Forming and Shaping Plastics and

Composite Materials
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Characteristics of Forming and Shaping
Processes for Plastics and Composite Materials ocesses o ast csa dCo poste ate as
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Extruder
Figure : Schematic illustration of a typical extruder.
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Injection Molding
Figure: Injection molding with (a) plunger, (b)
reciprocatingrotatingscrew reciprocating rotating screw
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Sequence of operation
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Reaction-Injection Molding
Figure : Schematic
illustration of the
reaction-injection
molding process.
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Thermoforming
Thermoforming is a manufacturing process where a plastic sheet is heated to a
pliable forming temperature, formed to a specific shape in a mold, and trimmed to
create a usable product.
The sheet or "film" is heated in an oven to a high-enough temperature that it can
be stretched into or onto a mold and cooled to a finished shape. p
Thin-gauge thermoforming is primarily the manufacture of disposable cups,
containers, lids, trays and other products for the food, medical, and general retail , , y p , , g
industries.
Thick gaugethermoformingincludespartsasdiverseasvehicledoor anddash Thick-gauge thermoforming includes parts as diverse as vehicle door and dash
panels, refrigerator liners, utility vehicle beds etc.
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Thermoforming
Types of Thermoforming
Vacuum Forming
Vacuum forming is a plastic thermoforming process that involves forming
thermoplastic sheets into three-dimensional shapes through the application of
heat and pressure.
Thegreatest advantagetovacuumformingisthat it involveslesspartsandtooling The greatest advantage to vacuum forming is that it involves less parts and tooling
than injection molding, and therefore is more cost-effective.
Pressure Forming
Pressureformingisavariationof vacuumformingthat utilizesbothvacuum Pressure forming is a variation of vacuum forming that utilizes both vacuum
and compressed air to force the plastic sheet against the mold.
The vacuum pulls on one side of the sheet and compressed air pushes on the
other.
Compressed air pressure reduces the cycle time and makes it possible to run at
lower temperatures.
Improves the distribution of the material creating a more even wall thickness
andenhancesthedetail of thepart toanearly-injection-moldedquality and enhances the detail of the part to a nearly-injection-molded quality.
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Thermoforming
Drape Forming
Drape forming is similar to straight vacuum forming except that after the sheet is
framed and heated, it is mechanically stretched, and a pressure differential is then framed and heated, it is mechanically stretched, and a pressure differential is then
applied to form the sheet over a male mould.
Faster cycle times.
Disadvantage is more scrap due to larger clamps and trim area
Plug assist forming
Plugassist formingisawidelyusedformingtechniqueandrequirestheuse Plug assist forming is a widely used forming technique and requires the use
of a female (cavity) mold.
The limited depth of draw of female molds is improved by the use of plug
assist.
With plug assist the plastic sheet is mechanically stretched by a plug that is
pushed into the hot plastic.
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Thermoforming Processes
Figure :Various thermoforming processes for thermoplastic sheet.
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Compression Molding
Figure : Types of compression
molding, a process similar to
forging: (a) positive, (b) forging: (a) positive, (b)
semipositive, and (c) flash.
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Transfer Molding
Figure : Sequence of operations in transfer molding for
thermosetting plastics. This process is particularly suitable for
intricate parts with varying wall thickness.
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Sheet and Film Extrusion
Figure : Die geometry (coat-hanger die) for
extruding sheet.
Figure: Schematic illustration of the production of thin
film and plastic bags from tube first produced by an
t d dth bl b i extruder and then blown by air.
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Casting, Potting and Encapsulation
Figure : Schematic
illustration of (a) casting, (b)
potting, (c) encapsulation of potting, (c) encapsulation of
plastics.
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Calenderingand Examples of Reinforced
Plastics Plastics
Figure: Schematic illustration
of calendering. Sheets produced by
this process are subsequently used
in thermoforming in thermoforming.
Figure : Reinforced- plastic
components for a Honda
motorcycle The parts shown are motorcycle. The parts shown are
front and rear forks, a rear
swingarm, a wheel, and brake
disks.
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Prepegs
Figure : Manufacturing process for polymer-matrix composite.
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Sheet MouldingCompound
Sheet moulding compound (SMC) or sheet moulding composite is a ready to
mould fibre-reinforcedpolyester material primarily used incompression moulding.
SMC is made of 3 basic components: the
base resign system (polyester vinylester base resign system (polyester, vinylester,
epoxy, phenolic or polyimide), the
reinforcements (fiberglass, graphite,
aramide), and additives which include inert
fillers, pigments, UV stabilizers, catalysts,
inhibitors, andthickeners.
Figure :The manufacturing
process for producing reinforced
Plasticsheets
Often used for larger parts where
higher mechanical strength is needed.
Is a continuous in-line process.
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Plastic sheets.
Bulk mouldingcompound
Bulk Molding Compound (BMC) is highly filled and reinforced with short
fibers.
Glass reinforcement represents between 10% and 30%, with glass length
typically between 1/32-inch and 1/2-inch.
Generally extruded into shapes for compression, transfer, or shot molding.
The compound is delivered to
the press in the formof a ball,
slab or an extruded log and
dropped into the bottom of a
mould.
Material is flowed outward until
it assumes the shape of the
mould.
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Examples of Molding Processes
HandLayUp:The oldest and simplest molding technique in which reinforcing
materials and catalyzed resin are laid into or over a mould by hand.
Mainadvantages
LowInvestment, any types of large
and small parts can be made, short
tooling lead time & higher glass
content ispossible content ispossible.
Maindisadvantages
Totally labour intensive, operator
dependent thicknessvariations& dependent, thickness variations &
material waste.
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Examples of Molding Processes
Spray up: spray gun is used to simultaneously deposit fiberglass and catalyzed
resin on a mould.
Advantages
Higher output than hand g p
lay-up
Disadvantages
Hi h i t t th Higher investment than
hand lay-up
Emissions
Material waste
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Examples of Molding Processes
Figure: (a) Vacuum-bag forming. (b) Pressure-bag forming.
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Filament Winding: The process of helically (spring like) wrapping reinforcements
and resin around a polar mandrel.
Main advantages
Low labor
High strength orientation
highpart output high part output
Reproducibility
Maindisadvantage
Unsuitable for complex shapes
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Pultrusion:The process of continuously pulling a resin-impregnated reinforcement
through a die in to its final shape.
Mainadvantages
L l b Low labor
Low waste
Disadvantages
Highinvestment
Longtoolingtime
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