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Special Machines Unit -1 MANUFACTURING OF PLASTIC COMPONENTS
- 3. TOPICS Manufacturing Of Plastic Components Reciprocating Machines Milling Machines And Gear Generating Processes Abrasive Process And Non-conventional Machining Process CNC Machines And Its Components 19-11-2017 3LAPC
- 4. UNIT 1 – MANUFACTURING OF PLASTIC COMPONENTS Plastic Components Processing of Plastics Composite Manufacturing 19-11-2017 4LAPC
- 5. UNIT – 2 RECIPROCATING MACHINES Planer Shaper Slotter Broaching 19-11-2017 5LAPC
- 6. UNIT – 3 MILLING MACHINES AND GEAR GENERATING PROCESSES Milling Machines Gear Generating Processes 19-11-2017 6LAPC
- 7. UNIT – 4 ABRASIVE PROCESS AND NON-CONVENTIONAL MACHINING PROCESS Abrasive Process Non-conventional machining Processes 19-11-2017 7LAPC
- 8. UNIT – 5 CNC MACHINES AND ITS COMPONENTS CNC Machines Components of CNC Machines 19-11-2017 8LAPC
- 10. UNIT – 1 MANUFACTURING OF PLASTIC COMPONENTS 19-11-2017 LAPC 10
- 11. Important Terms • Plastic - Synthetic Organic Polymer • Composite - Combination of two dissimilar materials ( Reinforcement + Matrix) • Elastomers - Thermoplastic Rubber • Engineering Plastics - Used in Engineering Applications • LCP - Liquid Crystal Polymer (Aromatic Polyesters) • Thermosets - Thermosetting Plastics • Polymer - Combination of Monomers • Degradation - Brake down of Chemical Structure • Twin screw Extruder - Two Screw Extruder
- 12. • Fatigue - Brittle Crack • Runner - Flow path of Molten material • Sandwich Moulding - Two different polymers injected one after another • Calendaring - Plastic film producing process • Filament - Single Fiber • Strands - Bundle of filaments • Prepregs - Pre-Impregnated ( Flexible Sheet of Fibers & Resin) • Glass Fiber - Amorphous Material • Epoxy Resin - Polymerizable thermosetting resins19-11-2017 LAPC 12
- 13. • Autoclave - Pressurized Oven • Bleeder Material - Absorb Excess Resin • Breather Material - Remove Excess Air • Bagging Film - Form vacuum bag • Barrier Film – Control the resin flow • Filament winding - Process of Making Hollow Section Components • Pultrusion - Process of Making Straight shape of Constant Cross-sectioned Components • LCM - Liquid Composite Moulding • RTM - Resin Transfer Moulding • COI - Critical Oxygen Index • Kevlar - Aramid Fibers 19-11-2017 LAPC 13
- 14. • Tow - Untwisted bundle of continuous filaments • Yarn - Twisted bundle of tow • Roving - Number of Untwisted bundle of yarns 19-11-2017 LAPC 14
- 15. I. Plastic Components Plastics: Plastics is an organic resin or synthetic resin which can be moulded to any required shape It contains Oxygen , Hydrogen , Carbon and Nitrogen 19-11-2017 15LAPC
- 17. Classification of Plastics 19-11-2017 17LAPC Thermoplastics Thermosetting Plastics
- 18. Thermoplastics: It Can Be Softened By Heating And Hardened By Cooling It can be remoulded Ex: PVC, Polyester Uses: Insulating Tapes, Toys. 19-11-2017 18LAPC
- 19. Thermosetting Plastics It Cannot Be Softened On Heating , Once hardened and set It cannot be remoulded Ex: Duroplast, Epoxy resin Uses: Automobile Parts, Electric Plugs 19-11-2017 19LAPC
- 21. Types of Plastics Engineering Plastics Thermosets Composites structural foam Elastomers Liquid Crystal Polymers 19-11-2017 21LAPC
- 22. Factors Influencing The Selection Of Plastics I. Mechanical Properties Strength Stiffness Fatigue Toughness Ductility 19-11-2017 22LAPC
- 23. II. Degradation Brake down of chemical structure by heat stress and radiation III. Wear resistance and Frictional Properties IV. Special Properties Optical properties Electrical properties Flammability V. Processing Cost VI. Processing Methods 19-11-2017 23LAPC
- 24. Processing of Plastics Extrusion Thermoforming Moulding Processes Calendaring Casting Twin Screw Extruder Single Screw Extruder Compression Moulding Roto Moulding Injection Moulding Expandable Bead Moulding Blow Moulding Gas Injection Moulding Sandwich Moulding Structural Foam Reciprocating Screw Ram or Plunger Type 19-11-2017 24LAPC
- 25. SINGLE SCREW EXTRUDER It has Three Zones Feed Zone Compression Zone Metering Zone Application: • It is used to make tubes, sheets, ropes 19-11-2017 25LAPC
- 31. TWIN SCREW EXTRUDES Types: Intermeshing counter rotating Intermeshing co-rotating Non- Intermeshing counter rotating Non- Intermeshing co-rotating Advantages: Output rate is high Mixing efficiency is more 19-11-2017 31LAPC
- 32. RAM or PLUNGER TYPE INJECTION MOULDING Advantages Complicated shapes of various sizes of products can be produced Good dimensional accuracy Disadvantages High tooling cost Suitable for mass production only High production rate 19-11-2017 LAPC 32
- 38. Extruder screw rotates in the normal way to transport, melt and pressurize the material in the barrel Extruder screw moves forward like plunger to inject melt into the mould Advantages High production rate. Low cost. 19-11-2017 38LAPC
- 39. STRUCTURAL FOAM INJECTION MOULDING Advantages: These plastics are rigid one. Free form shrinkage. Cost of the mould is less. Very thick sections can be moulded. 19-11-2017 39LAPC
- 42. SANDWICH INJECTION MOULD Sandwich moulding is defined as two or more polymers are injected one after the other through the dame gate in one or cavities. Advantages: Material, weight and cost is saved. Increased stability and strength. Decorative effects. Combination of characteristics. 19-11-2017 42LAPC
- 46. GAS INJECTION MOULDING • The gas-assisted injection molding process begins with a partial or full injection of polymer melt into the mold cavity. Compressed gas is then injected into the core of the polymer melt to help fill and pack the mold Advantages: Lower cycle time. No surface imperfections Clamping forces are much lower 19-11-2017 46LAPC
- 50. INJECTION MOULDING FOR THERMOSETTING MATERIALS Thermosets molding is the reverse process of thermoplastic. Special barrel and screw are used in this process. Advantages: Fastest cycle. Efficient pre heating material Easiest finishing Mould cost is low. 19-11-2017 50LAPC
- 52. CALENDARING Calendaring is the process of producing the sheet of materials by rolling the plastics between multiple rollers. & Its only for thermoplastic Applications: • Thermoplastic films • Sheets & Coatings Advantages: • High accuracy • High rate of production 19-11-2017 52LAPC
- 56. ROTATIONAL MOULDING Used for producing hollow plastics. Advantages This process is suitable for making the products with complicated shapes and size. Less expanse than injection moulding. Less expanse for manufacturing few parts than the other process. Disadvantages This process is suitable for manufacturing hollow parts only. Cycle time is slow. It is not easy to get varying wall thickness within a part. Only limited number of materials only can be mould. 19-11-2017 56LAPC
- 59. 19-11-2017 LAPC 59 Applications: • Used for producing toys in PVC • Used to make petrol tank
- 61. DESIGN CONSIDERATIONS FOR PLASTIC COMPONENTS 1) Avoid under cuts. 2) Provide shrinkage allowance. 3) Avoid sharp corners. 4) long cored holes should be avoided. 5) Location of the parting surface of the mould should be in one plane 6) Maintain uniform wall thickness 7) Ribs provided for increase strength 19-11-2017 LAPC 61
- 62. 8) try to design projections to have circular cross sections 9) Use suitable size inserts 10) Considered material properties 19-11-2017 LAPC 62
- 63. COMPOSITE MANUFACTURING A combination of two or more materials to form a new material with enhanced material properties. Ex: Wood, Concrete, Brick 19-11-2017 LAPC 63
- 64. CONSTITUENTS OF COMPOSITE 19-11-2017 LAPC 64 Characteristics: Provide strength & Stiffness Reinforcement CompositeMatrix Forms: Fibers, Filament Forms: Polymers, Metals, Ceramics. Characteristics: Provide Toughness Materials: Metals, Ceramics, Polymer Materials: Glass Fibers, Carbon , Graphite, Kevlar
- 65. CHARACTERISTICS OF COMPOSITE MANUFACTURING • Good Bonding between Fibers and Matrix • Proper Orientation of the fibers • Uniform Distribution • Good dimensional Control 19-11-2017 LAPC 65
- 66. APPLICATIONS OF COMPOSITE MATERIALS • Automotive Applications • Aerospace Applications • Marine Applications • Construction Applications • Sanitary Applications • Building Applications • Sports Applications 19-11-2017 LAPC 66
- 68. Light weight High strength High stiffness High corrosion resistance Low ductility More expensive Difficult in manufacturing Slow manufacturing process 19-11-2017 LAPC 68 ADVANTAGES OF COMPOSITE MATERIALS DISADVANTAGES COMPOSITE MATERIALS
- 69. GLASS FIBER MANUFACTURING PROCESS Raw materials : Silica sand Boric acid Minor ingredients (clay, coal) 19-11-2017 LAPC 69
- 70. Raw Materials Mixed & Weighed Fed into Furnace In Furnace , At refining stage - 1425°C In Furnace, At forehearth stage - 1260°C Sizing Chemical is Added Finish Chemical is Added Filaments Are Bundled Together In Furnace, At melting stage - 1540°C Smaller Filaments Formed Filaments Formed Through Batch unit Molten glass flows through Platinum plate Tiny holes Pulled Mechanically Strands Formed
- 74. HAND LAMINATING PROCESS • Simplest Method of Composite manufacturing • Glass fiber & epoxy resin common material Advantages: Simple process Low cost Disadvantages: Time consuming Not suitable for mass production 19-11-2017 LAPC 74
- 77. 19-11-2017 LAPC 77 Applications: Boats Tanks Bath Ware Housings RV/Truck/Auto Components Architectural Products
- 78. FILAMENT WINDING • Used For Making Hollow , Circular, Oval Sectioned Components Like Pipes, Storage Tanks, Pressure Vessel Advantages • Economic Process • Very Fast Process Disadvantages • Poor Surface Finish • Complex Shapes Difficult To Produce 19-11-2017 LAPC 78
- 83. PULTRUSION PROCESS • Continues process used to produce long, straight, constant cross section products like beams, rods, pipes. Advantages: Automated process Continuous & high speed process Disadvantages: Expensive die Difficult to produce thin wall , tapered, complex shape products LAPC 83
- 87. LIQUID COMPOSITE MOULDING 19-11-2017 LAPC 87 • It is also called as Resin Transfer Moulding (RTM) • It is used to produce Small complex aircraft and automotive components, train seats • It is cost effective process • Consists of Injection ports, Air vents, Guide Pins & gaskets
- 89. Advantages • Good moulded surface • High production rate • Low initial cost • Low manufacturing cost Disadvantages • Limited to smaller components • Tooling is expensive 19-11-2017 LAPC 89
- 94. AUTOCLAVE PROCESSING 19-11-2017 LAPC 94 Materials Used: Reinforcement: Glass & Kevlar fibers Matrix: Polypropylene Mould tool: Stainless Steel Or Aluminium Autoclave - Pressurized Oven Prepregs - Pre-Impregnated Materials
- 95. Processing Steps Prepregs Preparation Mould Preparation Laying Up Prepregs Vacuum Bag Curing
- 100. 19-11-2017 LAPC 100 Advantages: • Simple • Mould tool design • Flexible method • Better surface finish Disadvantages: • High capital cost • Skill laminators need • High maintenance cost
- 101. BOARD EXAM QUESTIONS Part A&B 1. Write the Advantages of Structural Foam Injection Moulding 2. Sketch &Show the parts of Calendaring 3. Differentiate between thermoplastics & thermosetting plastics 4. What are Engineering Plastics? Give Example. 5. Define Autoclave Processing 6. What is Filament Winding? 19-11-2017 LAPC 101
- 102. 7. What is Liquid Composite Moulding? 8. Write the Advantages and Disadvantages of Pultrusion process 9. Define Pultrusion 10. List out Various Matrix materials 11. What is Elastomers? 12. Define Composite 13. Mention the Application of Filament Winding 14. List out the Constituents of Composite 15. Name the Different Composite manufacturing Techniques 16. What are the two major types of plastics?LAPC
- 103. 17. Write the properties of plastics 18. What are the design consideration of plastic components? 19. What are the two types of twin screw extruder? 20. What are the frictional properties of plastics? 19-11-2017 LAPC 103
- 104. Part C 1. With a simple sketch, Explain Rotational Moulding 2. Explain the manufacturing Process of Glass Fibers with a schematic diagram. 3. Explain with neat sketch the Single Screw Extruder 4. Explain with neat sketch the Plunger type Extrusion 5. Explain the Reciprocating Screw Injection Moulding 6. Explain the Gas Injection Moulding process 7. With a neat sketch explain Calendaring Process
- 105. 8. Explain the various types of Plastics available 9. Explain the various factors to be considered for the selection of Plastic Material 10.With a neat sketch explain the functioning of twin screw extruder 11.Briefly explain the characteristics of Composite Manufacturing 12.With a neat sketch, Explain the Filament Winding Process 13.Explain the Pultrusion process of composite manufacturing with neat sketch 14.Write the short notes on (i) Structural Foam Injection Moulding (ii) Rotational Moulding 19-11-2017 LAPC 105
- 106. 19-11-2017 106