Tooling, Testing and Processing of polymeric materials,describe about machines tooling, how's processing unit working and testing of polymeric materials.....

1. INDUSTRIAL/SUMMER TRAINING
at
Central Institute Of Plastic Engineering and Technology (CIPET)
Lucknow
Aadrsh Kumar Tiwari
M.Sc. polymer chemistry
Roll No – 131021
Enrollment no. - 1750016

2. OUTLINE
1. Tool Room
2. Testing
3. Processing

3. Tool Room
1. Power Hacksaw Machine.
2. Pillar Type Machine.
3. Shaper Machine.
4. Horizontal Machine.
5. Vertical Machine.
6. Lathe Machine

4. 1- Tool Room
Power Hacksaw Machine
Introduction:-
• The metal to be cut is held in a machine vice which is an
integral part of the base.
• Power hacksaw have electric motors that power the blade
through a pulley system.
• Top quality blade are manufactured from High speed steel.
• In general the number of teeth per inch (TPI) range from 14
to 24.
• The more teeth per inch the smoother the cut.

5. Fig1:- power hacksaw machine

6. Working of Hacksaw machine
 When the metal is placed and fixed in the vice, the
blade is lowered onto its surface.
 The diagram be low shows the ‘arm’ being lowered
with adjusting handle.
 Most power hacksaw have two pulley wheels. If the
belt is placed on the smaller pulley wheel the speed of
cut will be fast.
 changing the belt so that it runs round the larger
pulley wheel reduce the speed.
 When cutting is taking place, the metal and especially
the blade heat up quickly. Coolant should be fed onto
the blade, cooling it down and lubricating it cuts
through the metal.

7.  Power hacksaw have electric motors that power the blade
through a pulley system.
 The pulley system shown below shows how rotary power is
transferred from the motor and changed to reciprocating
motion, allow the blade to cut through the material.
APPLICATION :-
 Hacksaw are used to cut thin and soft metal.
 There are numerous type of cutting machine in engineering
field.
 which are used to fulfill requirement for cutting purpose.
 Hacksaw are used to cut hard and soft Plastic specimen in
industries.

8. 2–PILLAR TYPE DRILLING MACHINE
Introduction:-
 The drilling machine or drill press is one of the most
common and useful machine employed in industry for
producing and finishing holes in a work piece. The unit
essentially consist of:
 A spindle which turns the tool (called drill) which can be
advanced in the work piece either automatically or by hand.
 A work table which holds the work piece rigidly in
position.

9. Fig 2 :- pillar type drilling machine

10. Working of pillar type drilling machine
 The rotating edge of the drill exerts a large force on
the work piece and the hole is generated.
 the removal of metal in a drilling operation is by
shearing and extrusion.
 The required the work piece.
 The slot are provided in most tables to the jigs,
fixtures or large work pieces to be securely fixed
directly to the table.
 The drilling head mounted close to the top of the
column, houses the driving arrangement and variable
speed pulleys.

11.  These unit transmit rotary motion at different speed to
the drill spindle.
Precaution
1. Adjust the working table.
2. The working table on pillar drills are adjust to different
depths to accommodate many different material types
and sizes.
3. Use the clamp
 The object to be drilled need to clamped down to the
working table, rather than held in place, as the power of
the drill will rotate the material, causing an unsafe
working environment.
 object must always be placed in the safety clamp before
drilling.

12. Application
 Pillar drills are used to accurately and precisely drill
holes through a variety of material in a workshop.
 Pillar drills utilize a column and a column and a base
plate that attach to the drill, making for a safe and
sturdy place to drill wood or other materials.

13. Shaper Machine
Introduction:-
The shaper is a machine tool used primarily for:
 Producing a flat or plane surface which may be in a
horizontal, a vertical or an angular plane.
 Making slots, grooves and keyways.
 Producing contour of concave/convex or a combination
of these.

14. Fig 4:- parts of shaper

15. Fig 5 :- Shaper Machine

16. Working
 The job is rigidly fixed on the machine table.
 The single point cutting tool held properly in the tool
post is mounted on a reciprocating ram.
 The ram reciprocates, the tool cuts the material during its
forward stroke.
 During return, there is no cutting action and this stroke is
called the idle stroke. The forward and return strokes
constitute one operating cycle of the shaper.

17. Parts of shaper machine
The main parts of the Shaper machine is Base,
Body (Pillar, Frame, Column), Cross rail, Ram
and tool head (Tool Post, Tool Slide, Clamper Box
Block).

18. Application
 The most common use is to machine straight, flat
surfaces, but with ingenuity and some accessories a wide
range of work can be done. Other examples of its use are.
 Cam drums with tool paths of the type that in CNC
milling terms would require 4- or 5-axis contouring or
turn-mill cylindrical interpolation.
 such as irregularly shaped holes with tight corners

19. Horizontal milling machine
Introduction:-
Milling is the machining process of using rotary cutters to
remove material.
 A work piece covers a wide variety of different
operations and machines, on scales from small
individual parts to large, heavy-duty gang milling
operations. It is one of the most commonly used
processes in industry and machine shops today for
machining parts to precise sizes and shapes.

20. Fig.6:- Horizontal milling Machine

21. Working
 The work piece is holding on the worktable of the
machine.
 The table movement controls the feed of work piece
against the rotating cutter. The cutter is mounted on a
spindle or arbor and revolves at high speed.
 Rotation the cutter has no other motion. As the work
piece advances, the cutter teeth remove the metal from
the surface of work piece and the desired shape is
produced.

22.  The most common use is to machine horizontal flat
surfaces, but with ingenuity and some accessories a
wide range of work can be done. Other examples of its
use are.
 Cam drums with tool paths of the type that in CNC
milling terms would require 4- or 5-axis contouring or
turn-mill cylindrical interpolation.
 such as irregularly shaped holes with tight corners
Application

23. Testing procedure of plastic
1. Melt Flow Index (MFI)
2. Izod Testing
3. Charpy Testing
4. Haze Meter

24. Melt Flow Index
Introduction:-
ASTM D – 1238 ISO 1133
American society of Testing material
The melt flow index (MFI) is a measure of the ease of
flow of the melt of a thermoplastic polymer. It is defined
as the mass of polymer, in grams, flowing in ten minutes
through a capillary of a specific diameter and length by a
pressure applied via prescribed alternative gravimetric
weights for alternative prescribed temperatures.
Melt flow rate is measure of molecular weight, with high
melt flow rate corresponding to low molecular weight. At
the same time.

25. Melt flow rate is a measure of the ability of the material's
melt to flow under pressure. Melt flow rate is inversely
proportional to viscosity of the melt at the conditions of the
test, though it should be borne in mind that the viscosity for
any such material depends on the applied force.
Melt flow rate is very commonly used for
polyolefin, polyethylene being measured at 190 °C
and polypropylene at 230 °C.

26. Fig.7 :- Melt Flow Index

27. Working
 A small amount of the polymer sample (around 4 to
5 grams) is taken in the specially designed MFI apparatus.
A die with an opening of typically around 2 mm diameter
is inserted into the apparatus.
 The material is packed properly inside the barrel to avoid
formation of air pockets.
 A piston is introduced which acts as the medium that
causes extrusion of the molten polymer.
 The sample is preheated for a specified amount of time: 5
min at 190 °C for polyethylene and 6 min at 230 °C
for polypropylene.

28.  After the preheating a specified weight is introduced
onto the piston. Examples of standard weights are
2.16 kg, 5 kg, etc.
 The weight exerts a force on the molten polymer
and it immediately starts flowing through the die.
 A sample of the melt is taken after the desired
period of time and is weighed accurately.
 MFI is expressed in grams of polymer per 10
minutes of duration of the test.

29. Carbon Black Content
Introduction:-
Carbon Black of Olefin Materials ASTM D1603
Determination of carbon black content in Olefin materials
like polyethylene or polypropylene that do not contain
nonvolatile additives or fillers. The test is often used as a
quality control measurement for black polyolefin.

30. Test procedure
 A sample weight is placed into a weighed combustion
boat.
 The sample is then placed into a 600°C tube furnace
under a dry oxygen free Nitrogen purge.
 After a set time the combustion boat with the burn
residue is cooled under the nitrogen purge and weighed.
 The combustion boat is then placed into a 600°C muffle
furnace to oxidize the carbon residue.
 When the carbon is completely oxidized the combustion
boat is cooled and weighed.

31. Fig.8:- Carbon Black Content

32. Specimen size:
One to a few grams
Equipment Used:
Tube furnace, Muffle furnace, Combustion boat,
Analytical balance, Oxygen free nitrogen, Flow meter

33. 3 Izod & Charpy Testing
The ASTM International standard for Izod Impact testing
of plastics is ASTM D256.
Izod impact testing method of determining the impact
resistance of materials. A pivoting arm is raised to a
specific height (constant potential energy) and then
released. The arm swings down hitting the sample,
breaking the specimen. The energy absorbed by the
sample is calculated from the height the arm swings to
after hitting the sample.
A notched 45 degree sample is generally used to
determine impact energy and notch sensitivity.

34. Fig.9:- Izod test

35. Charpy Test
The Charpy test, Izod test and other impact testing
determines material toughness or impact strength in the
presence of a flaw or notch and fast loading conditions.
This destructive test involves fracturing a notched
specimen and measuring the amount of energy absorbed
by the material during fracture.

36. The Izod impact test differs from the Charpy impact test in
that the sample is held in horizontal mode.
Charpy impact test but uses a different arrangement of the
specimen under test.
It must also be calculated for roads if speed breakers are
present, in bridge construction where vehicles punch an
impact load, etc.

37.  A material's toughness is a factor of its ability
to absorb energy during plastic deformation.
 Brittle materials have low toughness as a result
of the small amount of plastic deformation that
they can endure.
 The dimensions of a standard specimen for
ASTM D256 are 63.5 × 12.7 × 3.2 mm (2.5 ×
0.5 × 0.125 in). The most common specimen
thickness is 3.2 mm (0.13 in), but the width can
vary between 3.0 and 12.7 mm (0.12 and
0.50 in).

38. Haze Meter
Introduction- ASTM 1003
 "A haze meter measures the transparency; haze, see-
through quality, and total transmittance of a material,
based on how much visible light is diffused or scattered
when passing through a material.
 "Haze is measured with a wide angle scattering test in
which light is diffused in all directions which results in
a loss of contrast.
 when passing through deviates from the incident beam
greater than 2.5 degrees on average is defined as haze.

39. Fig :- Haze meter

40. Working
 A haze meter measures the amount of light that is
diffused or scattered when passing through a transparent
material.
 A high gloss surface with haze exhibits a milky finish
with low reflective contrast- reflected highlights and
lowlights are less pronounced.
 On surfaces with haze, halos are visible around the
reflections of strong light sources.
 When light strikes the surface of a transparent material.
Light is reflected from the front surface of the material

41.  Some light is refracted within the material
(depending on thickness) and reflected from the
second surface.
 Light passes through the material at an angle which
is determined by the refractive index of the
material.
 Transmission – The amount of light that passes
through the material without being scattered
 Haze – The amount of light that is subject to Wide
Angle Scattering (ASTM D1003))
 Clarity – The amount of light that is subject to
Narrow Area Scattering.

42. Application
 Measurement of reflection haze is confined to
high gloss paints and coatings and highly
polished metals.
 Measurement method for films, gloss,
background color on which the film sample is
placed.

43. Processing of polymer
These are many type process for plastic selection of a
process depends on many factors.
1. Quantity and production rate.
2. Dimensional accuracy and surface finish.
3. Form and detail of the product.
4. Nature of material.
5. Size of the product.
In general plastic process have three phases.
1. Heating – to soften or melt the plastic granules.
2. Shaping/forming under constraint of some kind.
3. Cooling – so that it retains its shape.

44. Fig.10:- processing of polymer in industry

45. Processing
1- Clamping:-
The injection of the material into the mold, the two
halves of the mold must first be securely closed by the
clamping unit. Each half of the mold is attached to the
injection molding machine.
The hydraulically powered clamping unit pushes the
mold halves together and exerts sufficient force to keep
the mold securely closed while the material is injected.
The time required to close and clamp the mold is
dependent upon the machine - larger machines (those
with greater clamping forces) will require more time..

46. 2 – Injection:-
 The raw plastic material, usually in the form of pellets,
is fed into the injection molding machine.
 During this process, the material is melted by heat and
pressure.
 The molten plastic is then injected into the mold very
quickly and the buildup of pressure packs and holds the
material. The amount of material that is injected is
referred to as the shot.
 The injection time is difficult to calculate accurately
due to the complex and changing flow of the molten
plastic into the mold. However, the injection time can
be estimated by the shot volume, injection pressure, and
injection power

47. 3 -Cooling
 The molten plastic that is inside the mold begins to cool as
soon as it makes contact with the interior mold surfaces. As
the plastic cools, it will solidify into the shape of the desired
part.
 during cooling some shrinkage of the part may occur. The
packing of material in the injection stage allows additional
material to flow into the mold and reduce the amount of
visible shrinkage.
 The mold cannot be opened until the required cooling time
has elapsed.
 The cooling time can be estimated from several
thermodynamic properties of the plastic and the maximum
wall thickness of the part.

48. 4. Ejection
 When the mold is opened, a mechanism is used to push
the part out of the mold. Force must be applied to eject
the part because during cooling the part shrinks and
adheres to the mold.
 Once the part is ejected, the mold can be clamped shut
for the next shot to be injected.