plastics processing techniques training
DESCRIPTION
A simple presentation on Plastics Processing TechniquesTRANSCRIPT
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 – 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
Applications of Plastics
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
Applications of Plastics
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
Applications of Plastics
Speedo meter Housing PP Talc Filled
Door Trim PP Talc Filled
Applications of Plastics
Reflector Housing
PP Talc Filled Hyundai Car Bumper
PP Talc Filled
Applications of Plastics
Seat Components
PP Unfilled
Applications of Plastics
Wheel Chair Base
PP Unfilled
Mixie Body
PP Unfilled
Applications of Plastics
Switch Frame ABS
Instrument Holder Ford
ABS
Applications of Plastics
Engine Manifold – Nylon 6 GF 30
Applications of Plastics
Toyota Tray – Nylon 6 GF 25
Applications of Plastics
Honda Tray – Nylon 6 GF 45
Applications of Plastics
Radiator Fan Nylon 6 GF 30
Fuel Sub Tank Nylon 66 GF 30
Applications of Plastics
Timing Chain Cover & Engine Oil Filter
Nylon 66 GF 30
Applications of Plastics
Glove Rail Nylon 66 GF 45
Seat Belt Anchor Nylon 6
Applications of Plastics
Lever Combination Switch
Nylon 6 GF 30
Relay Box Nylon 6 Alloy
Applications of Plastics
Wire Harness Connector
PBT
ECU Case PBT GF 30
Applications of Plastics
Switch Base PBT GF 40%
Actuator Case PBT GF 30%
Applications of Plastics
Air Conditioner Fin
PBT GF 45% Mirror Housing
PBT GF 30 Alloy
Applications of Plastics
Alternator Parts PPS GF/ MD 30
Power Module PPS GF/ MD 50
Neutral Start Switch PPS GF 40 Alloy
Applications of Plastics
Engine Mounting parts PPS GF 40
Lamp Reflector PPS GF/ MD 60
Lamp Socket PPS 40
Applications of Plastics
Applications of Plastics
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
55
2. Extruder
2.3 Film Extrusion
5 FRP Processing
64
5.a. Processing of Composites
• Open Mold processes – Hand lay-up and Spray-up
– Filament winding
6. Compression Molding Process
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
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.