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MANUFACTURING OF PLASTIC
COMPONENTS
UNIT - 5
ORGANIC MATERIALS
 Natural – Wood, Coal, Petroleum &
Natural Rubber
 Synthetic – Plastics, Synthetic rubber,
Ceramics & Glass
 Organic material - Polymers
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
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)
Hydrogen peroxide
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
 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
Properties of Plastics
 Elongation
 Heat resistance
 High rigidity
 Surface hardness
 High viscosity
 Density
 Chemical resistance
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
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
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
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
INJECTION MOULDING
1) RAM OR PLUNGER TYPE INJECTION MOULDING
THERMOPLASTICS - INJECTION MOULDING
2) SCREW TYPE INJECTION MOULDING
THERMOPLASTICS – INDUSTRIAL APPLICATION
2) BLOW MOULDING
THERMOPLASTICS – INDUSTRIAL APPLICATION
3) ROTATIONAL MOULDING
THERMOPLASTICS – INDUSTRIAL APPLICATION
4) FILM BLOWING
THERMOPLASTICS – INDUSTRIAL APPLICATION
5) SHEET MAKING
THERMOPLASTICS – INDUSTRIAL APPLICATION
6) EXTRUSION PROCESS
THERMOPLASTICS – INDUSTRIAL APPLICATION
7) VACUUM FORMING PROCESS ( THERMO FORMING)
THERMOSETS
1) COMPRESSION MOULDING
THERMOSETS
2) TRANSFER MOULDING
BONDING OF THERMOPLASTICS
YoucaN
YoucaN
YoucaN

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Mp 1-unit - v - processing of plastic components

  • 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) Hydrogen peroxide
  • 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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