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Lecture 8

SHAPING PROCESSES FOR


POLYMERS
Polymers
A polymer is a compound consisting of long-chain molecules, each
molecule made up of repeating units connected together.
Polymers can be separated into three major groups:
Thermoplastic polymers (thermoplastics)
Thermosetting polymers (thermosets)
Elastomers (rubbers)
Thermoplastic polymers
(thermoplastics)
Solid materials at room temperature, become viscous liquids when
heated.
The most important thermoplastics are:

Acrylics (Plexiglas): lenses, window glazing
Fluorocarbons (Teflon): nonstick coatings, bearings, seals
Polyamides (Nylons, Kevlar): fibers
Polycarbonates (Lexan): helmets, bullet-resistance windows, wind
shields
Polyesters (Dacron, Mylar, Kodel): gears, cams, rollers
Polyvinyl chloride (PVC): pipes, cable insulation, packaging, flooring,
toys
Polyethylene: bottles, cans, packaging materials

Thermosetting polymers
(thermosets)
When initially heated, soften and flow for molding. After cooling,
harden into an infusible solid. No repeated heating cycle is possible.
The most important thermosets are:
Epoxies: fiber-reinforced materials
Phenolics (Bakelite): knobs, handles, cases
Polyesters: fiber-reinforced materials
Silicones: waterproof and heat resistance materials
Elastomers (rubbers)
Exhibit extreme elastic extensibility under low mechanical
stresses.
The most important rubbers are:
Natural rubber (Latex): tires, shoes, seals
Silicones: seals, thermal insulation, electronics
Polyurethane: seals, gaskets
The difference in properties of the polymers are attributable to so-
called cross-linking, which occurs in thermosets and partially in
elastomers.
Cross linking
Manufacturing processes for polymers
Extrusion
In twin-screw extruders
both screws are parallel
and side-by-side inside
the barrel. These
extruders are
suitable for extrusion of
difficult-to-extrude
polymers, and for
materials that require
greater mixing.
Extrusion
Dies for
extrusion
Injection Molding
Injection Molding is a process, in which a polymer is heated to a highly
plastic state and forced to flow under pressure into a mold cavity, where
it solidifies. The part, called a molding, is then removed from the cavity
The production molding cycle time is in the range 10 to 30 sec
Typical molding cycle
Mold Features for Injection Molding
Blow Molding
Blow molding is a modified extrusion and injection molding process,
wherein a tube is extruded, clamped into a mold with a cavity much
larger than the tube diameter, and then blown outward to fill the mold
Blowing is done with a hot-air blast at a pressure of 350~700 kPa.
Compression Molding
In compression molding, the workpiece (pre-shaped part, volume of
powder, mixture of liquid resin and fillers) is placed in the heated mold
and is formed under pressure.
Compression molding of thermosets: (1) charge is loaded, (2)
charge is compressed and cured, and (3) part is ejected and
removed.
Transfer Molding
Transfer molding is a similar to compression molding process, but the
charge is placed not in the die cavity but into a chamber next to the die
cavity. Pressure is then applied to force the material to flow into the
heated mold where curing occurs.
Thermoforming
Thermoforming is a process in which a flat thermoplastic sheet is heated
and deformed into desired shape. The classical process involves the use of
vacuum and is called vacuum forming.
Calendering
- used for shaping high melt viscosity
thermoplastic sheet
1-feed pass
2-metering pass
3-sheet formation
-gauging-finishing

Crown-crossing-bending

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