PLASTIC PROCESSING

Fine powder (plastic, ceramic, metal) Shape by compacting in a die

Join powder particles (heat to just below melting point) balls used in ball-point pens gears, cams cutting tools (inserts) porous metal filters oil-impregnated bearings piston rings in engines
Prof. Pramod R. Wadate

Plastics Processing
Plastics are usually supplied as moulding powder, granules or chips which have to be processed. Processing includes the thorough mixing of additives with the moulding powder, granules or chips to produce plastic compounds.

The use of additives allows a relatively small number of base plastics to be transformed into wide range of very versatile materials.

Types of Plastic Processing

Injection Moulding Usually for thermoplastics. Molten plastics are injected under pressure into a mould. The mould surface detail (profile of the product) can be accurately reproduced. Compression Moulding Usually for thermosetting plastics. Plastic is moulded under pressure before the polymerisation begins. Extrusion Usually for thermoplastics. The molten plastics are fed under pressure by a screw through a hole or a die. Long continuous lengths, such as sheets, rods and tubes, can be produced.

Types of Plastic Processing

Thermoforming (Vacuum Forming)- Heat-softened thermoplastic sheet is drawn or sucked over a mould. It can be used for a variety of products from chocolate box trays to acrylic baths. Blow Moulding An extruded thermoplastic tube is heated and air is blown into it to force the plastic to take on the form of the mould in which it is enclosed. Rotational Moulding Usually for thermoplastics. Powder is heated inside a closed mould which is then rotated around two or three axes. This forces the plastic to take the form of the surface of the mould. It can be used to make very large hollow articles.

Types of Plastic Processing

Calendering Usually for thermoplastics. Molten plastics are squeezed between hot rollers to form film or sheets. Casting Useful for thermosetting plastics. Molten plastic is poured into a mould. Bending Thermoplastics can be heated along a line using an electric strip heater and then folded to the desired angle. A bending jig is sometimes used to hold the plastic in position until it resets.

Types of Plastic Processing

Fabrication Plastics can be joined together using a variety of fixings and adhesives. Coating Powdered thermoplastic melts on the surface of a heated product giving it a thin film coating.

Forming Layers of glass fibre (Glass Reinforced Plastic) matting and polyester resin can be formed over a mould. As the resin cures it will harden to give rigidity to this fibre/resin matrix. Thermoplastic can also be formed by heating the whole sheet in an oven until it becomes floppy. The sheet is then pressed between two formers.

Compression Molding
The process requires plastic to be placed into a mould cavity where it is heated and plasticised. It is then compressed into shape by a heated punch. The materials used melamine formaldehyde phenol formaldehyde urea formaldehyde. These materials can be formed into different shapes through applying both heat and pressure, other plastics do no have these properties

Injection Moulding
The Process Injection moulding is one of the most important industrial processes in the mass production of plastic goods. The cost of machining the original moulds can be very high. Therefore it is necessary to sell large numbers of the products being manufactured to recover costs
Thermoplastic granules are heated until they soften. Then the material is forced under pressure into a mould. When cool, the mould is opened and a component which is the exact shape of the cavity is extracted

Injection Molding

Ram / Plunger Injection Molding

Screw Type Injection Molding

Blow Molding

Thermoforming Vacuum Forming

Clamping The clamp frame ensures the plastic sheet is held firmly in place during the forming process. Heating Radiant heaters are normally used to heat the sheet which has been positioned over the aperture of the vacuum forming machine. For thicker sheet both surfaces may need to be heated and more sophisticated machines allow this. Heaters move into position both above and below the sheet. Pre-stretch Is used to achieve "even" wall thickness. Air is introduced to blow a small "bubble" and the mould is then raised into the pre-stretched sheet. Vacuum A vacuum is applied, the sheet is drawn into intimate contact with the mould and the mould detail is picked up. Plug Assist Where a deep draw is required a top "plug" may be used to push material into the mould during the forming process. Cooling and Release The material is allowed to cool. The cooling process may be shortened with blown air or even a fine water spray. The moulding may then be released from the mould by introducing a small air pressure. Finishing After moulding, any mould finishing may be performed, trimming, cutting, drilling, polishing, decorating etc.

Thermoforming Pressure Forming

Extrusion
A machine used to extrude materials is very similar to the injection moulding machine. A motor turns a thread which feeds granules of plastic through a heater. The granules melt into a liquid which is forced through a die, forming a long 'tube like' shape. The extrusion is then cooled and forms a solid shape. The shape of the die determines the shape of the tube.

Extrusion of Film

Extrusion of Sheet

Extrusion of Pipe

Extrusion of Cables