Pratik Chaudhari

MIS- 111210015
TY Mechanical div-1
Subject – Advanced manufacturing techniques
Conventional materials
 Conventional materials are shows more crystallinity.
Shows deflection under service load
 More crystallinity , harder, stiffer and less ductile
 Structure sensitive
 Problems with sophastication,
machinability,tolerance, etc.
 Changed by small changes in chemical composition
Plastics
 Material of New age
 Its basic constituent is prepared synthetically or semi-
synthetically from monomer.
 Easily machined , cast and joined
 Ease of manufacturing and versatility
 hardness, elasticity, breaking strength, temperature
resistance, thermal dimensional stability, chemical
resistance
Plastics - Classification

Elastomers thermosets

Thermoplastics
Thermoplastics
 Polymers which moulds above Glass transition
temperature and returns to normal state upon cooling
Thermoplastics
 Most commonly used engineering thermoplastics as
matrices
 Nylon
 Polycarbonate (PC)
 Polyethylene terephthalate (PET)
 Polypropylene (PP)
 Stronger and stiffer but lower toughness
 Have engineering as well as advanced applications
Glass transition temperature
Amorphous polymers do
not have a specific
melting point. At low
temp., they are hard,
brittle, rigid and glassy
and at a high temp.
rubbery and leathery.

The temperature at
which this transition
occurs is called Glass
transition temperature
(Tg).
Effect of temperature
• Above glass-transition
temp. – polymers
become leathery and
then rubbery

• At higher
temperatures,
polymers become a
viscous fluid, with
viscosity decreasing
with increasing
temperture.
Behaviour under temperature
conditions
• Below temperature Tg, plastic polymers are glassy ,rigid,
hard or brittle and behave as a elastic body.
• If the load exceeds the certain critical value, it fractures as
a piece of glass

• 1. Elastic deformation
2. Viscous deformation
3. Maxwell Model of Viscoelastic deformation
4. Voigt or Kelvin Model of Viscoelastic deformation
Viscoelastic behavior
 When heated above Tg , It becomes leathery first and
then rubbery with increasing temperature
 If we increase above Tm (melting point ), it becomes
viscous and viscosity goes on decreasing with increase
in temperature and strain rate
 As viscosity is not constant, thermoplastic shows
visco-elastic behavior
Draw diagrams on page 569
Orientation
 When thermoplastics are permanently deformed by
stretching, long chain molecules align in general
direction of elongation. This is known as orientation.
 The polymer becomes stiffer and stronger in the
elongation direction as compared to transverse
direction
 This technique is used to enhance the strength and
toughness of polymers
Crazing & stress whitening
 Some thermoplastics such as polystyrene develop
localized,wedge shaped narrow regions of highly
deformed material when subjected to high tensile
stresses or bending
 Presence of various additives, solvents, water vapour
favours crazing
 Stress whitening - When polymer subjected to tensile
stresses such as by folding or bending, the plastic
becomes lighter in color due to formation of micro-voids
in the material.
Water absorption
 This is limitation of thermoplastics
 Water acts as plasticizing agent. Thus, it makes
polymer more plastic
 It lowers the glass transition temperature, yield stress
and elastic modulus of polymer
 Sometimes,Undesired dimensional changes occur
Classificatio …
Amorphous thermoplastic polymers
 Molecule chains are completely chaotically arranged
and tangled with each other like the threads of a
cotton wool pad
 amorphous structure means that these materials
cannot be subjected to loads above the glass transition
point
 Properties :
 Low tendency to creep
 Good dimensional stability
 Tendency to brittleness
 Sensitive to stress cracking
Semi-crystalline thermoplastics
 Molecules form crystalline structure
 Due to the crystalline areas, the materials are
extremely tough (strong intermolecular forces) and are
capable of withstanding mechanical loads
 Properties :
 Opaque
 Good fatigue resistance
 Tendency to toughness
 Good chemical resistance
 Wear resistance
So e e a ples…
Polyamides or Nylons (PA)
Acetals or Polyoxymethylenes (POM)
Acetals or Polyoxymethylenes (POM)
and Polyamides characteristics
•Mechanical—do not embrittle, good impact
strength
•Moisture—very little (shower heads)
•Chemical resistance—very high, resists
stains, sensitive to strong acids and
bases
•Electrical resistance - good
•Machining—like cutting brass
•Adhesion—epoxy glues
Thermoplastic Polyesters (PET/PBT)
 Thermoplastic Polyester General
Family Characteristics
• PET
– Higher mechanical stiffness
– Strength by orienting chains not by H-bonding
– Get 50% crystallinity
• forced by mechanical stretching
• PBT
– crystallizes rapidly
– processes faster
– lower overall properties
Polycarbonate
Flouropolymers
Other aspects …
 Cost challenge

Materials:
Typical Aerospace Structure Carbon Fiber / Epoxy, Carbon
Fiber / BMI, Carbon Fiber /
$50 - $100/lb PEEK
and more Processes:
Hand Lay Up
Costs in $/lb

Apply Materials and

Processing Techniques
being Developed for
Automotive Applications to
Aerospace Applications

Materials:
Thermoplastic Woven Sheets, Glass,
Innovative Materials and Carbon and Kevlar Fiber, Engineering
Processes Polymers
$5 - $20/lb Processes:
Co-Compression Molding, Co-
Automotive Structures Injection Molding, Thermoforming
$1 - $3/lb Materials:
Glass Fiber / Polypropylene, SMC/BMC
Processes:
Compression Molding, Injection Molding
 Short fiber, Long Fiber and
Continuous Fiber Composites

Typical short fiber Long fiber

thermoplastic thermoplastic Continuous
material, material, pellets of ½ reinforced
granules with fiber and 1 fiber length, thermoplastic
length of approx. 2 resulting fiber length material, tape
to 4 mm, in a part of approx. 4- used for woven
resulting fiber 6 mm in injection sheets
length in a part of molding and approx. (thermoforming),
approx. 0.4 mm 20 mm in filament winding
compression molding or pultrusion
Composite Performance versus Fiber Length

1.2

1.0
Relative Property Level

0.8
Modulus
0.6 Strength
Impact
0.4 Processibility

0.2

0.0
0.1 1 10 100
Length (mm)
Processi g…
Current Composite Materials and
Processes
Process Type of Application

Injection Molding
Low-Structural
Components

Compression
Molding

Semi-Structural
Components
Thermoforming

Hand Lay Up / Structural Components

Vacuum Bag /
Autoclave
Thermoplastic − Ther ofor i g
Press (in two modes)

Blanks

Clamp Finished
Oven Part

Clamping Pressing
Extrusion
Injection Molding Machine Basics

34
 Blow Molding
Plastic

Extruded Mold Closed and Finished Bottle

Parison- Bottle Blown Removed from
Mold Open Mold

35
 Compression Molding

Platen
Heat
and Mold
Cooling Plunger

Guide
Heat Pins
and
Cooling Mold
Cavity
Compound to be molded

Platen
Hydraulic
Pressure Hydraulic
Plunger

Plastic Materials and Pocesses 36

Applicatio s…
 Applications For High-Performance
Thermoplastics
•Aerospace and defense:
•Radomes, wing and fuselage sextions, anti-ballistics
•Infrastructure and Construction
•Window profiles, rebar, beams, structures, composite bolts
•Consumer / recreational
•Orthotics, safety shoes, sporting goods, helmets, personal
injury protextion, speaker cones, enclosures, bed suspension
slats
•Auto and truck
•Bumper beams, skid plates, load floor, seat structures
•Transportation
•Railcar structure, body structure and closures
•Energy production and storage
•Oil and gas structura tube, wind turbines
Future ?
• Thermoplastics polymers go to more structural
applications using different technical
thermoplastics in combination with glass, carbon
and synthetic fibers.
• Thermoplastics will replace metal applications and
reduce weight.
• Improved processing methods will be developed
and applied.
Tha k ou…