10/19/2015

Polymer Processing
PE-4104
Lecture 1
Introduction To Polymer Processing

Course Outline
Processing
- Fundamentals

Rheology and Non-Newtonian Fluid dynamics

Processing aids

Mixing

- Operations
Dies

Extruders
Extruder Types, Various Parts of Extruders
Forming Operations
Injection Molding, Blow Molding,
Compression Molding

Text Book: Z. Tadmor and C. G. Gogos, Principles of Polymer Processing

10/19/2015

Forms of Plastics
Thermoplastics
- Softened by heat and can be molded
- Processing Techniques
Injection Molding
Blow Molding

- Examples
Acrylic
Polypropylene
Polystyrene
Polyethylene
Polyvinylchloride

Forms of Plastics (Contd.)

Thermosets
- Formed by heat process and take shape permanently
- Processing Techniques
Compression Molding
Pultrusion
Injection Molding
Reaction Injection Molding

- Examples
Melamine
Bakelite
Polyester
Epoxy Resins

10/19/2015

Rheological Influence
Rheology is the study of flow of matter in the liquid state
under the condition of Plastic flow and deformation of
materials.
High molecular weight polymer melts are structurally
complex and are Non-Newtonian fluids.
- Stretched under flow
- Recovering to random confirmation when flow stops
- Polymer chains conformations recovers from stretched state to
random during flow.

Macromolecular conformations affects intermolecular

interactions during flow.
Viscosity of polymer melt depends upon
- Flow velocity gradient

Rheological Influence (Contd.)

Polymer melt consist of
- Viscous
- Elastic

The behavior of polymer melt is characterized as

Viscoelastic

10/19/2015

Rheological Influence (Contd.)

Newtonian= Shear
Rate Independent
Pseaudoplastic= Shear
Thinning
Dilatant= Shear
Thickening
Plastic= Flow above a
certain yield stress

Processing Aids
Various additives are added in order to ease
processing (Reduction in Melt viscosity)
- Plasticizers and Softeners
- Lubricants and flow Promoters
- Anti-Aging Additives (To avoid discoloration and
structural degradation)
- Blowing agents (Products which involves blowing of
parison)
- Antioxidants

10/19/2015

Polymer Processing
Extrusion
- Pipe Extrusion
- Sheet Extrusion

Blow Molding
Film Blowing
Injection Molding
Coating
Calendaring

Extrusion
Polymer is propelled continuously along a screw
through regions of high temperature and pressure.
Polymer is melted and compacted.
Forced through a die to give die shaped product.
Cooled by air or immersed in water.
Method is used to make
-

Rods
Tubing and hoses
Sheets (>0.254mm thick)
Films (<0.254mm thick)

10/19/2015

Extrusion (Contd.)

Film Extrusion
The extrusion can be carried out by
- Sheet Extrusion
- Blown Film Process

In Blown film process tubular die is used.

- Hallow tube of product is extruded upward.
- Air is used as a medium to inflate the tube to avoid
collapse.

10/19/2015

Film Extrusion (Contd.)

A- Film Die
B- Die Inlet from Extruder
C- Air Inlet
D- Plastic Tube
E- Air Ring for cooling
F- Guide rolls
G- Collapsing Frame
H- Pull Rolls
I- Windup roll

Blow Molding

Extruder or reciprocating-screw injection machine can be used.

Molten polymer tubing (Parison) is extruded in open mold.
By means of compressed air or steam the parison is blown into the configuration of
mold.
Used for making bottles and similar products.

10/19/2015

Injection Molding

Polymer is preheated in the chamber to a flow

temperature.
Melt is forced into a relatively cold, closed mold by
high pressure applied by reciprocating screw.
Cycle time is 10-30 seconds and multi-cavity molds
allow the production of many parts per cycle.

Calendering
Used for the manufacturing of
sheets or films.
Granular resin or thick sheet is
passed between pairs of highly
polished heated rolls under high
pressure.
For thin films a series of rolls are
used with a gradual reduction in
nip.