Lesson Outcomes:

After todays lecture, students are

expected to:

Analyze the process of elastomer

and polymer composite production,

metal-matrix composite processes
Analyze the design considerations
for plastics technology
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Processing Elastomers
Commonly shaped by extrusion or

injection moulding.
Extruded parts such as tubing, hoses &
inner tubes.
Injection-moulded parts mostly used for
automobiles.
Also can be shaped by blow moulding &
thermoforming.
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Calendering
For rubber & some thermoplastic sheet.

A warm mass of the compound is fed

into a series of rolls and then stripped

off in the form of a sheet.
Sheets produced are subsequently used
in thermoforming.

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Calendering

Schematic illustration of calendering. Sheets produced by this process

subsequently are used in thermoforming. The process also is used in
the production of various elastomer and rubber products.
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Dipping
Discrete rubber

product likes
glove.
Metal form
repeatedly
dipped into a
liquid compound.

Processing Reinforced
Plastics
To obtain good bonding between the

reinforcing fibers and the polymer

matrix, fibers surface treated by
impregnation (sizing).
Short fibers added to thermoplastics for
Injection moulding.
Long fibers used in the compression
moulding.
Partially cured sheets called by various
terms such as;
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Processing Reinforced
Plastics (cont.)
1. Prepregs

The continuous fibers aligned.

Through surface treatment to
enhance adhesion to the matrix.
Individual sheet combined into
laminated structures
Eg : Stabilizer for the jet fighter
Typical products from prepreg are
panels for construction and electrical
insulation.
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Tapes used in
Making Reinforced
Plastic Parts

(b)

(a) Manufacturing process for polymer-matrix composite tape. (b) Boron-epoxy prepreg
tape. These tapes are then used in making reinforced plastic parts and components with
high strength-to-weight ratios, particularly important for aircraft and aerospace applications
and sports equipment. Source: (a) Courtesy of T. W. Chou, R. L. McCullough, and R. B.
Pipes. (b) Courtesy of Avco Specialty Materials/Textron.
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Tape and Tape-Laying System

(a)

(b)

(a) Single-ply layup of boron-epoxy tape for the horizontal stabilizer for an F-14 fighter
aircraft. (b) A 10-axis computer-numerical-controlled tape-laying system. This machine
is capable of laying up 75- and 150-mm (3- and 6-in.) wide tapes on contours of up to +/30 degrees and at speeds of up to 0.5m/s (1.7 ft/s). Source: (a) Courtesy of Grumman
Aircraft Corporation. (b) Courtesy of The Ingersoll Milling Machine Company.
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Processing Reinforced
Plastics (cont.)

Forms of fibreglass (a) continuous strand roving (b)

chopped strand (c) chopped strand mat (d) woven
roving
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Production of Fiber-Reinforced
Plastic Sheets

Schematic illustration of the manufacturing process for producing fiber-reinforced

plastic sheets. The sheet still is viscous at this stage and later can be shped into
various products. Source: After T. W. Chou, R. L. McCullough, and R. B. Pipes.
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Processing Reinforced
Plastics (cont.)
2. Sheet moulding compound

(SMC)

Chopped fibers deposited in random

directions over a layer of resin paste.
Second layer of resin paste is deposited on
top, then pressed between rollers.

3. Bulk moulding compound (BMC)

The compounds are in the shape of billets

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Processing Reinforced
Plastics (cont.)
4. Thick moulding compound (TMC)
Combines a characteristics of lower cost
BMC & higher strenghth SMC

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Moulding of Reinforced Plastics

Common moulding processes for

reinforced plastics are;

1. Compression moulding

Material placed between two moulds and

pressure is applied.

2. Vacuum-bag moulding/Pressure
Prepregs are laid in the mould
Pressure to shape the product obtained by
covering the lay-up with a plastic bag and
creating a vacuum
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Vacuum-Bag Forming and

Pressure-Bag Forming

Schematic illustration of (a) vacuum-bag forming, and (b) pressure-bag

forming. These processes are used in making discrete reinforced plastic
parts. Source: After T. H. Meister.
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Moulding of Reinforced Plastics

(cont.)
3. Contact moulding (Open mould

processing)

Used in making products with high surfacearea-to-thickness ratios.

Use a single male or female mould.
Can be done by hand lay-up or spray layup.

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Open-Mold Processing

Manual methods of processing reinforced

plastics: (a) hand lay-up, and (b) spray
lay-up. Note that, even though the
process is slow, only one mold is
required. The figures show a female
mold, but male molds also are used.
These methods also are called open-mold
processing. (c) A boat hull made by
these processes.
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Processing Reinforced
Plastics (cont.)
Some other processes for reinforced

plastics are:
1. Filament Winding

Resin and fibers are combined at the time

of curing
Parts are formed on a rotating mandrel
The reinforcing filament, tape is wrapped
continuously around the mandrel.
Products example: pressure vessel,
propellers, blades
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Filament-Winding

(b)

(a) Schematic illustration of the filament-winding process; (b) fiberglass being

wound over aluminum liners for slide-raft inflation vessels for the Boeing 767
aircraft. The products made by this process have high strength-to-weight ratio and
also serve as lightweight pressure vessels. Source: Courtesy of Brunswick
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Corporation.

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Processing Reinforced
Plastics (cont.)
2. Pultrusion
Produces long parts with various uniform
cross-section such as rod, flat strips and
tubing.
Continuous reinforcement is supplied
through bobbins (prepreg feed system)
The bundle is mixed with a thermosetting
bath then a performing die and a heated
steel die.
The product is cured then.
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Pultrusion

(b)

(a) Schematic illustration of the pultrusion process. (b) Examples of parts

made by pultrusion. The major components of fiberglass ladders (used
especially by electricians) are made by this process. Unlike aluminum
ladders, they are available in different colors but are heavier because of the
presence of glass fibers. Source: Courtesy of Strongwell Corporation.
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Processing Metal-matrix
Composite
Metal matrix-compostie can be made by

the following processes:

1. Liquid-phase processing

Casting involving liquid-matrix material

(aluminium, titanium) and solid reinfoircement
(graphite, SiC, Al2O3)

2. Solid-phase processing
Powder-metallurgy techniques including cold
and hot isostatic pressing.
Products examples, tungsten-carbide tools and
dies with cobalt as the matrix.
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Design Considerations of
plastics
Considerations for product design:
Material selection to meet product
requirements
Product without stress concentration, sink
marks, ...
Position of gate, runner, ejection pin for
tool design,
Elimination of premature failures based on
literature reviews.
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Design Considerations of plastics

(cont.)
Considerations for tool design:
Tool material for manufacturing volume
and life
Tonnage of press & number of cavities in a
tool
Position of gate, runner, ejection pin for
tool design, ...

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Design Modifications to Minimize

Distortion in Plastic Parts

Examples of design modifications to eliminate or minimize distortion in plastic parts:

(a) suggested design changes to minimize distortion; (b) stiffening the bottoms of
thin plastic containers by doming a technique similar to the process used to shape
the bottoms of aluminum beverage cans; and (c) design change in a rib to minimize
pull-in (sink mark) caused by shrinkage during the cooling of thick sections in
molded parts.
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Example of Design Considerations

for Plastics Processing
Avoid sharp variation of wall thickness
Avoid sharp corners

Example of Design Considerations

for Plastics Processing
Provide generous draft angles, 5o or more
Avoid needs of side-pull (reading assignment)

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Example of Design Considerations

for Plastics Processing

Core bosses to ensure uniform thickness (minimize impact of

variable shrinkage)

Thats all for today..

Any questions??

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IQ + EQ + SQ = TQ
Thank You for coming and
see you again..

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