Polymer Processing

Polymers
o Large molecules made by smaller constituents (monomers)
o Polymerisation The process of joining the molecules
Degree of polymerization the number of units in the molecule
o Rarely 100% crystalline since it is hard to align all chains
o Can be formed by molding into shapes
o Cost competitively with metals
o Require less energy to make than metals
o Low density
o Good strength-to-weight ratios (for some)
o High corrosion resistance
o Low electrical and thermal conductivity
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Main Additives in Plastics
o Fillers short inorganic fibers/flakes that improve mechanical properties; lets a large
volume of plastic to be made with little polymer
Eg. Calcium carbonate, silica, clay
o Flame retardants Contain chlorine, bromine, phosphorus, or metallic salts that reduce
combustion likelihood
o Lubricants ie. Wax or calcium stearate reduce viscosity; improve forming
characteristics
o Pigments colours
o Other additives: stabilizers (prevent deterioration), antistatic, plasticisers
Thermoplastics
o Long chain-like molecules held together by relatively weak Van der Waals forces
o When heated, intermolecular forces are weakened so becomes soft and flexible; becomes
viscous melt at high temperatures
o Always possess linear or branched structures, or mix
Branches increase entanglement, making polymer
Stronger in solid state
More viscous at a certain temperature
o Solidifies when cools
o Softening by heating and solidifying by cooling can be repeated
o Amorphous polymers
Usually transparent loose structure lets light through
Low shrinkage random molecule arrangement produces little volume change
Low chemical resistance
Poor fatigue and wear
o Crystalline polymers
Sharp melting point
Usually opaque amorphous and crystalline areas cause interference
High shrinkage as material solidifies from amorphous state, polymers take up a
closely packed, highly aligned structure, producing great shrinkage.
Good fatigue and wear resistance
Thermosetting materials

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Cannot tolerate repeated heating cycles

Curing Material is shaped them chemically cross-linked
Creates an infusible, insoluble, highly cross linked 3D network
Cross-linking is irreversible
Presence of carbon-carbon double bonds
Supplied as pellets, powders, grains
Dont undergo chemical reaction
Thermoset resins
Supplied as liquid chemicals (low weight, low viscosity)
Undergo a chemical reaction featuring polymerization and crosslinking
Curing Reaction
Gelation Liquid-to-rubber transition
System will no longer flow; the two phases coexist: gel and sol phase
Drastic increase in viscosity
Vitrification Liquid/Rubber-to-glass transition
Occurs when class transition temperature of curing resin increases to
current curing temperature
Rate of cure reaction greatly reduced
Final physical phase depends on temperature the process was at
Resin in not 100% cured

Injection Molding

3 Parts: Injection unit, mold, clamping system

Injection cycle
o Plastification
o Packing/cooling
o Injection
o Ejection
Parameters
o Melting temperature
Generally below plastics melting point
Depends on polymer morphology
o Temperature of the mold
Controlled with water that can be circulated through mold
o Factors affecting system temperature
Shot size large shots take more heat
Injection rate- faster filling means higher melt temperature due to shearing
Runner size long runners need higher temperatures
Part thickness Thick needs more cooling time, molded at lower temperatures
o Conformal cooling
Makes use of cooling lines that curve, follow geometry of the part
Faster cooling time, reduces injection cycle
o Injection pressure, holding pressure
Should be done at lower practical pressures possible, without resulting in short
shorts

High enough to minimize shrinkage by putting in more plastic into mold

(packing process) during time that shrinking occurs (cooling process)
o Injection rate and time
Controlled by fill rate
Mold temperature is below freezing point of material. Long injection times will
increase likelihood of premature freezing.
At thick sections or will small gates, injection rate is lowered for steady passage
of material to prevent freezing, allowing to fill completely
Thin sections filled at high injection rates to prevent freezing before filling
o Dwell time
Time that force/pressure is applied to cavity after its filled
Helps with packing
Ensures appropriate dimensions
o Freeze/Cooling time
Interval after pressure is relieved and before mold is opened
Governed by ability of part to harden enough to be ejected
Often shortened by cooling the mold
o Ejection time
Time to open mold, eject part, close again
Special injection molding processes
o Co-injection molding creates a skin-and-core material
Short shot of skin melt injected into mold
Core melt injected until nearly filled
Skin melt injected again, pushing core polymer, filling cavity
Machines more expensive/difficult to maintain
Reduces cost by using cheaper fill material as core of product
Combines desired properties of polymers
Fountain flow keep core material inside skin as they flow and subsequently
harden the mold
o Bi-injection molding two different polymers are both injected at different places on
same mold at same time
Used to produce simple, low-tolerance parts
o Gas-assisted injection molding
Can take place through same nozzle as melt, or via special gas injection needles
located at runner or thicker areas
Starts with injection of plastic into cavity
When at 50-95% full, barrel is closed by a shut off and gas is injected
(controlled by pressure or volume)
Gas in cavity expands, pushing plastic out until cavity is filled
Gas-pressure is reduced by taking out injection nozzle from sprue, so gas can
escape
Part can be ejected when ambient pressure is reached
Capable of producing hollow, lightweight, rigid parts
Reduced cycle time
Reduced pressure/clamp force tonnage
Part consolidation with thick/thin sections

Typical\ applications include: tube/rod-like parts, large sheet-like parts, complex

parts
Effects of melt viscosity
Thicker walls narrower and shorter gas channels with more remaining
material in the end, allowing high reproducibility
Low melt viscosities produce longer gas clannels with a larger cross
sectional area, but usually with less uniform wall thicknesses
Decreasing melt viscosity also decreases melt strength, so gas can break
through the melt front more readily