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Plastics
Technology
Practice
The Hong Kong Polytechnic University
Industrial Centre
IC LEARNING SERIES
Plastics Technology
Practice
Suitable for the following learning modules offered by the Industrial Centre:
Plastics Technology
P ract ic e
Objectives:
1. Introduction
In general term, plastic refers to the suitability for manufacturing and moulding
into different shapes. Technically, plastics are polymers of high molecular weight
by linking together many small monomers and may contain other organic, semi-
organic or inorganic chemical substances to improve performance and/or reduce
costs.
On the other side of the coin, plastic packaging offers a superior ability to protect
products against contamination; plastic pipes safely transport water or waste for
their superior corrosion resistance and high strength to weight ratio; plastic
vehicle parts consume less fuel for it weight to fuel impact; in electrical and
electronics enable plastics to make our living easier, safer, less expensive and more
fun for their ease of fabrication into complex shapes, insulation and colourful or
transparent aesthetic aspect.
Furthermore most plastics are petroleum base product and the energy required to
produce plastics is just half of the energy required in producing paper and 1/5 in
producing steel. Plastics can be firstly reused, replaced, and reduced and
ultimately recycled at the end of their useful life. Plastic parts are littered because
they are unfashionable rather than because they are worn out. Our living style is
harming the earth not the plastics.
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The European Union has enforced a series of directives to ensure the sustainable
development of mankind in using our nature resources.
In the past thirty years, China has grown into a giant in the plastics industry,
ranking first in the world in the production volume of plastics processing
machines, second in the production of plastic products, and third in the
consumption of plastic resins and the largest importer of nature rubber. In 2007
annual plastics consumption in China is over 40 million tons and rubber
consumption will reach 3.8 million tons in 2008. China is developing into one of
the largest markets for plastic and rubber products in the world.
2. Plastic Material
Plastics can be classified into three main types, namely the thermoplastics,
thermosets and the elastomers, accordingly to their physical or chemical
hardening processes.
2.1 Thermoplastics
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weak Van der Waals forces or stronger hydrogen bonding or stacking of aromatic
rings, while a highly crystalline structure is well order, an amorphous structure is
random. Most of the plastics are in form of semi-crystalline by a combination of
these two structures with certain degree of intra-molecular forces into a semi-
ordered structure.
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2.2 Thermosets
Thermoset materials are heat-sensitive
synthetic materials which, when subject to
heat and usually pressure, will undergo
chemical change with their molecules cross-
linked together to become permanently
insoluble and infusible. Thermosets cannot
be remelted and reformed after cured and
the process is irreversible. This reaction is
somewhat like cooking an egg: once cooked, it is set permanently.
2.3 Elastomers
Elastomers are natural or synthetic materials with rubbery properties that can be
stretched to at least 200 percent of their original length repeatedly (at room
temperature) and which will return with force to their approximate original length
when the applying stress is released. Natural rubber is an agricultural products
harvested mainly from Thailand, Indonesia and Malaysia in meeting the rapid
demand of automobile tyre industry, latex gloves, high pressure hydraulic hoses,
escalator handrails, rubber seals, rubber pad, elastic rubber thread and ribbed
rubber sheets. Thermoplastic elastomers (TPSs) is a kind of injection mouldable
plastics that are low modulus, flexible with both thermoplastic and elastomeric
properties in replacing traditional rubbers. The TPE is a class of copolymers based
on urethanes, polyesters, styranics and olefins. TPSs are found in products for the
consumers, medical, sports and leisure, automotive, lawn and personal care
market segments for their ease of processing and soft to touch texture.
Additives and fillers are added to improve the performance or to reduce cost of
polymer during processing, or their servicing capabilities. The followings are some
common additives and fillers.
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• Density is equal to mass per volume. Density = mass (g) / volume (cm3), by
knowing the volume of the material, the weight of the material can be
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• Flexural Strength is the measure of how much stress (load) can be applied
to a material before it breaks. ISO 181, 871, 1210.
• Ductility describes the extent to which a material can be deformed
without fracture.
• Hardness is the resistance to compression, indentation and scratch.
Durometer hardness tester is used to measure the material resistance
against the indentor spring load balance. The hardness is ranging from 1
to 100 with Shore A. B, C, D, DO, E, M, O, OO, OOO,OOO-Sand R standards.
The general Shore A standard is for normal elastomer and Shore D is for
hard plastics (ASTM D2240 A and D testing standards). ISO 868.
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Lastly, there is only less than 1% of plastics consumption that is classified as high
technology plastics. These plastics are with superior high temperature with much
improved mechanical properties such as liquid crystalline polymers (LCPs),
polyetheretherketone (PEEK), Polysulfones (PSU), Polyphenylene sulfide (PPS,
Polyarylates (PAR), Polyimides (PEI) and the others.
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Thermoplastics
High Density Polyethylene (HDPE): is one of the most stable and inert polymers,
exhibiting very high resistance to chemical attack including alkalis, aqueous
solutions, non-oxidising acids and to a lesser extent, concentrated oxidising acids.
HDPE is used in hollow toys, playground equipment, tanks, milk bottles and water
pipe and very thin carry bags.
Polyvinyl Chloride (PVC): is commonly used as for the insulation on electric wires
and over 50% of PVC manufactured is used in construction.PVC is used as
magnetic stripe cards, window profiles, pipe, plumbing and conduit fixtures.
Low Density Polyethylene (LDPE): is used for plastic wrap, plastic bags, dispensing
bottles, wash bottles and food storage containers for its flexibility and soft
features.
Polypropylene (PP): has a melting point of ~160°C and is rated as 120°C operating
temperature and is suitable for food containers that need to be dishwasher safe.
Polypropylene is also very easy to add dyes to, and is used as hinges, food
packaging, textiles, laboratory equipment, automotive components, and polymer
banknotes.
Polystyrene (PS): Pure solid polystyrene is a colourless, hard plastic and brittle, can
be transparent for plastic assembly kits, plastic cutlery, rigid, economical plastics.
Expanded polystyrene for packaging is used as foam for protection.
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Polyamide (PA): is commonly known as nylon for its trade name, it is High
mechanical strength, rigidity and thermal stability, good impact resistance even at
low temperatures, advantageous sliding friction properties.
Thermosets
Phenol-formaldehyde (PF): is the most widely used of all the thermosets for its
excellent dimensional stability under thermal cycling and high stress conditions,
low water absorption, and high surface hardness, compressive strength and highly
resistant to petrochemicals and hydrocarbons. An Modified injection moulding
method is by preheating, metering and plunging the PF resins into a mould that is
embedded with heaters to cure the resin after the injection.
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Elastomers
Synthetic rubber: is made from the polymerization of monomers for a wide range
of physical, mechanical and chemical properties while maintaining the elasticity
properties.
MF 1.41-1.49 345 - 45 -
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3. Plastics Processing
Many different methods are employed to convert plastics from their raw state into
finished products or to fabricate stock plastics materials into finished products. In
the industry the mass production processes are moulding and thermoforming.
Moulding includes injection moulding, extrusion, blow moulding, compression and
transfer moulding.
Injection moulding is the best process to use for high-speed, low-cost moulding
of intricate plastics parts required in high volume. In this process, thermoplastic is
fed from the hopper through an opening at the rear of the heated injection barrel
(charging). The resin is forced forward to the front of the heated barrel by the
rotation of a reciprocating screw, where the material is heated in various stages
until it reaches a molten state. The injection screw forces the measured amount of
molten resin into the shaped cavity of a closed mould through the
nozzle/sprue/runner/gate by a ram action. The molten resin cools and solidifies in
the mould cavity. After cooling, the mould is opened and the moulding is ejected.
Almost all thermoplastics can be injection moulded and even some thermosets are
being injection moulded with modified equipment. PE, ABS, nylon PA, acrylic and
polystyrene are amongst the leading thermoplastics used in injection moulding.
Typical injection moulded products include appliance housings, camera cases,
lenses, gears, fan blades, spoons, wastebaskets etc…
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An injection moulding machine consists of three units; they are the plasticating &
injection unit, the clamping unit and the mould cavity.
Clamping Unit
• Plasticating & Injection Unit : The major tasks of the plasticating &
injection unit are to melt the polymer, to accumulate the melt in the screw
chamber, to inject the melt into the cavity and to maintain the holding
pressure during cooling.
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• Clamping Unit
The major tasks of the clamping unit are opening and closing the mould, close
the mould tightly during injection. There are three clamping types: mechanical,
hydraulic and their combination.
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Shot size and clamping force are usually used to describe a machine. We need
to consider both shot size and clamp tonnage when choosing a machine.
i) Shot size is the maximum amount of material the machine will inject
per cycle (single shot) and the unit is ounces (oz) or grams (g). The
standard for shot size measurement is general purpose polystyrene
moulding in single shot.
ii) Clamping Force is the maximum force a machine can apply to a
mould. The unit of clamping force is tons.
Part design is a very important in injection moulding, good part design can reduce
the manufacturing cost and reduce the defects during manufacturing.
• Draft Angles
• Radii/Fillet
Internal sharp corners and notches are the leading cause of failure in injection
moulded thermoplastic parts. To avoid the problem occurred, radii / fillet is
commonly employed to all “sharp” feature.
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Fillet radius is determined by the wall thickness and the carrying load. Fillet
radius should be between 25 to 60% the nominal wall thickness. The larger
fillet radius is suggested for load carrying features.
• Ribs
Ribs are used to strength the structure and reduce the weight of the product.
Rib thickness should be 50 to 60% of the nominal wall thickness t, the rib
height h should not excess three times of the nominal wall thickness.
Spacing between two parallel ribs should be more than two times of the
nominal wall thickness. Draft angle for ribs is 1 to 1.5°.
• Bosses
Bosses are thermoplastic cylinders attached to a side wall or end corners. They
can be used for assembly with self-tapping screws. A boss should not be
attached directly to a side wall because it will cause sinks or voids.
The outer diameter of the boss should be two times the inner diameter of the
boss. The height of the boss should be less than three times of the outer
diameter of the boss. The distance between two bosses should be more than
two times of the nominal wall thickness t, the wall thickness at the base of the
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boss should less than 60% of the nominal wall thickness t. the minimum draft
angle on the outer diameter of the boss is 1/2° and inner diameter is 1/4°.
• Snap-fit Design
Snap fits are commonly used as an assembly method for injection moulded
parts. Snap fits are very useful because they eliminate screws, clips, adhesives,
or other joining methods. The snaps are moulded into the product, so
additional parts are not needed to join them together. There are three main
types of snap fits: Annular, Cantilever, and Torsional.
• The torsional snap-fit relies for its spring effect on twisting rather than
flexing like the other types. It is a good way of fastening a hinged lid on a
box or container.
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The mould is comprised of mould base, core and cavity that determine the
feature of the product, sprue, runner and gate that deliver the melt to the cavity,
cooling system and ejection system.
• Mould Base: As a matter of fact, nearly all moulds consist of the same
basic components. There are some standard mould bases in the market
that provide cheaper and more reliable than custom design mould base.
The followings are some standard mould bases.
In very broad sense, moulds can be classified as cold runner and hot runner
moulds. Two-plate mould and three-plate mould are most common in cold
runner moulds.
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There are other types of cold runner moulds like external under-cut mould,
internal under-cut mould, side core mould, unscrewing mould, stack mould.
A hot runner mould refers to a mould in which the runner stays molten and is
not ejected during the moulding cycle. In hot runner mould, the runner is
eliminated so that the shot size, plastification time, runner cooling time and the
clamping force can be reduced. The hot runner system is comprised of two
primary components that are the manifold and the drop.
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A mould must consist of core and cavity. The core (male) is fixed on the
moving half of the mould and the cavity (female) is fixed on the stationary
half of the mould. Gate is always on the cavity.
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• Feed System
The feed system is the flow-way of plasticized material to the cavity; it consists of
a sprue, runner and gate.
• Cooling system
• Ejection system
Ejection is necessary for part to be removed from the mould. The hot
materials injected into the cavity will shrink and stick tightly onto the mould
core. The ejector plate will be driven by the injection machine to carry the
whole Ejection system travels sufficiently to clear the moulding from the
mould.
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The extrusion-blow moulding process is extensively used for making bottles and
other hollow plastics parts having relatively thin walls. To blow mould a part, the
extruder first extrudes a hollow tube (parison) in a downward direction, where it
is captured at the proper time between two halves of a shaped mould. After
trimming the top and bottom of the parison, air is blown into the soft parison,
expanding it until it uniformly contacts the inside contours of the cold mould
and solidifies. Then the mould automatically opens, the part is ejected and a
new cycle begins.
PE, PVC, PP and PS are commonly used plastics for blow moulded articles. Typical
products include bottles, watering cans, display fruit and other hollow parts.
In the injection blow moulding process, the polymer is injection moulded onto a
core pin; then the core pin is rotated to a blow moulding station to be inflated
and cooled. The process is divided into three steps: injection, blowing and
ejection.
The injection blow moulding machine is based on an extruder barrel and screw
assembly which melts the polymer. The molten polymer is fed into a
manifold where it is injected through nozzles into a hollow, heated
preform mould. The preform mould forms the external shape and is clamped
around a mandrel (the core rod) which forms the internal shape of the preform.
The preform consists of a fully formed bottle/jar neck with a thick tube of
polymer attached, which will form the body.
The preform mould opens and the core rod is rotated and clamped into the
hollow, chilled blow mould. The core rod opens and allows compressed air into
the preform, which inflates it to the finished article shape.
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3.3 Extrusion
ABS, PE, PS and PVC are extensively used in extrusion. Typical product includes
piping, drinking straw, window track, wire and cable coating, film and sheet.
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Almost all thermoplastics sheet can be used in this process. The commonly used
plastics are HIPS, ABS, PVC, acrylic, cellulosic. Typical application includes blister
pack, suitcase and disposable plate.
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4.1.1 Cutting Plastics - Plastics can be cut by methods commonly employed for
wood, metals and paper. Among the various cutting methods sawing is the most
effective one.
• Circular Saws - Circular saws are suitable for straight cuts. A speed of
about 1,500 m/min is a reasonable average for cutting plastics. Carbide-
tipped saw blades will hold up longer with less maintenance, but hollow-
ground cross-cutting blades with zero rake and 2-3 mm pitch will do
many jobs well. All blades must be kept clean and sharp.
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• Band Saws - Band saws are generally used for cutting curbes, irregular
cuts, and thick materials. The advantage of using a band saw instead of a
circular saw is that the cut is cooler. It is, however, more difficult to obtain
as straight and as smooth a cut as with a circular saw.
• Jig Saws - Power jig saws are more efficient than hand jig saws. They are
suitable for cutting intricate curves and holes.
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4.1.2 Cementing- There are two basic methods of cementing plastics, i.e.
Cohesive and Adhesive-bonding.
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4.2 Welding
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Hot-air Welding involves the heating of the plastics joining area to fusion state
by a jet of hot air from a hot air gun and then filling up the joint by a filler rod
which is similar in properties with the plastics sheet being welded.
For Resin casting please refer to the rapid tooling section in the reading material
of Rapid Prototyping & Manufacturing
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References
• Manas Chanda, Salil K. Roy, (2009) “Plastics Fabrication and Recycling”, CRC
Press.
• Erik Lokensgard, (2004) “Industrial Plastics Theory and Applications”, Thomson.
• http://www.matweb.com
• http://www.dukcorp.com/us/PPL_WhatIsUPA.htm
• Osswald, T., Hernandez-Ortiz, J. P., (2006) Polymer Processing-modeling and
simulation, Hanser
• Hans-Georg, E. (2003) An Introduction to Plastics, Wiley-Vch
• Friedrich Johnnaber, (2008) Injection Molding Machine- A Use’s Guide, Hanser
• Osswald, T.,Turng, L.S., Gramann, P. (2008), Injection Molding Handbook,
Hanser
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