Manufacturing

Processes

Chapter 20
Forming and Shaping of Plastics
 Plastics Review
• Thermoplastics (TPs)
– Polymers in which, after heating and cooling,
properties return to original values.
– Behavior depends on: structure, composition,
temperature, rate of deformation.
– Glass transition temperature (Tg): the temperature
at which the transition in behavior (solid to liquid)
takes place.
– Below Tg, behavior is like an elastic solid.
 Plastics Review
• Thermoplastics (TPs)
– Plastics have a high strain-rate sensitivity exponent
(m).
– This enables them to undergo high deformation
before fracture.
– When a plastic undergoes tensile stresses, the plastic
changes in color due to the formation of microvoids.
– The material becomes translucent.
– This phenomena is referred to as Stress Whitening.
Commonly Known Thermoplastics
– Acrylics – Polystyrene
– Polycarbonates – Polytetrafluoroethylene
– Polyesters (Teflon)

– Polyethylene – Polyurethane

– Polypropylenes – Polyvinyl Chloride

(PVC) Vinyl

See last slide for commercial names.

 Plastics Review
• Thermosets (TSs)
– Long molecules are cross-linked three-dimensionally
during polymerization
– This creates one big molecule and a complex 3D
structure.
– The name thermoset is due to the fact that the
polymerization is complete and the final shape is set.
– The reaction, in this case is IRREVERSIBLE.
– Thermosets are rarely used in injection molding.
 Plastics Review
• Thermosets (TSs)
– Thermosets have no set glass Transition temperature
(Tg).
– Temperature and Rate of Deformation do not affect
the strength and hardness of thermosets.
– Sample products: knobs, handles, switches.
Commonly Known Thermosets

• Epoxy

• Melamine

• Natural Rubber

• Polyester

• Silicone.

See last slide for more info.

 Plastics Review
• Biodegradable Plastics
– The disposal of plastic products is a major concern, given the limited
landfill space available.
– Degrade over time with exposure to microorganisms in soil and water.
• Some bioplastics available:
– Starch-based: a pelletized form of starch is added to the plastic during
processing.
– Lactic-based: Lactic acid is polymerized to form a polyester resin.
– Sugar-based.
 Plastics Review
• Elastomers (Es) & Rubbers
– Amorphous polymers having a very low Tg.
– Can undergo large elastic deformation without rupture.
– Soft.
– Very low Elastic Modulus
– Return to original shape after an applied load is removed.
– Rubber is a good example of cross-linked polymer. Its hardness
increases with increased cross-linking of molecular chains.
 Forming and Shaping of Plastics
• Plastics can be shaped easily into many shapes
with few operations.
• Plastics melt at relatively low temperatures.
• Properties of resulting parts depend on
manufacturing method, process parameters.
 Most common methods for Plastic Forming

1. Extrusion 6. Thermoforming
2. Injection Molding 7. Compression
2a. Reaction Molding
Injection Molding
8. Transfer
3. Structural Foam
Molding
Molding
4. Blow Molding 8a. Foam Molding
5. Rotational 9. Casting
Molding 10. Cold Forming
 1. Extrusion
• Raw Material: thermoplastic pellets, granules
or powder.
• Material is placed in hopper and fed into
extrusion barrel.
• Screw inside barrel blends pellets and
conveys them down barrel.
• Heaters and friction heat pellets and liquify
them.
 1. Extrusion (cont.)
• Screw
– Feed section: conveys material from hopper to
center of barrel.
– Transition region: where melting begins.
– Pumping section: where shearing, melting and
pressure buildup begins.
 1. Extrusion (cont.)
• You can adjust the length of these sections
depending on the melting characteristics of different
plastics.
• Once molten plastic is fed through die, it is air-
cooled or via cooling tubes.
• Cooling rate is critical to avoid shrinkage, distortion.
• Can make long sections with no problem due to
continuous feed from hopper.
 1. Extrusion (cont.)
• Sheet film extrusion
– Performed with a flat extrusion die. (See figs. 18.3,4)
– Plastic bags are made with an extruder (blown film
process).
– Thin walled tube is extruded vertically upward.
– Air is blown through center and expand into a balloon
shape.
– Balloon is air cooled, blown film is wound up.
 2. Injection Molding
• A barrel is heated to promote melting.
• Friction promotes heating dramatically.
• Pellets are fed into heated cylinder.
• Melt is forced into split die chamber by hydraulic
plunger or rotating screw.
• Thermosets require that mold be heated as well to
promote polymerization & cross-linking.
• Part cools (if thermoplastic) or cures (if thermoset).
• Mold is opened, part is ejected.
 2. Injection Molding (cont.)
• Mold components:
– Runners
– Cores
– Cavities
– Cooling Channels
– Inserts
– Knockout pins
– Ejectors
 2. Injection Molding (cont.)
• Other metal components can be placed inside
the mold.
• They become integral part of the product.
– Example: electrical connectors/components.

• Multi-component injection molding allows

forming of parts having different shapes/colors.
– Example: tail light lenses for automobiles.
 2. Injection Molding (cont.)
• Process capabilities
– Can achieve good dimensional accuracy, complex
shapes.
– Cycle time ranges 5-60 seconds.
– Molds made of tool steels -cost: hundreds of
thousands.
– Must justify expenditure with high volume
production.
– Cycles:
• Steel molds: 2 million cycles - Aluminum 10,000 cycles.
 2. Injection Molding (cont.)
• Machines
– Injection molding machines are typically horizontal
(fig. 18.7)
– Typical pressures in injection molding: 10,000 -
30,000 psi.
– Forces range from 100 to 250 tons.
– Largest machine: 5000 tons - makes parts up to 55
lbs.
3. Injection Molding (cont.)
 2a. Reaction Injection Molding
• Resin and catalysts are forced into mold cavity
at high speed.
• Reaction is fast, part solidifies into a thermoset.
• Can add reinforcing fibers to increase product
strength & stiffness.
– Typical parts: bumpers, fenders, water skis.
 3. Structural Foam Molding
• Used to make plastic products with a solid outer skin
and a cellular inner structure.
• Injection Foam Molding uses a blowing agent
(Nitrogen gas) to expand the material.
• Can create skin thicknesses as much as 2 mm.
• Good stiffness to weight ratio.
– Typical parts: furniture parts, TV shells, computer printer
housings.
3. Structural Foam Molding
 4. Blow Molding
• Extrusion Blow Molding
– A tube is extruded & then clamped into a mold with
larger cavity cross section..
– Tube is blown outward to fill cavity (50 - 100 psi).
– All ends of mold close in as air is injected into
tubular piece.
– Part is cooled and ejected.
 4. Blow Molding
• Injection Blow Molding
– A short piece tubular piece is mold-injected
(called the parison).
– Dies open, parison is transferred to blow-
molding die.
– Hot air is injected, expands to walls of cavity.
• Typical products: plastic bottles, hollow
containers, shampoos.
4. Blow Molding
 5. Rotational Molding
• Can form large hollow parts by this method .
– Two piece mold is designed such that it can be rotated
about 2 perpendicular axes.
– Pre-measured amount of powder plastic is placed inside
warm mold.
– Mold is heated further and rotated about the two axes.
– Powder tumbles against mold walls, causing it to fuse
without melting.
– Additional cross-linking occurs via a chemical agent.
• Typical products: trash cans, buckets, toys, boat hulls.
 6. Thermoforming
• Used for forming TP sheet or film over a mold.
• Done by applying heat and pressure.
– Sheet is heated to the sag point (soft but not to he
point of melting)
– Sheet is taken form oven, placed over mold, forced
against it via a vacuum.
– Mold is at room temp., and plastic takes shape of
mold immediately.
 6. Thermoforming (cont.)
– Material undergoes drawing (vertically) and

stretching (horizontally).

– It must exhibit high uniform elongation (high m).

– Parts with holes cannot be made by this method.

– Typical products: refrigerator liners, packaging,

appliance housings.
 7. Compression Molding
• Very similar to forging.

• A pre-measured amount of material is placed into

heated mold cavity.

• Dies are moved/pressed together, forming the part.

• An amount of flash results, which is trimmed off.

 7. Compression Molding (cont.)
• Primarily for TSs: material is partially
polymerized prior to molding.

• Cross linking is finished in heated die: times

range from ½ to 5 minutes.

• Typical parts: dishes, container caps, handles,

washing machine agitators.
 8. Transfer Molding
• Similar to Compression Molding, but dies are
not preheated.
• Friction caused by ram forcing material into
mold generates frictional heat.
• Heat makes material homogenous.
• Curing takes place by cross linking
– Typical parts: electrical connectors, rubber and
silicone parts.
 8a. Foam Molding
• Polystyrene beads are placed in mold cavity.
• Heat is added via steam and air.
• Beads expand as much as 50 times to take shape
of mold.
• Expansion is controlled by varying time and
temperature.
– Typical products: styrofoam cups, food containers,
packaging materials for appliances.
 8a. Foam Molding (cont.)
• Can also use polyurethane foam.
• Mix two or more chemicals to form a cellular
structure.
• This fills and solidifies in mold.
– Typical uses: auto seat cushions, insulation,
packaging.
 9. Casting
• Some TPs (nylons, acrylics) and TSs (epoxies,
polyester) can be cast in rigid or flexible molds.
• Conventional Casting:
– TPs: create mixture of monomer, catalyst, heat and pour
into mold
– Polymerization occurs at ambient pressure.
 9. Casting (cont.)
• Potting & Encapsulation:

– Involves casting the plastic around another component to

embed it in the plastic.

– Typical applications: electrical plugs, coils, solenoids,

electronic ignitions.
 10. Cold Forming Processes
• Processes used to form many TPs at room
temperature (cold forming) (10 - 20 deg C)
• Processes include rolling, extrusion, deep drawing,
others.
• Materials include ABS, PVC, polypropylene,
polycarbonate.
 10. Cold Forming Processes
• Materials for cold working must:
– be ductile at room temp. (This eliminates polystyrene,
acrylics, thermosets.)
– not recover from deformation.

• Cold forming of plastics creates products with

higher strength, toughness.
 10. Cold Forming Processes
• Elastomers
– Usually by extrusion or injection molding, but also
blow molding and thermoforming
– Typical products: tubing, hoses, molding, inner tubes.

• Rubber gloves are made by dipping a metal form

(a hand) many times in a liquid compound that
adheres to form, which is later vulcanized and
stripped.
 Summary
Plastic Type Raw Material Form
Forming
Process
Thermoplastics Thermosets Elastomers Pellets, Granules, Liquid, Sheet Tube
(TPs) (TSs) (E) Powder Paste
1. Extrusion X X X
2. Injection X X X X
Molding
2a. Reaction IM X X
3. Structural X X X X
Foam Molding
4. Blow Molding X X X
5. Rotational X X
Molding
6. Thermoformin X X
g
7. Compression X X X X
Molding
8. Transfer X X X
Molding
9. Casting / Foam X X X X
Casting
10. Cold Forming X X
 Some Common Thermoplastics
Name Good Properties Main uses aka
Acetals Strength, stiffness, resistance to harsh Mechanical components Delrin
elements & conditions
Acrylics Good optical properties, moderate strength. Displays, window glazing, sky lights, Plexiglas
lighting fixtures.
Acrylonitrile- rigid, strong, tough, chemical resistance, low Piping, auto components, consumer ABS
butadiene- temp. performance. goods.
styrene
Fluorocarbons Resistance to temperature, weather, low Non-stick coatings, low-friction Teflon
friction, non-adhesive properties. applications
Polyamids- Good Mechanical properties- abrasion fasteners, zippers, electrical Nylon
Nylon resistant components
Polyamids- High tensile strength-stiffness. Bullet proof vests, radial tires Kevlar
Aramids
Polycarbonate Good mechanical properties, impact Helmets, windshields, protection Lexan
s resistance. equipment.
Polyesters Good mechanical properties, good abrasion Mechanical components Mylar, Dacron
resistance
Polyvynil Wear resistant, flexible or rigid, now strength, Pipes, conduits, tubing, hosing, PVC, Saran
Chloride heat resistance. Toughness, Hardness. gaskets, film, sheeting
 Some Common Thermosets
Name Good Properties Main uses
Aminos f (composition): hard, rigid, resistant to elec. Appliances, handles, distrib. caps.
arcing
Epoxies Good mechanical/electrical properties, adhesive High strength mech. components,
properties, resistance to heat, chemicals insulation.
Polyesters Good mechanical/electrical / chemical properties, Auto bodies, casting resins
typically reinforced with another fiber (i.e. glass)
Silicones f (composition) good weathering properties, resist Heat resistant gaskets, waterproofing
chemicals, heat. applications.
Rubber Elastomer Hoses, inner tubes, sports equipment.