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UNIT IV
Suverna Trivedi
What is Polymer Processing???
Processing techniques
Raw Material Final product of
desired shape.
Hydrostatic
Forward Extrusion
Extrusion
(Direct)
Backward:
Material flow in opposite
direction of RAM.
Difference between Forward and Backward extrusion
processes
Similar to forward extrusion but it can solve the problem of forward extrusion.
Force is applied to the hydrostatic fluid due to this force work piece move forward.
Impact Extrusion
When impact is applied, work piece will flow on the clearance between punch
and container.
Speed of screw
Cooling medium
Defects of Extrusion process
Plastic can be moulded into various forms and hardened for commercial use.
Insertion of molten liquid plastic into shaped mold.
Examples: Jars, Protective caps, Plastic tubes, Grips, Toys, Bottles, Kitchen utensils, etc.
The keyboard and the mouse that you use are made through plastic moulding. Even the
plastic parts of the chair that you are sitting on are created this way.
Some other examples:
Garden pots
Cabinet
Office trays & boxes
Barriers
Barricades
Selection of plastic molding process
Your budget
Your expertise
Your resources
Types of molding process
Injection Moulding
Blow Moulding
Compression Moulding
Film Insertion Moulding
Gas Assist Moulding
Rotational Moulding
Structural Foam Moulding
Injection Molding
It is used to process thin walled plastic parts for a variety of shapes and
sizes.
Injection
Cooling
Ejection
Reaction injection molding
Merits of Injection Molding
The thermostat is used to maintain the temperature of the heater. When the
temperature becomes substantially high in the mold, the temperature is controlled
by adjusting the heater and providing the cooling air.
Types of Thermoforming
Pressure forming
Vacuum forming
Heating ------Heater
Forming-------Application of Vacuum
Cooling
Pressure forming
Heating ------Heater
Forming-------Application of high pressure
Cooling
Match Die forming
Heating ------Heater
Forming-------Application of punch
Cooling
Parameters that are considered during the thermoforming process:
Heating temperature
Heating time
Vacuum pressure
High pressure
Mechanical pressure,
Cooling time and
Ejection mechanism.
Materials Used
Food packaging,
Automotive parts,
Trays,
Building products and aircraft windscreens.
Thick gauge parts are used as cosmetic surfaces on permanent structures such
as. medical equipment, material handling equipment, electrical and
electronic equipment, spas and shower enclosures, vehicle door and dash
panels, refrigerator liners, utility vehicle beds, and plastic pallets
Thin gauge parts are primarily used to package or contain a food item,
disposable cups, containers, lids, blisters and clamshells.
Advantages
Application: Floor tiles; Coated fabrics and Covering for car interiors.
Types of calenders
Stack arrangement
(Each pair of rollers at right
Stack arrangement Vertical Mirror (for rigid vinyl) angles to the next pair in the
chain)
They loses less heat.
Advantages/Merits:
This is a very good job with polymers that are sensitive to heat
because it causes very little thermal decomposition.
It is good when mixed polymers that contain a large quantity of solid
additives that do not receive mixed or flux in very well.
If the thickness is less than 0.006 inches, it has a tendency to pores and
voids appear in the sheets.