SHAPING PROCESSES FOR PLASTICS One Word Properties of polymer melts Extrusion Production of sheet, film, fiber, and filaments Injection molding Compression and transfer molding Blow molding, rotational molding, & thermoforming Casting Polymer foam processing Product design considerations ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 1

Plastic Products Molded parts Extruded sections Films Sheets Plastics can be shaped into a wide variety of products: Molded parts Extruded sections Films Sheets Insulation coatings on electrical wires Fibers for textiles ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 2

Plastic Shaping Processes are Important Almost unlimited variety of part geometries Plastic molding is a net shape process Further shaping is not needed Less energy is required than for metals due to much lower processing temperatures Handling of product is simplified during production because of lower temperatures Painting or plating is usually not required ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 3

Two Types of Plastics 1. Thermoplastics Chemical structure remains unchanged during heating and shaping Comprises ~ 70% of total plastics tonnage Thermosets Undergo a curing process during heating and shaping, causing a permanent change in molecular structure (called cross‑linking) Once cured, they cannot be remelted ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 4

Classification of Shaping Processes Extruded products with constant cross section Continuous sheets and films Continuous filaments (fibers) Molded parts that are mostly solid Hollow molded parts with relatively thin walls Discrete parts made of formed sheets and films Castings Foamed products ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 5

Polymer Melts Viscosity Viscoelasticity To shape a thermoplastic polymer it must be heated so that it softens to the consistency of a liquid In this form, it is called a polymer melt Important properties of polymer melts: Viscosity Viscoelasticity ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 6

Viscosity of Polymer Melts Fluid property that relates shear stress to shear rate during flow Due to its high molecular weight, a polymer melt is a thick fluid with high viscosity Most polymer shaping processes involve flow through small channels or die openings Flow rates are often large, leading to high shear rates and shear stresses, so significant pressures are required in these processes ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 7

Viscosity and Shear Rate Viscosity of a polymer melt decreases with shear rate Thus the fluid becomes thinner (flows more easily) at higher shear rates ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 8

Viscosity and Temperature Viscosity decreases with temperature Thus the fluid becomes thinner at higher temperatures ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 9

Viscoelasticity Combination of viscosity and elasticity Example: die swell in extrusion - hot plastic expands when exiting the die opening (memory) ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 10

Extrusion Material is forced to flow through a die orifice to provide long continuous product whose cross‑sectional shape is determined by the shape of the orifice Widely used for thermoplastics and elastomers to mass produce items such as tubing, pipes, hose, structural shapes, sheet and film, continuous filaments, and coated electrical wire Carried out as a continuous process; extrudate is then cut into desired lengths ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 11

Extruder Components and features of a (single‑screw) extruder for plastics and elastomers Plastics extrusion ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 12

Two Main Components of an Extruder Barrel Screw Die - not an extruder component Special tool that must be fabricated for particular profile to be produced ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 13

Extruder Barrel Internal diameter typically ranges from 25 to 150 mm (1.0 to 6.0 in.) L/D ratios usually ~ 10 to 30: higher ratios for thermoplastics, lower ratios for elastomers Feedstock fed by gravity onto screw whose rotation moves material through barrel Electric heaters melt feedstock; subsequent mixing and mechanical working adds heat which maintains the melt ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 14

Extruder Screw Divided into sections to serve several functions: Feed section - feedstock is moved from hopper and preheated Compression section - polymer is transformed into thick fluid, air mixed with pellets is extracted from melt, and material is compressed Metering section - melt is homogenized and sufficient pressure developed to pump it through die opening Extrusion video ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 15

Extruder Screw Details of an extruder screw inside the barrel ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 16

Die End of Extruder Die Zone – end of extruder barrel Before reaching the die, the melt passes through a screen pack - series of wire meshes supported by a stiff plate containing small axial holes Functions of screen pack: Filters out contaminants and hard lumps Builds pressure in metering section Straightens flow of polymer melt and remove its "memory" of circular motion from screw ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 17

Melt Flow in Extruder As screw rotates, polymer melt is forced to move forward toward die; as in an Archimedian screw Principal transport mechanism is drag flow, Qd, resulting from friction between the viscous liquid and the rotating screw surfaces Compressing the polymer melt through the die creates a back pressure that reduces drag flow transport (called back pressure flow, Qb ) Resulting flow in extruder is Qx = Qd – Qb ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 18

Die Configurations and Extruded Products The shape of the die orifice determines the cross‑sectional shape of the extrudate Common die profiles and corresponding extruded shapes: Solid profiles Hollow profiles, such as tubes Wire and cable coating Sheet and film Filaments ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 19

Extrusion of Solid Profiles Regular shapes such as Rounds Squares Irregular cross sections such as Structural shapes Door and window moldings Automobile trim House siding ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 20

Extrusion Die for Solid Cross Section (a) Side view cross section of extrusion die for solid regular shapes, such as round stock; (b) front view of die, with profile of extrudate ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 21

Hollow Profiles Examples: tubes, pipes, hoses, and other cross sections containing holes Hollow profiles require mandrel to form the shape Mandrel held in place using spider legs Polymer melt flows around legs supporting the mandrel to reunite into a monolithic tube wall Mandrel often includes an air channel through which air is blown to maintain hollow form of extrudate ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 22

Extrusion Die for Hollow Shapes Side view of extrusion die for hollow cross sections; Section A‑A is a front view of how mandrel is held in place; Section B‑B shows tube prior to exiting die; die swell enlarges diameter Plastic tubing production ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 23

Wire and Cable Coating Polymer melt is applied to bare wire as it is pulled at high speed through die A slight vacuum is drawn between wire and polymer to promote adhesion of coating Wire provides rigidity during cooling Usually aided by passing coated wire through a water trough Product is wound onto large spools at speeds up to 50 m/s (10,000 ft/min) ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 24

Extrusion Die for Coating Wire Plastic coating of wire ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 25

Polymer Sheet and Film Film - thickness below 0.5 mm (0.020 in.) Packaging - product wrapping material, grocery bags, and garbage bags Stock for photographic film Pool covers and irrigation ditch liners Sheet - thickness from 0.5 mm (0.020 in.) to about 12.5 mm (0.5 in.) Flat window glazing Thermoforming stock ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 26

Materials for Polymer Sheet and Film All thermoplastic polymers Polyethylene, mostly low density PE Polypropylene Polyvinylchloride Cellophane ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 27

Sheet and Film Production Processes Most widely used processes are continuous, high production operations Processes include: Slit‑Die Extrusion of Sheet and Film Blown‑Film Extrusion Process Calendering ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 28

Slit‑Die Extrusion of Sheet and Film Production of sheet and film by conventional extrusion, using a narrow slit as the die opening Slit may be up to 3 m (10 ft) wide and as narrow as around 0.4 mm (0.015 in) A problem is thickness uniformity throughout width of stock, due to drastic shape change of polymer melt as it flows through die Edges of film usually must be trimmed because of thickening at edges ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 29

Slit Die Extrusion ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 30

Blown‑Film Extrusion Process Combines extrusion and blowing to produce a tube of thin film Process sequence Extrusion of tube Tube is drawn upward while still molten and expanded by air inflated into it through die Air is blown into tube to maintain uniform film thickness and tube diameter ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 31

Blown-film Process PLastic sheet production ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 32

Calendering Feedstock is passed through a series of rolls to reduce thickness to desired gage Expensive equipment, high production rates Process is noted for good surface finish and high gage accuracy Typical materials: rubber or rubbery thermoplastics such as plasticized PVC Products: PVC floor covering, shower curtains, vinyl table cloths, pool liners, and inflatable boats and toys ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 33

Calendering ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 34

Fiber and Filament Products Definitions: Fiber - a long, thin strand whose length is at least 100 times its cross‑section Filament - a fiber of continuous length Applications: Fibers and filaments for textiles Most important application Reinforcing materials in polymer composites Growing application, but small relative to textiles ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 35

Materials for Fibers and Filaments Fibers can be natural or synthetic Natural fibers constitute ~ 25% of total market Cotton is by far the most important staple Wool production is significantly less than cotton Synthetic fibers constitute ~ 75% of total fiber market Polyester is the most important Others: nylon, acrylics, and rayon ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 36

Fiber and Filament Production - Spinning For synthetic fibers, spinning = extrusion of polymer melt or solution through a spinneret, then drawing and winding onto a bobbin Spinneret = die with multiple small holes, the term is a holdover from methods used to draw and twist natural fibers into yarn or thread Three variations, depending on polymer : Melt spinning Dry spinning Wet spinning ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 37

Melt Spinning Starting polymer is heated to molten state and pumped through spinneret Typical spinneret is 6 mm (0.25 in) thick and contains ~ 50 holes of diameter 0.25 mm (0.010 in) Filaments are drawn and air cooled before being spooled onto bobbin Final diameter wound onto bobbin may be only 1/10 of extruded size Used for polyester and nylon filaments ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 38

Melt spinning of continuous filaments ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 39

Dry Spinning Similar to melt spinning, but starting polymer is in solution and solvent can be separated by evaporation First step is extrusion through spinneret Extrudate is pulled through a heated chamber which removes the solvent, leaving the polymer Used for filaments of cellulose acetate and acrylics ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 40

Wet Spinning Similar to melt spinning, but polymer is again in solution, only solvent is non‑volatile To separate polymer, extrudate is passed through a liquid chemical that coagulates or precipitates the polymer into coherent strands which are then collected onto bobbins Used for filaments of rayon (regenerated cellulose) ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 41

Subsequent Processing of Filaments Filaments produced by any of the three processes are usually subjected to further cold drawing to align crystal structure along direction of filament axis Extensions of 2 to 8 are typical Effect is to significantly increase tensile strength Drawing is done by pulling filament between two spools, where winding spool is driven at a faster speed than unwinding spool ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 42

Injection Molding Polymer is heated to a highly plastic state and forced to flow under high pressure into a mold cavity where it solidifies and the molding is then removed from cavity Produces discrete components to net shape Typical cycle time 10 to 30 sec, but cycles of one minute or more are not uncommon Mold may contain multiple cavities, so multiple moldings are produced each cycle ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 43

©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes

Injection Molded Parts Complex and intricate shapes are possible Shape limitations: Capability to fabricate a mold whose cavity is the same geometry as part Shape must allow for part removal from mold Part size from  50 g (2 oz) up to  25 kg (more than 50 lb), e.g., automobile bumpers Injection molding is economical only for large production quantities due to high cost of mold ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 45

Injection Molding Machine Two principal components: Injection unit Melts and delivers polymer melt Operates much like an extruder Clamping unit Opens and closes mold each injection cycle ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 46

Injection Molding Machine Diagram of an injection molding machine, reciprocating screw type (some mechanical details are simplified) How Injection Molding works ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 47

Injection Unit of Molding Machine Consists of barrel fed from one end by hopper containing supply of plastic pellets Inside the barrel is a screw which: Rotates for mixing and heating polymer Acts as a ram (i.e., plunger) to inject molten plastic into mold Non‑return valve near tip of screw prevents melt from flowing backward along screw threads Later in cycle ram retracts to its former position ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 48

Clamping Unit of Molding Machine Functions: Holds two halves of mold in proper alignment with each other Keeps mold closed during injection by applying a clamping force sufficient to resist injection force Opens and closes mold at the appropriate times in molding cycle ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 49

Injection Molding Cycle (1) Mold is closed ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 50

Injection Molding Cycle (2) Melt is injected into cavity ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 51

Injection Molding Cycle (3) screw is retracted ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 52

Injection Molding Cycle (4) mold is opened and part is ejected Optimizing Injection molding ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 53

The Mold Two-plate mold Three-plate mold Hot-runner mold The special tooling in injection molding Custom‑designed and fabricated for the part to be produced When production run is finished, the mold is replaced with a new mold for the next part Various types of mold for injection molding: Two-plate mold Three-plate mold Hot-runner mold ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 54

Two-Plate Mold Details of a two‑plate mold for thermoplastic injection molding: (a) closed Mold has two cavities to produce two cup‑shaped parts with each injection shot ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 55

Two-Plate Mold Details of a two‑plate mold for thermoplastic injection molding: (b) open ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 56

Two‑Plate Mold Features Cavity – geometry of part but slightly oversized to allow for shrinkage Fabricated by machining the mating surfaces of two mold halves Distribution channel through which polymer melt flows from nozzle into mold cavity Sprue - leads from nozzle into mold Runners - lead from sprue to cavity (or cavities) Gates - constrict flow of plastic into cavity ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 57

More Two‑Plate Mold Features Ejection system – to eject molded part from cavity at end of molding cycle Ejector pins built into moving half of mold usually accomplish this function Cooling system - consists of external pump connected to passageways in mold, through which water is circulated to remove heat from the hot plastic Air vents – to permit evacuation of air from cavity as polymer melt rushes in ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 58

Three‑Plate Mold Uses three plates to separate parts from sprue and runner when mold opens Advantages over two-plate mold: As mold opens, runner and parts disconnect and drop into two containers under mold Allows automatic operation of molding machine ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 59

Hot‑Runner Mold Eliminates solidification of sprue and runner by locating heaters around the corresponding runner channels While plastic in mold cavity solidifies, material in sprue and runner channels remains molten, ready to be injected into cavity in next cycle Advantage: Saves material that otherwise would be scrap in the unit operation ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 60

Shrinkage Reduction in linear size during cooling Polymers have high thermal expansion coefficients, so significant shrinkage occurs during solidification and cooling in mold Plastic Typical Shrinkage, mm/mm (in/in) Nylon‑6,6 0.020 Polyethylene 0.025 Polystyrene 0.004 PVC 0.005 ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 61

Compensation for Shrinkage Dimensions of mold cavity must be larger than specified part dimensions: Dc = Dp + DpS + DpS2 Dc = dimension of cavity; Dp = molded part dimension S = shrinkage value Third term on right hand side corrects for shrinkage in the shrinkage ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 62

Shrinkage Factors Fillers in the plastic tend to reduce shrinkage Injection pressure – higher pressures force more material into mold cavity to reduce shrinkage Compaction time - similar effect – longer time forces more material into cavity to reduce shrinkage Molding temperature - higher temperatures lower polymer melt viscosity, allowing more material to be packed into mold to reduce shrinkage ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 63

Thermoplastic Foam Injection Molding Molding of thermoplastic parts that possess dense outer skin surrounding lightweight foam center Part has high stiffness‑to‑weight ratio Produced either by introducing a gas into molten plastic in injection unit or by mixing a gas‑producing ingredient with starting pellets A small amount of melt is injected into mold cavity, where it expands to fill cavity Foam in contact with cold mold surface collapses to form dense skin, while core retains cellular structure ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 64

Injection Molding of Thermosets Equipment and operating procedure must be modified to avoid premature cross‑linking of Thermoset polymer Reciprocating‑screw injection unit with shorter barrel length Temperatures in barrel are relatively low (lower than glass transition temperature) Melt is injected into a heated mold, where cross‑linking occurs to cure the plastic Curing is the most time‑consuming step in cycle Mold is then opened and part is removed ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 65

Reaction Injection Molding (RIM) Two highly reactive liquid ingredients are mixed and immediately injected into a mold cavity where chemical reactions leading to solidification occur RIM was developed with polyurethane to produce large automotive parts such as bumpers and fenders RIM polyurethane parts possess a foam internal structure surrounded by a dense outer skin Other RIM materials: epoxies and urea‑formaldehyde ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 66

Compression Molding Widely used molding process for thermosetting plastics Also used for rubber tires and polymer matrix composite parts Molding compound available in several forms: powders or pellets, liquid, or preform Amount of charge must be precisely controlled to obtain repeatable consistency in the molded product ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 67

Compression Molding (1) TS charge is loaded, (2) and (3) compression and curing, and (4) part is ejected and removed ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 68

Molds for Compression Molding Simpler than injection molds No sprue and runner system in a compression mold Process itself generally limited to simpler part geometries due to lower flow capabilities of TS materials Mold must be heated, usually by electric resistance, steam, or hot oil circulation ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 69

Compression Molding Molding materials: Phenolics, melamine, urea‑formaldehyde, epoxies, urethanes, and elastomers Typical compression-molded products: Electric plugs, sockets, and housings; pot handles, and dinnerware plates ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 70

Transfer Molding TS charge is loaded into a chamber immediately ahead of mold cavity, where it is heated; pressure is then applied to force soft polymer into heated mold where it cures Two variants: Pot transfer molding - charge is injected from a "pot" through a vertical sprue channel into cavity Plunger transfer molding – plunger injects charge from a heated well through channels into cavity ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 71

Pot Transfer Molding (1) charge loaded into pot, (2) soft polymer is pressed into mold cavity and cured, and (3) part is ejected ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 72

Plunger Transfer Molding (1) charge loaded into pot, (2) soft polymer is pressed into mold cavity and cured, and (3) part is ejected ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 73

Blow Molding Molding process in which air pressure is used to inflate soft plastic into a mold cavity Important for making one‑piece hollow plastic parts with thin walls, such as bottles Because these items are used for consumer beverages in mass markets, production is typically organized for very high quantities ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 74

Blow Molding Process Fabrication of a starting tube, called a parison Accomplished in two steps: Fabrication of a starting tube, called a parison Inflation of the tube to desired final shape Forming the parison is accomplished by either Extrusion or Injection molding ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 75

Extrusion Blow Molding (1) Extrusion of parison; (2) parison is pinched at top and sealed at bottom around blow pin as the mold closes; (3) tube is inflated; and (4) mold is opened ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 76

Injection Blow Molding (1) Parison is injected molded around blowing rod; (2) mold is opened and parison is moved to blow mold; (3) soft polymer is inflated; and (4) mold is opened ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 77

Stretch Blow Molding Ideal as container for carbonated beverages Variation of injection blow molding in which blowing rod stretches the soft parison for a more favorable stressing of polymer than conventional blow molding Resulting structure is more rigid, more transparent, and more impact resistant Most widely used plastic is polyethylene terephthalate (PET) which has very low permeability and is strengthened by stretch blow molding Ideal as container for carbonated beverages ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 78

Stretch Blow Molding (1) Injection molding of parison; (2) stretching; and (3) blowing Making Plastic Bottles ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 79

Materials and Products in Blow Molding Blow molding is limited to thermoplastics Materials: high density polyethylene, polypropylene (PP), polyvinylchloride (PVC), and polyethylene terephthalate Products: disposable containers for beverages and other liquid consumer goods, large shipping drums (55 gallon) for liquids and powders, large storage tanks (2000 gallon), gasoline tanks, toys, and hulls for sail boards and small boats ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 80

Rotational Molding Process uses gravity inside a rotating mold to produce a hollow part shape Alternative to blow molding for larger parts with more complex external geometries But lower production rates than blow molding Principally for thermoplastic polymers but thermoset and elastomer applications becoming common Products: boat and canoe hulls, sandboxes, buoys, garbage cans, large containers and storage tanks Making kayaks ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 81

Thermoforming Flat thermoplastic sheet or film is heated and deformed into desired shape using a mold Heating usually accomplished by radiant electric heaters located on one or both sides of starting plastic sheet or film Widely used in packaging of products and to fabricate large items such as bathtubs, contoured skylights, and internal door liners for refrigerators ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 82

Vacuum Thermoforming (1) Flat plastic sheet is softened by heating ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 83

Vacuum Thermoforming (2) The softened sheet is placed over a concave mold cavity ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 84

Vacuum Thermoforming (3) Vacuum draws the sheet into the cavity ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 85

Vacuum Thermoforming (4) plastic hardens on contact with the cold mold surface, and the part is removed and later trimmed from the web ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 86

Negative Molds vs. Positive Molds Negative mold has concave cavity Positive mold has convex shape Both types are used in thermoforming For positive mold, heated sheet is draped over convex form and negative or positive pressure forces plastic against mold surface ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 87

Vacuum Thermoforming using a Positive Mold (1) Heated plastic sheet is positioned above the convex mold ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 88

Vacuum Thermoforming using a Positive Mold (2) Clamp is lowered into position, draping the sheet over the mold as a vacuum forces the sheet against the mold surface ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 89

Materials for Thermoforming Only thermoplastics can be thermoformed, Sheets of thermosetting or elastomeric polymers have already been cross‑linked and cannot be softened by reheating Common TP polymers: polystyrene, cellulose acetate, cellulose acetate butyrate, ABS, PVC, acrylic (polymethylmethacrylate), polyethylene, and polypropylene ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 90

Applications of Thermoforming Thin films: blister packs and skin packs for packaging commodity products such as cosmetics, toiletries, small tools, and fasteners (nails, screws, etc.) For best efficiency, filling process to containerize item(s) is immediately downstream from thermoforming Thicker sheet stock: boat hulls, shower stalls, advertising displays and signs, bathtubs, certain toys, contoured skylights, internal door liners for refrigerators ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 91

Polymer Foam A polymer‑and‑gas mixture that gives the material a porous or cellular structure Most common polymer foams: polystyrene (Styrofoam, a trademark) and polyurethane Other polymers: natural rubber ("foamed rubber") and polyvinylchloride (PVC) ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 92

Properties of a Foamed Polymer Low density High strength per unit weight Good thermal insulation Good energy absorbing qualities ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 93

Classification of Polymer Foams Elastomeric - matrix polymer is a rubber, capable of large elastic deformation Flexible - matrix is a highly plasticized polymer such as soft PVC Rigid - polymer is a stiff thermoplastic such as polystyrene or a thermoset such as a phenolic ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 94

Applications of Polymer Foams Characteristic properties of polymer foams, and the ability to control elastic behavior by selection of base polymer, make these materials suitable for certain applications Applications: hot beverage cups, heat insulating structural materials, cores for structural panels, packaging materials, cushion materials for furniture and bedding, padding for automobile dashboards, and products requiring buoyancy ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 95

Extrusion of Polystyrene Foams Polystyrene (PS) is a thermoplastic polymer A physical or chemical blowing agent is fed into polymer melt near die end of extruder barrel Thus, extrudate consists of expanded polymer Products: large sheets and boards that are subsequently cut to size for heat insulation panels and sections ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 96

Molding Processes for Polystyrene Foams Expandable foam molding Molding material consists of prefoamed polystyrene beads Beads are fed into mold cavity where they are further expanded and fused together to form the molded product Products: hot beverage cups ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 97

Shaping of Polyurethane Foams Polyurethane can be thermosetting, elastomer or thermoplastic (less common) Polyurethane foam products are made in a one‑step process in which the two liquid ingredients are mixed and immediately fed into a mold or other form Polymer is synthesized and part geometry is created at the same time Shaping processes for polyurethane foam: Spraying Pouring ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 98

Product Design Guidelines: General Strength and stiffness Plastics are not as strong or stiff as metals Avoid applications where high stresses will be encountered Creep resistance is also a limitation Strength‑to‑weight ratios for some plastics are competitive with metals in certain applications ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 99

Product Design Guidelines: General Impact Resistance Capacity of plastics to absorb impact is generally good; plastics compare favorably with most metals Service temperatures Limited relative to metals and ceramics Thermal expansion Dimensional changes due to temperature changes much more significant than for metals ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 100

Product Design Guidelines: General Many plastics are subject to degradation from sunlight and other forms of radiation Some plastics degrade in oxygen and ozone atmospheres Plastics are soluble in many common solvents Plastics are resistant to conventional corrosion mechanisms that afflict many metals ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 101

Product Design Guidelines: Extrusion Wall thickness Uniform wall thickness is desirable in an extruded cross section Variations in wall thickness result in non-uniform plastic flow and uneven cooling which tend to warp extrudate ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 102

Product Design Guidelines: Extrusion Hollow sections Hollow sections complicate die design and plastic flow Desirable to use extruded cross sections that are not hollow yet satisfy functional requirements ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 103

Product Design Guidelines: Extrusion Corners Sharp corners, inside and outside, should be avoided in extruded cross sections They result in uneven flow during processing and stress concentrations in the final product ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 104

Product Design Guidelines: Moldings Economic production quantities Each part requires a unique mold, and the mold for any molding process can be costly, particularly for injection molding Minimum production quantities for injection molding ~ 10,000 pieces For compression molding, minimum quantities are 1000 parts, due to simpler mold designs Transfer molding lies between injection molding and compression molding ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 105

Product Design Guidelines: Moldings Part complexity Allows multiple functional features to be combined into one part Although more complex part geometries mean more costly molds, it may nevertheless be economical to design a complex molding if the alternative involves many individual parts that must be assembled ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 106

Product Design Guidelines: Moldings Wall thickness Thick cross sections are wasteful of material, more likely to cause warping due to shrinkage, and take longer to harden Reinforcing ribs Achieves increased stiffness without excessive wall thickness Ribs should be made thinner than the walls they reinforce to minimize sink marks on outside wall ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 107

Product Design Guidelines: Moldings Corner radii and fillets Sharp corners, both external and internal, are undesirable in molded parts They interrupt smooth flow of the melt, tend to create surface defects, and cause stress concentrations in the part Holes Holes are quite feasible in plastic moldings, but they complicate mold design and part removal ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 108

Product Design Guidelines: Moldings Draft A molded part should be designed with a draft on its sides to facilitate removal from mold Especially important on inside wall of a cup‑shaped part because plastic contracts against positive mold shape Recommended draft: For thermosets, ~ 1/2 to 1 For thermoplastics, ~ 1/8 to 1/2 ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 109

Product Design Guidelines: Moldings Tolerances Although shrinkage is predictable under closely controlled conditions, generous tolerances are desirable for injection moldings because of Variations in process parameters that affect shrinkage Diversity of part geometries encountered ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 110