Proses Pembentukan Plastik

Sumber:
MANUFACTURING ENGINEERING & TECHNOLOGY
Oleh: Serope Kalpakjian 1
Plastik:
Berasal dari kata Yunani (Greek) plastikos yg
berarti “mudah untuk dicetak dan dibentuk”.

Plastik juga disebut polymer.

Polymer merupakan makro-molekul yg

terdiri dari banyak monomer yang terikat
menjadi suatu rantai molekul yang panjang
melalui proses polimerisasi.

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Figure 7.2 Basic structure
of polymer molecules:
(a) ethylene molecule;
(b) polyethylene, a linear
chain of many ethylene
molecule; and
(c) molecular structure of
various polymers. These
are examples of the basic
building blocks for plastics.

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 Proses Pembentukan Plastik
• Proses pembentukan plastik
hampir mirip dgn proses
pembentukan logam (casting,
molded, extruded, joined).
• Plastik lebih mudah dibentuk
bila dibandingkan dengan
logam.
• Plastik bisa dicairkan dalam
temperatur yg jauh lbh rendah
dp logam.
• Penanganan proses lebih
mudah dan memerlukan lbh
sedikit energi.

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 Bahan baku
pembentukan plastik

• Pellet/granules: bahan
plastik ini berbentuk butiran-
butiran.
• Serbuk (powder): bahan
berbentuk serbuk. Pellet/granules
• Pewarna plastik: memberi
warna sesuai dgn yg
diinginkan.
Pewarna Plastik

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 Beberapa jenis plastik:
1. Poly Propylene (PP)
• Polypropylene (PP) is a
thermoplastic polymer, used
in a wide variety of applications,
including packaging, textile,
stationery, plastic parts, food
containers, woven bags,
laboratory equipment,
automotive components and
many more. Polypropylene is
commonly recycled product

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 Beberapa jenis plastik:
2. Poly Ethylene (PE)
• HDPE (high density PE): is resistant to
many different solvents and has a wide
variety of applications, including: Containers,
Fuel Tanks for vehicles, Folding tables and
chairs, Storage sheds, Plastic bags, Water
supply pipes, bottles - suitable for use as
refillable bottles etc. and many more.

• LDPE (low density): is widely used for

manufacturing various containers, dispensing
bottles, wash bottles, tubing, plastic bags for
computer components and various molded
laboratory equipment. Its most common use
is in plastic bags.

• PE is thermoplastic polymers.

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 Beberapa jenis plastik:
3. Poly Vinyl Chloride (PVC)
• Poly Vinyl Chloride (PVC): is
the third most widely used
thermoplastic polymer after
polyethylene and polypropylene.
It is used in clothing and
upholstery and tubing, flooring
and electrical cable insulation. It
is also commonly used
in pool toys, sewerage pipes,
Electric wires, Pipes, Signs
boards (sheets), PVC Ceiling
Tiles etc. and many more.

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 Beberapa jenis plastik:
4. Epoxies, Phenolics, Silicones.
• Epoxies, Phenolics, Silicones adalah jenis
polymer yang masuk kategori
thermosetting plastics.
• Rantai polymer nya jenis cross-linked
structure.
• Memiliki sifat kekerasan, kekuatan,
kekakuan dan dimensional stability yg lebih
baik.
• Memiliki sifat getas (brittle).

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 Polymer Chains

Figure 7.5 Schematic illustration of polymer chains. (a) Linear structure –

thermoplastics such as acrylics, nylons, polyethylene, and polyvinyl chloride have linear
structures. (b) Branched structure, such as in polyethylene. (c) Cross-linked
structure – many rubbers or elastomers have this structure, and the vulcanization of
rubber produces this structure. (d) Network structure, which is basically highly cross-
linked – examples are thermosetting plastics, such as epoxies and phenolics.
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 Behavior of Polymers

Figure 7.6 Behavior of polymers as a function of temperature and (a) degree

of crystallinity and (b) cross-linking. The combined elastic and viscous
behavior of polymers is known as viscoelasticity.
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Amorphous and Crystalline Regions in a Polymer

Effects of Crystallinity:

Polymer become stiffer,

harder, less ductile, more
rubbery, more resistant
to solvents and heat

Figure 7.8 Amorphous and crystalline regions in a polymer. The

crystalline region (crystallite) has an orderly arrangement of molecules.
The higher the crystallinity, the harder, stiffer, and less ductile the
polymer.
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 Characteristics of Forming and Shaping
Processes for Plastics and Composite Materials

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 Forming and Shaping Processes for Plastics,
Elastomers, and Composite Materials

Figure 19.1 Outline of forming and shaping processes for plastics, elastomers, and composite
materials. (TP = Thermoplastics; TS = Thermoset; E = Elastomer.)
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 Proses Ekstrusi Plastik
• Bahan baku bisa berbentuk pellet, granules
maupun serbuk.
• Screw mencampur material, menekannya
sepanjang barrel.
• Campuran material akan dipanaskan dan
dicairkan saat melewati barrel (mulai melting
zone).
• Fungsi screw: (1) feeding, (2) melt or
transition, (3) pumping.

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 Extruder Schematic

Figure 19.2 (a) Schematic illustration of a typical screw extruder. (b) Geometry of an
extruder screw. Complex shapes can be extruded with relatively simple and inexpensive dies.

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 Extrusion Die Geometries

Figure 19.3 Common extrusion die geometries: (a) coat-hanger die for extruding sheet;
(b) round die for producing rods; and (c) dies for producing square cross-sections. Note
the non-uniform recovery of the part after it exits the die. Source: (a) Encyclopedia of
Polymer Science and Engineering (2nd ed.). Copyright © 1985. Reprinted by permission of
John Wiley & Sons, Inc.
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 Extrusion of
Tubes
Figure 19.4 Extrusion of tubes.
(a) Extrusion using a spider die
(see also Fig. 15.8) and
pressurized air. (b) Coextrusion
for producing a bottle.

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 Production of Plastic Film and Bags

(b)

Figure 19.5 (a) Schematic illustration of the production of thin film and plastic bags from
tube – first produced by an extruder and then blown by air. (b) A blown-film operation. This
process is well developed, producing inexpensive and very large quantities of plastic film and
shopping bags. Source: Courtesy of Windmoeller & Hoelscher.

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 Melt-Spinning
Process
Figure 19.6 The melt-spinning process
for producing polymer fibers. The fibers
are then used in a variety of
applications, including fabrics and as
reinforcements for composite materials.

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 Injection Molding
• Proses injection molding u/ plastik,
prinsipnya sama dgn hot-chamber die casting
u/ logam.
• Bahan baku berupa pellet atau granulle.
• Tekanan yg diperlukan u/ injection molding
berkisar 70 MPa – 200 MPa (10.000 – 30.000
psi)
• Skema proses bisa dilihat di Fig. 19.7

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 Injection
Molding
Figure 19.7 Schematic
illustration of injection molding
with (a) plunger and (b)
reciprocating rotating screw.

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 Injection Molding Sequence

Figure 19.8 Sequence of operations in the injection molding of a part with a reciprocating
screw. This process is used widely for numerous consumer and commericial products,
such as toys, containers, knobs, and electrical equipment (see Fig. 19.9). 23
 Products Made by Injection Molding

(a) (b)

Figure 19.9 Typical products made by injection molding, including examples of insert
molding. Source: (a) Courtesy of Plainfield Molding, Inc. (b) Courtesy of Rayco Mold and
Mfg. LLC.

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Mold Features for Injection Molding

Figure 19.10 Illustration of mold features for injection molding. (a) Two-plate
mold with important features identified. (b) Four parts showing details and the
volume of material involved. Source: Courtesy of Tooling Molds West. Inc.
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 Types of Molds used in Injection Molding

Figure 19.11 Types of molds used in injection molding: (a) two-plate mold; (b) three-plate
mold; and (c) hot-runner mold.
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 EPOCH Hip Stem
Figure 19.12 The EPOCH hip stem. This
design uses a PAEK (polyaryletherketone)
layer and bone-ingrowth pad around a
cobalt-chrome core in order to maximize
bone ingrowth. Source: Courtesy of
Zimmer, Inc.
Figure 19.13 An EPOCH hip is
removed from the mold after an
insert injection-molding operation.
Source: Courtesy of Zimmer, Inc.
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 Injection-Molding Machine

Figure 19.14 A 2.2-MN (250-ton) injection molding machine. The tonnage is the
force applied to keep the dies closed during the injection of molten plastic into the
mold cavities and hold it there until the parts are cool and stiff enough to be removed
from the die. Source: Courtesy of Cincinnati Milacron, Plastics Machinery Division.
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 Reaction-Injection Molding Process
• Disebut RIM karena dlm prosesnya resin (bhn
plastik) dicampur dan direaksikan dgn dua
atau lebih ‘reactive fluid’, sehingga terjadi
reaksi kimia secara cepat di dalam cetakan.
• Hasilnya berupa thermoset part.
• Aplikasi proses: pembuatan fender & bumper u/
otomotif, insulator termal u/ kulkas & freezers,
water skis, stiffeners.
• Skema ada di Fig 19.15 berikut.
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 Reaction-Injection Molding Process

Figure 19.15 Schematic illustration of the reaction-injection molding

process. Typical parts made are automotive-body panels, water skis,
and thermal insulation for refrigerators and freezers.
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Blow-Molding
Figure 19.16 Schematic illustrations of
(a) the extrusion blow-molding process
for making plastic beverage bottles; (b)
the injection blow-molding process;
and (c) a three-station injection
molding machine for making plastic
bottles.

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 Rotational Molding Process
• Umumnya digunakan u/ produk axy-simetric
besar (misalnya tangki air/tandon air, bucket,
dll).
• Bahan baku berupa serbuk plastik (powder), yg
volume/jumlahnya disesuaikan dgn volume celah
yg ada di dlm mold/cetakan.
• Mold yg sudah berisi serbuk plastik diputar (dua
sumbu putar), diberi campuran zat kimia dan
dipanaskan dlm oven; sehingga campuran
mencair (melt) & terbentuk produk sesuai yg
diinginkan.

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 Rotational
Molding
Process
Figure 9.17 The rotational molding
(rotomolding or rotocasting)
process. Trash cans, buckets, and
plastic footballs can be made by
this process.

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 Thermoforming Process

Figure 19.18 Various thermoforming processes for a thermoplastic sheet. These processes
commonly are used in making advertising signs, cookie and candy trays, panels for shower
stall, and packaging.

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 Compression Molding

Figure 19.19 Types of compression molding – a process similar to forging: (a) positive,
(b) semipositive, and (c) flash, which is later trimmed off. (d) Die design for making a
compression-molded part with external undercuts.
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 Transfer Molding

Figure 19.20 Sequence of operations in transfer molding for thermosetting plastics.

This process is suitable particularly for intricate parts with varying wall thickness.

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 Processes for Plastics and Electrical
Assemblies

Figure 19.21 Schematic illustration of (a) casting, (b) potting, and (c) encapsulation
processes for plastics and electrical assemblies, where the surrounding plastic serves as a
dielectric.

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 Calendering

Figure 19.22 Schematic illustration of calendering. Sheets produced by this

process subsequently are used in thermoforming. The process also is used in
the production of various elastomer and rubber products.

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 Motorcycle Components

Figure 19.23 Reinforced plastic components for a Honda motorcycle. The

parts shown are front and rear forks, rear swing-arm, wheel, and brake disks.

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 Methods of Reinforcing Plastics

Figure 9.2 Schematic illustration of methods of reinforcing plastics (matrix)

with (a) particles, (b) short or long fibers or flakes, and (c) continuous fibers.
The laminate structures shown in (d) can be produced from layers of
continuous fibers or sandwich structures using a foam or honeycomb core
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(see also Fig. 16.50).
 Tapes used in Making
Reinforced Plastic Parts

(b)

Figure 19.24 (a) Manufacturing process for polymer-matrix composite tape. (b) Boron-
epoxy prepreg tape. These tapes are then used in making reinforced plastic parts and
components with high strength-to-weight ratios, particularly important for aircraft and
aerospace applications and sports equipment. Source: (a) Courtesy of T. W. Chou, R. L.
McCullough, and R. B. Pipes. (b) Courtesy of Avco Specialty Materials/Textron.

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 Tape and Tape-Laying System

(a) (b)

Figure 19.25 (a) Single-ply layup of boron-epoxy tape for the horizontal stabilizer for an
F-14 fighter aircraft. (b) A 10-axis computer-numerical-controlled tape-laying system.
This machine is capable of laying up 75- and 150-mm (3- and 6-in.) wide tapes on
contours of up to +/- 30 degrees and at speeds of up to 0.5m/s (1.7 ft/s). Source: (a)
Courtesy of Grumman Aircraft Corporation. (b) Courtesy of The Ingersoll Milling
Machine Company.

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 Production of Fiber-Reinforced Plastic
Sheets

Figure 19.26 Schematic illustration of the manufacturing process for producing fiber-
reinforced plastic sheets. The sheet still is viscous at this stage and later can be shped
into various products. Source: After T. W. Chou, R. L. McCullough, and R. B. Pipes.
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 Vacuum-Bag Forming and Pressure-Bag
Forming

Figure 19.27 Schematic illustration of (a) vacuum-bag forming, and (b) pressure-bag forming.
These processes are used in making discrete reinforced plastic parts. Source: After T. H.
Meister.
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 Open-Mold Processing

Figure 19.28 Manual methods of processing

reinforced plastics: (a) hand lay-up, and (b)
spray lay-up. Note that, even though the
process is slow, only one mold is required.
The figures show a female mold, but male
molds also are used. These methods also
are called open-mold processing. (c) A boat
hull made by these processes.

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 Filament-Winding

(b)

Figure 19.29 (a) Schematic illustration of the filament-winding process; (b) fiberglass being
wound over aluminum liners for slide-raft inflation vessels for the Boeing 767 aircraft. The
products made by this process have high strength-to-weight ratio and also serve as
lightweight pressure vessels. Source: Courtesy of Brunswick Corporation.
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 Pultrusion

(b)

Figure 19.30 (a) Schematic illustration of the pultrusion process. (b) Examples of
parts made by pultrusion. The major components of fiberglass ladders (used
especially by electricians) are made by this process. Unlike aluminum ladders, they
are available in different colors but are heavier because of the presence of glass fibers.
Source: Courtesy of Strongwell Corporation.

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Design Modifications to Minimize Distortion in
Plastic Parts

Figure 19.31 Examples of design modifications to eliminate or minimize distortion in

plastic parts: (a) suggested design changes to minimize distortion; (b) stiffening the
bottoms of thin plastic containers by doming – a technique similar to the process
used to shape the bottoms of aluminum beverage cans; and (c) design change in a
rib to minimize pull-in (sink mark) caused by shrinkage during the cooling of thick
sections in molded parts.
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Production Characteristics of Molding Methods

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