1. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. Chapter 19 Forming and Shaping Plastics and Composite Materials

2. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. Characteristics of Forming and Shaping Processes for Plastics and Composite Materials

3. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. 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.)

4. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. 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.

5. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. 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 nonuniform recovery of the part after it exits the die. Source: (a) Encyclopedia of Polymer Science and Engineering (2 nd ed.). Copyright © 1985. Reprinted by permission of John Wiley & Sons, Inc.

6. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. 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.

7. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. Production of Plastic Film and Bags 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. (b)

8. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. 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.

9. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. Injection Molding Figure 19.7 Schematic illustration of injection molding with (a) plunger and (b) reciprocating rotating screw.

10. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. 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).

11. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. Products Made by Injection Molding 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. (b) (a)

12. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. 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.

13. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. 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.

14. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. 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.

15. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. 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.

16. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. 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.

17. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. 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.

18. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. 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.

19. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. 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.

20. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. 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.

21. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. 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.

22. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. 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.

23. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. 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.

24. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. 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.

25. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. Tapes used in Making Reinforced Plastic Parts 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. (b)

26. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. Tape and Tape-Laying System (b)(a) 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.

27. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. 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.

28. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. 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.

29. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. 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.

30. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. 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.

31. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. Pultrusion 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. (b)

32. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. 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.

33. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. Production Characteristics of Molding Methods