objective
 To study the working of a vertical injection molding machine
 To examine the effects of process variables (cooling rate, clamping
pressure and injection pressure) on dog bone structure weight,
dimensions, and machine output.
Equipment
Vertical Injection moulding machine, Vernier calliper, Cutting tools, Scrapper, Weight
balance.
Material
HDPE, LDPE and PP. Report material type, grade, and manufacturer.
Safety Aspects
Use heat resistant gloves when working close to the vertical injection molding machine.
Safety glasses are also provided.

Procedure
Turn on the power supply button. Set the temperature of the barrel at 140-180°C
(depending upon polymer) and allow the preheating of the barrel. Allow almost half an
hour for the temperature to be uniform throughout the barrel. Insert the material (HDPE,
LDPE, PP) in the hopper. Turn on the switch by which the hydraulic ram will push the
material into the barrel. Wait for some time so that the material gets heated and the
solid bed of pellets is transformed into a uniform polymer melt pool. Turn the button for
clamping unit towards right and the clamping unit will be moved upward at the set
pressures. Turn on the button for the injection unit which will cause the injection unit to
be moved downward at the set pressures. The material will then pass through the
nozzle and enter into the mold. Leave the material in the mold for 10-30 seconds for it to
cool down. Remove the sample at different cooling rates and observe the dog bone
structure weight, dimensions, and machine output.

For each run, make the following measurements:

(a) Weight of deflashed dog bone structure (i.e. after removing the flash and pinch-
off) – at least 5 dog bone structure should be weighed and a mean established.

(b) Dog bone structure thickness distribution along the length of dog bone structure.

(c) Extrudate weight extruded per unit time.

Observations and Calculations:

Cooling Rate:

Injection Pressure Clamping pressure Cooling rate Thickness Weight

No.
(kg/cm2) (kg/cm2) (s) (mm) (g)

1 20 30 10

2 20 30 20

3 20 30 30

Injection Pressure:

Injection Pressure Clamping pressure Cooling rate Thickness Weight

No.
(kg/cm2) (kg/cm2) (s) (mm) (g)

1 35 40 10

2 30 40 10

3 25 40 10

Clamping Pressure:

No. Injection Pressure Clamping pressure Cooling rate Thickness Weight

(kg/cm2) (kg/cm2) (s) (mm) (g)

1
25 50 10

2
25 45 10

3
25 40 10
Report:

1. For each of the experimental run, represent the results in tabulated and graphical
form. Also include the pics of each specimen manufactured with proper labelling.
Questionnaire:

2. Account for the changes in deflashed dog bone structure weight and dimensions,
measured in different parts of the dog bone structure, and as a result of changing
the machine variables, by reference to the Rheological properties of plastics
relevant to vertical injection molding machine.
3. How does cooling rate correlate with the morphology (spherulite size, crystalline
region, etc) developed in the molded plastic articles?
4. Explain with reference to the machine operation, why the extruder barrel needs
to be heated for half an hour before production.
5. With regards to the material change on the vertical injection molding machine in
this experiment, draw a scenario chart to highlight the relationship between
molding temperature, material viscosity and material compatibility (polarity
difference, chemical decomposition, degradation etc).
6. Explain the following observations:
a. Screw-machine-made end products generally have better physical properties,
e.g., lower shrinkage, than the same products made from plunger-type machines.
b. Polymers like PVC and HDPE are easier to handle in screw machines than
plunger machines.
DEPARTMENT OF POLYMER AND PROCESS ENGINEERING

POLYE-308L POLYMER PROCESSING DESIGN

POLYMER IDENTIFICATION

Objective
 To examine some commodity plastics and perform several simple tests to
identify them.
Safety Aspects
The copper wire will get hot when heated in a flame. Hold the wire with tongs or forceps
to avoid burns. Keep containers closed and cover any beakers of acetone with a watch
glass. Work in a well ventilated area. Avoid flames. Safety glasses are also provided.

Introduction
Polymers may be identified by a wide variety of tests and instrumental techniques,
depending on the amount of information required and the complexity of the material
under examination. In this experiment, identifications will be carried out using simple
test methods and infra-red spectroscopy.

It is possible to identify many plastics and rubbers by simple tests, without resorting to
the use of advanced instrumental techniques or detailed chemical analysis. A
knowledge of mechanical properties of polymers and processing methods can also be
used as an aid in identification. The effects of fillers, plasticisers and other additives
must, however, be considered.

If these simple testing methods do not provide adequate information, it may be

necessary to resort to the use of instrumental techniques. The most commonly used
technique is infra-red spectroscopy.

Because of the large number of absorptions which occurs in the infra-red region, an i.r.
spectrum serves as a fingerprint for a polymer, and, hence, a useful aid to identification,
in conjunction with element analysis, if necessary.

Experiment
Choose five items for identification from the collection of polymers and polymer products
supplied. Use appropriate tests as described below to identify these.
Simple Tests
Cut Test
The sample is cut with a blade to see if it produces powder form or a continuous strip.

Drop Test
The sample is dropped on the floor to hear if the drop sound is a dull sound or metallic
sound.

Density Test
Density Table
At your lab desk, place one pellet of each of the recycled
resin samples in 100 mL of tap water at room temperature in Substance Density
a 250 mL beaker. Poke the pieces with a glass stirring rod to Water 1.00
knock off any adhering bubbles and try to make them sink.
(1) PET 1.38-1.39
Note whether the sample floats or sinks. Do not pour the
resin samples down the sink — they are insoluble in water! (2) HDPE 0.95-0.97
Take the resin pellets out of the water with your fingers and (3) PVC 1.16-1.35
save the pellets for later. Use the Density Table to find the
(4) LDPE 0.92-0.94
density ranges for each type of plastic. Proceed down the
flow chart, do the tests indicated, and record all your (5) PP 0.90-0.91
observations on the sheet provided. (6) PS 1.05-1.07

Beilstein Test
A copper wire is heated to redness. The heated wire is inserted into the sample. The
wire is then returned to Bunsen flame to detect for a green flame.

Heating Test
Sample is heated to observe the melt flow.

Burning Test
Sample is burnt to see the flammability, acidic/alkaline fumes, nature of flame, self-
extinguishing properties of the sample and nature of the residue.
During the cut test, if the polymer sample exhibits a continuous strip, it is a
thermoplastic. However, if it produces powder form, it is a thermoset.

For drop test, if the polymer sample produces a dull sound, it is an amorphous polymer.
However, if it produces a metallic sound, it is a crystalline polymer.

Polymers that float in water are polyolefins and those that sinks are ruled out as
polyolefins.
Polymers that burn with a greenish flame during the Beilstein test contain halogens
such as chlorine and fluorine.

For a step by step analysis, follow the attached flow charts given with the manual.
Observations:

Sample Appearance Description

Sample Visual Density Cutting Belstein Burning Test Short-
& Test (water Test Test list of
Drop as medium) Polyme
Self Carbon Melt Smoke pH Fire
Test rs
extinguish residue type Observations indicator colour
Questionnaire:

1. Explain the importance of polymer identification with regards to polymer waste

management.
2. What major recycling problems are caused by PVC and PET, which aretwo of the
major commodity thermoplastics?
3. Suggest the methods which can be adopted for the recycling of mixed polymer
waste.
4. Compare mechanical recycling of polymers with incineration or pyrolysis based
recycling.
DEPARTMENT OF POLYMER AND PROCESS ENGINEERING

PPE-308 - POLYMER PROCESSING DESIGN

BLOW MOLDING

Objectives
To study the working of a blow molding machine
To examine the effects of process variables on product weight, dimensions, and
machine output

Equipment
Extrusion blow moulding machine, Vernier calliper, Cutting tools, Scrapper, Weight
balance.

Material
HDPE, blow moulding grade. Report material type, grade, and manufacturer.
Safety Aspects
Use heat resistant gloves when working close to the extruder. Safety glasses are also
provided.

Procedure

Turn on the machine. Switch on the feeding zone, metering zone and compression zone
heaters and adjust the temperatures at 190⁰C, 200⁰C and 220⁰C respectively and leave
the extruder free for 45 minutes. Fill the hopper with High Density Polyethylene pellets,
heated to a molten state. Give a small push to the extruder screw to ensure that the
material which is already present inside the extruder barrel is melted. Switch on the
extruder. HDPE is then extruded through a die head to form a hollow tube called a
parison. The parison is dropped between two mold halves, which close around it.
Open the mould and take the extrudate from die and again close it. Open the air supply
valve for few seconds and close it. The air is forced into the container, where it remains
during the entire blow-cycle. The parison is inflated. Air is allowed to escape during the
exhaust cycle. The plastic solidifies as it is cooled inside the mold. Finally after
sometime open the mould and get the required product.
For each run, make the following measurements:

(a) Weight of deflashed bottle (i.e. after removing the flash and pinch-off) – at least 5
bottles should be weighed and a mean established.

(b) Bottle thickness distribution along the length of one bottle only (per run) and
around the circumference of one bottle only (per run).

(c) Parison weight extruded per unit time (output date required to calculate shear
rate at the die).

QUESTIONNAIRE

1 Calculate the apparent shear rate (s-1) in the annular die for processing run.
(Approximate die exit dimensions are 18 mm diameter and 1 mm gap; assume
that the melt density of HDPE is 800 kg/m3 at each melt temperature).

Apparent shear rate, a  6Q / WH 2 ( for an annular die )

Where Q = volumetric output rate, W = mean circumference, and H = die gap.

2 Account for the effects of melt temperature and screw speed on shear rate
3 State two aspects of melt flow during extrusion blow moulding for which the
elongational viscosity is an important property. How does this relate to the
chosen grade (i.e molecular weight or melt flow index) used for this process.

4 The increase in parison length (L) due to vertical sagging can be estimated by:

L = gtL2/2

Where  is melt density, g is acceleration due to gravity, t is time, L is nominal

parison length (17 mm), and  is the elongational viscosity (at low strain
rate).Estimate L and therefore the modified parison length, L assuming that
HDPE has an elongational viscosity of 0.3MPa.s (note 1 MPa.s = 1 MN.s/m 2).

Can you suggest some factors that influence the value of  in extrusion blow
moulding?

5 With reference to the Rheological properties of plastics relevant to extrusion blow

moulding, account for the observed changes in bottle weight as a result of
changing the machine variables.

Show all steps in any calculations.

Discussion

These points should form the basis of the discussion/interpretation section if this
experiment is to be written up into a major report.

1 Account for the changes in bottle weight and dimensions, measured in different
parts of the bottle, and as a result of changing the machine variables, by
reference to the Rheological properties of plastics relevant to extrusion blow
moulding.

2 Attempt to calculate the shear rate at the die, for each process. (Approximate die
exit dimensions are 18 mm diameter, and 1 mm gap, and volumetric output rate
(Q) can be calculated from the cycle time and the parison mass data). Assume
that the melt-phase density of HDPE at each temperature is 800 kg/m 2.

Apparent shear rate,  a  6Q /WH2 (for an annular die)

Where W = mean circumference, and H = die gap.

3 How does shear rate correlate with screw speed, melt temperature, die swell,
and bottle thickness?

Reference

A W Birley, B Haworth and J Batchelor, Physics of Plastics, Chapter 5, Hanser, 1991

DEPARTMENT OF POLYMER AND PROCESS ENGINEERING

POLYE-308L POLYMER PROCESSING DESIGN

LABORATORY SCALE INTERNAL MIXER

Objective
 To study the preparation routes involved in the manufacturing of master
batches for commodity thermoplastics on a laboratory scale internal mixer
 To examine the effects of process variables (mixing time, mixing
temperature, mixing speed) on polymer blend formation in a laboratory
scale internal mixer.

Equipment
Laboratory scale internal mixer, Vernier calliper, Cutting tools, Scrapper, Weight
balance.
Material
HDPE, LDPE, PS, Carbon black and gelatin. Report material type, grade, and
manufacturer.

Safety Aspects
Use heat resistant gloves when working close to the laboratory scale internal mixer.
Safety glasses are also provided.

Procedure
Turn on the power supply button. Set the temperature of the mixing chamber at 140-
180°C (depending upon polymer) and allow the preheating of the mixing chamber. Allow
almost half an hour for the temperature to be uniform throughout the mixing chamber.
For the preparation of HDPE/PS blends (75/25 w/w), premix the two ingredients in a
plastic bag for a complete sample size of 45 g. Start the motor and allow the screw
rotation to stabilize. Then Insert the premixed material in the mixing chamber. Wait for
some time so that the material gets heated and the solid bed of pellets is transformed
into a uniform polymer melt pool. Keep on mixing the material for 10 minutes. Then stop
the screw and remove the material from the mixing chamber. Repeat the same
experiment by changing the mixing time, mixing temperature and screw rotational
speed.

No. Blend Mixing time Temperature Rpm of

(min) (oC) screw

1 HDPE/PS (75/25 w/w) 5 180 45

2 HDPE/PS (75/25 w/w) 10 180 45
3 HDPE/PS (75/25 w/w) 5 220 45
4 HDPE/PS (75/25 w/w) 5 180 70

For the preparation of master batch (LDPE/LLDPE-g-MA/CB 40/10/50 w/w), premix half
of the carbon black with the LDPE pellets in a plastic bag. Start the motor and allow the
screw rotation to stabilize. Then Insert the premixed material in the mixing chamber.
Wait for some time so that the material gets heated and the solid bed of pellets is
transformed into a uniform polymer melt pool. Keep on mixing the material for 5 minutes
and then start adding the rest of the carbon black slowly into the mixing chamber. After
a mixing time of ten minutes add the calculated quantity of LLDPE-g-MA and mix for
more minutes, then stop the screw and remove the material from the mixing chamber.

Observations and Calculations:

1. A typical internal rheogram generated during the development of a thermoplastic-

elastomer blend is shown in figure above. With reference to the rheological
characteristics of polymers explain the various regions of the rheogram shown
above.
2. Tabulate the formulation for the blend of HDPE/PS and LDPE/LLDPE-g-MA/CB
masterbatches for a total batch size of 45 grams.

Questionnaire:

1. Explain why it is necessary to incorporate compatibilizers and filler surface

treatment in the preparation of masterbatches.
2. What are color masterbatches? Explain their advantages and disadvantages in
polymer compounding.
3. Prepare a list of the commercially important masterbatches available in Pakistan.
The list should include their names, formulation, functions and concentrations
required.
4. Explain the importance of using laboratory scale internal mixers for carrying out
product development of polymer blends
DEPARTMENT OF POLYMER AND PROCESS ENGINEERING

POLYE-308L POLYMER PROCESSING DESIGN

HORIZONTAL INJECTION MOLDING MACHINE

Objective
 To introduce the plastics injection moulding conversion process and to examine
the influence of some process variables on the process efficiency and some
properties of moulded high density polyethylene.

Equipment
Horizontal Injection moulding machine, Vernier calliper, Cutting tools, Scrapper,
Weight balance.

Material
HDPE-Injection Grade. Report material type, grade, and manufacturer.

Safety Aspects
Use heat resistant gloves when working close to the vertical injection molding
machine. Safety glasses are also provided.

Machine Specifications
Manufacturer KAWAGUCHI
Clamp tonnage 175 ton
Screw diameter 50mm
Shot volume 373cm3
Injection pressure 1420kg\cm2
Cycle 60 Hz
Motor 200V
Main 200V
Screw RPM 100
Motor RPM 1400

Modes of Operation
Machine can be operated in following three modes
i- Semi (manual)
ii- Semi-auto
iii- Auto

Procedure
Turn on the injection molding machine and fill the hopper with the material to be
processed. Here we will be using injection grade of HDPE, so the hopper will be filled
with HDPE pellets. Adjust the temperature and other required parameters according to
the type of material being processed. For HDPE the temperature of feeding zone,
compression zone, metering zone and nozzle was adjusted to be 190°C, 180°C, 180°C
and 180°C respectively. Adjust the speed and pressure of injection unit using scales.
For this machine, 1 inch on linear scale refers to a pressure of 5 bars. When the
required temperatures are attained switch the machine to semi manual mode to check
that all the material inside the barrel has melted. Before starting experiment switch the
machine to become neutral. First attach screw unit to mold manually then switch to semi
auto mode and window operation will start. Injection unit will move forward. Then move
the window in close position, Clamping unit (movable platen) will move forward, then the
material will enter into the mold. Backward movement of clamping unit will indicate the
formation of product Whole cycle will take approximately 22 to 23 seconds. Repeat the
process to get more products.

For the moldings collected from each experimental runs, record the following details:

1. Specimen weight (weigh all the components together without the runners);
2. Any visible defects, e.g. flow marks, sinking, surface roughness, mold flashing,
short shots, voids, etc;

Report:

1. For each of the experimental run, represent the results in tabulated and graphical
form. Also include the pics of each specimen manufactured with proper labelling.

Questionnaire:

1. How will cycle time be affected by doubling the thickness of the product? By
decreasing temperature of cooling water? By increasing pressure? Comment.
2. Compare processing by blow molding to injection molding in regard to the
following variables: (a) temperature; (b) pressure; (c) molecular-weights
(viscosity).
3. If cooling time represents 75% of the total cycle time in injection molding,
determine the change in output if the thickness of the product is doubled.
4. In injection molding it was found that the product as obtained is too short.
Suggest three possible solutions. What are the limitations?
5. What is the advantage of using a “hot mold” in injection molding
DEPARTMENT OF POLYMER AND PROCESS ENGINEERING

POLYE-308L POLYMER PROCESSING DESIGN

EXTRUSION WIRE COATING

Objective
 To introduce the plastics extrusion wire coating process and to examine the
influence of some process variables on the process efficiency and some
properties of PVC coated copper wire.
Equipment
Extrusion Wire Coating machine, Vernier calliper, Cutting tools, Scrapper, Weight
balance.

Material
PVC formulation and copper wire. Report material type, grade, and manufacturer.

Safety Aspects
Use heat resistant gloves when working close to the vertical injection molding
machine. Safety glasses are also provided.

Procedure
Switch on the equipment and adjust the parameters i.e. temperatures of each zone of
extruder and rpm according to requirement. In this experiment, adjust the temperatures
of feeding, compression, metering zones and die of extruder to 160, 165 and 170° C
respectively. Conveyor rpm will be adjusted to be 22. Allow the machine to attain the
required temperatures As the material inside the extruder has melted properly and
begins to ooze out of the side feed die start the experiment. Adjust the three copper
wires coming from stand and align them properly through the machine. When material
begins to coat the wire properly stretch the wire up to winders along with proper cooling
so that coating becomes uniform. In this way wire will be coated to a particular
thickness. In order to get a wire of different dimension (thickness) change the rpm of
conveyor to get a wire of changed dimension. In this experiment rpm will be changed
from 22 to 26 and effect of thickness will be studied by changing rpm.

For the coatings collected from each experimental runs, record the following details:

1. Specimen thickness distribution;

2. Any visible defects, e.g. flow marks, sinking, surface roughness, mold flashing,
voids, etc;

Report:

1. For each of the experimental run, represent the results in tabulated and graphical
form. Also include the pics of each specimen manufactured with proper labelling.
DEPARTMENT OF POLYMER AND PROCESS ENGINEERING

POLYE-308L POLYMER PROCESSING DESIGN

COMPRESSION MOLDING

Objective
1. To utilize compression molding as a tool for facilitating sample
preparation.
 2. To investigate the effect of cure time and cure temperature on the polymer
sheet weight, thickness distribution and surface characteristics

Equipment
Compression moulding machine, Rectangular mould, Vernier calliper, PET sheets,
Cutting tools, Scrapper, Weight balance.

Material
HDPE, LDPE and PP. Report material type, grade, and manufacturer.

Safety Aspects
Use heat resistant gloves when working close to the compression molding machine.
Safety glasses are also provided.

Procedure
Turn on the main supply of the machine. Set the molding temperatures (140-200 oC)
on the control unit to heat the upper and lower platens of the compression molding
machine. Place the upper and lower plates of the mold along with the mold cavity in
the compression molding machine. Let the temperature to be maintained by letting
the machine to be heated up for 30 minutes. Calculate the mold cavity volume and by
using density of material being used, find how much amount of material is needed in
the compression process. After attaining the require temperature, take the mold
plates out and pour material in it uniformly. Place back the mold plates along with the
mold cavity in compression molding machine and give it few minutes to pre-heat the
material. Close the mold and apply pressure according to material used. Give it some
time to melt and cure in the mold. Take out the mold plates and then cool down the
material while it is still inside the mold cavity. For cooling three strategies are
employed:
1. Cooling in the open air while the material is still inside the mold cavity and the
cavity is in between the mold plates,
2. Cooling in a water cooled compression molding machine while the material is still
inside the mold cavity and the cavity is in between the mold plates
3. Removing the material from the mold plates and putting it in cold water (10-20 oC)
After cooling, take the sheet out and examine the properties of sample

For each run, make the following measurements:

(a) Weight of plastic sheets (i.e. after removing the flash and pinch-off).

(b) Plastic sheets thickness distribution along the length of plastic sheets.

(c) Mold cavity volume and the amount of material required in each compression
molding operation

Observations and Calculations:

HDPE:

Cooling
Temperature Heating time Thickness Weight
No. procedure
(0C) (min) (mm) (g)

1 180 10 Open air

Compression
2 180 10
cooling

LDPE:

Cooling
Temperature Heating time Thickness Weight
No. procedure
(0C) (min) (mm) (g)

1 140 10 Open air

Compression
2 140 10
cooling

PP:

Cooling
Temperature Heating time Thickness Weight
No. procedure
(0C) (min) (mm) (g)
 1 200 10 Open air

Compression
3 200 10
cooling

Report:

1. For each of the experimental run, represent the results in tabulated and graphical
form. Also include the pics of each specimen manufactured with proper labelling.
2. Report the surface characteristics in term of the appearance of Areas of gas
entrapment (blister), dull appearance, excessive flash, warpage, mold stickiness.

Questionnaire:

1. Suggest the trouble shooting steps that can be taken to remove the surface
characteristics observed during the compression molding of HDPE, LDPE and
PP
2. Explain why compression molding of thermoplastics is limited to small quantity
production while screw injection molding of thermoset is also currently used on a
limited scale.
3. Explain the following observations:
a. It is generally necessary to mold plastics at the lowest possible melt
temperature.
b. For crystalline polymers, high mold temperatures result in enhanced tensile
strength but reduced clarity of the molded part.
4. Explain the difference between thermoforming and compression molding.
DEPARTMENT OF POLYMER AND PROCESS ENGINEERING

POLYE-308L POLYMER PROCESSING DESIGN

BLOWN FILM EXTRUSION LINE
Objective
1. To get "hands on" experience on the blown film extrusion process and
learn how the extruder works.
2. To learn how processing parameters affect the properties of thermoplastic
polymers.
Equipment
Blown film extrusion line, Vernier calliper, Cutting tools, Scrapper, Weight balance.

Material
PP-Blown Film grade. Report material type, grade, and manufacturer.

Safety Aspects
Use heat resistant gloves when working close to the Blown film extrusion line. Safety
glasses are also provided.

Procedure
Turn on the Machine and set the temperatures of the extruder zones and die and allow
them to warm up for 1 hr before starting up the machine. Add polypropylene in the form
of pellets through the hopper and adjust the temperature of each zone. For
polypropylene temperature of die is set at 220°C, temperature of compression zone is
maintained at 200°C and melt temperature is maintained at 190°C. Allow the machine
to attain the required temperatures so that the material can melt properly and film
formed should be free of flaws. When the polymer melt starts to flow through the die
mould, start the experiment. Adjust the air flow through the duct. Mark a point on nip
rolls to measure the rpm. Adjust the speed adjustment screw at any particular speed
level for example low and note the rpm at this speed for particular time say 30 seconds.
After 30 seconds cut the film and measure its thickness using micrometer. Note the
effect of speed on film thickness and calculate the blow up ratio.
BLOWN UP RATIO:
“Ratio of Bubble Diameter to the Die Diameter is called Blown up Ratio.”

𝐁𝐮𝐛𝐛𝐥𝐞 𝐃𝐢𝐚𝐦𝐞𝐭𝐞𝐫
Blow up Ratio (BUR) = 𝐃𝐢𝐞 𝐃𝐢𝐚𝐦𝐞𝐭𝐞𝐫
It is difficult to use calipers on the bubble to measure its thickness unless you knock it
down, a more practical formula is:

(𝟎.𝟔𝟑𝟕∗𝐋𝐚𝐲 𝐟𝐥𝐚𝐭 𝐖𝐢𝐝𝐭𝐡)

Blow up Ratio (BUR) = 𝐃𝐢𝐞 𝐃𝐢𝐚𝐦𝐞𝐭𝐞𝐫

where diameter of die was found to be 51mm. Repeat the same procedure for other
speed levels i.e. intermediate and high and check the film thickness. Report the effect of
changing speed on thickness of polypropylene film.

For each run, make the following measurements:

(a) Thickness and width dimensions of the PP-film.

(b) PP-film thickness distribution along the length of film.

(c) Extrudate flow rate in g/min

Observations and Calculations:

No. Speed Level Revolutions Thickness Lay Flat Width

Per Minute (mm) (mm)
(rpm)
1 Low

2 Moderate

3 High

Report:

7. For each of the experimental run, represent the results in tabulated and graphical
form. Also include the pics of each specimen manufactured with proper labelling.
8. Discuss the appearance of the extruded films? Discuss optical clarity and explain
the origin of the observed appearance.
Questionnaire:
5. Suggest the trouble shooting steps that can be taken to remove the surface
characteristics observed during the blown film extrusion of PP.
6. Address the importance of the blown film extrusion of PP in industry and how the
objectives of this laboratory relate.
7. What are dispersive and distributive mixing?
8. List the advantages and disadvantages of both single and double screw
extruders as far as mixing is concerned?
9. In general, which type, if not both of mixing is accomplished using the processing
employed in this laboratory?