INTRODUCTION
Definition : Plastics are defined as organic materials that
can be easily shaped or molded by mechanical or
chemical action to give non-crystalline substance that are
solid at ordinary temp.
THERMO PLASTIC PLASTICS
THERMOSETTING PLASTICS
THERMO PLASTIC PLASTICS
No chemical change during molding operation , soften with the
application of heat and harden on cooling
Can be reshaped
No wastage
No environmental hazards
THERMOSETTING PLASTICS
It is formed from the intermediate products which under the
influence of heat and pressure
It undergoes chemical changes of consideration and
polymerization to form a rigid shape which is unaffected by
heat or solvents
Rigid ,harder and heat resisting properties due cross linked net
structure
WHY USE THERMOPLASTICS ?
First and foremost is the corrosion resistance advantage of
plastics over metal. a plastic one will never jam, stick, or fail
because of rust or corrosion.
Another benefit of corrosion resistance is that plastic valves
never have to be painted to withstand corrosive environments
or harsh climatic conditions.
Different types of plastics can be manufactured to be flexible in
different sizes, shapes, and thickness
Another benefit is cost .When all costs are considered, including
freight, installation and service life, a metal system will in most
cases be more expensive.
THERMOPLASTICS TYPES SPI
NUMBER
The Society of the Plastics Industry introduced the Resin
Identification Code (RIC) system in 1988 as a growing number
of communities were implementing recycling programs. The
code is simply meant to identify what type of plastic resin was
used when making the product.
SPI code: 1
PETE or PET: Polyethylene Terephthalate
Used in
Carpet , films , food packaging
Liquids packaging (bottles) , textiles
Oven-ready food trays
SPI code: 2
HDPE: High-Density Polyethylene
Used in
Bottles , containers , grocery bags
Hand soap containers , plastic bags
Playground materials
SPI code : 3
PVC: Polyvinyl Chloride (Vinyl)
Used in
Cables, carpet backing , decks
Electrical boxes , fencing , floor tiles
Pipes
SPI code : 4
LDPE: Low-Density Polyethylene
used in
Computer components, food containers
Plastic wraps, trays , tubing
Six-pack beverage rings
SPI code: 5
PP: Polypropylene
Used in
Auto accessories, bike racks , garden rakes
Microwavable meal trays , sheeting , shipping pallets
Storage bins
SPI code: 6
PS: Polystyrene
Used in
Cameras , rules
Some vending cups , thermal insulation
Thermometers
SPI code: 7
Others(acrylic, nylon, polycarbonate etc.)
Used in
Bottles, headlight lenses, and safety shields/glasses.
PLASTIC MATERIAL APPLICATIONS
AEROSPACE
Have outstanding flame, smoke, and toxicity characteristics
Can handle 400°F and higher for long periods of time, and can
withstand large temperature swings
Are tough, impact resistant, and stand up to vibration
CUNSTRUCTION
They have great versatility and combine excellent strength to
weight ratio, durability, cost effectiveness, low maintenance
and corrosion resistance which make plastics an economically
attractive choice throughout the construction sector.
ELECTRICAL AND ELECTRONIC APPLICATIONS
Electricity powers almost every aspect of our lives, at home
and in our jobs, at work and at play. And everywhere that we
find electricity, we also find plastics.
PLASTICS PACKAGING
Plastics is the perfect material for use in packaging goods.
Plastics is versatile, lightweight, flexible and highly durable. It
accounts for the largest usage of plastics world wide and is
used in numerous packaging applications including containers,
bottles, drums, trays, boxes, cups and vending packaging, baby
products and protection packaging.
TRANSPORT
The cost-effective and safe transportation of people and goods
is vital to our economy. The lightness of plastics therefore
makes them in valuable to the transport industry.
DESIGN CONSIDERATIONS FOR PLASTICS
COMPONENTS
CORNERS
There is less stress concentration on the part and on the tool.
Because of sharp corners, material flow is not smooth and
tends to be difficult to fill, reduces tooling strength and causes
stress concentration.
Inner radius should be at least the thickness of walls
UNIFORM WALL THICKNESS
Decrease the maximum wall thickness of a part to shorten the cycle time
(injection time and cooling time specifically) and reduce the part volume
In correct correct
Thick wall Thin walls
Uniform wall thickness will ensure uniform cooling and reduce defects
In correct correct
Non-uniform wall thickness (t1 ≠ t2) Uniform wall thickness (t1 = t2)
IF NON UNIFORM THICKNESS NOT MAINTAINED?
As the plastics solidifies in the mold , it freezes from outside (near the
mold surface) toward the inside. In thick sections the results in inward
pulling stresses(due to contraction) that can cause sink marks in the outer
surfaces of the [Link] addition , because thinner sections will freeze
faster than thicker sections , there is also the possibility of stresses
building up between thick and thin sections , resulting in part warpage
So the design of parts to be injection molded , it is a good to maintain
consistent wall thickness and avoid thick areas whenever possible
DRAFT ANGLES
It is an important factor when designing plastic parts. Because
of shrinkage of plastic material, injection molded parts have a
tendency to shrink onto a core. This creates higher contact
pressure on the core surface and increases friction between
the core and the part, thus making ejection of the part from
the mold difficult. Hence , it reduces cycle time and improves
productivity. Draft angles should be used on interior and
exterior walls of the part along the pulling direction.
BOSS
Boss, a basic design element in plastics, is typically cylindrical and used
as a mounting fixture, location point, reinforcement feature
Wall thickness of walls should be more than 60% of wall thickness
Radius of base should be at least 25% of wall thickness
Should be supported ribs that connect adjacent wall or by gussets at the
base
RIBS
Rib features help in strengthening the moulded part without
adding to wall thickness. In some cases, they can also act as
decorative features. Ribs also provide alignment in mating
parts
TYPES OF INJECTION MOULDINGS
REACTION INJECTION MOULDINGS
Process for moulding polyurethane, epoxy, and other liquid chemical
systems. A mixture of two to four components in the proper chemical
ratio is accomplished by a high-pressure impingement-type mixing head,
from which the mixed material is delivered into the mold at low pressure,
where it reacts (cures).
GAS ASSIST INJECTION MOULDINGS
Plastic moulding process in which a high-pressure gas is co-injected
along with the plastic part to produce discrete internal hollow sections.
It differs from blow moulding in that one large hollow product is not
created; rather, a solid piece with hollow sections is produced.
Co injection moulding
this process that creates a skin & core material arrangements
in a moulded part. The skin is injected first into the mould
cavity & it is immediately followed by core material
Skin material follows into the cavity
the material next to the cavity walls
freezes and material flow down to
the center channel
when a core material enters it
displaces the skin material in to the
center of channel by pushing the
skin ahead
As it flows ahead continues to freeze
the wall and producing skin layer
ABS
Acrylonitrile butadiene styrene, otherwise known as ABS
plastic, is a heat resistant lightweight material popularly used
in children's toys
For applications requiring extra toughness, this plastic is often
shot through with microscopic glass fibers. This adds
significant strength to the material.
Its considerable shock-absorbent properties also make ABS
plastic ideal for luggage, laptop cases and similar protective
items.
One of the most unusual uses for brightly hued ABS plastic is
as a component in tattoo ink. The plastic is pulverized into an
extremely fine powder and mixed with a carrier fluid. Because
this plastic is highly colourfast and fade-resistant, tattoos
made with ABS ink stay vibrant for many years
DEFECTS CAUSES
Bubbles Injection temperature too high
Too much moisture in material
Non-uniform cooling rate
Unfilled sections Insufficient shot volume
Flow rate of material too low
Sink marks Injection pressure too low
Non-uniform cooling rate
warping Non-uniform cooling rate
