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This document discusses various shaping processes for polymers. It begins by defining polymers as long-chain molecules made of repeating units. Polymers are separated into three main groups: thermoplastics, thermosets, and elastomers. Several important polymers in each group are listed, along with their key properties and applications. The document then describes several common manufacturing processes for shaping polymers, including extrusion, injection molding, blow molding, compression molding, transfer molding, thermoforming, and calendering. Each process is briefly explained in one or two sentences.
This document discusses various shaping processes for polymers. It begins by defining polymers as long-chain molecules made of repeating units. Polymers are separated into three main groups: thermoplastics, thermosets, and elastomers. Several important polymers in each group are listed, along with their key properties and applications. The document then describes several common manufacturing processes for shaping polymers, including extrusion, injection molding, blow molding, compression molding, transfer molding, thermoforming, and calendering. Each process is briefly explained in one or two sentences.
This document discusses various shaping processes for polymers. It begins by defining polymers as long-chain molecules made of repeating units. Polymers are separated into three main groups: thermoplastics, thermosets, and elastomers. Several important polymers in each group are listed, along with their key properties and applications. The document then describes several common manufacturing processes for shaping polymers, including extrusion, injection molding, blow molding, compression molding, transfer molding, thermoforming, and calendering. Each process is briefly explained in one or two sentences.
POLYMERS Polymers A polymer is a compound consisting of long-chain molecules, each molecule made up of repeating units connected together. Polymers can be separated into three major groups: Thermoplastic polymers (thermoplastics) Thermosetting polymers (thermosets) Elastomers (rubbers) Thermoplastic polymers (thermoplastics) Solid materials at room temperature, become viscous liquids when heated. The most important thermoplastics are:
Thermosetting polymers (thermosets) When initially heated, soften and flow for molding. After cooling, harden into an infusible solid. No repeated heating cycle is possible. The most important thermosets are: Epoxies: fiber-reinforced materials Phenolics (Bakelite): knobs, handles, cases Polyesters: fiber-reinforced materials Silicones: waterproof and heat resistance materials Elastomers (rubbers) Exhibit extreme elastic extensibility under low mechanical stresses. The most important rubbers are: Natural rubber (Latex): tires, shoes, seals Silicones: seals, thermal insulation, electronics Polyurethane: seals, gaskets The difference in properties of the polymers are attributable to so- called cross-linking, which occurs in thermosets and partially in elastomers. Cross linking Manufacturing processes for polymers Extrusion In twin-screw extruders both screws are parallel and side-by-side inside the barrel. These extruders are suitable for extrusion of difficult-to-extrude polymers, and for materials that require greater mixing. Extrusion Dies for extrusion Injection Molding Injection Molding is a process, in which a polymer is heated to a highly plastic state and forced to flow under pressure into a mold cavity, where it solidifies. The part, called a molding, is then removed from the cavity The production molding cycle time is in the range 10 to 30 sec Typical molding cycle Mold Features for Injection Molding Blow Molding Blow molding is a modified extrusion and injection molding process, wherein a tube is extruded, clamped into a mold with a cavity much larger than the tube diameter, and then blown outward to fill the mold Blowing is done with a hot-air blast at a pressure of 350~700 kPa. Compression Molding In compression molding, the workpiece (pre-shaped part, volume of powder, mixture of liquid resin and fillers) is placed in the heated mold and is formed under pressure. Compression molding of thermosets: (1) charge is loaded, (2) charge is compressed and cured, and (3) part is ejected and removed. Transfer Molding Transfer molding is a similar to compression molding process, but the charge is placed not in the die cavity but into a chamber next to the die cavity. Pressure is then applied to force the material to flow into the heated mold where curing occurs. Thermoforming Thermoforming is a process in which a flat thermoplastic sheet is heated and deformed into desired shape. The classical process involves the use of vacuum and is called vacuum forming. Calendering - used for shaping high melt viscosity thermoplastic sheet 1-feed pass 2-metering pass 3-sheet formation -gauging-finishing
Interacademic Collaboration Involving Higher Education Institutions in Tlaxcala and Puebla, Mexico. Presented in Collaboration with Université Clermont Auvergne (France): Case Studies of Collaborative, Multidisciplinary Applications.