PLASTICS PROCESSING

TECHNIQUES
Defined as the process of converting the
plastic raw materials into Semi-finished
or finished products.
Plastics Processing Techniques

Injection Molding
Extrusion
Blow Molding
Rotational Molding
Thermoforming
Calendaring
Compression Molding
Transfer Molding
 SUMMARY OF PROCESS

S.NO PROCESS TIPICAL PRODUCTS

1 INJECTION MOULDING $ Combs $ Mugs

$ Automobiles parts $ Soap boxes
$ Gears $ Crates, etc

2 BLOW MOULDING $ Water Bottles $ Jerry Cans

$ Shampoo Containers
$ Pharmaceutical Containers, etc

3 EXTRUSION $ Pipes $ Sheets

$ Ropes $ Monofilaments
$ Profiles $ Blown films
$ Cast Films $ Bopp, etc

4 COMPRESSION MOULDING $ Cooker handles $ Knobs

$ Washing Machine Parts
$ Engine Casings
$ Plug & Sockets
5 TRANSFER MOULDING $ Housewares
$ Switches
$ Electrical Connectors
$ Junction Boxes

6 ROTATIONAL MOULDING $ Water Tanks

$ Dustbins
$ Double walled trays
$ Balls, etc

7 THERMOFORMING $ Disposable Cups

$ Trays
$ Sign boards
$ Wall Covering

8 FILAMENT WINDING $ FRP Pipes

$ Pressure Vessels, etc
9 CALENDARING $ PVC Sheets
$ Rain Curtains
10 MATCHED DIE MOULDING $ SMC / DMC Components
$ FRP Bath Tubs
$ FRP Chairs
11 PLASTISOL PROCESSING
1 Dip Moulding $ Hand Gloves
2 Slush Moulding $ Toys, Squeeze Bulbs
3 RotoCasting $ Artificial Fruits, Toys, Balls, etc
 Injection Moulding Process

Solid Wide neck, Flat Product is made

like bucket, cabinets, Automobile &
Industrial parts etc., by injecting molten
thermoplastic material in to a closed
mould which is relatively cool.
 Type of Injection Moulding
Machine
Hand Injection Moulding M/C

Plunger type Injection Moulding M/C

Reciprocating Screw Type Injection

Moulding M/C
 Hand Injection Moulding Machine

vertical machine consists of Barrel, Plunger, Band

Heaters along with energy regulator, Rack & Pinion
system for Injecting the material by the plunger, a torpedo
and nozzle.
The torpedo helps spread the plastic material uniformly around the
inside wall of the hot cylinder and thus ensures uniform heat
distribution.
Plunger Type Injection Moulding Machine

Vertical & Horizontal Plunger Type Injection Moulding Machine

 The Reciprocating Screw
The feeding zone
The compressing (or transition) zone
The metering zone
Machine components
 The Injection Process
Plasticises the material by reciprocating Screw.
Injects the molten material to a closed mould
via a channel system of gates and runners.
Cools the Mould.
Refills the material for the next cycle.
Ejects the Product.
Closes the Mould for further cycle.
Injection Moulded Items
Injection Moulded Items
Injection Moulded Items
 Advantages of Injection
Moulding Process
Parts can be produced at high production rates.
Large volume production is possible.
Relatively low labour cost per unit is obtainable.
Process is highly susceptible to automation.
Parts require little or no finishing.
Many different surfaces, colours, and finishes are
available.
Good decoration is possible.
For many shapes this process is the most economical way
to fabricate.
Process permits the manufacture of very small parts which
are almost impossible to fabricate in quantities by other
methods.
 Advantages ...

Minimal scrap loss result as runners, gates, and rejects

can be reground and reused.
Same items can be moulded in different materials,
without changing the machine or mould in some cases.
Close dimensional tolerances can be maintained.
Parts can be moulded with metallic and non-metallic
inserts.
Parts can be moulded in a combination of plastic and
such fillers as glass, asbestos, talc and carbon.
The inherent properties of the material give many
advantages such as high strength-weight rates,
corrosion resistance, strength and clarity.
Limitations of Injection Moulding
Intense industry competition often results in low profit
margins.

Mould costs are high.

Moulding machinery and auxiliary equipment costs are

high.

Lack of knowledge about the fundamentals of the

process causes problems.

Lack of knowledge about the long term properties of the

materials may result in long-term failures.
 Machine operation sequence
The mould closes and the screw begins moving forward for
injection.

The cavity fills as the reciprocating screw moves forward, as a

plunger.
 Machine operation sequence
The cavity is packed as the screw continuously moves forward.

The cavity cools as the gate freezes off and the screw begins
to retract to plasticize material for the next shot.
 Machine operation sequence
The mould opens for part ejection

The mould closes and the next cycle begins

Injection Mould
 Mould system
A typical (three-plate) moulding system
A two-plate mould. A three-plate mould.

The moulded system includes a delivery system and moulded parts.

 Screw Used in Injection Moulding Machines

The screw has three zones with a ring-plunger assembly. The Feed
Zone, where the plastic first enters the screw and is conveyed along a
constant root diameter; the Transition Zone, where the plastic is
conveyed, compressed and melted along a root diameter that increases
with a constant taper; and the Metering Zone, where the melting of the
plastic is completed and the melt is conveyed forward along a constant
root diameter reaching a temperature and viscosity to form parts.
 L/D RATIO

The L/D ratio is the ratio of the flighted length (Effective

Length) of the screw to its outside diameter.

Most injection screws use a 20:1 L/D ratio. But it may

range from 18:1 to 24:1

In the case of Thermoset it may range from 12:1 to 16:1.

 High L/D Ratio results the following .

More shear heat can be uniformly generated in the

plastic without degradation;

Greater the opportunity for mixing, resulting in a better

homogeneity of the melt.

Greater the residence time of the plastic in the barrel

possibly permitting faster cycles of larger shots.
 COMPRESSION RATIO (CR)
The ratio of the first flight depth of feed zone to the last
flight depth of meter zone ,
Or,
First Channel Volume of feed zone to last channel
volume of metering zone,

Typically ranges from 1.5:1 to 4.5:1 for most

thermoplastic materials.

Most injection screws classified as general purpose have

a compression ratio of 2.5:1 to 3.0:1.

Thermo set screws have a 1:1 ratio.

Higher the CR results the following .

Greater shear heat imparted to the resin

Greater heat uniformity of the melt

High Potential for creating stresses in some

resins

High energy consumption

Back Pressure 2
(Kg/Cm or bar)
Back pressure is the amount of pressure
exerted by the material ahead of the
screw, as the screw is pushed back in
preparation for the next shot.

Effect of Back Pressure

More Homogeneous Mix
Proper Melting
More compact
Sometime leads degradation
 Injection Speed (Cm/Sec)
The injection speed is the forward
speed of the screw during its injection
operation per unit time.

Effect of Injection Speed

Easy Injection of Material
Avoid Short-Shot
Some times leads more orientation & burn
marks
 Screw Rotation Speed
The screw rotation speed (RPM) is the rate at which the
plasticizing screw rotates.

The faster the screw rotation result the following ..

Faster the material is compressed by the screw flights

Increasing the amount of shear heating

Low residence time, some less melting

 Cushion
The cushion is the difference in the final forward position
of the screw and its maximum allowable forward
position.

More Cushion results more residence time, some time

degrades.

If the screw were allowed to travel its full stroke and stop
mechanically against the nozzle, the cushion would be
zero.

With zero Cushion no hold on works.

Typically a cushion of 3 to 6 mm is used.

 Materials for Injection Moulding
Acrylonitrile butadiene styrene (ABS)
Acetal
Acrylic
Polycarbonate (PC)
Polyester
Polyethylene
Fluoroplastic
Polyimide
Nylon
Polyphenylene oxide
Polypropylene (PP) **
Polystyrene (PS)
Polysulphone
Polyvinyl chloride (PVC)
Plastic Product Properties can change 10% or more by
changing Process Conditions
During Refilling
During Injection
When Plastics flow in the cavity, the pressure decreases along
the delivery system and the cavity
Injection pressure as a function of melt viscosity, flow length,
volumetric flow rate, and part thickness
Cycle time in injection moulding
Faults & Remedies
 Flash

Excess plastic around the area of the

mould parting line on a moulded
part.
 Flash - Problems
mould parting surfaces do not seal properly.
Injection pressure too high.
Clamp pressure set too low or projected area
or item too large for clamp pressure of the
machine.
Injection temperature too high.
Feed needs adjustment.
Hold time too long.
Inadequate mould supports.
Oversize vents.
 Crazing

Fine cracks in part surface. May

extend in a network over the surface
or through the part.
 Crazing - Problems
Insufficient drying of the material.
Contamination.
Injection temperature too high (crazing
accompanied by dis-coloring or yellowing).
mould surface contaminated
Inadequate injection speed.
Inefficient injection forward time.
Excessive injection pressure.
mould temperature too low.
Gate too large.
 Cracking

Fracture of the plastic material in an

area around a boss, projection, or
moulded insert.
 Cracking - Problems

Parts cool too quickly

moulded-in stress
Wall thickness too heavy for compound.
 Short Shot

Injection of insufficient material

to fill the mould.
 Short Shot - Problems
Insufficient feed, cushion.
Inadequate injection pressure.
Inadequate injection speed.
Insufficient booster or injection high-
pressure time.
Inefficient screw delay.
Inadequate injection back pressure.
Melt temperature too low.
Cylinder temperature inadequate.
mould temperature too low.
 Short Shot - Problems
Gates, sprues, and/or runners too small.
Excessive screw flights in metering zone.
Insufficient venting.
Improper gate location.
Melt index of resin too low.
Excessive clearance between non-return
valve and barrel.
Screw bridging.
Injection press of insufficient capacity.
Ohm!
Ohm!
Ohm!