LJMU HD in AME

Module Name with Code -Automotive materials and

manufacturing processes -5501ICBTAE
Semester - Semester 3
Batch Number -
Lecturer Name -
Center Name -

LJMU Higher Diploma 1

Content

• Plastic processing

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 INTRODUCTION

POLYMER
Term derived from two Greek words:
POLY means MANY MEROS means PARTS/UNITS

➢ Thus polymers are composed of a large number of

repeating units called monomers.
➢ Monomers are joined together end to end in a
polymerization reaction.
 INTRODUCTION

POLYMERIZATION
✓ The process of linking together of monomers or
obtaining macromolecules is called polymerization.
✓ There are two types of polymerization techniques.
1. Addition Polymerization
2. Condensation Polymerization
 Classification of Plastics

➢ There are many ways of classifying plastics. They can be

classified considering various aspects, as according to
their :
1. Behaviour with respect to heating,
2. Structure, and
3. Physical and mechanical properties.
 Classification of Plastics

Physical and
Behaviour with
respect to heating Structure mechanical
properties

Rigid Plastics
Thermo-
Homogeneous
plastics Semi-rigid
Plastics

Thermo-
Heterogeneous Soft Plastics
setting

Elastomers
 Classification of Plastics

1. Behaviour with respect to heating

THERMOPLASTICS THERMO-SETTING
PLASTICS
❖ Thermoplastics variety softens ❖ Thermosetting plastics can
by heat and hardens when not be reused.
cooled down. ❖ This variety requires a great
❖ It can be used by remolding as pressure and momentary heat
many times as required. during molding which hardens
❖ E.g. Polyethylene, on cooling.
polypropylene, polystyrene, ❖ E.g. Phinolics, Unsaturated
PVC, polyamides, cellulosics, polysters, Ureas, melamines,
polycarbonate. Urethanes.
 2. Based on structure

Heterogeneous
Homogeneous
Plastics
Plastics

➢ They contains carbon chain ➢This variety of plastic is

i.e. the plastics of this composed of the chain
group are composed only of containing carbon and
carbon atoms and they oxygen, the nitrogen and
exhibit homogeneous other elements and they 8

exhibit heterogeneous
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structure.
structure.
 Classification of Plastics

3. Based on physical and chemical properties

Semi-rigid
Rigid Plastics
Plastics
➢ These plastics have a high ➢ These plastics have a
modulus of elasticity and medium modulus of
they retain their shape elasticity and the elongation
under exterior stresses under pressure completely
applied at normal or disappears, when pressure is
moderately increased removed.
temperatures.
 Classification of Plastics

Soft Plastics

➢ These plastics have a low modulus of elasticity and the

elongation under pressure disappears slowly, when pressure
is removed.
➢ Soft plastics are available in a large range of colours, sizes
and particularly shapes.
➢ Used in making children’s toys eg: rattles etc., fishing baits.
 Classification of Plastics
Elastomers

• Elastomers
➢ These plastics are soft and elastic materials with a low modulus of
elasticity.

➢ They deform considerably under load at room temperature and return to

their original shape, when the load is released.

➢ The extensions can range upto ten times their original dimensions.
 Additives In Plastics

1. Plasticizers
• They are liquids of high boiling
point, low moleculer weight.
• They are added to improve the
plastic behavior of polymer.
• They separate the macro molecules, decreasing inter
molecule forces, facilitates relative movement between
molecules of polymer.

• e.g. Organic solvents, resins, water etc.

 Additives In Plastics
2. Fillers
• They are inexpensive materials used for
reducing the cost of plastics and/or to
vary the properties of plastic to some
extent.

• It must be chemically inert with parent material.

• e.g : wood flour (improve mouldability), cellulose, cotton flock,
paper (improving mechanical strength), mica and asbestos
(heat resistance), talc (acid resistance).
• Reinforcing filler agents are fibers of glass, aramid, graphite.
 Additives In Plastics
3. Catalysts
• They are added to promote faster and
more complete polymerization.

• They are also known as accelerators.

• e.g : ester is used as catalyst for urea
formaldehyde.

4. Initiators
• Added to initiate or allow polymerization process to begin.
• e.g : H2O2
 Additives In Plastics
5. Dyes & Pigments
• Added to impart a desired colour.
• E.g : titanium oxide (white pigment), iron oxide
(yellow/brown/red), carbon black (black pigment + UV light
absorbent).
 Additives In Plastics
6. Lubricants
• They are added for following purposes.
• To reduce the friction during processing, Prevents parts
from sticking to mould walls, Prevent polymer films from
sticking to each other, to impart elegant finishing.

• E.g : oils, soaps, waxes etc.

 Additives In Plastics
7. Flame Retardants
• Added to enhance non inflammability.
• It can be done by producing them from less inflammable
materials or by adding Flame Retardants.
• e.g : compounds of chlorine, bromine and phosphorous.

8. Stabilisers
• Stabilisers and anti-oxidents are added to retard the
degradation of polymres due to heat, light and oxidation.
 Additives In Plastics
9. Solvents
• They are useful for dissolving certain fillers or plasticizers.
• E.g : alcohol is added in cellulose nitrate plastics to dissolve
camphor.
• Subsequently, Solvents must be removed by evaporation.
 Additives In Plastics

10. Elastomers
• They are added to enhance elastic properties of plastic.
 Properties of Plastics

a. Density of plastics is very low as compared to metals.

b. Strength of plastics is sufficient to make low weight, high

strength machine parts.

c. Antifriction and self- lubricating properties of plastics

enables it to be a good replacement of metal parts.

d. Plastics components offer noiseless operation of moving parts,

corrosion resistance, water proofing ,leak proof joints, etc.

e. Its production is very easy due to low melting point and

excellent flow ability in liquid state into the mold cavity.
 Properties of Plastics

f. Low cost of manufacturing in case of plastics.

g. Plastics exhibits insulation for heat and electricity.
h. Plastics are chemically stable when subjected to solvents, oxidizing
agents, gases, etc.

i. Plastics are less brittle than glass, yet they can be

made equally transparent and smooth.

j. They possess good toughness.

 Properties of Plastics

k. Plastics can be easily molded to desired shape.

l. They having very good damping characteristics, colour

ability, deformability and weather ability.
 Plastic part manufacturing processes
➢ Plastic manufacturing processes are used to convert plastic
materials in the form of pellets, powders, sheets etc.
➢ Different types of plastic manufacturing processes are:

a. compression moulding f. Calendaring

b. Transfer moulding g. Thermoforming
c. Injection moulding h. slush moulding
d. Extrusion moulding i. laminating
e. Blow moulding
Compression Moulding
 Compression Moulding

▪ First, the charge is loaded into the lower half of mold which is
preheated to maintain the temperature of charge during the
process.
▪ The placed charge is compressed by bringing both halves of
mold close together.
▪ The charge is heated by means of the hot mold to polymerize
and cure it into a solidified desired shaped molded plastic
component.
▪ Then, the halves are opened & molded plastic part is removed
by pressing knockout pins towards inside.
 Compression Moulding
• Advantages
▪ Low initial setup costs and fast setup time
▪ Heavy plastic parts can be molded
▪ Complex intricate parts can be made
▪ Good surface finish of the molded parts
▪ Wastes relatively little material as compared with other methods
▪ The molding process is cheaper as compared to injection molding
• Disadvantages
▪ Low production rate
▪ Limited largely to flat or moderately curved parts with no undercuts
 Compression Moulding

Applications

▪ Electrical and electronic equipments, brush and mirror

handles, trays, cookware knobs, aircraft main power
terminal housing, pot handles, dinnerware plates,
automotive parts.
Transfer Moulding
 Transfer Moulding

▪ It is similar to compression molding. The difference is,

instead of loading the polymer into an open mold, the
plastic material is preheated and loaded into a holding
chamber called pot.
▪ The material is then forced into a preheated mold cavity
using a ram or hydraulic plunger through a channel called
sprue.

▪ The mold remains closed until the material inside is cured.

▪ Then, the final molded part is removed by using ejector pin.
 Transfer Moulding

Advantages
▪Fast setup time and lower setup costs
▪Low maintenance cost
▪Plastic parts with metal inserts can be made
▪Design flexibility
▪Dimensionally stable
▪Uniform thickness of parts
▪Large production rate
Disadvantages
▪ Wastage of material
▪ Production rate lower than injection molding
▪ Air can be trapped in the mold
 Transfer Moulding

Applications

➢ Integrated circuits, plugs, connectors, pins, coils, studs,

radio, television cabinets and car body shells.
Injection Moulding
 Injection Moulding

➢ Palletized material is fed with use of hopper into a cylinder

where material melts due to heating coils.
➢ Molten metal is impelled through nozzle into the enclosed
cavity.
➢ Outstanding characteristic of this mounding process is
cycle time is very less. i.e. rate of production is very high.

➢ The complete injection molding process is divided into four

stages: clamping, injection, cooling and ejection.
 Injection Moulding

❖ Clamping: The two halves of the mold must be tightly

closed, before the molten plastic material is injected into
the mold.
➢ One half of the mold is attached to the injection unit
(nozzle) and other half is allowed to slide on the guide
ways.

❖ Injection: During this process, the plastic material is

melted by the application of heat and forwarded through
the piston towards the nozzle and finally into the mold.
➢ The amount of material that is injected into the mold is
referred to as the shot volume.
 Injection Moulding

❖ Cooling: The injected molten plastic begins to cool as soon

as it comes in contact with the mold surfaces.
➢ As the molded part cools, it will solidify into the desired
shape of the product.

❖ Ejection: The molded part, which is attached to the rear

half of the mold has to be ejected from the mold.
➢ An ejector mechanism is used to push the part out of the
mold.
➢ Force must be applied to eject the plastic part because
during cooling the molded part shrinks and adheres to the
mold surface.
➢ A mold release agent should be sprayed onto the mold
surfaces prior to injection of the material.
 Injection Moulding

Advantages
▪ Higher production rate
▪ Close tolerances on small intricate parts
▪ Minimum wastage of material
▪ Complex geometry can be easily produced

Disadvantages
▪ Tooling cost higher
▪ High setup cost
▪ Large undercuts can’t be formed

Applications
▪ household appliances, electronics, and automotive
dashboards, buckets etc…
Extrusion moulding
 Extrusion Moulding

➢ Similar to injection molding except long uniform sections

are produced.
➢ The material which is fed through hopper, is conveyed
forward by a feeding screw & forced through a die,
converting to continuous polymer product.

➢ Heating is done in order to soften or melt the polymer. The

temp is controlled by thermocouples.
➢ The product going out of the die is cooled by blown air or in
water bath.
 Extrusion Moulding

Advantages
▪ High production volumes
▪ Relatively low cost as compared with other molding
process
▪ Design flexibility
▪ Short lead times
▪ Coating of wire can be done to achieves desired properties
▪ Continuous part can be produced

Disadvantages
▪ Limited complexity of parts
▪ Uniform cross section can only be produced
 Extrusion Moulding

Applications

▪ The extrusion process is used for manufacturing rods,

plates and tubes, wire and cable coating, hose liners, hose
mandrels, filaments, sheet, multilayer film, medical
packaging and food packaging, etc.
 Plastic part manufacturing processes

Blow moulding
 Plastic part manufacturing processes

Blow moulding
 Blow Moulding

➢ Using this manufacturing process blind parts are made like

bottle or sphere etc.
➢ Air is blown into a thin walled plastic cylinder called the
parison. The parison is formed by melted plastic material
being pushed through an extruder.
➢ When the parison reaches a certain length, the two halves
of the mould close around the parison sealing it at the
bottom.

➢ Compressed air is then used to inflate the parison to form

the shape of the cavity inside the mould.
 Blow Moulding

Advantages
▪ Low tooling cost
▪ Fast production rates
▪ Ability to mold complex part with uniform thickness
▪ Little scrap generated
▪ Large hollow shape can be produced
▪ Produced parts can be recycle

Disadvantages
▪ Limited to hollow parts
▪ Thick parts can’t be manufactured
 Blow Moulding

Applications

▪ bottles in different shape and size, jars, and containers,

ducting, fluid oil tanks, mugs, and toys etc.
 Plastic part manufacturing processes

Calendaring
 Plastic part manufacturing processes

Calendaring
 Calendaring
➢ In this process the plastic material is allowed to pass
between the cylindrical rollers.
➢ The process is used to prepare plain flat sheets of
plastics.
 Plastic part manufacturing processes
Thermoforming
➢ Thermoforming is a plastic manufacturing process in which the
thermoplastic sheets are formed with the application of heat and
pressure in a mold.
➢ The thermoplastic sheet is held horizontally over a mold surface
and clamped with a holding device. The sheet is heated up to
predetermined temperature using a heating element called heater.
➢ The thermoplastic sheet softens with the application of heat and is
pressed into or stretched over the mold surface by application of
air pressure or by any other means.
 Plastic part manufacturing processes
Thermoforming
➢ The softened sheet conforms to the mold shape and it is held in
place until it cools.

➢ The mold cavity is opened and the thermoformed part is released.

➢ The excess material is then trimmed out from the formed part.
Excess material can be reground, mixed with unused plastic, and
again reformed into thermoplastic sheets.
➢ There are mainly three different types of thermoforming process
depending upon the pressure required i.e., vacuum thermoforming,
pressure thermoforming and mechanical thermoforming.
 Thermoforming

a. vacuum thermoforming
 Thermoforming

b. pressure thermoforming
 Thermoforming

c. mechanical thermoforming
 Thermoforming

Advantages
▪ Extremely adaptive to design requirement
▪ Rapid prototype development
▪ Low initial setup costs
▪ Low production costs
▪ Less thermal stresses than injection molding and
compression molding
▪Good dimensional stability
Disadvantages
▪ Poor surface finish
▪ Parts may have non-uniform wall thickness.
▪ All parts need to be trimmed
▪ Ribs and bosses cannot be molded easily
▪ Very thick plastic sheets can’t be formed
 Thermoforming

Applications

➢ food packaging, automotive parts, trays, building products,

aircraft windscreens, medical equipment, material handling
equipment, electrical and electronic equipment, spas and
shower enclosures etc.
 Recommended readings

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