Polymer Engineering

Engineer.Dr.Naveed Ahmad
Department of Chemical and Material
Engineering,NBU,Arar
KSA

1
Polymer Processing Methods
Polymers are formed by many low temperature
processes.

Extrusion
Film Blowing
Injection Molding
Blow Molding
Compression Molding
Reaction Injection Molding

2
 Extrusion
The polymer is heated to the liquid state and
forced through a die under pressure resulting
in an endless product of constant cross section.
60% of polymers are prepared in this way.
Examples: tubing, pipes, window frames, sheet,
insulated wire.

. Film Blowing
Using the same method as extrusion the material
coming out of the die is blown into a film.
An example is plastic wrap.
3
 Injection Molding
Similar to extrusion, the polymeris heated to the
liquid state, but it is prepared in metered amounts,
and the melt is forced into a mold to create the
part. It is not a continuous process. Many toys are
made by injection molding.
Blow Molding
The melted polymer is put into a mold, then
compressed air is used to spread the polymer into
the mold. It is used to make many containers such
as plastic soda containers and milk
jugs.
4
 Compression Molding
Solid polymer is placed in a mold, the mold is heated
and puts pressure on the polymer to form the part.

Reaction Injection Molding

Liquid monomers are placed in the mold avoiding
the need to use temperature to melt the polymer or
pressure to inject it. The monomers polymerize in
the mold forming the part.

5
Injection Molding

Nozzle Feed hopper,

contains polymer pellets

Hydraulic
Pressure

6
 Compression Molding

Platen
Heat and
Cooling Mold
Plunger

Guide
Heat and Pins
Cooling
Mold
Cavity
Compound to be molded
Platen
Hydraulic
Pressure Hydraulic
Plunger

7
 Blow Molding—e.g. milk bottle

Plastic

Extruded Mold Closed and Finished Bottle

Parison- Bottle Blown Removed from
Mold Open Mold

8
 A Plastics Extruder

Feed hopper

Cores for
Heaters cooling water

Drive shaft

Die

Screw

9
Single Screw Plastic Extruder

10
Plastic Extruder

11
 Extrusion Problems
1. Melt Fracture
One of the basic problems when the polymer exits too fast from
an extruder, the the surface starts to exhibits undulations
or irregularities.

Five pictures of a of molten polyethylene flowing out of a pipe, visible at the top.
The flow rate increases from left to right. Note that in the two leftmost photographs the
extrudates are nice and smooth, while in the middle one undulations start to develop.
As the flow rate increases even further towards the right, the amplitude of the
undulations gets stronger. When the flow rate is enhanced even more, the extrudate
12
can break. Hence the name "melt fracture".
1. Granules of plastic powder (note the plastics listed above) are
poured or fed into a hopper which stores it until it is needed.
2. A heater heats up the tube and when it reaches a high temperature
a screw thread starts turning.
3. A motor turns a thread which pushes the granules along the heater
section which melts then into a liquid.
4. The liquid is forced into a mould where it cools into the shape
(in this case a sphere).
5. The mould then opens and the sphere is removed. 13
INJECTION MOULDING
Part design
The principles behind part design are

1. Cooling and heat transfer for various sections

2. Thermal shrinkage of the plastic parts.

14