The document provides an introduction to plastics processing methods. It discusses that plastics processing involves converting plastic raw materials into semi-finished or finished products through techniques like deformation of polymer melts, rubbers, solutions, and more. The main processing methods include injection molding, extrusion, blow molding, compression molding, and thermoforming. The selection of the right processing method depends on factors like the product design, material properties, production quantities, quality requirements, and costs. The document provides an overview of various common processing methods and their basic workings.
Polymer processing involves converting plastic raw materials into finished products. There are primary, secondary, and tertiary processing methods. The selection of a processing method depends on factors like the product design, material properties, production quantity, and cost. Common primary methods include injection molding, extrusion, blow molding, and compression molding. The polymer properties like water absorption, physical form, thermal stability, and melt flow properties affect the suitable processing technique. Proper consideration of these factors ensures efficient processing and quality product manufacture.
This document describes the development of a small plastic injection moulding machine for producing small plastic articles in small-scale industries. It discusses the design, construction, and testing of the machine. The machine is capable of injecting molten resins into a closed, cooled mould to produce plastic products. The design concept, operation, and assembly of component parts are covered. The document also provides details on the working principle of plastic injection moulding, including the various constructional parts of the machine like the PID controller, band heaters, thermocouple, and solid state relay. It discusses the assembly procedure and includes calculations and results from the first trial using polypropylene plastic.
This document describes the development of a small plastic injection moulding machine for producing small plastic articles in small-scale industries. It discusses the design, construction, and testing of the machine. The machine is capable of injecting molten resins into a closed, cooled mould to produce plastic products. The design concept, operation, and assembly of component parts are covered. The document also provides details on the working principle of plastic injection moulding machines in general and discusses the various constructional parts of the developed machine such as the PID controller, band heaters, thermocouple, and solid state relay.
A Review on Composite Filaments for Fused Deposition Modeling ProcessIRJET Journal
This document provides a review of composite filaments used in Fused Deposition Modeling (FDM) 3D printing. It discusses how FDM works by extruding thermoplastic filaments through a heated nozzle to build parts layer-by-layer. A wide variety of composite filaments have been developed for different applications, including carbon fiber reinforced PLA and ABS. The document also examines the manufacturing of filaments and key factors for selecting different filaments based on the required properties and application. Researchers are developing new composite filaments to improve mechanical properties and expand the capabilities of FDM for functional end-use parts.
IRJET-Design Optimization of Mold for Dust Proof CapIRJET Journal
The document discusses the design optimization of a mold for a dust proof cap. It begins by describing the 3D modeling and drafting of the plastic cap component. Then, it discusses how 3D printing was used to create prototypes of the mold design to validate it before full production. The mold design was created using mold wizard software to generate an optimal solution. Key factors that affect injection molding quality like part design, mold design, machine parameters and processing conditions are reviewed. The methodology involves part design, 3D printing, mold wizard, mold design and manufacturing. The optimized mold design allows for production of over 10 caps using interchangeable cavity plates, improving over the initial design that produced only 4 caps.
This document discusses the conceptual design of an injection mould tool for the inlet chamber of an air inflator. It describes injection moulding and the basic injection moulding cycle. It outlines the design considerations for the mould tool, including the use of ABS material, a two-plate design with a cold runner system, and a stripper plate ejection system. The design of the core, cavity, sprue, spoke gate and stripper plate ejection system are presented. The conceptual mould tool design aims to produce a high quality component efficiently with minimal defects and cost.
DESING OF MOULD TOOL & COOLING CHANNEL OPTIMIZATION OF INDUSTRIAL HELMETIjripublishers Ijri
A Plastic Material Is Any of A Wide Range of Synthetic Or Semi-Synthetic Organic Solids That Are Moldable. Plastics
Are Typically Organic Polymers Of High Molecular Mass, But They Often Contain Other Substances. They Are Usually
Synthetic, Most Commonly Derived From Petrochemicals, But Many Are Partially Natural.
Molding Is The Process of Manufacturing By Shaping Liquid Or Pliable Raw Material Using A Rigid Frame Called A Mold
Or Matrix. This It May Have Been Made Using A Pattern Or Model of The Final Object.
Conceptual design of transfer mould tool for rubber bumper springeSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Polymer processing involves converting plastic raw materials into finished products. There are primary, secondary, and tertiary processing methods. The selection of a processing method depends on factors like the product design, material properties, production quantity, and cost. Common primary methods include injection molding, extrusion, blow molding, and compression molding. The polymer properties like water absorption, physical form, thermal stability, and melt flow properties affect the suitable processing technique. Proper consideration of these factors ensures efficient processing and quality product manufacture.
This document describes the development of a small plastic injection moulding machine for producing small plastic articles in small-scale industries. It discusses the design, construction, and testing of the machine. The machine is capable of injecting molten resins into a closed, cooled mould to produce plastic products. The design concept, operation, and assembly of component parts are covered. The document also provides details on the working principle of plastic injection moulding, including the various constructional parts of the machine like the PID controller, band heaters, thermocouple, and solid state relay. It discusses the assembly procedure and includes calculations and results from the first trial using polypropylene plastic.
This document describes the development of a small plastic injection moulding machine for producing small plastic articles in small-scale industries. It discusses the design, construction, and testing of the machine. The machine is capable of injecting molten resins into a closed, cooled mould to produce plastic products. The design concept, operation, and assembly of component parts are covered. The document also provides details on the working principle of plastic injection moulding machines in general and discusses the various constructional parts of the developed machine such as the PID controller, band heaters, thermocouple, and solid state relay.
A Review on Composite Filaments for Fused Deposition Modeling ProcessIRJET Journal
This document provides a review of composite filaments used in Fused Deposition Modeling (FDM) 3D printing. It discusses how FDM works by extruding thermoplastic filaments through a heated nozzle to build parts layer-by-layer. A wide variety of composite filaments have been developed for different applications, including carbon fiber reinforced PLA and ABS. The document also examines the manufacturing of filaments and key factors for selecting different filaments based on the required properties and application. Researchers are developing new composite filaments to improve mechanical properties and expand the capabilities of FDM for functional end-use parts.
IRJET-Design Optimization of Mold for Dust Proof CapIRJET Journal
The document discusses the design optimization of a mold for a dust proof cap. It begins by describing the 3D modeling and drafting of the plastic cap component. Then, it discusses how 3D printing was used to create prototypes of the mold design to validate it before full production. The mold design was created using mold wizard software to generate an optimal solution. Key factors that affect injection molding quality like part design, mold design, machine parameters and processing conditions are reviewed. The methodology involves part design, 3D printing, mold wizard, mold design and manufacturing. The optimized mold design allows for production of over 10 caps using interchangeable cavity plates, improving over the initial design that produced only 4 caps.
This document discusses the conceptual design of an injection mould tool for the inlet chamber of an air inflator. It describes injection moulding and the basic injection moulding cycle. It outlines the design considerations for the mould tool, including the use of ABS material, a two-plate design with a cold runner system, and a stripper plate ejection system. The design of the core, cavity, sprue, spoke gate and stripper plate ejection system are presented. The conceptual mould tool design aims to produce a high quality component efficiently with minimal defects and cost.
DESING OF MOULD TOOL & COOLING CHANNEL OPTIMIZATION OF INDUSTRIAL HELMETIjripublishers Ijri
A Plastic Material Is Any of A Wide Range of Synthetic Or Semi-Synthetic Organic Solids That Are Moldable. Plastics
Are Typically Organic Polymers Of High Molecular Mass, But They Often Contain Other Substances. They Are Usually
Synthetic, Most Commonly Derived From Petrochemicals, But Many Are Partially Natural.
Molding Is The Process of Manufacturing By Shaping Liquid Or Pliable Raw Material Using A Rigid Frame Called A Mold
Or Matrix. This It May Have Been Made Using A Pattern Or Model of The Final Object.
Conceptual design of transfer mould tool for rubber bumper springeSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
The document provides information about plastic injection moulding. It defines plastic as a polymeric substance that can be easily shaped and moulded. Plastics are used for their ability to be formed into complex shapes, their light weight, strength and availability in different colors. The main types of plastics are thermoset and thermoplastic. Injection moulding is described as the process of injecting melted plastic into a mould to form a part. Key aspects of the injection moulding process like the machine, mould, raw materials and defects are discussed. Injection moulding is concluded to be a very versatile process for producing a wide variety of plastic products.
The document provides information about Ritik Chauhan's industrial training at Prince Pipes and Fittings in Haridwar from July 12th to August 4th 2023. It discusses the various manufacturing processes used at Prince Pipes including injection molding, extrusion, CNC machining, and recycling. Injection molding is used to make plastic fittings using materials like PPR, CPVC, and UPVC. The extrusion process is used to make pipes from materials like PPR and HDPE. CNC lathes and electrical discharge machines are used for machining. The training helped Ritik learn about these processes and Prince Pipe's products.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
IRJET- Simulation for Optimum Gate Location in Plastic Injection Moulding for...IRJET Journal
1) The document discusses simulation of gate locations for an injection molded plastic spanner component using Moldflow analysis software.
2) Two potential gate locations are analyzed - at the center of the spanner handle and at the center of the curved surface.
3) The simulation results, including fill time, quality predictions, injection pressure, air traps, and weld lines are compared between the two gate locations to determine the optimum location.
IRJET- Optimisation Technique for Design and Fabrication of ASTM Based Multit...IRJET Journal
This document describes the design and optimization of a die for manufacturing parts of varying thicknesses according to ASTM standards. Key points:
1) The multi-thickness die has three sections - a male part, holding plate, and female part. Variable thickness parts can be made by inserting shims of different thicknesses between the male and female parts.
2) The die design was optimized to reduce costs by machining cavities directly into the core plate, eliminating the need for a separate cavity plate.
3) Total manufacturing cost, material cost, tooling cost, and processing cost formulas were developed and optimized to reduce the cost per part. Process optimization focused on streamlining machining steps.
This document provides an overview of the IPE 111 manufacturing processes course, including a classification and description of various manufacturing processes. It discusses machining processes like turning, drilling, and grinding. It also covers forming processes, molding, casting, and joining processes like welding. The syllabus outlines topics like the interaction of manufacturing processes with materials, machines, energy, labor, and tools. It lists reference books and defines manufacturing from both a technical and economic perspective.
1. Manufacturers of critical devices need precision and efficiency in production to get products to market quickly amid competition. Scientific molding uses data collection and analysis to create a repeatable manufacturing process that produces defect-free parts consistently.
2. Scientific molding involves engineers overseeing different phases of product development and production. They collect data during tool debugging to create a template for production. This template ensures repeatability when specifications change or production moves to different machines.
3. RJG, Inc. provides scientific molding education and tools like the eDARTTM system. Their decoupled molding techniques separate filling, packing, and holding stages to control the process more precisely, minimizing defects. Data from these
IRJET- Design of Spoon Mold using Flow Analysis and Higher End Design SoftwareIRJET Journal
This document discusses the design of a multi-cavity mold for producing plastic spoons using flow analysis software. The objectives are to reduce defects and optimize the mold design. The methodology involves 3D modeling the spoon, designing a multi-cavity mold, and performing flow analysis simulations to determine the optimal gate locations and process parameters. This optimized design aims to improve productivity by producing more spoons per cycle in the multi-cavity mold compared to previous single-cavity mold designs.
Ch1 introduction Erdi Karaçal Mechanical Engineer University of GaziantepErdi Karaçal
Manufacturing involves applying physical or chemical processes to alter the form of materials. It can be defined technologically as altering geometry, properties, or appearance of a starting material. Economically, it is transforming materials into items of greater value through processing or assembly. Common production types include continuous, mass/flowline, batch, and one-off. The document discusses various manufacturing processes, production systems, and layouts. It provides an overview of key concepts in manufacturing and production.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
IRJET- Development of Ejection System to Improve ProductivityIRJET Journal
This document describes a project to improve the ejection system of an injection molding machine to increase productivity. The existing system uses two ejectors but takes a long time (80 seconds) per cycle. The proposed new system adds two additional ejectors on the front corners. This allows the molded component to be ejected with only one stroke, reducing the cycle time to 54 seconds. Calculations show the production rate increased by 48% with the modified system. Benefits include balanced ejection, eliminating component catching issues, and improved part quality. The objectives are to reduce ejection time, cycle time, and improve production rate and efficiency.
IRJET- Development of Ejection System to Improve ProductivityIRJET Journal
This document describes a project to improve the ejection system of an injection molding machine to increase productivity. The current machine uses two ejectors but it takes a long time and worker effort to remove molded components from the mold. The project aims to add two additional ejectors positioned at the corners of the ejector plate so that only one stroke is needed to eject components. This is expected to reduce ejection time, cycle time, and worker effort, while increasing production rates and part quality. The document provides background on injection molding and discusses the methodology and literature review conducted to support modifying the ejection system.
This document summarizes bottle blow molding and finite element modeling (FEM) analysis of the process. It discusses how blow molding works by melting plastic into a parison shape, clamping the parison into a mold, and injecting air to push the plastic to the mold shape. FEM analysis can simulate the process to optimize parameters like pressure and temperature for uniform wall thickness. The document also outlines the different types of blow molding (extrusion, injection, stretch), commonly used materials like polyethylene, and applications like bottles. It concludes that FEM analysis can validate stress levels are within limits to ensure product quality and reduce costs and time compared to physical prototyping.
Plastic Extrusion, Moulding and Mould Designs (Plasma Films, Acrylic Fabrication, Design, Gas Injection Moulding, Thin Walled Injection Moulding, Injection Moulding, Blow Molding, Extrusion, Transfer Molding, Reinforcements for Thermosets, Welding Plastics, Carving Plastics)
Plastics extrusion is a high-volume manufacturing process in which raw plastic is melted and formed into a continuous profile. Extrusion produces items such as pipe/tubing, weather stripping, fencing, deck railings, window frames, plastic films and sheeting, thermoplastic coatings, and wire insulation.
See more
https://goo.gl/IjHE14
https://goo.gl/AefgZo
https://goo.gl/g1bXnK
Contact us:
Niir Project Consultancy Services
106-E, Kamla Nagar, Opp. Spark Mall,
New Delhi-110007, India.
Email: npcs.ei@gmail.com , info@entrepreneurindia.co
Tel: +91-11-23843955, 23845654, 23845886, 8800733955
Mobile: +91-9811043595
Website: www.entrepreneurindia.co , www.niir.org
Tags
Plastics Extrusion, Plastic Extrusion Machines, Plastic Extrusion Process, Extrusion Moulding Process, Plastic Extrusion Plants, Industrial Plastic Extrusion, Plastic Extrusion Line, Plastic Moulding, Plastic Moulding Business, Products For Plastic Injection Moulding, Plastic Moulding Process, Injection Molding Process, Plastic Injection Molding Machines, Plastic Mould Design, Plastics Injection Mould Design, Injection Moulding Design Guide, Product Design for Plastic Moulding, Design for Injection Moulding, Preparation of Plasma Films, Transport Phenomena in Polymer Films, Acrylic Fabrication, Reinforcements for Thermosets, Miscellaneous Thermoplastic Process, Compression and Transfer Molding, Disciplined Process Stategy for Injection Moulding, Injection Molding, Blow Molding, Extrusion, Newly Developed Injection Moulding Technology, Injection Moulding, Plastic Injection Moulding Environment in India, Tiebarless and 2-Platen Injection Moulding Machines, Thin Walled Injection Moulding, Mold Cooling Best Bet for High Profits, Gas Injectionmoulding Technology, Mould Materials and Processing Methods, Laminate Composition, Reinforcements for Filament Winding, Fiberglass Technology, Making Glass Fibers, Glass Composition, Glass Fabric Construction and Weaves, Plastisol Molding, Injection Molding Machines, Injection Unit, Mold Clamping Unit, Functions of Mold Components, Injection Moulding Technique, Economical Production of Parts, Thermosetting Materials and Elastomers, Tiebarless Machine, Two-Shot Moulding Process, Assisted Injection Moulding Process, Hand Injection Moulds, Single Cavity Two Plate Moulds, Multi Cavity Moulds, Three Plate Moulds, Multi Colour Moulds, Making of Glass Fiber, Glass Fiber Manufacture, Glass Fiber Manufacturing Process, Glass Fiber Manufacturing, Making Glass Fibers, Method for Making Fiber Glass, Npcs, Niir, Process Technology Books, Business Consultancy, Business Consultant
IRJET- Simulation of Blow Molding of Polyethylene Bottle using Ansys Poly...IRJET Journal
This document summarizes a simulation of blow molding a polyethylene bottle using ANSYS Polyflow software. The simulation aims to predict the final wall thickness distribution and stresses. The study models blow molding of a 100ml polyethylene medicine bottle. The simulation is divided into geometry creation, meshing, setting material properties and operating conditions as inputs, running the simulation, and analyzing output results of wall thickness variation over time. The results show wall thickness contour maps at different time steps, with thicker regions at the top and bottom of the bottle and a thinner, more uniform thickness in the body region. The study concludes the simulation can optimize the blow molding process to achieve required thicknesses with material efficiency.
The document summarizes a student project on improving the quality of plastic injection mould design using mould flow analysis. It describes the objectives of designing and developing an automatic injection moulded product for a glass. Design concepts were developed in CATIA software and analyzed in Plastic Advisor/Pro-E software. The results revealed improvements in the quality of the mould design using concurrent engineering and computer-aided design approaches. The project aimed to improve the design of an existing product and its mould through mould flow analysis.
Injection Moulding Tool Design Manufacturing, Estimation and Comparison of L&...IOSR Journals
This document discusses the design, manufacturing, and analysis of an injection molding tool for an L&T power box side panel using different plastic materials. It first provides background on injection molding and describes the power box component. It then details the modeling of the part in Pro/E and analysis of the mold flow using plastic advisor to optimize filling. Mold calculations are presented to determine clamping force, shot capacity, cooling requirements, and machine specifications. The extraction of the core and cavity from the mold is illustrated along with the CNC manufacturing process. Cost comparisons of producing the part in different plastics are estimated.
Technology for Plastic Mold Tooling - Direct Metal Deposition HCL Technologies
This whitepaper highlights the benefits of DMD(Direct Metal Deposition) technology in mold cycle time reduction. It presents a comparative analysis conducted for cycle time performance of a mold consisting of a conventionally machined tool steel insert to a mold fitted with a Chromium Copper insert with a coating of tool steel deposited by the DMD process.
Manufacturing involves transforming raw materials into finished goods through various processes. The key steps in manufacturing include prefabrication, welding, painting, assembly, testing, finishing and delivery. Manufacturing processes can be classified as casting, forming and machining. Implementing lean manufacturing principles such as reducing waste, batch sizes and inventories can improve productivity, quality and reduce costs. The 5S methodology is a common starting point that involves sorting, simplifying, sweeping, standardizing and sustaining work areas to increase organization and efficiency.
The pancreas is both an exocrine and endocrine organ. Its exocrine function involves secreting enzymes to aid digestion. Its endocrine function involves producing hormones like insulin and glucagon that regulate blood sugar levels. The document discusses pancreatic anatomy, functions, and diseases like pancreatitis and diabetes that can arise from pancreatic dysfunction. It provides details on the causes, symptoms, diagnosis, and treatment of these conditions.
This document discusses how to have difficult conversations as an engineer by acknowledging your own fears and checking your ego, recognizing the other person's fears and pride, communicating as equals focused on resolution, asking questions to understand the problem, avoiding defensiveness, and following up. Difficult conversations are made easier through practice rather than procrastination. Key tips include taking a deep breath, leaving jargon at the door, watching your body language, and building a toolbox of helpful metaphors.
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The document provides information about plastic injection moulding. It defines plastic as a polymeric substance that can be easily shaped and moulded. Plastics are used for their ability to be formed into complex shapes, their light weight, strength and availability in different colors. The main types of plastics are thermoset and thermoplastic. Injection moulding is described as the process of injecting melted plastic into a mould to form a part. Key aspects of the injection moulding process like the machine, mould, raw materials and defects are discussed. Injection moulding is concluded to be a very versatile process for producing a wide variety of plastic products.
The document provides information about Ritik Chauhan's industrial training at Prince Pipes and Fittings in Haridwar from July 12th to August 4th 2023. It discusses the various manufacturing processes used at Prince Pipes including injection molding, extrusion, CNC machining, and recycling. Injection molding is used to make plastic fittings using materials like PPR, CPVC, and UPVC. The extrusion process is used to make pipes from materials like PPR and HDPE. CNC lathes and electrical discharge machines are used for machining. The training helped Ritik learn about these processes and Prince Pipe's products.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
IRJET- Simulation for Optimum Gate Location in Plastic Injection Moulding for...IRJET Journal
1) The document discusses simulation of gate locations for an injection molded plastic spanner component using Moldflow analysis software.
2) Two potential gate locations are analyzed - at the center of the spanner handle and at the center of the curved surface.
3) The simulation results, including fill time, quality predictions, injection pressure, air traps, and weld lines are compared between the two gate locations to determine the optimum location.
IRJET- Optimisation Technique for Design and Fabrication of ASTM Based Multit...IRJET Journal
This document describes the design and optimization of a die for manufacturing parts of varying thicknesses according to ASTM standards. Key points:
1) The multi-thickness die has three sections - a male part, holding plate, and female part. Variable thickness parts can be made by inserting shims of different thicknesses between the male and female parts.
2) The die design was optimized to reduce costs by machining cavities directly into the core plate, eliminating the need for a separate cavity plate.
3) Total manufacturing cost, material cost, tooling cost, and processing cost formulas were developed and optimized to reduce the cost per part. Process optimization focused on streamlining machining steps.
This document provides an overview of the IPE 111 manufacturing processes course, including a classification and description of various manufacturing processes. It discusses machining processes like turning, drilling, and grinding. It also covers forming processes, molding, casting, and joining processes like welding. The syllabus outlines topics like the interaction of manufacturing processes with materials, machines, energy, labor, and tools. It lists reference books and defines manufacturing from both a technical and economic perspective.
1. Manufacturers of critical devices need precision and efficiency in production to get products to market quickly amid competition. Scientific molding uses data collection and analysis to create a repeatable manufacturing process that produces defect-free parts consistently.
2. Scientific molding involves engineers overseeing different phases of product development and production. They collect data during tool debugging to create a template for production. This template ensures repeatability when specifications change or production moves to different machines.
3. RJG, Inc. provides scientific molding education and tools like the eDARTTM system. Their decoupled molding techniques separate filling, packing, and holding stages to control the process more precisely, minimizing defects. Data from these
IRJET- Design of Spoon Mold using Flow Analysis and Higher End Design SoftwareIRJET Journal
This document discusses the design of a multi-cavity mold for producing plastic spoons using flow analysis software. The objectives are to reduce defects and optimize the mold design. The methodology involves 3D modeling the spoon, designing a multi-cavity mold, and performing flow analysis simulations to determine the optimal gate locations and process parameters. This optimized design aims to improve productivity by producing more spoons per cycle in the multi-cavity mold compared to previous single-cavity mold designs.
Ch1 introduction Erdi Karaçal Mechanical Engineer University of GaziantepErdi Karaçal
Manufacturing involves applying physical or chemical processes to alter the form of materials. It can be defined technologically as altering geometry, properties, or appearance of a starting material. Economically, it is transforming materials into items of greater value through processing or assembly. Common production types include continuous, mass/flowline, batch, and one-off. The document discusses various manufacturing processes, production systems, and layouts. It provides an overview of key concepts in manufacturing and production.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
IRJET- Development of Ejection System to Improve ProductivityIRJET Journal
This document describes a project to improve the ejection system of an injection molding machine to increase productivity. The existing system uses two ejectors but takes a long time (80 seconds) per cycle. The proposed new system adds two additional ejectors on the front corners. This allows the molded component to be ejected with only one stroke, reducing the cycle time to 54 seconds. Calculations show the production rate increased by 48% with the modified system. Benefits include balanced ejection, eliminating component catching issues, and improved part quality. The objectives are to reduce ejection time, cycle time, and improve production rate and efficiency.
IRJET- Development of Ejection System to Improve ProductivityIRJET Journal
This document describes a project to improve the ejection system of an injection molding machine to increase productivity. The current machine uses two ejectors but it takes a long time and worker effort to remove molded components from the mold. The project aims to add two additional ejectors positioned at the corners of the ejector plate so that only one stroke is needed to eject components. This is expected to reduce ejection time, cycle time, and worker effort, while increasing production rates and part quality. The document provides background on injection molding and discusses the methodology and literature review conducted to support modifying the ejection system.
This document summarizes bottle blow molding and finite element modeling (FEM) analysis of the process. It discusses how blow molding works by melting plastic into a parison shape, clamping the parison into a mold, and injecting air to push the plastic to the mold shape. FEM analysis can simulate the process to optimize parameters like pressure and temperature for uniform wall thickness. The document also outlines the different types of blow molding (extrusion, injection, stretch), commonly used materials like polyethylene, and applications like bottles. It concludes that FEM analysis can validate stress levels are within limits to ensure product quality and reduce costs and time compared to physical prototyping.
Plastic Extrusion, Moulding and Mould Designs (Plasma Films, Acrylic Fabrication, Design, Gas Injection Moulding, Thin Walled Injection Moulding, Injection Moulding, Blow Molding, Extrusion, Transfer Molding, Reinforcements for Thermosets, Welding Plastics, Carving Plastics)
Plastics extrusion is a high-volume manufacturing process in which raw plastic is melted and formed into a continuous profile. Extrusion produces items such as pipe/tubing, weather stripping, fencing, deck railings, window frames, plastic films and sheeting, thermoplastic coatings, and wire insulation.
See more
https://goo.gl/IjHE14
https://goo.gl/AefgZo
https://goo.gl/g1bXnK
Contact us:
Niir Project Consultancy Services
106-E, Kamla Nagar, Opp. Spark Mall,
New Delhi-110007, India.
Email: npcs.ei@gmail.com , info@entrepreneurindia.co
Tel: +91-11-23843955, 23845654, 23845886, 8800733955
Mobile: +91-9811043595
Website: www.entrepreneurindia.co , www.niir.org
Tags
Plastics Extrusion, Plastic Extrusion Machines, Plastic Extrusion Process, Extrusion Moulding Process, Plastic Extrusion Plants, Industrial Plastic Extrusion, Plastic Extrusion Line, Plastic Moulding, Plastic Moulding Business, Products For Plastic Injection Moulding, Plastic Moulding Process, Injection Molding Process, Plastic Injection Molding Machines, Plastic Mould Design, Plastics Injection Mould Design, Injection Moulding Design Guide, Product Design for Plastic Moulding, Design for Injection Moulding, Preparation of Plasma Films, Transport Phenomena in Polymer Films, Acrylic Fabrication, Reinforcements for Thermosets, Miscellaneous Thermoplastic Process, Compression and Transfer Molding, Disciplined Process Stategy for Injection Moulding, Injection Molding, Blow Molding, Extrusion, Newly Developed Injection Moulding Technology, Injection Moulding, Plastic Injection Moulding Environment in India, Tiebarless and 2-Platen Injection Moulding Machines, Thin Walled Injection Moulding, Mold Cooling Best Bet for High Profits, Gas Injectionmoulding Technology, Mould Materials and Processing Methods, Laminate Composition, Reinforcements for Filament Winding, Fiberglass Technology, Making Glass Fibers, Glass Composition, Glass Fabric Construction and Weaves, Plastisol Molding, Injection Molding Machines, Injection Unit, Mold Clamping Unit, Functions of Mold Components, Injection Moulding Technique, Economical Production of Parts, Thermosetting Materials and Elastomers, Tiebarless Machine, Two-Shot Moulding Process, Assisted Injection Moulding Process, Hand Injection Moulds, Single Cavity Two Plate Moulds, Multi Cavity Moulds, Three Plate Moulds, Multi Colour Moulds, Making of Glass Fiber, Glass Fiber Manufacture, Glass Fiber Manufacturing Process, Glass Fiber Manufacturing, Making Glass Fibers, Method for Making Fiber Glass, Npcs, Niir, Process Technology Books, Business Consultancy, Business Consultant
IRJET- Simulation of Blow Molding of Polyethylene Bottle using Ansys Poly...IRJET Journal
This document summarizes a simulation of blow molding a polyethylene bottle using ANSYS Polyflow software. The simulation aims to predict the final wall thickness distribution and stresses. The study models blow molding of a 100ml polyethylene medicine bottle. The simulation is divided into geometry creation, meshing, setting material properties and operating conditions as inputs, running the simulation, and analyzing output results of wall thickness variation over time. The results show wall thickness contour maps at different time steps, with thicker regions at the top and bottom of the bottle and a thinner, more uniform thickness in the body region. The study concludes the simulation can optimize the blow molding process to achieve required thicknesses with material efficiency.
The document summarizes a student project on improving the quality of plastic injection mould design using mould flow analysis. It describes the objectives of designing and developing an automatic injection moulded product for a glass. Design concepts were developed in CATIA software and analyzed in Plastic Advisor/Pro-E software. The results revealed improvements in the quality of the mould design using concurrent engineering and computer-aided design approaches. The project aimed to improve the design of an existing product and its mould through mould flow analysis.
Injection Moulding Tool Design Manufacturing, Estimation and Comparison of L&...IOSR Journals
This document discusses the design, manufacturing, and analysis of an injection molding tool for an L&T power box side panel using different plastic materials. It first provides background on injection molding and describes the power box component. It then details the modeling of the part in Pro/E and analysis of the mold flow using plastic advisor to optimize filling. Mold calculations are presented to determine clamping force, shot capacity, cooling requirements, and machine specifications. The extraction of the core and cavity from the mold is illustrated along with the CNC manufacturing process. Cost comparisons of producing the part in different plastics are estimated.
Technology for Plastic Mold Tooling - Direct Metal Deposition HCL Technologies
This whitepaper highlights the benefits of DMD(Direct Metal Deposition) technology in mold cycle time reduction. It presents a comparative analysis conducted for cycle time performance of a mold consisting of a conventionally machined tool steel insert to a mold fitted with a Chromium Copper insert with a coating of tool steel deposited by the DMD process.
Manufacturing involves transforming raw materials into finished goods through various processes. The key steps in manufacturing include prefabrication, welding, painting, assembly, testing, finishing and delivery. Manufacturing processes can be classified as casting, forming and machining. Implementing lean manufacturing principles such as reducing waste, batch sizes and inventories can improve productivity, quality and reduce costs. The 5S methodology is a common starting point that involves sorting, simplifying, sweeping, standardizing and sustaining work areas to increase organization and efficiency.
Similar to 1._introduction_to_plastics_processing..ppt (20)
The pancreas is both an exocrine and endocrine organ. Its exocrine function involves secreting enzymes to aid digestion. Its endocrine function involves producing hormones like insulin and glucagon that regulate blood sugar levels. The document discusses pancreatic anatomy, functions, and diseases like pancreatitis and diabetes that can arise from pancreatic dysfunction. It provides details on the causes, symptoms, diagnosis, and treatment of these conditions.
This document discusses how to have difficult conversations as an engineer by acknowledging your own fears and checking your ego, recognizing the other person's fears and pride, communicating as equals focused on resolution, asking questions to understand the problem, avoiding defensiveness, and following up. Difficult conversations are made easier through practice rather than procrastination. Key tips include taking a deep breath, leaving jargon at the door, watching your body language, and building a toolbox of helpful metaphors.
Management of Patients With Diabetes Mellitus.pptssusera85eeb1
This document discusses diabetes mellitus and its management. It defines diabetes as a group of diseases characterized by hyperglycemia. It describes the two main types as type 1, where the pancreas produces little to no insulin, and type 2, where cells become resistant to insulin. Treatment involves dietary management, exercise, glucose monitoring, and insulin or oral medications. The goals of treatment are to normalize blood glucose levels and prevent complications through intensive control.
The document discusses guidelines for developing muscular endurance through circuit training, including FITT principles and exercises targeting different muscle groups to include in a circuit.
Lent is the 40 day period before Easter that commemorates Jesus fasting in the desert for 40 days. Traditionally, Christians give up luxuries like meat or indulgences like chocolate during this time to remember Jesus' sacrifice and strengthen their willpower against temptation. Lent ends with the celebration of Easter and Jesus' resurrection.
The document discusses Lent, the 40 day period before Easter. It explains that Lent begins on Ash Wednesday and is meant to commemorate the 40 days Jesus spent fasting in the desert. Traditionally, people would give up certain foods like meat or sweets during Lent as a form of fasting and sacrifice. Now people often give up something like chocolate or complete acts of service instead. The purpose of Lent is to prepare spiritually for Easter through prayer, penance, and good works.
Sheet metal processes unit_iv_origional.pptssusera85eeb1
Sheet metal processes involve cutting, bending, and forming thin metal sheets. Common processes include shearing to cut sheets, bending using various dies, drawing to make hollow parts, and stamping using progressive dies. Other specialized processes such as roll forming, spinning, and superplastic forming provide unique shapes through techniques like continuous bending over rolls or stretching over mandrels at high temperatures. A variety of automotive, aircraft, and household goods are produced from sheet metal using these forming techniques.
This document provides an overview of manufacturing processes and engineering. It discusses key topics like process planning, industrial engineering, layout engineering, and material handling. Process planning involves defining the sequential operations and equipment needed for manufacturing. Industrial engineering activities include capacity planning, manpower planning, and recommending the type of manufacturing and layout. Layout engineering deals with arranging facilities, lines, and equipment within buildings and on the site. The document compares different types of layouts like process, product, and fixed position layouts.
Tribology is the study of friction, wear, and lubrication between interacting surfaces. There are several types of wear including adhesive wear, abrasive wear, surface fatigue, and fretting wear. Adhesive wear occurs due to direct contact and plastic deformation between surfaces, while abrasive wear involves hard particles forcing against and moving along a softer surface. Lubrication reduces wear by interposing a lubricant between surfaces to help carry the load. Different lubrication regimes exist including fluid film, boundary, and hydrodynamic lubrication. Wear measurement techniques include using the Archard equation and analyzing wear debris and worn surface characteristics.
This document provides an introduction to the basics of tribology, which is the study of friction, lubrication, and wear between surfaces in contact. It discusses how tribology encompasses many fields of engineering and industry. Surfaces in contact are not flat and have roughness at multiple scales, from nanometers to centimeters. Both the physical roughness and chemical properties of surfaces need to be considered in tribology as they influence contact area, stresses, lubrication, and compatibility. A variety of methods can characterize surface properties. Understanding surfaces is fundamental to tribology as the interaction between surface asperities dictates tribological forces.
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Fettling is the process of preparing castings for use by removing unwanted material like gates, risers, fins, and imperfections. It involves several steps and techniques. First, dry sand cores are knocked out and gates and risers are removed through chipping, cutting, flame cutting, or abrasive machines depending on the material. Then fins and other projections on the casting surface are chipped off. Finally, the casting is cleaned through tumbling or modern blasting processes to produce a quality final product meeting customer standards. Fettling transforms crude castings into functional components through various removal and finishing operations.
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This document discusses heat treatment processes for metals. It covers various heat treatment methods like annealing, normalizing, hardening and tempering. It describes processes like case hardening, through hardening, induction hardening and vacuum heat treatment. Key information covered includes different heat treatment methods for ferrous and non-ferrous metals, advantages of various processes, factors influencing heat treatment selection, and details of specific processes like carburizing and quenching methods.
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This document provides an overview of forging processes and operations. It describes various forging techniques including open die forging, impression die forging, closed die forging, precision forging, coining, heading, piercing, hubbing, orbital forging, and isothermal forging. Equations for calculating forging forces are provided. Examples of typical forged products like bolts, gears, and hand tools are given. Diagrams illustrate the different steps in various forging processes.
This document provides an overview of quality management concepts. It discusses why quality is important, different dimensions of quality, quality control methods like control charts, the costs of quality, and statistical process control. Key points covered include defining quality from the perspectives of producers and consumers, determining optimal quality levels, setting quality standards, and using various tools like histograms, Pareto charts, and fishbone diagrams to identify quality issues. The document also distinguishes between chance and assignable causes of process variation.
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Using recycled concrete aggregates (RCA) for pavements is crucial to achieving sustainability. Implementing RCA for new pavement can minimize carbon footprint, conserve natural resources, reduce harmful emissions, and lower life cycle costs. Compared to natural aggregate (NA), RCA pavement has fewer comprehensive studies and sustainability assessments.
ACEP Magazine edition 4th launched on 05.06.2024Rahul
This document provides information about the third edition of the magazine "Sthapatya" published by the Association of Civil Engineers (Practicing) Aurangabad. It includes messages from current and past presidents of ACEP, memories and photos from past ACEP events, information on life time achievement awards given by ACEP, and a technical article on concrete maintenance, repairs and strengthening. The document highlights activities of ACEP and provides a technical educational article for members.
International Conference on NLP, Artificial Intelligence, Machine Learning an...gerogepatton
International Conference on NLP, Artificial Intelligence, Machine Learning and Applications (NLAIM 2024) offers a premier global platform for exchanging insights and findings in the theory, methodology, and applications of NLP, Artificial Intelligence, Machine Learning, and their applications. The conference seeks substantial contributions across all key domains of NLP, Artificial Intelligence, Machine Learning, and their practical applications, aiming to foster both theoretical advancements and real-world implementations. With a focus on facilitating collaboration between researchers and practitioners from academia and industry, the conference serves as a nexus for sharing the latest developments in the field.
Introduction- e - waste – definition - sources of e-waste– hazardous substances in e-waste - effects of e-waste on environment and human health- need for e-waste management– e-waste handling rules - waste minimization techniques for managing e-waste – recycling of e-waste - disposal treatment methods of e- waste – mechanism of extraction of precious metal from leaching solution-global Scenario of E-waste – E-waste in India- case studies.
Literature Review Basics and Understanding Reference Management.pptxDr Ramhari Poudyal
Three-day training on academic research focuses on analytical tools at United Technical College, supported by the University Grant Commission, Nepal. 24-26 May 2024
DEEP LEARNING FOR SMART GRID INTRUSION DETECTION: A HYBRID CNN-LSTM-BASED MODELgerogepatton
As digital technology becomes more deeply embedded in power systems, protecting the communication
networks of Smart Grids (SG) has emerged as a critical concern. Distributed Network Protocol 3 (DNP3)
represents a multi-tiered application layer protocol extensively utilized in Supervisory Control and Data
Acquisition (SCADA)-based smart grids to facilitate real-time data gathering and control functionalities.
Robust Intrusion Detection Systems (IDS) are necessary for early threat detection and mitigation because
of the interconnection of these networks, which makes them vulnerable to a variety of cyberattacks. To
solve this issue, this paper develops a hybrid Deep Learning (DL) model specifically designed for intrusion
detection in smart grids. The proposed approach is a combination of the Convolutional Neural Network
(CNN) and the Long-Short-Term Memory algorithms (LSTM). We employed a recent intrusion detection
dataset (DNP3), which focuses on unauthorized commands and Denial of Service (DoS) cyberattacks, to
train and test our model. The results of our experiments show that our CNN-LSTM method is much better
at finding smart grid intrusions than other deep learning algorithms used for classification. In addition,
our proposed approach improves accuracy, precision, recall, and F1 score, achieving a high detection
accuracy rate of 99.50%.
Comparative analysis between traditional aquaponics and reconstructed aquapon...bijceesjournal
The aquaponic system of planting is a method that does not require soil usage. It is a method that only needs water, fish, lava rocks (a substitute for soil), and plants. Aquaponic systems are sustainable and environmentally friendly. Its use not only helps to plant in small spaces but also helps reduce artificial chemical use and minimizes excess water use, as aquaponics consumes 90% less water than soil-based gardening. The study applied a descriptive and experimental design to assess and compare conventional and reconstructed aquaponic methods for reproducing tomatoes. The researchers created an observation checklist to determine the significant factors of the study. The study aims to determine the significant difference between traditional aquaponics and reconstructed aquaponics systems propagating tomatoes in terms of height, weight, girth, and number of fruits. The reconstructed aquaponics system’s higher growth yield results in a much more nourished crop than the traditional aquaponics system. It is superior in its number of fruits, height, weight, and girth measurement. Moreover, the reconstructed aquaponics system is proven to eliminate all the hindrances present in the traditional aquaponics system, which are overcrowding of fish, algae growth, pest problems, contaminated water, and dead fish.
Presentation of IEEE Slovenia CIS (Computational Intelligence Society) Chapte...University of Maribor
Slides from talk presenting:
Aleš Zamuda: Presentation of IEEE Slovenia CIS (Computational Intelligence Society) Chapter and Networking.
Presentation at IcETRAN 2024 session:
"Inter-Society Networking Panel GRSS/MTT-S/CIS
Panel Session: Promoting Connection and Cooperation"
IEEE Slovenia GRSS
IEEE Serbia and Montenegro MTT-S
IEEE Slovenia CIS
11TH INTERNATIONAL CONFERENCE ON ELECTRICAL, ELECTRONIC AND COMPUTING ENGINEERING
3-6 June 2024, Niš, Serbia
A SYSTEMATIC RISK ASSESSMENT APPROACH FOR SECURING THE SMART IRRIGATION SYSTEMSIJNSA Journal
The smart irrigation system represents an innovative approach to optimize water usage in agricultural and landscaping practices. The integration of cutting-edge technologies, including sensors, actuators, and data analysis, empowers this system to provide accurate monitoring and control of irrigation processes by leveraging real-time environmental conditions. The main objective of a smart irrigation system is to optimize water efficiency, minimize expenses, and foster the adoption of sustainable water management methods. This paper conducts a systematic risk assessment by exploring the key components/assets and their functionalities in the smart irrigation system. The crucial role of sensors in gathering data on soil moisture, weather patterns, and plant well-being is emphasized in this system. These sensors enable intelligent decision-making in irrigation scheduling and water distribution, leading to enhanced water efficiency and sustainable water management practices. Actuators enable automated control of irrigation devices, ensuring precise and targeted water delivery to plants. Additionally, the paper addresses the potential threat and vulnerabilities associated with smart irrigation systems. It discusses limitations of the system, such as power constraints and computational capabilities, and calculates the potential security risks. The paper suggests possible risk treatment methods for effective secure system operation. In conclusion, the paper emphasizes the significant benefits of implementing smart irrigation systems, including improved water conservation, increased crop yield, and reduced environmental impact. Additionally, based on the security analysis conducted, the paper recommends the implementation of countermeasures and security approaches to address vulnerabilities and ensure the integrity and reliability of the system. By incorporating these measures, smart irrigation technology can revolutionize water management practices in agriculture, promoting sustainability, resource efficiency, and safeguarding against potential security threats.
2. CORPORATE TRAINING AND
PLANNING
1.0 INTRODUCTION
Plastics – The unique class of wonder materials – came into existence by
virtue of their superior performance and cost effectiveness over to
conventional materials.
Over the years the applications spectrum of plastics have been
widened with the advent of new generation Polymers, blend alloys
and composites
. Every day newer and newer application are being promoted in all the key
sectors of Indian Economy viz, Automobiles, Agriculture, Aerospace. Building
& Construction, Infrastructure, Telecommunication, IT, Medical & Bio Medical
engineering, Packaging, etc.
This inturn necessitates the need for different types processing methods and
machinery to produce quality plastics products at affordable cost
Today a host of processing methods and machinery are available to manufacture
plastics products meeting stringent quality requirements and cost to performance
balance.
3. CORPORATE TRAINING AND
PLANNING
1.1 DEFINITION:
Plastics Processing – in a simple layman’s language – can be defined as the process of
converting the plastic raw materials into Semi-finished or finished products.
Raw Materials
(Powder/granules)
Semi-finished
or
Finished Products
Processing
4. CORPORATE TRAINING AND
PLANNING
In a more technocrate way we may say “Get the Shape and set the Shape”.
Technique to get the shape and Set the shape varies depending on Process and
Material employed.
Principles:
Deformation of a polymer melt (ex) Injection, Extrusion, Blow Moulding etc
Deformation of a polymer in Rubbery state
Ex: Thermoforming
Vacuum Forming
Pressure Forming
Deformation of a Suspension
Ex: PVC Plasticsol Processing / Coating
Deformation of a Solution
Ex : Solvent Casting of CN Film
Deformation of a low melt polymer / monomer
Ex: Acrylic Sheet Casting
Preparation of GR Laminates
Machined Structures
Secondary fabrication operation
5. CORPORATE TRAINING AND
PLANNING
1.2 CLASSIFICATION OF PROCESSING METHODS
1. Primary Processing Methods:
u More importance by virtue of
o Extent of utilisation for Varied applications
o Growth Potential
Ex: Injection Moulding, Extrusion, Blow Moulding, Compression / Transfer
Moulding,
2. Secondary Processing Methods
u Lesser extent of utilisation
u Acts as supplementary to primary operation
Ex: Roto Moulding, Thermoforming, Coating, Casting, FRP Fabrication
Methods, Calendaring, etc.,
6. CORPORATE TRAINING AND
PLANNING
Performance Requirements
Practical
Approach
Engineering
Approach
Material Selection
Properties Process Cost
Ideal Choice
Product Manufacture : A Simplified Flow Diagram
1.3 PROCESSING FUNDAMENTALS
7. CORPORATE TRAINING AND
PLANNING
The process selection depends on several interrelated factors:
(1) Designing a part to meet performance and manufacturing requirements at the
lowest cost;
(2) Specifying the plastic;
(3) Specifying the manufacturing process, which requires
Designing a tool ‘around’ the part,
Putting the ‘Proper Performance’ fabricating process around the tool,
Setting up necessary auxiliary equipment to interface with the main processing
machine
Setting up ‘Completely integrated’ controls to meet the goal of zero defects;
(4) Purchasing equipments and materials, and warehousing the materials.
8. CORPORATE TRAINING AND
PLANNING
COMPETITIVE PROCESSES
S.
N
o
Product
Inj.
Moulding
Extrusion
Thermo
forming
Blow
Moulding
Comp./
Transfer
Moulding
Roto
Moulding
1 Narrow neck
container
- - - 1 - -
2 Oil Barrels
Upto (200 ltrs)
- - - 1 - 1
3. Tanks (20000
ltrs)
- - - - - 1
4. Films,Profiles,
Pipes
- 1 - - - -
5 Housing, Auto
parts
1 - 2 2 2 -
6. Wider Neck
parts
1 - - - - -
7. Hallow
Containers
- - - - - 1
1. Best Process 2. Supplementary Process
9. CORPORATE TRAINING AND
PLANNING
1. Setting up specific performance requirements;
2. Evaluating material requirements and their processing capabilities;
3. Designing parts on the basis of material and processing characterstics, considereing
part complexity and size as well as a product and process cost comparison
4. Designing and manufacturing tools (Moulds, Dies, etc) to permit ease of processing;
5. Setting up the complete line, including auxliliary equipment;
6. Testing and providing quality control, from delivery of the plastics, through
production, to the product
7. Interfacing all these parameters by using logic and experience and / or obtaining a
required update on technology.
Parameters that help one to select the right options are
10. CORPORATE TRAINING AND
PLANNING
1.4 PROCESSABILITY:
Processability means generally the ease or difficulty with which a plastic can be
handled during its fabrication into film, moulded products, pipe, etc.
A plastic with good processability possesses the properties necessary to make it
easy to process the plastics into desired shapes.
The main characterstics or properties which determine a plastic’s processability are
molecular weight, uniformity, additive type and content, and plastic feed rates.
11. CORPORATE TRAINING AND
PLANNING
1.5 PROCESSING METHODS:
The type of process to be used depends on a variety of factors, including product
shape and size, plastic type, quantity to be produced, quality and accuracy
(Tolerances) required, design load performance, cost limitation, and time schedule.
Each of the processes provides different methods to produce different products. As
an example, extrusion with its many methods produces films, pipe,sheet, profile,
wire coating, etc.
Almost all processing machines can provide useful products with relative ease, and
certain machines have the capability of manufacturing products to very tight
dimensions and performances. The coordination of plastic and machine facilities
these processes.
12. CORPORATE TRAINING AND
PLANNING
PROCESSING METHODS – An Overview:
Machine Operation Terminology
Terminology in the plastics industry regarding the operation of machinery is as follows:
Manual Operation
Each function and the timing of each function is controlled manually by an operator.
Semiautomatic Operation
A machine operating semi automatically will stop after performing a complete cycle of
programmed moulding functions automatically. It will then require an operator to start
another complete cycle manually.
Automatic Operation
A Machine operating automatically will perform a complete cycle of programmed
moulding functions repetitively; it will stop only for a malfunction on the part of the
machine or mould, or when it is manually interrupted.
Depending upon the configuration of the part, economic viability and the part
tolerance, etc the process can be selected.
13. CORPORATE TRAINING AND
PLANNING
An extruded parison tube of heated thermoplastic is positioned between two halves of an
open split mould and expanded against the sides of the closed mould via air pressure. The
mould is opened and the part ejected. Low tool and die costs, rapid production rates, and
ability to mould fairly complex hollow shapes in one piece.
BLOW MOULDING :
Description :
Limitations:
Generally limited to hollow or tubular parts; some versatile mould shapes, other than
bottles and containers.
15. CORPORATE TRAINING AND
PLANNING
Very widely used. High automation of manufacturing is standard practice. Thermoplastic
or thermoset is heated to plasticate in cylinder at controlled temperature, then forced
under pressure through a nozzle into sprue, runners, gates, and cavities of mould. The
resin undergoes solidification rapidly. The mould is opened, and the part ejected, Injection
Moulding is growing in the making of glass-reinforced parts. High production runs, low
labour costs, high reproducibility of complex details, and excellent surface finish are the
merits.
INJECTION MOULDING :
Description :
Limitations:
High initial tool and die costs; not economically practical for small runs.
17. CORPORATE TRAINING AND
PLANNING
Widely used for continuous production of film, sheet, tube, and other profiles; also used
in conjunction with blow moulding. Thermoplastic moulding compound is fed from a
hopper to a screw pump where it is heated to plasticate then pumped out through the
shaping orifice (die) to achieve desired cross section. Production lines require input and
takeoff equipment that can be complex. Low tool cost, numerous complex profile shapes
possible, very rapid production rates, can apply coatings or jacketing to core materials
(Such as wire).
EXTRUSION :
Description :
Limitations:
Usually limited to sections of uniform cross section.
19. CORPORATE TRAINING AND
PLANNING
Thermoset compound, usually preformed, is positioned in a heated mould cavity; the
mould is closed (heat and pressure are applied) and the material flows and fills the mould
cavity. Heat completes polymerization and the part is ejected. The process is sometimes
used for thermoplastics, e.g. Vinyl phonograph records. Little material waste is attainable;
large, bulky parts can be moulded; process is adaptable to rapid automation.
COMPRESSION MOULDING :
Description :
Limitations:
Extremely intricate parts containing undercuts, side draws, small holes, delicate inserts,
etc.; very close tolerances are difficult to produce. Time consuming process.
20. CORPORATE TRAINING AND
PLANNING
Widely used to produce Thermoset products with part complexity. Thermoset moulding
compound is fed into transfer chamber where it is then heated to plasticate; it is then fed
by a plunger through sprues, runners, and gates into a closed mould where it cures; mould
is opened and part ejected. Good dimensional accuracy, rapid production rate, and very
intricate parts can be produced.
TRANSFER MOULDING
Description :
Limitations:
High mould cost; high material loss in sprues and runners; size of parts is somewhat
limited.
21. CORPORATE TRAINING AND
PLANNING
Dough-consistent thermoplastic mass is formed into a sheet of uniform thickness by
passing it through and over a series of heated or cooled rolls. Calenders are also utilized to
apply plastic covering to the backs of other materials. Low cost, and sheet materials are
virtually free of moulded-in stresses.
CALENDERING :
Description :
Limitations:
Limited to sheet materials and very thin films are not possible.
22. CORPORATE TRAINING AND
PLANNING
A predetermined amount of powdered thermoplastic material is poured into mould; mould
is closed, heated, and rotated in the axis of two planes until contents have fused to the
inner walls of mould; mould is then opened and part is removed. Low mould cost, large
hollow parts in one piece can be produced, and moulded parts are essentially isotropic in
nature.
ROTATIONAL MOULDING
Description :
Limitations:
Limited to hollow parts; production rates are usually slow.
24. CORPORATE TRAINING AND
PLANNING
Heat-softened thermoplastic sheet is positioned over male or female mould; air is
evacuted between sheet and mould, forcing sheet to conform to contour of mould.
Variations are vacuum snapback, plug assist, drape forming, etc. Tooling costs are
generally low, large part production with thin sections possible, and often comes out
economical for limited part production.
THERMOFORMING
Description :
Limitations:
Limited to parts of simple configuration, high scrap, and limited number of materials from
which to choose.
26. CORPORATE TRAINING AND
PLANNING
Liquid plastic which is generally thermoset except for acrylics is poured into a mould
without pressure, cured, and taken from the mould. Cast thermoplastic films are produced
via building up the material (either in solution or hot-melt form) against a highly polished
supporting surface. Low mould cost, capability to form large parts with thick cross
sections, good surface finish, and convenient for low-volume production.
CASTING
Description :
Limitations:
Limited to relatively simple shapes. Most thermoplastics are not suitable for this method.
Except for cast films, method becomes uneconomical at high volume production rates.
27. CORPORATE TRAINING AND
PLANNING
Reinforcement is placed in mould and is rotated. Resin distributed through pipe;
impregnates reinforcement through centrifugal action. Utilized for round objects,
particularly pipe.
CENTRIFUGAL CASTING:
Description :
Limitations:
Limited to simple curvatures in single axis rotation. Low production rates.
COATING
Process methods vary. Both thermoplastics and thermosets widely used in coating of
numerous materials. Roller coating similar to calendaring process. Spread coating
employs blade in front of roller to position resin on material. Coatings also applied via
brushings, spraying, and dipping.
Description :
Limitations:
Economics generally depends on close tolerance control.
28. CORPORATE TRAINING AND
PLANNING
Excellent strength-to-weight. Continuous, reinforced filaments, usually glass, in the form
of roving are saturated with resin and machine-wound onto mandrels having shape of
desired finished part. Once winding completed, part and mandrel are cured; mandrel can
then be removed through porthole at end of wound part. High-strength reinforcements can
be oriented precisely in direction where strength is required. Good uniformity of resin
distribution in finished part; mainly circular objects such as pressure vessels, pipes, and
rocket cases.
FILAMENT WINDING :
Description :
Limitations:
Limited to shapes of positive curvature; openings and holes can reduce strength if not
properly designed into moulding operations.
29. CORPORATE TRAINING AND
PLANNING
Material, usually in form of reinforcing cloth, paper, foil, metal, wood, glass fibre, Plastic
etc., preimpregnated or coated with thermoset resin (sometimes a thermoplastic) is
moulded under pressure greater than 1000psi (7Mpa) into sheet, rod, tube, or other simple
shapes. Excellent dimensional stability of finished product; very economical in large
production of parts.
LAMINATING :
Description :
Limitations:
High tool and die costs. Limited to simple shapes and cross sections.
30. CORPORATE TRAINING AND
PLANNING
A variation of the conventional compression moulding, this process employs two metal
moulds possessing a close-fitting, telescoping area to seal in the plastic compound being
moulded and to allow trim of the reinforcement. The mat or preform reinforcement is
positioned in the mould and the mould is closed and heated under pressures of 150 –
400psi (1-3MPa). The mould is then opened and the part is removed after curing.
MATCHED-DIE MOULDING :
Description :
Limitations:
Prevalent high mould and equipment costs. Part often require expensive surface finishing.
31. CORPORATE TRAINING AND
PLANNING
Liquid thermoplastic material (Plastisol) is poured into a mould to capacity; mould is
closed and heated for a predetermined time in order to achieve a specified buildup of
partially fused material on mould walls; mould is opened and excess material is poured
out; and semifused part is removed from mould and fully fused in oven. Low mould costs
and economical for small production runs.
SLUSH MOULDING :
Description :
Limitations:
Limited to hollow parts; production rates are very slow; and limited choice of materials
that can be processed.
33. CORPORATE TRAINING AND
PLANNING
1.6 EFFECT OF POLYMER PROPERTIES ON PROCESS
TECHNIQUE
(1) Water absorption of Raw materials,
(2) Physical form of raw material,
(3) Thermal stability of polymer,
(4) Flow properties,
(5) Adhesion of melt to metal,
(6) Thermal properties affecting, Heating and cooling of melt,
(7) Compressibility and shrinkage,
(8) Frozen in Orientation.
When processing thermoplastic melts the following factors should be taken into
account in order both to process efficiently and obtain quality products.
34. CORPORATE TRAINING AND
PLANNING
Water / Moisture is the greatest enemy for processing of plastics.
Hygroscopic Materials
Absorption phenomena - Ex: Nylon, POM, PC.
Adsorption phenomena - Ex: HIPS, PS, ABS.
All these materials should be pre-dried.
Non-Hygroscopic material - Ex: PVC, Polyolefins, etc.
Need not be predried. Except when completely wet during monsoon.
WATER ABSORPTION
35. CORPORATE TRAINING AND
PLANNING
Actions Necessary
1. Use granules as soon as the bag is opened.
2. Pre-drying ovens, Hopper drier, Dehumidifying drier can be used.
3. For PC - Dehumidifying drier preferable
Physical form of Raw Material
Powder form, granular form, lumpy/slab form
Slab Form - Calendering,Compression Moulding
Granular Form – Preferred - Uniform pellet size ensures even and faster feeding.
Powder Form - Difficulty in feeding - But savings in cost because of the ability to
avoid pelleting stage - Special feeder attachment essential to ensure proper feeding.
36. CORPORATE TRAINING AND
PLANNING
Thermal stability of polymers
PVC thermally sensitive material - Little higher melt temp. may lead to depredation - HCL is
released - This can leads to corrosion and harmful to human being. PID Temperature
controller can be used.
PMMA, POM upon depredation liberates MMA & formaldehyde respectively - MMA
volatilize and cause bubbles - Formaldehyde gas causes “eye-irritation”.
PVC & POM (acetal) should never be processed one after the other. This may lead to
explosion
Adhesion of melt to metal:
Wetting of the polymer melt against the metal wall of processing equipment can
lead to strong adhesion of polymer to metal. Ex: difficulty in removing PVC - Mix
from two roll mill.
PC has a strong adhesion to metal. It can take away the skin of the barrel if not
properly purged
37. CORPORATE TRAINING AND
PLANNING
THERMAL PROPERTIES AFFECTING HEATING AND COOLING
In the case of polymer melts the specific heat varies with temperature. For crystalline
polymers such as POM, NYLON etc. latent heat of fusion and sp.heat should be taken in to
account. i.e Total heat content (Enthalpy) =LH of fusion + sp.heat.
POLYMER PROCESS TEMP 0C ENTHALPY / KJ / KG
PS 200 310
LDPE 200 500
HDPE 260 810
PP 260 670
Because of higher enthalpy PP requires more cooling time than LDPE and PS.
38. CORPORATE TRAINING AND
PLANNING
COOLING SHRINKAGE AND COMPRESSIBILITY
When polymers are in molten stage the vibrations of the molecules results in the polymer
chain being pushed apart so that the volume occupied by a given polymer mass is higher
than when the material is solid.
POLYMER
DENSITY AT 20
C(G/CC)
DENSITY AT PROCESS
TEMP (G/CC)
LDPE 0.923 0.746(210c)
PP 0.905 0.765(210c)
PMMA 1.180 1.105(210c)
SPVC 1.48 1.390(190c)
Because polymer melts are compressible moulding shrinkage is much less than the above
fig.
39. CORPORATE TRAINING AND
PLANNING
FROZEN-IN ORIENTATION
When polymer melts are being shaped by either injection moulding or Extrusion the
long polymer chains tend to be elongated or uncoiled in the direction of flow.
After shaping, the melt is usually cooled rapidly and there is seldom time for the
oriented molecules to return to a random coiled shape by the process known as
relaxation.
Some orientation is thus “Frozen-in” the product. Such stressed parts are very weak.
Hence annealing is must.
40. CORPORATE TRAINING AND
PLANNING
PROCESS SELECTION CRITERIA FOR PLASITC PRODUCTS
Introduction:
With the advent of New Generation Polymers, blends alloys and composites,
over the last decade, the application spectrum of plastics has been widened.
Today with the result, the plastics have penetrated deeply in all the key sectors
of economy which includes
Automobiles Telecommunication
Aerospace Defence
Biomedical Building & Construction etc
In the liberalized economy the survival of plastic industries largely depends
upon timely delivery, quality, cost and cost / performance balance of plastics
products.
41. CORPORATE TRAINING AND
PLANNING
With the availability of host of plastic raw materials and a wide range of
plastic processing methods and technologies, it is a difficult task for the
processor to select a suitable cost effective process for a specific product.
Although in some cases one or more processes may be suitable for producing a
specific plastics product A plastics processor can select a specific process
keeping in mind the key parameters such as cost, quality and cost/performance
balance.
In this presentation, a few selected case - studies were made for the benefit of
plastic processors.
42. CORPORATE TRAINING AND
PLANNING
Process Selection Criteria
The following parameters play a key role in selecting the best suited process
to produce a specific product for a specific application.
1. Material Processibility - Limitations
2. Volume of production
3. Size & shape of the product (configuration)
4. Cost to performance balance
5. Quality
43. CORPORATE TRAINING AND
PLANNING
Material Processibility Limitations
If a specific material is suitable for a particular application, then material
processibility will decide the specific method of Processing / Production.
Case :1
Product : PET bottle
Process : Blow Moulding
Specific process : Injection stretch Blow moulding
Not possible by : Extrusion Blow moulding or Extrusion Stretch blow
moulding
Reason:
PET material used today does not have the required hot melt strength to
hold/self support a parison.
44. CORPORATE TRAINING AND
PLANNING
Case: 2
Product : PTFE sheets
Process : Compression moulding following by sintering process.-The sintered
sheets are subsequently machined to the required dimension.
Other Conventional Process:
Extrusion - Not possible.
Reason:
PTFE exhibits - very high melt viscosity above its melting temperature. Hence only
best suited process is compression moulding followed by sintering.
45. CORPORATE TRAINING AND
PLANNING
Configuration of Product
- Size & shape governs the process selection.
Case 1:
Narrow neck containers like Shampoo bottles, Pharmaceutical
containers, soft drink bottles will have to be produced by Blow moulding only.
Case 2:
Hollow containers such as Tanks (20,000ltrs) will have to be produced by
Roto moulding inspite of higher initial cost on plant & machinery.
46. CORPORATE TRAINING AND
PLANNING
Case 3:
Product : FRP Boat
Raw materials : Fiber glass material, Polyester resin and other
additives
Process : 1. Hand lay-up 2. Spray up
Most suitable process:
If volume of production is less then hand lay up. If more then spray up
technique. Spray up technique calls for higher initial investment.
47. CORPORATE TRAINING AND
PLANNING
Cost / Performance Balance
If more than one process is suitable for producing a product based
on performance, then cost plays a crucial role in process selection.
Case: 1
Product : 200 litres chemical container
Material : HDPE
Process : 1. Blow Moulding 2. Roto Moulding
48. CORPORATE TRAINING AND
PLANNING
Sl.
No.
Parameter Blow Moulding Roto Moulding
1.
Specific Process
Accumulator
Blow Moulding
Three arm
rotomoulding
2. Volume of Production High Low
3. Initial investment on
plant & machine
High Moderate
4. Performance Good Good
5. Cost/performance Best good
Hence accumulator type blow moulding process can be selected.
49. CORPORATE TRAINING AND
PLANNING
Case - 2
Product : FRP pipe
Material : Glass fiber, Polyester resin & other additives
Process : 1. Limited lengths & high strengths - Filament winding
2. Continuous lengths & high strength - pultrusion
3. Centrifugal casting - Batch process
If medium strength and relatively stress free pipes are required with better optical
properties, then centrifugal casting is the best method.
50. CORPORATE TRAINING AND
PLANNING
Case: 3
Product : PVC Flexible sheet
Material : Compounded PVC with additives such as plasticizer, stabilizer,
colourants etc.
Process : 1. Calendering 2. Extrusion
Suitable process : Calendering
Reason : Wider width, cost effectiveness
Case: 4
Product : Acrylic sheet
Material : PMMA
Process : 1. Casting 2. Extrusion
51. CORPORATE TRAINING AND
PLANNING
Sl.
No.
Parameter Casting Extrusion
1. Mechanical Properties Lower Higher
2. Optical properties High Low
3. Initial investment Low High
4. Stress built-up
Almost stress
free
Stress built-up
due to
orientation.
Since optical properties are very essential based on cost/performance & quality
casting process is best.
52. CORPORATE TRAINING AND
PLANNING
Quality
Mainly due to quality reasons, inspite of higher cost of manufacture, certain products
are produced by a specific process only.
Case:1
PVC - gramaphone records - even today produced by compression moulding.
Reason: Stress-free moulding
Case:2
Product: PP Blown film
Process: Only downward extrusion process should be used instead of upward blown
film process.
Reason:
PP, being a crystalline polymer,in order to get transparency, the film emerging out of
die lips needs to be quenched.The best /economical way of quenching is to dip in
water which is possible only in downward extrusion. So due to quality reason this
process is selected.
54. CORPORATE TRAINING AND
PLANNING
Sl.
No.
Parameter Roto Moulding Injection Moulding
& Welding
1. Initial Investment Moderate High
2. Quality Good Moderate
3. Production rate Low High
4. Low volume / prototype Best -
5. High volume Production - Best