MI 102 Plastic Processing 3

Manufacturing Processes for Plastics
With caution same as described earlier

for chapter 1 and 2 regarding use of ppts
MI-102: Manufacturing Techniques I. I. T. ROORKEE

Introduction
• Use of plastics has increased at much faster than
metals in last 60 yrs
• Applications range from toys, bottles to air craft
components
• Why so
– Large no. of processes available for variety of shapes
– Most of them produce “near net” shape process (no
further processing is needed)
– Low melting point of plastics results less energy
requirement for processing and ease of handling

Common processes are
– Extrusion
– Injection moulding
– Compression moulding
– Transfer moulding
– Rotational moulding
– Thermoforming
– Casting

Plastics History

Plastic types: Thermosets
General properties: more durable, harder,
tough, light.
Typical uses: automobile parts, construction
materials.
Unsaturated Polyesters: boat hulls, furniture,
electrical fittings
Epoxies and Resins: coating of electrical
circuits, composites (fiberglass in helicopter
blades, boats, …)

Plastic types: Elastomers
General properties: these are thermosets, and
have rubber-like properties.
Typical uses: medical masks, gloves, rubber-
substitutes
Polyurethanes: mattress, cushion, insulation,
toys
Silicones: surgical gloves, oxygen masks in
medical applications,

Plastic types: Thermoplastics
General properties: low melting point, softer, flexible.
Typical uses: bottles, food wrappers, toys, …
Polyethylene: packaging, electrical insulation, milk and
water bottles,
Polypropylene: automotive bumpers, microwave
containers
Polyvinyl chloride (PVC): electrical cables cover, credit
cards, car panels
Polystyrene: disposable spoons, forks
Polyamide (nylon): textiles and fabrics, gears, bushing
and washers, bearings
PET (polyethylene terephthalate): bottles for acidic foods
like juices, food trays
PTFE (polytetrafluoroethylene): non-stick coating, raincoats
Extrusion
It is a compression process in which material is forced
to flow through an orifice in die to produce long
slender shaper products.
The cross section of product depends on shape of orifice
open cross-sections (channels) closed cross-sections (tubes, pipes) pellets

Animation

Extrusion Process
• Used for producing pipes, cables, tubes, coated
electrical wires (most of thermoplatics and rare of
thermosets).
• Extrudate are then cut into desired length
• Three steps are feed stock in form of pellets or powder

into extrusion barrel followed by heating, melting then
forced flow through die opening.

Extrusion process

Extrusion
¾ Thermoplastic pellets or powder are fed through
hopper into extruder barrel with a screw.
¾ External as well as frictional heating results in
softening and melting of the plastics.
¾ Screw builds up pressure in the barrel extrudes through
die orifice.
¾ Feed section: material from hopper area into central
region of the barrel;
¾ Compression section: heat from shearing of the plastic
and external heaters causes melting and extracts the
trapped air and materials is compressed
¾ Metering section: involves homogenization with
pressure buildup at the die for pumping through die
orifice.
Injection moulding
• Plastic is heated to highly plastic state and then forced
to flow into a mould cavity under high pressure where it
solidifies. Mostly used for thermoplastics.
• The moulded parts, mostly of near net shape are called
moulding is then removed.
• Production cycle is very short 10-20s.
• Multiple moulding can be used for further higher
production rates

Injection moulding
¾ Melting of plastic pellets or powder in barrel is done
by external heating (hot gases, steam, electrical
resistance etc.) and frictional effects.
¾ Melt is forced into a split-die chamber, either by a
hydraulic plunger or by the rotating screw system
of an extruder.
¾ Molten plastic is forced into the mould cavity in
pressure range from 70 MPa to 200 MPa.
¾ Typical injection-moulded products are cups, fridge
doors, auto bumpers, housings, tool handles, knobs,
electrical and communication components etc.

Steps of injection moulding

Injection Moulding Process

Injection moulding Machines
Injection
moulding
with a
Plunger
Injection
moulding with
a reciprocating
and rotating
screw

Compression moulding
• Involves feeding of the precise
amount of moulding materials
“charge” into lower heated mould
and deforming the charge under
compression by forcing it to flow
and conform to the shape of cavity
followed by removal from mould.
• Mostly for thermosetting plastics
(tp) and elstomers
• Typical parts are dishes, handles,
container caps, fittings, electrical
and electronic components,
washing machine agitators, and
housings.
¾ Flash is formed which is removed
by trimming or by other means.
Types of Compression moulding
(a) positive (for high density parts),
(b) semi-positive (for quality production)
(c) flash type (for shallow or flat parts).

Transfer moulding
• Charge (preform) is loaded in chamber ahead of mould
followed by heating and pressure application to force
softened polymer to flow into the heated mould where
curing occurs.
• This process results in scrap in form of left over
materials called “cull”
• Mainly used for thermosets and elastomers
• There are variants of the process based on how
charge enter the mould
– Pot transfer moulding: (vertical channels)
– Plunger transfer moulding (lateral channels)
POT TRANSFER Types of transfer moulding
PLUNGER TRANSFER

Blow Molding
¾ Blow molding is a modified
extrusion and injection molding
process for developing hollow
products using a tube called
parison.
¾ Extrusion blow molding, a tube is
first extruded, then after clamping
into a mold blowing into the cavity.
¾ In injection blow molding, parison is
first injection molded then hot air is
injected into the parison for
blowing.
¾ Typical products plastic beverage
bottles and hollow containers.
Blow Molding

Rotational Molding
¾ In this a thin-walled metallic split
mold rotated about two
perpendicular axes with
predetermined amount of plastic
followed by heating and cooling
sequence.
¾ Mostly used for thermoplastics
and some thermosets to develop
large hollow parts.
¾ Typical parts tanks, trash cans,

boat hulls, buckets, housings,
toys, carrying cases etc.
Rotational moulding

Thermoforming
¾ It is a forming process of
thermoplastic sheet in a mold by
application of heat and force (positive
or negative).
¾ Heat is applied only for softening in
oven first and force is applied using
positive pressure or vacuum.
¾ Low strength of the plastics are
formed with pressure difference
caused by the vacuum is usually
found sufficient for forming.
¾ Typical parts advertising signs,
refrigerator liners, packaging,
appliance housings, and panels for
shower stalls.
Thermoforming

Thermoforming

Pressure/vacuum thermoforming

Two sheet thermoforming

Casting
¾ Some TP and TS can be cast, in either
rigid or flexible molds, into a variety of
shapes.
¾ Typical cast plastic parts are gears,
bearings, wheels, thick sheets,
components requiring resistance to
abrasive wear.
¾ In the conventional casting of
thermoplastics is heated and poured into
the mold.
¾ The part forms after polymerization taking
place at ambient pressure. Intricate
shapes can be produced with flexible
molds, which are then peeled off.
Variant of casting process plastics
¾ Potting and encapsulation: a variant of plastic
casting important to the electrical and
electronics industry is potting and encapsulation
involves casting the plastic around an electrical
component to embed it in the plastic.
potting is done in a housing which is an
integral part of the product.
in encapsulation the component is coated
with a layer of the plastic.
in both applications, the plastic serves
insulator.
(a)Casting,
(b) Potting
(c) Encapsulation of Plastics

Joining
Chapter 3

What is it?
• A positive (addition) process used for
assembling different members to get
desired the configuration. FUSION WELD
• Joint can be temporary or permanent in
nature produced by mechanical or
atomic bond.
ADHESIVE JOINING SPOT WELD

GAS WELDING
BRAZE WELD
MECH. JOINTS SOLDERING

Classification
• Joining processes can classified in different ways:
– Fusion or plastic state
• Fusion: Gas, arc
• Plastic: Friction and resistance welding
– Source of heat generation
• Gas, arc, laser, electron, friction, ultrasonic
– Composition of welds
• Heterogeneous: a filler material different from the
parent material is used. i.e. soldering and
brazing
• Autogeneous: no filler (TIG with filler and resistance
welding)
• Homogeneous: filler is same as the parent i.e. arc,
gas, and thermit welding
[4.2] CLASSIFICATION of JOINING PROCESSES

Conventional Joining Processes
Bond Nature Examples
Type
Mech. Tempor Threaded Fasteners: Screws,
Joining ary Nuts, Bolts
Perman Riveting and Crimping
ent or Press/Shrink Fit: Pulley, Gear on
Semi- Shaft
perman Snap Fit: C-Rings, Snap Rings,
ent Retainers
Sewing, Stitching, Stapling: for,
cloths, Leather, thin plastics
MI-102:
MI-102: Manufacturing
Manufacturing Techniques
Techniques I. I. T. ROORKEE
I. I. T. ROORKEE

MI 102 Plastic Processing 3

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Manufacturing Processes for Plastics

With caution same as described earlier

MI-102: Manufacturing Techniques I. I. T. ROORKEE

MI-102: Manufacturing Techniques I. I. T. ROORKEE

MI-102: Manufacturing Techniques I. I. T. ROORKEE

MI-102: Manufacturing Techniques I. I. T. ROORKEE

MI-102: Manufacturing Techniques I. I. T. ROORKEE

MI-102: Manufacturing Techniques I. I. T. ROORKEE

MI-102: Manufacturing Techniques I. I. T. ROORKEE

MI-102: Manufacturing Techniques I. I. T. ROORKEE

• Extrudate are then cut into desired length

• Three steps are feed stock in form of pellets or powder

MI-102: Manufacturing Techniques I. I. T. ROORKEE

MI-102: Manufacturing Techniques I. I. T. ROORKEE

MI-102: Manufacturing Techniques I. I. T. ROORKEE

MI-102: Manufacturing Techniques I. I. T. ROORKEE

MI-102: Manufacturing Techniques I. I. T. ROORKEE

MI-102: Manufacturing Techniques I. I. T. ROORKEE

MI-102: Manufacturing Techniques I. I. T. ROORKEE

MI-102: Manufacturing Techniques I. I. T. ROORKEE

MI-102: Manufacturing Techniques I. I. T. ROORKEE

MI-102: Manufacturing Techniques I. I. T. ROORKEE

¾ Typical parts tanks, trash cans,

MI-102: Manufacturing Techniques I. I. T. ROORKEE

MI-102: Manufacturing Techniques I. I. T. ROORKEE

MI-102: Manufacturing Techniques I. I. T. ROORKEE

MI-102: Manufacturing Techniques I. I. T. ROORKEE

MI-102: Manufacturing Techniques I. I. T. ROORKEE

MI-102: Manufacturing Techniques I. I. T. ROORKEE

MI-102: Manufacturing Techniques I. I. T. ROORKEE

ADHESIVE JOINING SPOT WELD

MECH. JOINTS SOLDERING

MI-102: Manufacturing Techniques I. I. T. ROORKEE

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