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FormingAndShapingPlastics

This document provides an overview of various plastic forming and shaping processes as well as composite material production. It describes common plastic molding techniques like extrusion, injection molding, blow molding, rotational molding, thermoforming, compression molding, and casting. For each process, it provides examples of typical products, illustrations of equipment used, and brief explanations of how the processes work. It also discusses composite material manufacturing methods like tape laying and prepregs. The document aims to inform readers about the different options for forming and molding plastics and composites.

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M Praveen
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56 views30 pages

FormingAndShapingPlastics

This document provides an overview of various plastic forming and shaping processes as well as composite material production. It describes common plastic molding techniques like extrusion, injection molding, blow molding, rotational molding, thermoforming, compression molding, and casting. For each process, it provides examples of typical products, illustrations of equipment used, and brief explanations of how the processes work. It also discusses composite material manufacturing methods like tape laying and prepregs. The document aims to inform readers about the different options for forming and molding plastics and composites.

Uploaded by

M Praveen
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Forming and shaping plastics

& composite materials

By,
Karthikeyan.R,
PGDTD,
NTTF , Bangalore
Topics

• Introduction
• Extrusion
• Injection molding
• Structured foam molding
• Blow molding
• Rotational molding
• Thermoforming
• Compression molding
• Casting
• Process of composite materials
Extrusion
• Raw materials in the form if thermoplastic
pallets,granules,or powder, placed into a hopper and fed
into extruder barrel.

• The barrel is equipped with a screw that blends the pallets


and conveys them down the barrel

• Heaters around the extruder’s barrels heats the pellets and


liquefies them

Screw has 3-sections


• Feed section
• Melt or transition section
• Pumping section.
• Complex shapes with constant cross-section

• Solid rods, channels, tubing, pipe, window frames,


architectural components can be extruded due to
continuous supply and flow.

• Plastic coated electrical wire, cable, and strips are also


extruded

Pellets :extruded product is a small-diameter rod which is


chopped into small pellets

Sheet and film extrusion :


Extruded parts are rolled on water and on the rollers
Extruder

Fig : Schematic illustration of a typical extruder for plastics, elastomers, and composite materials.
Sheet and Film Extruder

Fig : Die geometry (coat-hanger) for extruding sheet.

Fig : Schematic illustration of the production of


thin film and plastic bags from tube first
produced by an extruder and then blown
by air.
Injection molding

Fig : Injection molding with (a) plunger, (b) reciprocating rotating screw, (c) a typical part made from
an injection molding machine cavity, showing a number of parts made from one shot, note also
mold features such as sprues, runners and gates.
Injection molding
• Similar to extrusion barrel is heated

• Pellets or granules fed into heated cylinder

• Melt is forced into a split-die chamber

• Molten plastic pushed into mold cavity

• Pressure ranges from 70 Mpa – 200 Mpa

• Typical products : Cups, containers, housings, tool


handles, knobs, electrical and communication
components, toys etc.
Injection molding

• Injection molds have


several components such
as runners, cores,
cavities, cooling
channels, inserts, knock
out pins and ejectors

3-basic types of molds


• Cold runner two plate
mold
• Cold runner three plate
mold
• Hot runner mold

Fig : Examples of injection molding


Injection Molding Machine

Fig : A 2.2-MN (250-ton) injection molding machine. The tonnage is the force applied
to keep the dies closed during injection of molten plastic into the mold cavities.
Process capabilities :
• High production rates
• Good dimensional control
• Cycle time range 5 to 60 sec’s
• Mold materials- tool steels, beryllium - Cu, Al
• Mold life- 2 million cycles (steel molds)
10000 cycles ( Al molds)

Machines :
• Horizontal or vertical machines
• Clamping – hydraulic or electric
Reaction Injection molding :

• Mixture of resin with 2 or more reactive


fluids forced into the mold cavity at high
speed .

• Applications : Bumpers, tenders, thermal


insulation, refrigerators and freezers,
water skis, stiffness
Reaction-Injection Molding

Fig : Schematic illustration of


the reaction-injection
molding process.
Blow molding
• Modified extrusion and Injection Molding process.

• A tube extruded then clamped to mold with cavity


larger than tube diameter.

• Finally blown outward to fill the cavity

• Pressure 350Kpa-700Kpa

Other Blow Molding processes


• Injection Blow molding
• Multi layer Blow molding
Blow
molding

Fig : Schematic
illustration of (a)
the blow-
molding process
for making
plastic beverage
bottles, and (b)
a three-station
injection blow-
molding
machine.
Rotational Molding
• Thermo plastics are thermosets can be formed into
large parts by rotational molding

• A thin walled metal mold is made of 2 pieces

• Rotated abut two perpendicular axes

• Pre-measured quantity of powdered plastic material


is rotated about 2-axes

• Typical parts produced-Trash cans, boat hulls,


buckets, housings, toys, carrying cases and foot
balls.
Rotational
Molding

Fig: The rotational molding


(rotomolding or
rotocasting) process.
Trash cans, buckets, and
plastic footballs can be
made by this process.
Slush-molding

• Plastisols are used in slush molding

• Plastic materials are forced against the inside


walls of the heated mold by tumbling action.

• The part is cooled while it is still rotating and then


removed by opening the mold
Thermoforming
• Series process for forming thermoplastic sheet or film over a mold by
applying heat and pressure.
• Typical parts : advertising signs, refrigerator liner, packaging , appliance
housing, and panels for shower stalls .

Fig : Various Thermoforming processes for thermoplastic sheet. These processes are
commonly used in making advertising signs, cookie and candy trays, panels for
shower stalls, and packaging.
Compression molding
• Pre-shaped charge ,pre-measured volume of powder and viscous mixture
of liquid resin and filler material is placed directly into a heated mold cavity.

• Compression mold results in a flash formation which is a n excess material.

• Typical parts made are dishes, handles, container caps fittings, electrical
and electronic components and housings

• Materials used in compression molding are thermosetting plastics &


elastomers

• Curing times range from 0.5 to 5 mins

3- types of compression molds are

• Flash type
• Positive type
• Semi-positive
Compression
Molding

Fig : Types of compression


molding, a process
similar to forging; (a)
positive, (b) semi
positive, (c) flash (d) Die
design for making
compression-molded
part with undercuts.
Transfer molding
• Transfer molding is an improvement if compression
molding

• Uncured thermosetting material placed in a heated


transfer pot or chamber, which is injected into heated
closed molds

• Ram plunger or rotating screw feeder forces material


into mold cavity through narrow channels

• This flow generates heat and resin is molten as it


enters the mold

Typical parts : Electrical & electronic components,


rubber and silicone parts
Transfer molding

Fig : Sequence of operations in transfer molding for thermosetting plastics. This


process is particularly suitable for intricate parts with varying wall thickness.
Casting
Conventional casting of thermo plastics :

• Mixture of monomer, catalyst and


various additives are heated and poured
into the mould

• The desired part is formed after


polymerization takes place.

Centrifugal casting :
Fig : Casting
• Centrifugal force used to stack the
material onto the mold

• Reinforced plastics with short fibers are


used
Potting & Encapsulation

• Casting the plastic


around an electrical
component to embed it
in the plastic is potting

• In both the plastic is


Dielectric

Fig : Potting & Encapsulation


Cold forming
• Processes such as rolling ,deep drawing extrusion closed die forging ,coining
and rubber forming can be used for thermoplastics at room temperatures

• Typical materials used : Poly propylene, poly carbonate, Abs, and rigid PVC

Considerations :

• Sufficiently ductile material at room temperature


• Non recoverable material deformation

Solid Phase forming


• Temperatures from 10oc to 20oc are maintained, which is below melting point

Advantages :
• Spring-back is lower
• Dimensional accuracy can be maintained
Calendaring and Examples of Reinforced
Plastics
Fig : Schematic illustration of calendaring,
Sheets produced by this process are
subsequently used in thermoforming.

Fig : Reinforced-plastic components for a Honda


motorcycle. The parts shown are front and
rear forks, a rear swing arm, a wheel, and
brake disks.
Prepegs

a
b

Fig : (a) Manufacturing process for polymer-matrix


composite. (b) Boron-epoxy prepeg tape.
Tape Laying
Fig : (a) Single-ply lay-up of boron-epoxy tape for
the horizontal stabilizer for F-14 fighter aircraft.
(b) A 10 axis computer-numerical controlled tape-
laying system. This machine is capable of laying
up 75 mm and 150 mm (3 in. and 6 in.) wide
tapes, on contours of up to 30 and at speeds of
up to 0.5m/s.
THANK YOU

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