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ME 303
SHAPING PROCESSES OR
P!ASTICS
"#00$ %ohn &iley ' Son() Inc* M P Groo+er) Fundamentals of Modern Manufacturing 3,e
SHAPING PROCESSES OR
P!ASTICS
un-a.ental( of Poly.er Science an- Technology
/* Pro0ertie( of Poly.er Melt(
#* E1tru(ion
3* Pro-uction of Sheet) il.) an- ila.ent(
2* Coating Proce((e(
3* In4ection Mol-ing
5* Other Mol-ing Proce((e(
$* Ther.ofor.ing
6* Ca(ting
7* Poly.er oa. Proce((ing an- or.ing
/0* Pro-uct 8e(ign Con(i-eration(
"#00$ %ohn &iley ' Son() Inc* M P Groo+er) Fundamentals of Modern Manufacturing 3,e
Poly.er
A co.0oun- con(i(ting of long chain .olecule()
each .olecule .a-e u0 of re0eating unit(
connecte- together
Ther.o0la(tic(>
Polyethylene) 0oly+inylchlori-e)
0oly0ro0ylene) 0oly(tyrene) an- nylon
Ther.o(et(>
Ela(to.er(>
Mol-e- 0art(
E1tru-e- (ection(
il.(
Sheet(
A-he(i+e(
Ca(ting(
oa.e- 0ro-uct(
"#00$ %ohn &iley ' Son() Inc* M P Groo+er) Fundamentals of Modern Manufacturing 3,e
Poly.er Melt(
Ai(co(ity
Ai(coela(ticity
"#00$ %ohn &iley ' Son() Inc* M P Groo+er) Fundamentals of Modern Manufacturing 3,e
Ai(co(ity
Ai(co(ity i( a flui- 0ro0erty that relate( the (hear
(tre(( e10erience- -uring flo: of the flui- to
the rate of (hear*
"#00$ %ohn &iley ' Son() Inc* M P Groo+er) Fundamentals of Modern Manufacturing 3,e
E1a.0le /3*/
"n extruder barrel has a diameter D # $% mm. &he screw
rotates at N # 1 re!'s. hannel depth d
c
# (.) mm and flight
angle A # 2)
o
. *ead pressure at the end of the barrel p # $.) x
1)
(
+a, length of the barrel L # 1.9 m, and !iscosity of the
polymer melt is assumed to be # 1)) +a-s. .etermine the
!olume flow rate of the plastic in the barrel Q
x
.
"#00$ %ohn &iley ' Son() Inc* M P Groo+er) Fundamentals of Modern Manufacturing 3,e
E1tru-er Characteri(tic( <Scre: Characteri(tic=
</3*/2=
</3*/3=
The t:o +alue( G
.a1
an- 0
.a1
are 0oint( along the a1e( of a
-iagra. ;no:n a( the e1tru-er characteri(tic*
Soli- 0rofile(
ila.ent(
"#00$ %ohn &iley ' Son() Inc* M P Groo+er) Fundamentals of Modern Manufacturing 3,e
E1tru(ion of Soli- Profile(
Roun-(
S?uare(
Structural (ha0e(
Auto.o9ile tri.
Hou(e (i-ing
"#00$ %ohn &iley ' Son() Inc* M P Groo+er) Fundamentals of Modern Manufacturing 3,e
E1tru(ion 8ie for Soli- Cro(( Section
igure /3*6 <a= Si-e +ie: cro(( (ection of an e1tru(ion -ie
for (oli- regular (ha0e() (uch a( roun- (toc;D <9= front
+ie: of -ie) :ith 0rofile of e1tru-ate* 8ie (:ell i( e+i-ent
in 9oth +ie:(*
"#00$ %ohn &iley ' Son() Inc* M P Groo+er) Fundamentals of Modern Manufacturing 3,e
E1tru(ion 8ie for Soli- Cro(( Section
Cooling i( acco.0li(he- 9y
/* air 9lo:ing)
#* :ater (0ray) or
3* 0a((ing the e1tru-ate through a :ater
trough*
Ther.ofor.ing (toc;
"#00$ %ohn &iley ' Son() Inc* M P Groo+er) Fundamentals of Modern Manufacturing 3,e
Material( for Poly.er Sheet an- il.
Poly0ro0ylene
Poly+inylchlori-e
Cello0hane
"#00$ %ohn &iley ' Son() Inc* M P Groo+er) Fundamentals of Modern Manufacturing 3,e
Sheet an- il. Pro-uction Proce((e(
Proce((e( inclu-e>
Calen-ering
"#00$ %ohn &iley ' Son() Inc* M P Groo+er) Fundamentals of Modern Manufacturing 3,e
Slit 8ie E1tru(ion of Sheet an- il.
Pro-uction of (heet an- fil. 9y con+entional
e1tru(ion) u(ing a narro: (lit a( the -ie
o0ening
0olyethylene
Poly0ro0ylene