Manufacturing of Plastic Components
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The document discusses various topics related to plastics manufacturing including types of plastics, polymerization processes, properties of plastics, types of resins, thermoplastics vs thermosetting plastics, and common shaping processes for plastics like injection moulding, blow moulding, rotational moulding, extrusion, compression moulding and transfer moulding. Key plastic shaping processes are injection moulding using ram or screw machines, blow moulding, rotational moulding, film blowing, sheet making and extrusion. Common applications of thermosets include compression moulding and transfer moulding.
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Er. Naresh Dhaker
(8890881858)
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Elastomeric materials like rubber can be stretched over 200% and return to their original shape. Elastomers include both thermoset polymers like natural rubber and synthetic rubbers, as well as thermoplastic elastomers. Natural rubber comes from trees and requires vulcanization with sulfur to improve properties. Synthetic rubbers are made from petroleum and include butadiene rubber, styrene-butadiene rubber, and neoprene. Thermoplastic elastomers have both hard and soft segments that provide elasticity without vulcanization. Elastomers are processed using methods like compression molding, extrusion, and injection molding.
Plastic presentation
Plastic can be natural or synthetic resins that can be molded into various shapes. The first synthetic plastic was phenol formaldehyde developed in 1900. Plastics come from sources like crude oil and natural resins from materials like plants, insects and animals. There are two main types of plastics - thermoplastics and thermosettings. Thermoplastics can be remolded when heated while thermosettings permanently harden when initially molded. Common plastics include polyethylene, PVC, nylon, and polystyrene. Plastics have various properties like being lightweight, resistant to heat and corrosion, and can be easily formed into various objects for uses like flooring, pipes, and toys.
Plastics: An Economical Synthesis of Aesthetics and Function
The document discusses plastics, including:
1. Plastics are polymers that can be molded into various shapes and are made from petroleum products and other raw materials.
2. There are two main types of plastics - thermoplastics, which can be remelted and reformed, and thermosets, which cannot be remelted once formed.
3. Common plastics include polyethylene, PVC, polystyrene, and nylon. Plastics have a wide range of applications from packaging to construction due to their properties like durability, insulation, and light weight.
Plastic Manufacturing Process of manufacturing practices
Plastics are organic polymers derived from carbon and hydrogen. They are either natural resins or synthetic resins produced through polymerization reactions. The document discusses the key types of polymers like thermoplastics and thermosets. It describes important plastics like polyethylene, PVC, nylon, etc. and their properties. It also covers plastic fabrication methods like injection molding, compression molding, blow molding, etc. and their uses in various applications.
plastics-140928093734-phpapp02.pptx
The document discusses plastics, including their definition, properties, types (thermoplastics and thermosetting plastics), manufacture, applications, disadvantages, and latest developments. Plastics are synthetic or semi-synthetic organic solids that are moldable and consist of large chain-like molecules containing carbon. They have properties like corrosion resistance, light weight, and heat resistance. The two main types are thermoplastics, which can be remolded, and thermosetting plastics, which set permanently. Plastics are manufactured through processes like polymerization, compounding, and molding/shaping techniques. They have various applications but also disadvantages like low strength and sensitivity to environment. New developments include bulletproof polymers
Plastics
The document discusses the process of obtaining plastics from raw materials through synthesis of monomers and polymers, addition of additives, shaping and finishing. It also covers the properties and classification of plastics, listing common thermoplastics and thermosetting plastics as well as their characteristics and uses.
Similar to Manufacturing of Plastic Components (20)
Plastics: An Economical Synthesis of Aesthetics and Function
Plastics: An Economical Synthesis of Aesthetics and Function
Plastic Manufacturing Process of manufacturing practices
Plastic Manufacturing Process of manufacturing practices
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HEAT TREATMENT
Heat treatment involves heating and cooling of metals to obtain desired properties. Common heat treatment processes include annealing, normalizing, and hardening. Quenching involves rapidly cooling heated steel to make it harder and stronger. Case hardening processes like carburizing add carbon to the surface of low-carbon steel to create a hard outer case. Induction and flame hardening are surface hardening techniques used for gears, shafts and other rotating components. Time-temperature transformation and continuous cooling transformation diagrams are used to determine the microstructures that form during heat treating processes.
NON-METALLIC MATERIALS
This document provides an overview of non-metallic materials including polymers, ceramics, and composites. It discusses key polymer types like polyethylene, polypropylene, polystyrene, polyvinyl chloride, and nylon. It describes their properties, production processes, and common applications. Terminology used in polymers like monomer, polymer, polymerization, homopolymer, and copolymer are also defined. The different types of polymerization and various polymer classifications are outlined.
TESTING OF MECHANICAL PROPERTIES
This document provides information on various mechanical tests conducted to evaluate properties of materials, including:
- Plastic deformation testing which evaluates a material's ability to deform permanently under load.
- Hardness testing methods like Brinell, Vickers, and Rockwell which indent materials with an indenter to assess hardness.
- Impact testing like Izod and Charpy tests which determine a material's resistance to sudden load by measuring how much energy is absorbed during fracture.
- Fatigue and creep testing which apply repeated or sustained loads to examine how materials withstand cyclic stresses or deformation over time.
A variety of destructive and non-destructive tests are described that are used industrially and for research to
FERROUS AND NON FERROUS METALS
- Steels are alloys of iron and carbon, with other common alloying elements including manganese, silicon, sulfur, and phosphorus.
- Carbon content determines the type of steel - low carbon (<0.35%) is mild steel, medium carbon (0.35-0.55%) is harder, and high carbon (0.55-1.55%) responds to heat treatment.
- Alloying elements like chromium, nickel, molybdenum increase properties like corrosion resistance, strength, and high temperature performance. Stainless steels contain a minimum of 10.5% chromium.
CONSTITUTION OF ALLOYS
1. Alloys are made of two or more metals to obtain desired properties like strength, toughness, corrosion resistance that pure metals lack.
2. A solid solution is a homogeneous mixture of atoms where solute atoms substitute or fit in the lattice structure of the solvent metal.
3. Cooling curves and phase diagrams are used to understand the solidification process of alloys and predict the phases present at various temperatures and compositions.
UNIT-II---FEA
A beam is a structural member that is supported along its length and subjected to external forces acting perpendicular to its central axis. There are different types of beams including cantilever, simply supported, overhanging, fixed, and continuous beams. Beams can experience different types of transverse loading such as point loads, uniformly distributed loads, and uniformly varying loads.
UNIT-IV-- FEA
This document discusses axisymmetric elements for finite element analysis. It covers the conditions required for a problem to be axisymmetric, including symmetry about the axis of revolution. It also discusses the derivation of shape functions for axisymmetric elements, including a three node axisymmetric triangular element. Finally, it mentions assembling the element stiffness matrix and calculating stresses and strains.
Unit-III---FEA
The Linear Strain Triangular (LST) element is a six noded triangular element that has 12 unknown displacement degrees of freedom. It can be used for finite element analysis of structures and materials. The LST element approximates strains and displacements using linear interpolation between its six nodes.
Unit-I--FEA
This document discusses the finite element method (FEM) for numerical analysis of engineering problems. It describes the general steps of FEM which include discretizing the domain into simple geometric elements, choosing interpolation functions, deriving the element stiffness matrices, assembling the matrices into a global system, applying boundary conditions, and solving for displacements/stresses. FEM allows for approximate solutions of complex problems involving various material properties, geometries, and loading conditions.
Unit 5--FEA
The document discusses the benefits of exercise for mental health. Regular physical activity can help reduce anxiety and depression and improve mood and cognitive functioning. Exercise boosts blood flow, releases endorphins, and promotes changes in the brain which help enhance one's emotional well-being and mental clarity.
Robotics - Unit-II
The document discusses various types of robot drive systems and end effectors. It describes hydraulic, pneumatic, and electric drive systems. Hydraulic drives use pressurized fluid and are suitable for heavy loads. Pneumatic drives use compressed air and are cheaper but generate more noise. Electric drives include AC servo motors, DC servo motors, and stepper motors. Stepper motors convert electrical pulses to rotational movement precisely. Servo motors are used in automatic control systems. The document also discusses actuators, motors, and end effectors like grippers used by robots.
Unit-V---Implementation of Robot
This document discusses material handling and various types of equipment used for moving materials within production environments, including automated guided vehicles (AGVs). It describes rail guided vehicles (RGVs) which use transportation rails to move multiple vehicles according to requirements. The document outlines different types of AGV navigation systems including laser target navigation and obstacle detection. It also discusses AGV control systems and batteries used to power AGVs. Laser guided vehicles are introduced which use laser scanners and targets for accurate positioning and guidance of material handling robots.
Economic analysis of robot
This document discusses different types of economic analysis used to evaluate robots, including cost effectiveness analysis, cost benefit analysis, and economic impact analysis. It describes return on investment (ROI) as a method that measures gains or losses from an investment relative to the amount invested. The document also explains that cash flow analysis evaluates a company's cash inflows and outflows from operations, financing, and investing to carefully manage cash flow.
UNIT-IV-- Robotics
The document discusses robot kinematics and robot programming. It covers topics like forward and inverse kinematics, Jacobian matrices, and manipulator dynamics. It also discusses trajectory generation and manipulator mechanism design. Finally, it discusses robot programming languages like VAL and how they are used to program motion commands, sensor commands, end effector commands, and simple programs.
Unit III-- senors in robotics
The document discusses various types of sensors and machine vision systems. It describes position sensors including piezoelectric sensors, LVDTs, optical encoders, and resolvers. It also covers range sensors, touch sensors, cameras, and image processing techniques. The key applications mentioned are inspection, identification, visual serving, and navigation.
Unit-2-- End effector
The document discusses various types of robot end effectors and grippers. It describes grippers classified based on the method used to hold objects like mechanical, vacuum, magnetic, etc. It also discusses gripper mechanisms, actuation methods, and factors to consider for gripper design and selection. The key types covered are mechanical, vacuum, magnetic, pneumatic, and hydraulic grippers.
Unit-I Robotics
This document provides an overview of robot fundamentals, including definitions, classifications, specifications, anatomy, and applications. It defines a robot as a reprogrammable mechanical device that performs tasks controlled by a human or automated system. Robots are classified based on their mechanical arm, degrees of freedom, power source, control system, sensors, movement, industry application and more. The document also describes common robot coordinate systems, joints, motions, and specifications for different robot configurations including Cartesian, cylindrical, polar, SCARA and more. It provides examples of various robot applications in industries.
Planning
The document discusses various aspects of planning including defining goals and strategies, types of plans such as strategic and operational, and the planning process. It also covers management by objectives (MBO) which involves employees and managers jointly determining goals and reviewing progress. Additional topics include objectives and their characteristics, contingency factors in planning like environmental uncertainty, and decision making under different conditions.
Overview of management
This document provides an overview of principles of management. It discusses key concepts such as organizations, goals, and the role of management. It also examines the four functions of management: planning, organizing, leading, and controlling. Additionally, it covers topics like management levels, managerial skills and responsibilities, and historical perspectives on the evolution of management thought, including scientific management and administrative management.
Cast iron
This document discusses different types of cast irons and their properties. It begins by describing the composition of cast iron which contains more than 2% carbon along with alloying elements like silicon, sulfur, manganese, and phosphorus. The main types discussed are grey cast iron, which is the most widely used due to its low cost; white cast iron, which is very hard and brittle; malleable cast iron, which is made by heat treating white cast iron to improve ductility; and spheroidal graphite cast iron, which has improved ductility from nodular graphite formation. The document also covers how alloying elements and heat treatments can impact the microstructure and properties of cast irons.
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Manufacturing of Plastic Components
- 1. MANUFACTURING OF PLASTIC COMPONENTS Types of plastics - Characteristics of the forming and shaping processes – Moulding of Thermoplastics – Working principles and typical applications of - Injection moulding – Plunger and screw machines – Compression moulding, Transfer moulding – Typical industrial applications – Introduction to Blow moulding – Rotational moulding – Film blowing – Extrusion - Thermoforming, - Bonding of Thermoplastics.
- 2. ORGANIC MATERIALS Natural – Wood, Coal, Petroleum & Natural Rubber Synthetic – Plastics, Synthetic rubber, Ceramics & Glass Organic material - Polymers
- 3. Polymers Poly means ‘Many’ & ‘Mers’ means ‘Parts’ Polymer built of several repeating units(Monomer) Monomer – small molecules Polymer is made up of thousands of monomers jointed together to form large molecule. Plastics – Organic polymer
- 4. Polymerization process A Polymer is made up of linking thousands of monomer and thus obtaining large molecule is called Polymerization process Additives – Plasticizers (liquid form) – Water, Organic solvents & resins Catalyst – Promote faster & complete Polymerization Dyes – Impart desired colour Initiators – Initiate the reaction (H2O2)
- 5. Plastics Can be moulded into required shape with the help of pressure or heat or both heat and pressure Resin – liquid form of plastics, also raw material for making plastics Types of resin: acrylic resin, Polyethylene resin & amino resin – Produced by polymerization process Catalysts, Binders & Lubricants added with resin to form plastics
- 6. Modifiers – To improve the mechanical properties of plastics Lubricants – To reduce friction during processing , Avoid sticking to mould walls(Oils, Soaps and waxes) Solvents – Dissolve fillers or Plasticizers & Allow the processing in fluid state(Alcohol) Fillers – Mica, Cloth fiber Elastomers – To enhance the elastic properties
- 7. Properties of Plastics Elongation Heat resistance High rigidity Surface hardness High viscosity Density Chemical resistance
- 8. Thermosetting Plastics Thermosetting - Plastics which are hardened by heat effecting non reversible chemical change . Molecules are formed by condensation polymerization process. All the molecules have three dimensional network and very strong binding force between molecules Bakelite, Polyester resin, Epoxy resin(Araldite), Silicones, Urea formaldehyde(Amino resin) & Alkyds
- 9. Thermo Plastics Have separate long and large size molecule arranged side by side When thermoplastics are heated it becomes very soft and rehardens on cooling During heating the linear bonding links between molecules are breakup and separated. Relinking takes place on cooling and retains their hardness. Cellulose nitrate – pen bodies, Table tennis balls, Frames Ethyl cellulose – Jigs, Fixtures, hose nozzles Cellulose acetate - Radio cabinets, steering wheels, Insulating tapes
- 10. Synthetic resins Polyethylene – Fabrics, tray, pipes, tubing chemical containers & corrosion resistant coatings Polystyrene - Battery boxes, radio parts, toys Vinyles(PVC) – Tarpaulin, Water roofing, raincoats, tubes Polytetra fluroethylene (Teflon)- Gaskets, Greaseless bearing, Electrical insulators, Chemical containers Polyamide(Nylon) – Gears, wire insulation, combs, Bearings and couplings
- 11. S. No Thermoplastics Thermosetting plastics 1 Softened by heating Cannot be softened by heating 2 Structure is made of linear chain molecule Structure is made of cross- linked molecule 3 Produced by addition polymerization process Produced by condensation polymerization process 4 Can be reproduced by heating and cooling Cannot be reproduced 5 When the temp increases the plasticity also increases Plasticity is stable at high temperature 6 Softer and less strong Harder and strong 7 Scrap can be reused Scrap can not be reused
- 12. INJECTION MOULDING 1) RAM OR PLUNGER TYPE INJECTION MOULDING
- 13. THERMOPLASTICS - INJECTION MOULDING 2) SCREW TYPE INJECTION MOULDING
- 14. THERMOPLASTICS – INDUSTRIAL APPLICATION 2) BLOW MOULDING
- 15. THERMOPLASTICS – INDUSTRIAL APPLICATION 3) ROTATIONAL MOULDING
- 16. THERMOPLASTICS – INDUSTRIAL APPLICATION 4) FILM BLOWING
- 17. THERMOPLASTICS – INDUSTRIAL APPLICATION 5) SHEET MAKING
- 18. THERMOPLASTICS – INDUSTRIAL APPLICATION 6) EXTRUSION PROCESS
- 19. THERMOPLASTICS – INDUSTRIAL APPLICATION 7) VACUUM FORMING PROCESS ( THERMO FORMING)
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