MANUFACTURING PROCESS EXTRUSION OF PLASTIC SKMM 2713

OUTLINE

1. Introduction 2. Properties And Features Of Plastic 3. Processing Method For Extrusion a. Sheet Extrusion b. Blown Film Extrusion c. Tubing Extrusion 4. Advantage And Disadvantage Of Plastic Extrusion

NAME: MATRIX NUMBER: LECTURER:

NIK AHMAD FAIZ NIK MAZLAM A12KM0119 ASSOC PROF ZAINAL ABIDIN AHMAD

INTRODUCTION

Extrusion of plastic in general is a process of plastic is being heated in the chamber. The plastic is carried by feedscrew throughout the heating process. Then, the plastic being conveyed to the next process. During conveying, the plastic is being melted, compressed and force out of the chamber through a die (orifice).As the plastic flow out from the die, it experience instant cooling and result resolidification process.

In process of extrusion, die plays important role for extrusion process occured. Proper selection of dies will result the desired shape with an accurate dimension.

Die is made of steel. During extrusion process, die is being heated. It is to ensure that that start-up of the process is safe. Cold start may cause the equipment being damaged. Next, by heating the die, the radiation loss during an operation will be reduced. Apart from that, this will reduce the viscosity at the inner metal surface. Last but not least, heating a die will result less swell of the product.

Each method of extrusion have specialized die to change the raw material into desired product. The common dies used in industry are sheet dies, flat film and blown-film dies, pipe and tubing dies, profile extrusion dies, and co-extrusion dies.

PROPERTIES AND FEATURES OF PLASTIC

Plastic have special properties that enable the process of plastic extrusion is being applied. 1. All plastic is being made up from a simple building block called monomer. Through the process of monomer linking or polymerization, thousands of monomer block react become polymer. 2. Polymer could be categorized as thermoset and thermoplastic. These differences arise due to their physical behavior which is polymer molecule that reacts with each other. Thermoplastic have little cross linking. Meanwhile for thermoset, it is highly cross linked polymers. 3. Heat conduction by plastic is inefficient. Overheat or low heat the plastic cause the extruded product is not in specification. 4. Extruded plastic contain other materials like stabilizer lubricant. Process adding other material to the extruded plastic called compounding prior 5. Molten plastic experience shear as it move through an extruder. As the melt viscosity is low, the torque required to extrude the plastic also become low.

PROCESS OF EXTRUSION

a. Sheet Extrusion

Sheet extrusion objective is to produce thin plastic sheet and film. This process makes the sheet being extruded through a horizontal die. For sheet extrusion, the plastic is being cooled by rollers. Besides cooling the plastic, rollers will set the size of the final product by varying the gap between each roller.

b. Blown Film Extrusion

Blown film extrusion objective is to produce plastic shopping bag. When the plastic (resin) pass through the die, the resin will be pulled out by a pair of nip rolls. Nip rolls function like a roller. It will set the size of plastic by varying the speed of nip roller. During extrusion of resin through the die, an airflow will cool the product eventually. Apart from cooling, the airflow blow will change the size of extruded product.

c. Tubing Extrusion

Tubing extrusion objective is to produce straw of medical tubing. Basic extrusion is same up till resin reach the die. But for tubing extrusion, a mandrel is place inside the die. As the resin pushed into the die, it will form a tube plastic inside the mandrel. During this process, the thickness of the extruded product is being set by using the air pressure.

ADVANTAGE AND DISADVANTAGE OF PLASTIC EXTRUSION

The criteria of plastic extrusion below will determine the pros and cons.

a. Production volume

Plastic extrusion technology enable manufacturer to produce high quantity of product.

b. Costing

Plastic extrusion process cost is low since the main material involved is plastic compared to other material.

c. Production Rate

Extrusion process have high production rate since it will produces long uniform of product continuously. As a result, the extruded product could undergo the next process without delaying.

d. Versatility

Plastic extrusion can produce complex shape continuously. Apart from that, the size, thickness hardness, and so on can be adjusted easily. For example to produce straw with more thickness can be done by increasing the air pressure inside mandrel.

e. Extrusion Coating

The material strength property of the product can be improved by coating the product.

f.

Size Variances

As the plastic exit from the extruder, naturally it will expand. This expansion of plastic called die swells. The expansion comes from many factor. As a result, manufacturer have difficulties to predict the degree of expansion of plastic.

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