Plastics Processing Techniques Training

Plastics in our Life

Plastics in our Life – Food & Beverages

Plastics in our Life – Clothings

Plastics in our Life – Furniture

Plastics in our Life – Building & Construction

Plastics in our Life – Household items

Plastics in our Life – Medical Equipments

Plastics in our Life – Footwear

Plastics in our Life – Baby Products

Plastics in our Life – Electronics

Plastics in our Life – Agriculture

Plastics in our Life – Amusement Parks & Entertainment

Plastics in our Life – Industrial Use

Plastics in our Life – Vehicles

PlasticsEverywhere

Plastics Everywhere – We really live in Plastics Era.

The word plastics is from the Greek word Plastikos, meaning “able to be shaped and molded”

Plastics - History - Introduction

What is a plastic? •Plastics are organic high polymers, consisting

of large chainlike molecules containing carbon.

•They are formed when the short-chain

molecules of chemicals and monomers are

blended together by the process of

polymerization to form large chain-like

molecules.

- mostly made from Oil.

•Plastics are known for their

*light weight,

*anti-rust and

*good insulation properties and

*are increasingly becoming substitutes for

major commodities such as

-metals, stones, wood, glass and cotton.

Plastics Compared to Metals and Ceramics

Disadvantage

Lower useful thermal range

High creep

Low structural strength

Low heat dissipation

Poor conductivity

UV degradation

Hard to color match

Affected by solvents

May cause fumes/fire hazard

Advantage

Ease of processing

Low brittleness

Lightweight products

Good thermal insulation

Good electric insulation

Utility as clear material

Use without painting

Can be dissolved (some)

Waste can be burned

Characteristic

Low melting point

High elongation

Low density

Low thermal conductivity

Electrical resistance

Optical clarity (some)

Easily colored

Solvent sensitivity

Flammable

Plastics Strengths Compared to Other

Plastics History

History of Polymers

Date 1868 1909 1919 1927 1927 1929 1936 1936 1938 1938 1938 1939 1939

Material Cellulose Nitrate Phenol-Formaldehyde Casein Cellulose Acetate Polyvinyl Chloride Urea-Formaldehyde Acrylic Polyvinyl Acetate Polystyrene or Styrene Nylon (Polyamide) Polyvinyl Butyrate Polyvinylidene Chloride Melamine-Formaldehyde

Example Use Figurines Electrical equipment Beauty accessories Cellophane package wrapping Pipe, Synthetic Leather Lighting fixtures, Plywood glue Brush backs, displays Synthetic flooring Disposable utensils Hosiery Safety glass interlayer Saran wrap Countertops, Cabinets

Date

1942 1942 1943 1943 1947 1948 1954 1956 1957 1957 1964 1964

Material

Polyester Polyethylene Fluorocarbon Silicone Epoxy Acrylonitrile-Butadiene-Styrene Polyurethane or Urethane Acetal Polypropylene Polycarbonate Ionomer Polyimide

Example Use

Clothing, Boat hulls Milk Jugs Industrial gaskets, Non-stick liners Gaskets, Tubing, Utensils Glues Luggage Foam cushions, Shoe soles, Wheels Automotive parts, Toilet parts Living hinges, Safety helmets Water bottles, Eye protection Golf balls, Skin packages Gears

History of Polymers

Developments in Polymers

• New types

– Electrically conductive

– Light sensitive

– Bio-degradable

– Bio-compatible

Uses

• Automobile

– Weight (mileage)

• Aviation

– 767, 787

– Voyager, Space Ship One

• Everywhere

Why use plastics?

Plastics are not simply replacement materials, whereas it is based on

technical merits, cost and other benefits makes plastics suitable due

to the following:

ECONOMY

WEIGHT REDUCTION

STYING – ASTHETICS

FUNCTIONAL DESIGN

DESIGN FLEXIBILITY

PROPERTIES

EASE OF MANUFACTURING

REDUCED MAINTENANCE

CORROSION AND CHEMICAL RESISTANCE

Types of Plastics

vs

Steel 53%

Plastics 14% Aluminium

5%

Glass 2%

Elastomers 4%

Fluids 13%

Cast iron 3% Others

6%

RM % used in Cars by Weight

Plastics being Used as Alternate Material to many components to reduce vehicle weight like: •Fuel Tank : Use of plastic in place of conventional steel in select models of Maruti Suzuki, Ford, Honda •Fenders: Use of plastic fenders in place of conventional steel by M&M •Body : Fibre bodies in place of steel bodies in scooters - Pleasure, Dio, Scooty •Wheel Covers: Usage of ABS plastic grade (having lower density) in place of PC+ABS material by Maruti Suzuki in Wheel Covers

Applications of Plastics

Plastics in automotive engineering

PLASTICS CONSUMPTION IN A CAR - ABOUT 162 Kg

11.6% of Total Weight of the car

TYPE OF PLASTICS Kg

Polypropylene (PP) 29

Polyurathane (PUR) 34

Polyvinyl Chloride (PVC) 5

Acrylonitrile – butadiene-

styrene (ABS)

6

PP+ EPDM 18

Polyamides (PA, Nylon) 22

Polyethelene 12

TYPE OF PLASTICS Kg

Polycarbonate (PC) 10

ABS + PC 10

Polyformaldehyde (POM, acetal) 2

Polymethyl methacrylate

(PMMA)

2

Thermoplastics Polyesters (PET

and PBT)

2

Others 10

TOTAL 162


PLASTICS IN AUTOMOBILES

UNDER THE BONNET SYSTEMS • Fuel Systems – Fuel Delivery,

Fuel Tanks • Air/ Water induction System –

engine cooling and climate control systems

INTERIOR SYSTEMS :

• Cockpit Systems

• Door Systems

• Interiors Hard Trims

• Overhead Systems

EXTERIOR SYSTEMS

• Bumper Systems (Lately integrated into Front-end systems)

• Body side claddings and cowl grills

• Spoilers, capping and exterior trims

• Body panels (Moving from sheet metal to plastics)

OTHER SYSTEMS • Safety related parts – impact

zones • Electrical & Electronics • Lighting Systems • Power train & chasis

systems – steering, pedal & braking system

• Soft Trim Systems – Headliners, acoustics & carpets


ADVANTAGES

• More complex assemblies can be easily produced as one unit

• Improved performance by reduction of vibration and noise

• Improved Impact Resistance

• Improved power to weight ratio

• Improved aesthetics

• Reduced Maintenance

• No corrosion


Speedo meter Housing PP Talc Filled

Door Trim PP Talc Filled


Reflector Housing

PP Talc Filled Hyundai Car Bumper

PP Talc Filled


Seat Components

PP Unfilled


Wheel Chair Base

PP Unfilled

Mixie Body

PP Unfilled


Switch Frame ABS

Instrument Holder Ford

ABS


Engine Manifold – Nylon 6 GF 30


Toyota Tray – Nylon 6 GF 25


Honda Tray – Nylon 6 GF 45


Radiator Fan Nylon 6 GF 30

Fuel Sub Tank Nylon 66 GF 30


Timing Chain Cover & Engine Oil Filter

Nylon 66 GF 30


Glove Rail Nylon 66 GF 45

Seat Belt Anchor Nylon 6


Lever Combination Switch

Nylon 6 GF 30

Relay Box Nylon 6 Alloy


Wire Harness Connector

PBT

ECU Case PBT GF 30


Switch Base PBT GF 40%

Actuator Case PBT GF 30%


Air Conditioner Fin

PBT GF 45% Mirror Housing

PBT GF 30 Alloy


Alternator Parts PPS GF/ MD 30

Power Module PPS GF/ MD 50

Neutral Start Switch PPS GF 40 Alloy


Engine Mounting parts PPS GF 40

Lamp Reflector PPS GF/ MD 60

Lamp Socket PPS 40



Wheel Frame

Cabling

Pillars & Panels

Processing Techniques Polymers are processed in a number of ways, to arrive at the end products. The

different types of processing include: 1. Injection Moulding

1. GAM 2. Insert moulding

2. Extrusion 1. Pipe Extrusion 2. Sheet Extrusion 3. Film Extrusion

3. Blow Moulding 1. Injection Blow Moulding 2. Injection Stretch Blow Moulding 3. Extrusion Blow Moulding

4. Roto Moulding 5. FRP processing 6. Compression Moulding 7. Pultrusion 8. Reaction Injection Moulding 9. Resin Transfer Moulding 10. Calendering 11. Thermoforming

1. Vaccum Thermoforming 12. Foam Molding

Popular (majority) processing methods include: • Extrusion – Typical extruded products include films, sheets, piles and filaments • Injection moulding – This is largely used for industrial applications and making moulded luggage • Blow moulding – Bottles, containers, toys, etc, are manufactured using the blow moulding process • Rotomoulding – Large circular containers such as water tanks are made using this process

Extrusion 76%

Rotomoulding 1%

Injection moulding

18%

Blow moulding

5%

Flexible Packaging

42%

Rigid Packaging

14%

Construction 12%

Household 9%

Appliances 7%

Cables 6%

Others 10%

Processing Techniques

1. Injection Molding Process

Link

Injection Moulding.swf

Injection Moulding.swf

1.1 Gas Assisted Injection Molding Process

Link

gas_injection_internal.swf

1.2 Insert Injection Molding Process

Link

insert_moulding.swf

55

2. Extruder

56

2.1 Pipe Extrusion

Link

Pipe_Extrusion.flv

2.2 Sheet Extrusion

Link

Sheet Extrusion.flv

2.3 Film Extrusion

3.1 Injection Blow Moulding

Link

Injection Blow Moulding.swf

3.2 Injection Stretch Blow Moulding

Link

injection stretch blow moulding.swf

3.3 Extrusion Blow Moulding

Link

Extrusion_Blow_Moulding.swf

4 Roto moulding

Link

Method - 1 Method - 2

rotational_moulding.swf

5 FRP Processing

64

5.a. Processing of Composites

• Open Mold processes – Hand lay-up and Spray-up

– Filament winding

6. Compression Molding Process

7. Pultrusion

Link

Kn

itte

d C

arp

ets

An

d F

RP

Clo

ths

Pultrusion.swf

8. RIM (Structural)

• Fiber preform is placed into mold.

• Polyol and Isocyanate liquids are injected into a closed mold and reacted to form a urethane.

9. Resin Transfer Molding Process

•Materials :Thermosets: Polyester, Vinyl ester, or Epoxy resins with glass fiber

10. Calendering

11. Thermoforming

Link

Thermoforming_RPC_BPF.swf

11.1. Vaccum Thermoforming

Link

vacuumform.swf

12. Foam (PU) Processing

• Polyurethane can be processed by – Casting, painting, foaming – Reaction Injection Molding (RIM)

Future of Plastics Industry in India As we already know, Plastics is widely used in Automobile industry, Let’s take a look on Auto industry.

5th in the World Commercial Vehicles

3rd in the World Small Cars

2nd in the World Two-Wheelers

• 15 manufacturers of passenger cars and multi-utility vehicles, • 9 manufacturers of commercial vehicles, • 16 manufacturers two/ three wheelers, • 14 manufacturers tractors, • 5 manufacturers of engines.

Future of Plastics Industry in India

Some growth forecasts for Indian auto industry

• The Passenger Vehicle market of India will even cross Japan by selling about 5 million

Vehicles by 2017-18.

• The Indian auto exports will be upto $9.62 billion in the year ending March 2013 and

the same will grow to $17.64 billion in 2015-16.

• India’s share in global auto exports may also triple by 2016.

• India’s passenger vehicle production projections :

In 2010 – 2.6 million Vehicles

By 2015 – 5.1 million Vehicles

By 2020 – 9.7 million Vehicles

Sources : -SIAM, ACMA & FICCI

Future of Plastics Industry in India

The Future of Plastics ?

As we saw, PLASTICS are used for almost all of the products we use in our daily

lives. The food packaging, medical, automotive, electronics, building construction,

and textile industries all make extensive use of plastics and elastomers. The

developments in new materials and process technologies that have occurred over

the past 150 years have been very significant. Exciting new developments and

discoveries related to plastics are happening all of the time.

What is the future in PLASTICS ? No one knows for sure. However, one thing is for

sure. It is the “PLASTICS ENGINEERS” of tomorrow that will “shape” the future of

the plastics industry. The future is limited only by their imagination and creativity.

Plastics Processing Techniques Training

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