CHAPTER 1: INTRODUCTION

Hot press moulding is a type of manufacturing process where plastic pellets is heated to certain
temperature inside the mould cavity until the plastic melts and give the desired shape based on the
mould itself. In moulding process, hot press method is used to make this product. It is because hot press
method is cost saving as this product does not require complex geometry in its design. As for the hot
press mould, it refers to an arrangement of hollow cavity spaces built to the shape of preferred product
in one assembly to produce plastic product in mass production. The cavity space consists of female
mould part known as cavity and male mould part known as core. There are limits in what material
should be used for making hot press moulding as this process usually use thermoplastic materials and
also applicable to certain thermoset material. Hot press moulding consists of multiple part as shown on
Figure 1 such as (1) pressure head, (2) upper shell, (3) upper heat retainer, (4) guide sleeve, (5) upper
asbestos insulation, (6) heating room, (7) die orifice, (8) female die, (9) roof plate, (10) punch, (11)
billet, (12) workbench, (13) lower template, (14) guide pin, (15) ejector pin, (16) electric iron core, (17)
lower shell, (18) lower asbestos insulation, (19) lower heat retainer, (20) fixed plate, (21) guide sleeve,
(22) upper insulation cushion, (23) movable beam and (24) upper template.

Figure 1: The cross sectional of a hot press mold

Hot pressing play an important role in powder metallurgy especially for the fabrication of dense
compacts from refractory materials, for examples metallic borides, carbides, nitrite and silicide. It is
regularly difficult to get these mixes as thick compacts by heating, in view of their high dissolving
focuses as well as in light of the fact that they may separate to form different compounds. Hot pressing
suggests that the powder conservative is heated to a temperature beneath the liquefying point and an
outside weight all the while connected to cause fast sintering of the powder into a thick homogeneous
body. In spite of the way that hot-pressing practices have been being used for a long time, it was just
amidst the 1950's that the main hypothesis with respect to the system of hot pressing was proposed
(Ramqvist, 1966). According to Ramqvist (1966), the cutting edge history of the procedure starts in the

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1870's, the point at which an American patent was taken out cover to the hot pressing of tin powder,
followed by two more patents, one Germany and the other was American forty years later that were
concerned with the possibility of producing dense bodies from powdered tungsten, tungsten carbide, by
a combination of pressure and temperature.

Flowchart 1: Process involved in the hot pressing (Upadhyaya, 2002)

Hot pressing is a suitable method for densifying materials with poor sintering behaviour. This
technique consist of combining the powder pressing and sintering into one single operation, offer many
advantages over conventional powder consolidation. With simultaneous application of temperature and
pressure, it is feasible to archive near theoretical density in wide range of hard to work materials. As
the resistance of metal particle s to plastic deformation decreases rapidly with increase in temperature
much lower pressures are required for consolidation by hot pressing. Pressing and sintering are the
mechanisms used to form solid parts from powders which is starts with pressing and follow by sintering.
Before pressing, the powder will be fully prepared. Powder pressing, and hence powder forming in
general, is best suited to flat parts with 2 dimensional geometry and little thickness. The main problems
as part complexity and thickness increase, are higher variations in density due to uneven compaction of
powder particles and limitations caused by the need for ejection of the pressed compact. Processing
methods are used to mitigate these problems.

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 Powder pressing is the compaction of powders into a geometric form. Pressing is usually
performed at room temperature. This creates a solid part called a green compact. The strength of this
pressed, unsintered part, (green strength), is dependent on compactability, binders may be used to
increase compactability. Typically a green compact can be broken apart by hand but is also strong
enough to be handled, gently. The geometry of the green compact is similar to that of the final part,
however, shrinkage will occur during the sintering phase of the manufacturing process and must be
calculated in. Amount of powder needed will be based on the bulk density of the powder and the amount
of material in the final part. Bulk density is important when measuring powder quantities. The effects
of additives such as lubricants must always be calculated. For example, a green compact has a certain
amount of lubricants and binders in it that add extra material. During sintering, these lubricants and
binders are burned off. Their material is no longer in the part after sintering and this must be a
consideration. To begin the manufacturing process, a certain amount of powder is filled into a die. Rate
of die filling is based largely on the flowability of the powder. Powders that flow readily can be poured
at higher rates. Pouring can be an automated process. Once the die is filled, a punch moves towards the
powder. The punch applies pressure to the powder, compacting it to the correct geometry.

Figure 2: Powder pressing overview

Powder sintering involves raising the temperature of the green compact, (pressed powder part), to a
certain level and keeping it at that temperature for a certain amount of time. The sintering temperature
is usually between 70% and 90% of the melting point of the powder metal (Groover, 2004). This will
cause bonding mechanisms to occur between powder particles pressed together in the compact. Bonding
within the green compact is weak and this pressed unsintered part usually has just enough structural
integrity to be handled. Bonding that occurs during sintering greatly strengthens the part.

During sintering, the individual particle structures disappear and the material forms as a mass.
Mechanisms that cause bonding during sintering are varied and complex. The main mechanism by
which bonding occurs is considered to be diffusion, mechanisms will vary based on manufacturing
process factors and powder characteristics. Physical characteristics of different types of bonding may
be different. Particle bonding by two different mechanisms is illustrated below. The diffusion bonding
shrinks the distance between particles, reducing space. The phase material transport adds material, while
keeping the particles the same distance apart.

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 Figure 3: Bonding mechanisms in powder sintering

CHAPTER 2: TYPE OF MACHINE, SPECIFICATION AND ITS APPLICATION

2.1 Hydraulic Shoe Hot Press Molding Machine

Picture 2.1: Hydraulic Shoe Hot Press Molding Machine

2.1.1 Characteristic of Machine:

i. Both-edge operation, each station simultaneously use two molds, to improve production
capability. The machine covers small area.

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 ii. Heating plate is adopted electricity control, up and low mold can be adjustable, to
guarantee the optimized vulcanization quality.
iii. Temperature of heat plate is adopted precious P.I.D control system, to accurately control
the temperature of mold.
iv. Each oil circuit system is independently controlled, station don't need to inter-waiting, and
production operation is better consistency.
v. The sliding mold is designed by separation, it would not affect operation to the machine
as it is moving, and the operation is smooth.
vi. Pre-plastic vulcanization deflation time, each station can be freely set according to the
mold, the production can be freely measured.
vii. Hand-made heat pressure mold can be shared to use.
viii. Direct press oil cylinder die clamper design, which is applicable to molds with different
thickness.
ix. Automatically mold=sliding design, plate is automatically side-turned mechanical hand,
which diminishes the collision of mold, reduce labor strength of workers, reach labor-
saving capability.
x. The heating method can tailor for the requirements of clients, it is applicable to
galvanothermy, heat coal oil and steam.

2.1.2 Electricity-controlled system:

i. It provides operation and abnormal inspection function, which can freely measure the
circumstance of machine, to guarantee smooth operation of production.

2.1.3 Operation Design:

i. One person can simultaneously operate multi-stations, to save labor cost.

ii. Automatically enter or exit sliding mold, automatically side-turned plate, conveniently to
take out finished-product, the operation is easy, female operator can shoulder the job.
iii. Inter-direction machine operation, featuring simultaneously inter-lock function, the
operation is safe.
iv. Fix up low mold to the sliding plate, it can be produced, the speed of mold change is quick.
v. Independently operate and control each station, relying on requirement of manufacture,
repair and maintenance, to decide station number, at the same time to save electric power.

CHAPTER 3: TYPE OF MATERIAL

3.1 Ceramic
Hot Press also known as high temperature injection molding, comprises the utilization of
outside strain to sinter and shape the ceramic at high temperature, and was first utilized as a part of the
creation of all ceramic redecoration for example, crowns, decorates, on-lays, lacquers and settled
halfway dentures (Henriques et al., 2013). As of late, this system wound up noticeably accessible
additionally for metalceramic redecoration efforts. According to the authors also hot pressing is
portrayed as keeping away from expansive pores and advancing great scattering of the crystalline stage
inside the polished framework, henceforth bringing about prevalent mechanical properties inside the

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pottery and in impeccable metalceramic interfaces. There is a few studies on the bond quality of hot
pressing porcelain to metal dental substructures although it is few.

3.2 Glass Reinforced Polyester (GRP)

Glass fiber-reinforced polyester, with its high quality to weight proportion, offers awesome potential as
a basic material for use in the structural building industry. One application in which it has indicated
specific guarantee is as repeatable essential units that can be collected together to frame a structure. In
his paper, the authors depicts the make of an embellishment instrument to empower a set number of
glass fiber-strengthened polyester parts to be made economically by the hot press moulding of sheet
moulding compound. Glass-reinforced polyester by using the hot press molding of sheet moulding
compound has been used for various years of manufacturing (Mallin and Hollaway, 1984).

3.3 Aluminum AA6061

Hot press has been used by Yusuf, Lajis and Ahmad (2017) in their study to recycle Aluminum
chip AA6061. The main focus of the authors was to prove the technical feasibility of these new approach
by utilizing hot press process under certain various temperature. Hot press process was used by authors
with the steady pressure at 47MPa with four times pre-compacting cycle. Shown in the figure below is
the process diagram of direct recycling hot press, with certain various temperature are used, 430, 480,
and 530 C. Furthermore, the three chose holding times are 60, 90 and 120 min. Instantly after the
producing procedure, the example will be extinguished in water at extinguish rate 100 C/s to perform
quick cooling into room temperature took after by counterfeit maturing at temperature 175 C with 120-
min span. As for result, the authors found that by used hot press process to direct recycle the AA6061-
T6 chip demonstrates great consequences for the mechanical properties and surface condition. In spite
of the fact that this is just the establishment of trial perceptions, its potential as an option system to the
immediate reusing strategies for delivering scrap can be unmistakably illustrated. This investigation
defended that hot press process obviously has noteworthy advantages contrasted with ordinary reusing.
Enhanced vitality proficiency is right now the attention of on-going examination, which permits
additionally affect diminishments.

2.4 Polypropylene with cocofiber

The use of polypropylene waste for biodegradable plastic has been finished with the expansion
of starch from durian seed (Liu J et al, 2016 cited in Pelita, Hidayani and Akbar, 2017). Coco fiber is a
considerable piece of the coconut natural product, in particular 35% of the aggregate weight of the
organic product. Coconut fiber comprise of fiber and plug connecting one fiber with different filaments.
Every coconut contains 525 g of fiber (75% of the coco fiber), and plug 175 g (25% of coco fiber)
(Orefice R L et al 2016 cited in Pelita, Hidayani and Akbar, 2017). The aim of the study that conducted
by the authors was to produce composite polymer with polypropylene plastic waste material and
cocofiber. With that new material that can replace the wood as the core in home furnishing industry. As
the result, the authors found that consequences of polymer composites showed ideal condition on the
expansion of 40% cocofiber with supple elasticity estimation of 90.800 kgf/cm2 and estimation of
stretching break at 3.6726 x 104 (kgf/cm2), liquefying point at 160.02oC, consuming point 463.43oC,
buildup of TGA is 19%, the thickness of 0.84 g/mL. From these information, the authors infer that the
subsequent polymer composites meet the SNI 03-2105-2006 about normal composite polymer and
polymer composite basic sort 8 customary sorts from 17.5 to 10.5.

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CHAPTER 4: NEW TECHNOLOGY / RECENT RESEARCH

4.1 Sustainable Direct Recycling Technique The used of hot press for aluminum
The carbon dioxide discharges and immense arrival of strong waste by modern procedures has
prompted a dangerous atmospheric devation, which realizes unfavorable impact to human action.
Different modern procedures represented roughly 14% of the aggregate carbon dioxide outflows and
20% of the aggregate nursery gas emanations in 2010 (Yusuf, Lajis and Ahmad, 2017). As per Jayal et
al. (2010) cited in Yusuf, Lajis and Ahmad (2017), the collecting division, which lies at the focal point
of the current economy, must be made to ensure raised expectations for everyday comforts finished by
industrialized social requests and, thusly, to engage social request to accomplish and support a
comparative level of wealth. Subsequently, the need of decrement in control usage in mechanical
strategies has transformed into a focal point in the advanced world.
Aluminum composites have been in exigency by the modern expert because of their particular
properties, which incorporates great quality and low thickness contrasted and steel. A large portion of
them were used for sustenance bundling, transportation, nourishment added substances, refreshment
jars, cooking utensils, building solutions, and surgery materials, as a result of their one of a kind physical
and synthetic properties (Yusuf, Lajis and Ahmad, 2017). At whatever point the request and application
expanded, the waste delivered from the machining will likewise altogether increment. This prompts the
creation of auxiliary aluminum to substitute the present utilization of essential aluminum.
Correspondingly, extraordinary techniques have risen in creating optional aluminum. The most
suitable aluminum reusing rehearses in many ventures depend on the traditional reusing utilizing a
dissolving method. As per Yusuf, Lajis and Ahmad (2017) in 2030, 6.1 megatons of scrap won't be
reused because of high grouping of aluminum alloying components caused by their wasteful or
potentially difficult expulsion amid re-dissolving. The customary reusing of aluminum is as of late less
great, as the strategy requires high vitality and expansive number of operations which prompted cost
increase. Rather than utilizing dissolving methods that utilization a high temperature to achieve the
softening point, reusing of fashioned aluminum compounds by strong state is ideal.
To beat the absence of essential assets, concentrating on lessening the use of vitality and
materials, the new technique has been used which is meltless recycling technique. According to the
authors, hot press was proposed as a novel direct reusing system which brings about astoundingly low
vitality utilization conversely with conventional recycling method. The main focus of the authors was
to prove the technical feasibility of this new approach by using AA6061 aluminum chip, by utilizing
hot press process under certain various temperature. Hot press process was used by authors with the
steady pressure at 47MPa with four times pre-compacting cycle. Shown in the figure below is the
process diagram of direct recycling hot press, with certain various temperature are used, 430, 480, and
530 C. Furthermore, the three chose holding times are 60, 90 and 120 min. Instantly after the producing
procedure, the example will be extinguished in water at extinguish rate 100 C/s to perform quick
cooling into room temperature took after by counterfeit maturing at temperature 175 C with 120-min
span.

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 Figure 4.1: Process of direct recycling hot press

As for result, the authors found that by used hot press process to direct recycle the AA6061-T6
chip demonstrates great consequences for the mechanical properties and surface condition. In spite of
the fact that this is just the establishment of trial perceptions, its potential as an option system to the
immediate reusing strategies for delivering scrap can be unmistakably illustrated. This investigation
defended that hot press process obviously has noteworthy advantages contrasted with ordinary reusing.
Enhanced vitality proficiency is right now the attention of on-going examination, which permits
additionally affect diminishments.

4.2 Fabrication of hybrid composite using hot-press molding technique

Composite field have been attempting to limit the utilized of oil based support in composites
because of ecological issues. It have to be other alternatives of petroleum-based or synthetic
reinforcement with addition of high performance. As there is inadequate with regards to data in regards
to the mechanical properties of such composite, the interwoven hemp/polyethylene terephthalate (PET)
fibre reinforced polyoxy methylene (POM) hybrid composites flexural properties were studied by the
authors. Normal fiber has many engaging properties, for example, high quality to weight proportion,
light weight, erosion protection, non-aggravating, low vitality utilization amid creation, carbon dioxide
free of outflow when consumed, and biodegradable (Chen, Khan and Tan, 2017). Because of its a fast
grown plan with extremely strong and sturdy attributes, hemp fiber was used as a part of their study.
Be that as it may, normal fiber turns out to be less attractive contrasted with manufactured fiber
because of low impervious to dampness assimilation, low corruption temperature and deficient of good
interfacial holding with hydrophobic network. PET is utilized as intertwine reinforcement since it is
light weighted and it makes a decent boundary for gas, dampness, and alcohol. Likewise, PET is solid

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and effect safe. Intertwined of hemp and PET altogether changes to wind up noticeably more grounded
and more sturdy. Besides, POM is utilized as grid since it has points of interest, for example, low fiction
coefficient, high scraped area protection, great electrical and dielectric properties, high warmth
protection, and low water ingestion.
One of the difficulties of using normal fiber as reinforcement in polymer composite is poor
interfacial holding with thermoplastic matrix. In their study, hemp and polyethylene terephthalate (PET)
fiber were chosen by the authors to build up the intertwined texture as support and polyoxymethylene
(POM) was picked as the matrix. According to the Chen, Khan and Tan (2017), Hemp and PET strands
that utilized as a part of their study were frame into curved yarn as its improved the composite's
mechanical properties. Hemp and PET yarns were utilized to deliver intertwined texture. A hot-press
machine and a rectangular mild steel mold were utilized to create the hybrid composites. From this
study, the authors found that the production strategies for utilizing pre-made POM layers and utilizing
POM pellets specifically demonstrates that the thermoplastic qualities of POM can give comparative
outcome without huge contrasts. Thusly, by utilizing POM pellets specifically can diminish the time
and vitality expended amid the mixture composite generation.

4.3 Analysis physical properties of composites polymer from cocofiber and polypropylene
plastic waste with maleic anhydrate as crosslinking agent
According to Pelita, Hidayani and Akbar (2017), the wood plastic composite (Wood-Plastic
Composite) is a standout amongst the most unique parts of the plastics business nowadays and this
material comprises of a assorted of wood filaments or the like with a polymer that is a thermoplastic,
for example, polyethylene (PE), polypropylene (PP). Thermoplastic polymer would be soft when
warmed and solidifies when cool. It makes these properties can be mixed with other material to form a
new composite material such as wood particles. Composite is a material framework comprise of blend
or mix from at least two diverse large scale constituents that are not commonly break up with comprises
of network and fortification. Matrix is the significant constituent of composite while the minor
constituent called fortification. PP is a plastic that is strong, hard, and water-safe, which is hard to be
dispose naturally, and has a solid capability of ecological contamination.
The usage of plastic waste is an attempt to surpress the plastic waste in degree to spare assets
and lessen reliance on imported crude materials. Parnas R S et al (2014) cited in Pelita, Hidayani and
Akbar (2017) mentioned that the use of plastic waste devided into reuse and reuse, all sorts of plastics
squander (80%) can be reuse and reuse over into the first thing, in spite of the fact that it must blend
with new crude materials and added substances to enhance its quality. The use of polypropylene waste
for biodegradable plastic has been finished with the expansion of starch from durian seed (Liu J et al,
2016 cited in Pelita, Hidayani and Akbar, 2017). Coco fiber is a considerable piece of the coconut
natural product, in particular 35% of the aggregate weight of the organic product. Coconut fiber
comprise of fiber and plug connecting one fiber with different filaments. Every coconut contains 525 g
of fiber (75% of the coco fiber), and plug 175 g (25% of coco fiber) (Orefice R L et al 2016 cited in
Pelita, Hidayani and Akbar, 2017). The aim of the study that conducted by the authors was to produce
composite polymer with polypropylene plastic waste material and cocofiber. With that new material
that can replace the wood as the core in home furnishing industry. To realize that idea, it have to go
through several stages (Pelita, Hidayani and Akbar, 2017), picturize as flowchart below.

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 STAGE 1

Process of soaking coco fiber with detergent to remove oil and 2% NaOH.

STAGE 2
Combining the polypropylene plastic waste with cocofiber, modification by adding maleic
anhydride as a crosslinking agent and benzoyl peroxide as an initiator each as much as 1%.

STAGE 3

Polymer composite molding process using hot press at a temperature of 158C

Flowchart 4.3: Stages of creating new material to replace the wood.

As the result, the authors found that consequences of polymer composites showed ideal
condition on the expansion of 40% cocofiber with supple elasticity estimation of 90.800 kgf/cm2 and
estimation of stretching break at 3.6726 x 104 (kgf/cm2), liquefying point at 160.02oC, consuming
point 463.43oC, buildup of TGA is 19%, the thickness of 0.84 g/mL. From these information, the
authors infer that the subsequent polymer composites meet the SNI 03-2105-2006 about normal
composite polymer and polymer composite basic sort 8 customary sorts from 17.5 to 10.5.

CONCLUSION

Moulding is the process of manufacturing by shaping liquid or pliable raw material using a
rigid frame called a mold or matrix. This may have been made using a pattern or model of the final
object. A mould is a hollowed-out block that is filled with a liquid or pliable material such
as plastic, glass, metal, or ceramic raw material. The liquid hardens or sets inside the mold, adopting its
shape. A mold is the counterpart to a cast. The very common bi-valve molding process uses two molds,
one for each half of the object. Piece-molding uses a number of different molds, each creating a section
of a complicated object. This is generally only used for larger and more valuable objects. Hot press
moulding is one of the methods used in the manufacturing industry for a long time. There are
various types of moulding process that available in industries, such as injection moulding,
compression moulding, transfer moulding and etc. For example, casting is a basic molding
process as it requires the least amount of complex technology. Plastic is simply heated so it
turns into a fluid, and then transferred into a mold. It is left to cool and the mold is removed.
This process can be used for intricate shapes and performed under a low pressure. However, it
is a common process used for making plastic sheeting, starting from 0.5 inches thick and
greater. Each moulding process consist of its own distinct advantages in terms of cost, process,
and suitability for the material used.

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