M&PII (Plastic I)
M&PII (Plastic I)
M&PII (Plastic I)
Material :Plastic
Compiled & Composed by:-K.Murugan. Assistant Professor. NIFT. New Delhi Mr.Abid Bilal. Professor (Guest faculty NIFT)
The English word "plastic" or "plastics" originated from the Greek word "plastikos," Which means to Grow" or Form." Used first as an adjective meaning "formative = plastic"
(capable of being deformed without rupture)
Plastic is an attractive all-around material It can be tailor made to Less flammable, Fire retardant, Self extinguish Soft, Scratch proof, Scratch resistant, Scratch repairable Hard, Brittle, Nun-breakable Transparent, Translucent, Crystal like Various improvements are made aggressively to produce attractive plastics that suit their purposes more precisely.
Preventing Decomposition
Plastics deteriorate gradually when expose to moisture and oxygen in the air. Deterioration is hastened by heat, acids, ultraviolet light, etc. To prevent such deterioration, additives are added during Processing. Typical additives are :
Heat stabilizer : Prevents decomposition by heat. Antioxidant : Prevents decomposition by oxygen in the air. Ultraviolet light absorber : Prevents deterioration caused by ultraviolet rays. Mildew proofing agent: Protects plastics from microorganisms such as bacteria and molds. Regarding decomposition of plastics, studies are being conducted aggressively on exactly opposite topics of stabilization and natural decomposition, Photolytic plastics: Plastics that are broken down when exposed to sunlight. Biodegradable plastics: Plastics that are broken down by microorganisms in soil if buried.
ng tro S lly Rea
The hardness of resins can be varied by changing the mixing ratio of plasticizer Moldings that are hard at room temperature if molded with the addition of a firming agent under heat They are used for water pipes, rain water gutters, cosmetics cabinets. Also, they are used for tanks and piping at chemical plants. On the other hand, plastics are also used for soft goods such as wrappers, belts, and handbags.
Plastics, which are made of petroleum, have the disadvantage of being flammable. To make them less flammable, a flame retardant agent is added. It can also be made self extinguisher.
PLASTIC
The family of plastics is broad and complex. However, some fairly broad and basic guidelines that can be followed when engineering or designing a product to be made out of plastic.
PLASTIC
For basic understanding Plastic can be broadly classified into two main group
GROUP I Thermoplastic Resins Consists of long molecules and are not crossed linked They can be repeatedly softened and hardened by heating and cooling. ( Recycled easily) Thermoplastic are purchased as granule polymer GROUP II Thermosetting Resins Once cured, the material cannot be softened by heating Normally available in liquid or Molding compound or powder In a uncured condition they can formed to finish shape with or without pressure & cured with heat
Balanced combination of toughness Good dimensional stability Good Electrical insulation Wide service temperature range (5C - 120C) Good Chemical Resistance Ease of fabrication
Typical Applications
AUTOMOBILES Dash board & grills, Knobs and handles, APPLIANCES, Mixy, Food processor, JMG, Knobs , handles, HOUSING & PARTS, Pipes & fittings, Luggage, Helmets, Telephones, Fridge, Air-conditioner, Door liners, AC Front, Split AC Indoor unite, Knobs and handles, etc. ELECTRICAL PRODUCTS Electrical connectors & Switches, etc. ELECTRONIC PRODUCTS Music system, Video System, Computers, etc. F & L ACCESSORY, Shoe heels, Hair clip, Bakes, Handles, Chairs & tables, etc. INDUSTRIAL PRODUCT & INSTRUMENTS, Business machine housing, Pump impellers, Electrical switches & connecters, etc.
Samples of ABS
Samples of ABS
This suitcase illustrates how a glossy surface is obtained using ABS plastic shaped with vacuum forming. The interior is made from PUR foam cut into shape using water jet cutting. The suitcase is only produced in a very limited number for the Danish Museum of Craft and Design. It is used for transporting a collection of designed products that introduce children and teenagers to good industrial design.
Samples of ABS
The ceramic blade razor is made from ABS plastic shaped with the insert molding technique.
Samples of ABS
This vacuum jug illustrates how chemical resistance and strength can be achieved at boiling temperatures. The black top of the jug is made from plastic which hardly absorbs the taste or smell from tea or coffee. The colored plastic jug furthermore shows how shiny scratch resistant surfaces are obtained using ABS plastic.
Samples of ABS
One of the strongest tensile strength and stiffest among the thermoplastics Excellent fatigue life and dimensional stability Low friction coefficients. Exceptional solvent resistance. High heat resistance to 220F
ACRYLIC
Good resistance to long exposure to sunlight and weathering Excellent optical properties (92% transparency) Good impact resistance Low water absorption Good electrical resistively Good tensile strength Good heat resistance (104C)
Typical Applications
Outdoor signs, Aircraft canopies, Wash basins, Lighting applications, Product decorative, Safety shields, Machines covers, Knobs, Handles Drugs and Food packaging, Carbonated beverages containers
Samples of Acrylic
Radiates a polychromatic effect Changes color at different viewing angles. Uses ambient light - creates its own lighting effects! Mirror like mirage Shifts through the light spectrum Can be cut, routed, drilled, line bent, and polished. Can be thermoformed in slight draws or shallow
Samples of Acrylic
PMMA (polymethyl-methacrylate) is thermoplastic material with very good optical properties (as transparent as glass and it allows 92% of the sunlight to pass!). PMMA is hard, stiff and medium strong, easy to scratch, notch sensitive, but easy to polish. Exceptional outdoor performance, such as weather and sunlight resistance, without reduction neither of optical nor mechanical properties.
Samples of Acrylic
Kitchen scale made from PMMA
Typical Applications
Gears, Bearings, Housing for appliances, Pulleys,
Typical Applications
Housing pipe, Grocery bags Heater ducts, House ware, Toys, Automobile interiors, Containers, Wires & Cables, Insulation, Bottles, Films, Shampoo bottles Bullet proof vests
Samples of Polyethylene
This bottle for mineral water is made from PET (polyethylene) plastic which is transparent and well suited for recycling.
Samples of Polyethylene
There are two basic families: LDPE (low density), HDPE (high density).
PET has good barrier properties against oxygen and carbon dioxide. Therefore, it is utilized in bottles for mineral water. Other applications include food trays for oven, tapes as well as mechanical components.
Samples of Polyethylene
LDPE Low density Polyethylene Soft plastic bags for ice cubes are made from LDPE plastic.
Samples of Polyethylene
Recycle PET
This thermo scarf is made of polyester. At least 50% of it comes from recycled PET bottles for mineral water. As it can be seen, recycled plastic has not necessarily boring colors.
Typical Applications
Portable Radio & Television cabinets, Pipe & fittings, Automotive interior parts, House wares, Bottles, Carrying Cases with integral hinges,(life hing) Fibers, (indoor-outdoor carpeting, miniature golf courses) Luggage, Electrical Connectors, Packaging Food containers ( melting temp. 160 oC )
Samples of Polystyrene
Polystyrene is an inexpensive thermoplastic that is vitreous, brittle and has low strength, but hard and stiff. It is not weather resistant, and therefore not suitable for outdoor uses. PS is transparent (it transmits about 90% of the sunlight) and has unlimited dyeing possibilities. It can be glued. Foamed PS is used for packaging and insulation purposes.
Samples of Polystyrene
Polystyrene is brittle and has low strength but hard and stiff. Polystyrene has unlimited dyeing possibilities. It can be glued.
Samples of Polystyrene
The disposable drinking glass is a typical example of the use of PS plastic. The glass can be used for most beverages like soft drinks, milk and beer. PS is transparent (it transmits about 90% of the sunlight)
Samples of Polystyrene
This hedge cutter shows how many different plastic are used in a product to obtain different properties. The handle and the shielding plate are made from ABS plastic which ensures good impact strength. The motor housing, in PA (Polyamide Nylon,) plastic, has good heat resistance. The sheath shows that a very long narrow hollow geometry can be produced in HDPE plastic by conventional injection molding
Typical Applications
Eyewear Sports & performance frame Wraparound styles sunglasses
Typical Applications
Pipes, plumbing fitting Siding used on houses linoleum floor tiles. Vinyl car tops Raincoats Shower curtains water pipes Housing for hand held power tools.
1908 It seems around a hundred years ago, a few German entrepreneurs decided they were going to
make loads of cash by lighting people's homes with lamps fueled by acetylene gas. By the time they had produced tons of acetylene to sell to everyone who was going to buy their lamps, new efficient electric generators were developed which made the price of electric lighting drop so low that the acetylene lamp business was finished. That left a lot of acetylene laying around.
1912 A German chemist, Fritz Klatte decided to try to do something with it, and reacted some
acetylene with hydrochloric acid (HCl). This reaction produce vinyl chloride, but at that time no one knew what to do with it, so he put it on the shelf, where it polymerized over time. Not knowing what to do with the PVC he had just invented, he told his bosses at his company, Greisheim Electron, who had the material patented in Germany. They never figured out a use for PVC, and in 1925 their patent expired.
1926 the very next year, a American chemist, Waldo Semon was working at B.F. Goodrich when he
independently invented PVC. But unlike the earlier chemists, He knew this new material would make a perfect shower curtain. He and his bosses at B.F. Goodrich patented PVC in the United States (Klatte's bosses apparently never filed for a patent outside Germany). Tons of new uses for this wonderful waterproof material followed, and PVC was a smash hit the second time around.
Typical Applications
Safety seals, Glazing, Gears, and Electrical relay covers, Helmets, Pump impellers, Side gazes, Aircraft components, Automotive fender extensions, Bezels, Telephone switch gears, Snow mobile components, Boat propellers, Water bottles, Housing for hand held power tools.
Samples of Polycarbonate
Samples of Polycarbonate
Samples of Polycarbonate
Samples of Polycarbonate
Samples of Polycarbonate
Samples of Polycarbonate
Samples of Polycarbonate
Samples of Polycarbonate
Samples of Polycarbonate
Samples of Polycarbonate
Samples of Polycarbonate
Samples of Polycarbonate
Housing for GSM phones must have high impact strength in order to protect the electronics inside in the case of an accidental drop. This ductile behavior and excellent surface appearance can be designed in a vast array of 'trendy' colors. Blended ABS & PC is used for this.
This stable chair is made from Stapron N which is a blend of ABS and PA plastics. The blend gives good acoustic properties (a sound unlike plastic!), a soft consistency, chemical resistance (coffee, food, alcohol), and good molding properties. Using air or Gas injection molding, air cavities are integrated into the seat and the back of the chair to give the right elasticity. In this way a good sitting comfort is achieved.
Typical Applications
Parachutes Ropes Toothbrush bristles Gears It is conceder as industrial grade plastic.
Polyamide Nylon
Sunglass
This sunglass is mostly nylon, with stainless steel hinges for extra strength.
Polyamide Nylon
Eye wear
This eye wear is mostly nylon, with stainless steel hinges for extra strength.
Polyamide Nylon
Polyamide plastic PA include strong wear resistance, barrier properties. Strength and stiffness are often improved using glass fiber reinforcement. PA absorbs water which makes it softer. UV-stabilizations are required for outdoor applications. PA is a group of transparent, and semi-crystalline (opal-white) plastics. Axe illustrates how plastic can be used in high quality products with strength requirements. The steel head is insert molded using glass fiber reinforced polyamide plastic. (Nylon)
Typical Applications
All types of foams for padded chair, cushioned. Etc. Insulation, Fridge lining, Hotpots etc, Exercise clothing Skin tight sports & athletic clothing.
Samples of Polyurethanes
Typical Applications
Lenses, for eye glasses Lenses, for cameras
Typical Applications
Dishware like plates Dinner sets Soup bowls & spoons Household goods Electrical Connecters & Switches.
UREA
Typical Applications
Decorative housing, Jewelry casings, Lighting fixtures, Buttons. Decorating Plastics
Excellent colourability Moderately good strength & low cost. Poor dimensional stability & Impact strength
Injection Molding
Injection Molding
Injection Molding
Injection Molding
For parts of all sizes which require accurate and complex geometry. Granular plastic or pellets are melted by friction with a rotating screw and actual heating, and then injected into the mould. Normally, the process is reserved to thermoplastics, but it can be used for shaping fiber reinforced thermoplastics or thermosetting. Production volumes are medium to large, and the cycle time per part is very short
Insert molding
Plastic parts containing metal inserts are produced using this variant of injection molding. Inserts made from metal or other materials are placed in the mould prior to the injection of plastic. The plastic flows around the inserts and fixes their position. Tools investments are slightly higher than for injection molding.
Outset molding
Similar to insert molding. Here though, a larger metal part surrounds one or more plastic elements like distance pins, flexible snap-locks, etc. A prepared sheet of metal with holes and gripping areas is placed in a mould. Then plastic is injected as in conventional injection molding. Tools investments are slightly higher than for injection molding.
Extrusion
Profiles of all shapes can be produced. In an extruder the material is heated and continuously pushed by a rotating screw through a die with the shape of the profile. After the die, the profile is cooled by air or water and cut into desired lengths. Production volumes are normally high.
Pultrusion
This process enables the production of large series of continuous fiber reinforced profiles with constant section. A set of fibers is pulled through a plastic bath and then through a heated die which give the profile its shape. After the die the profile is cooled by air or water and cut into desired lengths. An advantage for the process is that it is a relatively inexpensive way to produce reinforced parts with long fibers. Strength and other properties are better in the fiber direction than across.
Matrix injection, also called resin transfer molding, produces strong fiber reinforced parts of thermosetting plastics with smooth surfaces on both sides. Mats of reinforcement material are placed in a mould which is then closed. Plastic is injected into the mould. After hardening the finished part can be removed from the mould. The process is used where advanced geometry is required, and for car parts. The cycle time per part is medium, and small to medium series can be produce.
Rotation molding
A plastic molding process carried out in four steps, especially suitable for hollow parts, parts with low residual stress and thick walled parts. Parts with negative draft-angles (undercuts) can be made as well. First, the required amount of plastic material is poured into the mould which is then closed. While rotating around two axes the mould is first heated to the melting-point of the plastic and then cooled again. Finally the mould is opened and the finished part is removed. No finishing operations, like removal of runners, are required. Mainly for small production volumes.
Used for hollow parts of all sizes. A tube of molten plastics is extruded into an open mould. The mould closes and thereby the bottom of the part welds. Hot air is blown into the tube and it is blown up until it fills out the mould cavity. Parts can be produced in small and large quantities, since setup cost is low and tools/moulds are often made of aluminum it is cheap.
Used for high quality bottles like bottles for mineral water containing Co2 under pressure. First a small part with a large wall thickness (preform or perison) is produced by injection molding. The preform is heated and then transferred to the blow molding machine where it is blown into final shape. Compared to blow molding, injection blow molding gives better definition of details (e.g. screw thread), and a better control of the distribution of the thickness of the material.
Suitable for achieving long thin parts with high stiffness in the longitudinal direction. The molecular structure of the parts is very uniform and internal welding lines are reduced. It is a relatively new variant of injection molding which improves strength. Unlike injection molding, two injection units are used for injection of plastic. While one unit is pushing plastic into the mould, the other one is pulling.
Cash Dispenser
Special range of Polycarbonate grades, suitable for structural foam injection moulding. This processing techniques makes it possible to attain a cost saving of up to 300%, when changing from cast aluminum to plastic molding.
END
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