Plastic Introduction

The word Plastic means substances which have Plasticity, and

accordingly anything that is formed in a soft state and used in a
solid state can be called a plastic.
Plasticity :-The Deformation of a material undergoing non-reversible
changes of shape in response to applied forces.

A plastic material is any of a wide range of Synthetic or semi-

synthetic organic solids that are moldable. Plastics are typically
organic polymers of high molecular mass, but they often contain
other substances. They are usually synthetic, most commonly
derived from petrochemical, but many are partially natural
 Plastic Introduction
The main source of synthetic plastics is crude oil.

Coal and natural gas are also used.

Petrol, paraffin, lubricating oils and high petroleum gases are bi-
products, produced during the refining of crude oil.

These gases are broken down into monomers. Monomers are chemical
substances consisting of a single molecule.

A process called Polymerisation occurs when thousands of monomers

are linked together. The compounds formed as called polymers.

Combining the element carbon with one or more other elements such
as oxygen, hydrogen, chlorine, fluorine and nitrogen makes most
polymers
 History of Plastic
1839 :- Charles Goodyear discovered the process of Vulcanized rubber
process. Goodyear discovers that adding sulfur to natural rubber greatly
enhances its elasticity and toughness.
Charles Goodyear

1847 :- Alfred Critchlow founded the Pro Molding Corporation. The mirror
frames shown above are among the earliest molded plastic parts ever made.

1862 :- Alexander Parkes unveiled a new semi-synthetic plastic at Great

International Exhibition in London, England. This new material, which the
public dubbed Parkesine, was an organic material consisting of cellulose nitrate
and a solvent. Alexander Parkes

1868 :- John Wesley Hyatt produce a durable, colorful, and moldable

thermoplastic known as celluloid (also known as Pyroxylin). Celluloid was the
first commercially successful semi-synthetic plastic.
John Wesley Hyatt
 History of Plastic
1907 :- Dr. Leo H. Baekeland discovered the first synthetic plastic. Dr. Leo
H. Baekeland, reacted phenol and formaldehyde under pressure using
hexamethylenetetramine as a catalyst for the reaction. The result was a
thermosetting phenolic plastic he named Bakelite. Dr. Leo H. Baekeland

1927 :- Waldo Semon does the commercialization of PVC. Waldo discovered

that PVC could be melt processed without degrading if a high boiling point
liquid plasticizer was added to it.

1937 :- PMMA or better known as Acrylic was introduced in market. PMMA

is a very hard material and is actually more transparent than glass.

1938 :- Dr. Wallace H. Carothers developed poly(hexamethylene

adipamide), commonly known as nylon 66. One of the earliest uses of nylon
66 fiber was for tooth brush bristles, previously made from animal
(Chinese boar) bristles.
 History of Plastic
1946 :- Dr. Roy Plunkett commercial introduced PTFE known as TEFLON.
Teflon is most widely known for its widespread use in nonstick cookware

1953 :- Glass reinforced plastic was used as a body material in Chevrolet

Corvette . A total of 300 Corvettes were produced in the first year of
production, each containing forty one glass fiber reinforced unsaturated
polyester body parts.

1955 :- High density polyethylene (HDPE) was first produced commercially

by Phillips Petroleum. It was used for Hula Hoop !

1960 :- Stephanie Kwolek invented Kevlar . The fiber was five times stronger
than steel (on a strength per weight basis) but about half the density of glass
fiber. Kevlar is best known to the public as the material from which
bulletproof vests
 Types of Plastic
Plastic can be classified in two categories.
Thermoplastic
Thermosetting Plastic

Thermoplastic plastics are made of long chains of polymers which dont cross over
very often. When heated, the molecules slip easily over one another.
Thermosetting plastics also have lots of long chain molecules, but there are links
between them. These cross links prevent the molecules from moving over one another.

Individual monomer molecule Individual monomer molecule

 Thermoplastics
As the temperature is raised above the melting point, the secondary bonds
weaken, making it easier to form the plastic into any desired shape. When
polymer is cooled, it returns to its original strength and hardness. The
process is reversible. Polymers that show this behavior are known as
thermoplastics.

Heat

HARDEN Soften

Cool
 Thermosetting Plastics
Thermosetting plastics are cured into permanent shape. Cannot be re-melted to the flow able
state that existed before curing, continued heating for a long time leads to degradation or
decomposition. This curing (cross-linked) reaction is irreversible. Thermo sets generally have
better mechanical, thermal and chemical properties. They also have better electrical resistance
and dimensional stability than do thermoplastics.

Heat

HARDEN
Soften

Cool
Advantages of Plastic

Light weight, high weight to strength ratio, particularly

when reinforced
Relatively low cost compared to metals and composites
Corrosion resistance
Low electrical and thermal conductivity, insulator
Easily formed into complex shapes, can be formed, casted
and joined.
Wide choice of appearance, colors and transparencies
Disadvantages of Plastics

Low strength
Low useful temperature range (up to 600 oF)
Less dimensional stability over period of time
(creep effect)
Aging effect, hardens and become brittle over
time
Sensitive to environment, moisture and chemicals
Poor machinability
 Popular Plastics
PET (PETE), Polyethylene terephthalate
HDPE, High density Polyethylene
PVC, Polyvinyl chloride
LDPE, Low-density polyethylene
PP, Polypropylene
PS, Polystyrene
Other types of plastics.
RECYCLING
SYMBOL
PP (Polypropylene)
PP, Polypropylene
Application in Kohler India :- In wall tank, Toilet Seats.

Advantages
Has a high melting temperature 160C (320F) which enables it to be
exposed to greater temperatures and keep its same shape. Example,
dishwasher safe Tupper ware
Environmentally safe so it can be used in everyday life
It is a thermoplastic polymer, can be recycled up to 5 times.

Disadvantages
Polypropylene is liable to chain degradation from exposure to UV radiation
The polymer can also be oxidized at high temperatures, a common problem
during molding operations
Quaternary ammonium biocides was found by researchers to be leaking out
of polypropylene plastics used in laboratory experiments. (A biocide is a
chemical substance capable of killing living organisms)
ABS (Acrylonitrile butadiene styrene)
ABS (Acrylonitrile butadiene styrene)
Application in Kohler India :- Faceplates

Advantages

It has a Very good surface finish.

It has a very good impact strength.
It can be easily formable.

Disadvantages

It tends to discolor from exposure to UV radiation

The polymer can be attacked by organic solvents.
It tends to absorb Water.
LDPE, Low-density polyethylene

LDPE, Low-density polyethylene

Application in Kohler India :- Connectors

Advantages

It has a good chemical resistivity.

It has high impact strength at low temperature.
Excellent electrical property.
Cheap.
Disadvantages

It has low strength.

Flammable.
Poor UV resistance.
Susceptible to environmental stress cracking.
Questions
Moulds
A mold or mould is a hollowed-out block that is filled with a liquid like
plastic, glass, metal, or ceramic raw materials. The liquid hardens or
sets inside the mold, adopting its shape.
Two Plate Mould
Two Plate Mould
Elements of Moulds
Sprue Bush :- A sprue is the passage through which liquid material
is introduced into a mold. During casting or molding, the material in
the sprue will solidify and need to be removed from the finished
part.
The function of the Sprue Bushing is to provide a seat at the
spherical radius for the Nozzle of the press. The Sprue Bushing
provides a "path" for the material from the nozzle to the runner
system.
Elements of Mould
Locating ring :- The function of a Locating Ring is to Align
the MoldBase to the Stationary Platen side of the
Press. The Sprue Bushing is also located via a hole in the
Locating Ring.
Elements of Mould
Top plate :- It holds the fixed side of the mold to attached at the
fixed plate of the injection machine. This plate will attach locate
ring, bolt, and Sprue bush.

Guide pins and guide bushes :- The function of the Guide Bushing is
to provide alignment of the two halves of the mold via the Guide
Pin. If the bushing is steel it is hardened and ground.
Elements of Mould
Cavity and Core plate :- The section that is engaged in
opening / closing movement is called a core plate, and the
section that is not is called a cavity plate. Generally, the
front side of a part is a cavity plate and the rear side is a
core plate.
Elements of Mould
Ejector pin:- A long pin that extends and retracts to force
the solid, molded part out of the cavity.
Ejector guide pin :- Ejector guide Pin is a hollow sleeve to
accommodate guide pins in order for extra strength.
Ejector plate :- A plate accomodating ejector pins.

Ejector Pin Ejector Guide Pin

Elements of Moulds
Return pin :- Projections that push the ejector assembly back as
the mold closes. also called surface pins.
Return Plate :- The function of the Ejector Retainer Plate is to
retain the Ejector Pins, Sprue Puller Pins, Guided Ejector Bushing
and the Return Pins to the Ejector Plate. There are drilled and
counter bored holes for each of the components mentioned above.

Return Pin

Return Plate
Elements of Mould
Spacer Block :- Mounted between the movable clamping plate
(bottom plate) and the movable cavity plate to give space and allow
the ejector plate to move when ejecting the
part. the required length of spacer block depend on ejector stroke
that needed to eject product.

Spacer Blocks
 Mould Process Cycle
The process cycle consists of the following four stages:

Clamping - The two halves of the mold is securely closed by the clamping unit. Each half of the
mold is attached to the injection molding machine and one half is allowed to slide. The
hydraulically powered clamping unit pushes the mold halves together and exerts sufficient force
to keep the mold securely closed while the material is injected.

Injection - The material is melted by heat and pressure. The molten plastic is then injected into
the mold very quickly and the buildup of pressure packs and holds the material. The amount of
material that is injected is referred to as the shot.

Cooling - The molten plastic that is inside the mold begins to cool as soon as it makes contact with
the interior mold surfaces. As the plastic cools, it will solidify into the shape of the desired part.
However, during cooling some shrinkage of the part may occur.

Ejection - After sufficient time has passed, the cooled part may be ejected from the mold by the
ejection system, which is attached to the rear half of the mold. When the mold is opened, a
mechanism is used to push the part out of the mold.
Mould Process Cycle
Material Flow

Sprue

Primary Runner

Secondary Runner

Gate
Questions
 Plastic Moulding Process

Plastic Molding Process

Extraction Injection Blow Molding Vacuum Pressure Rotational

Molding Molding Machines forming Forming Molding
( Pipe, etc ) ( Bucket, Case, Box etc ) Container, Bottle Package for egg
( thin film products)
Suitcase ( Thick film
products)
Machines
Bottle, Doll

Vertical Horizontal
Injection Injection
Molding Molding
Size ( Tonnage )

30 50 80 100 120 150 200 250 350 450 550 650 750 850 1000 1200 1300 2000 3000 4000
Advantages & Disadvantages of Injection
Moulding
Advantages
High production rates
Large volume production possible
Low labor cost per unit
Little or no post-processing required
Many colors and finishes available
Good for many complex shapes
Good for small parts
Minimal scrap
Close tolerances can be maintained
Insert molding possible
Disadvantages
Machine costs are high
Mold costs are high
Process control issues
Part design issues
Injection Moulding Machine

Fig : A 2.2-MN (250-ton) injection molding machine. The tonnage is the force applied
to keep the dies closed during injection of molten plastic into the mold cavities.
Injection Moulding Machine

An Injection molding machine,

also known as an injection press, *

is a machine for manufacturing

plastic products by the injection
molding process. It consists of
two main parts, an injection unit
and a clamping unit.

Injection molding machine are

categorized in four types.
Hydraulic
Mechanical
Electric
Hybrid
Injection Molding Process
Filling Hopper
Mold closes Barrel
Screw forward
Frozen polymer skin forms
at mold walls Screw
Mold

Packing Time
Cavity filled
Pressure applied to
polymer Screw is applying a specified pressure
Cooling occurs to the polymer melt in order to pack
more plastic into the cavity.
Gate freezes
Injection Molding Process

Cooling
Part continues to cool until rigid
enough to withstand ejection
Screw moves back plasticating
resin for next shot
Mold Open
Part is ejected
Injection molding process
 Injection molding cycle
Filling process

Screw rotates and fill molten

material in the barrel
Hydraulic acts and pushes the
material in the mold.
Screw rotates filling more
material and returning to base
point for next cycle.

Dwelling

After Pushing the material in

the mold the hydraulic again
pushes some material in the
mold after a span of few
seconds.
Injection molding process cycle
Questions
Thank you