Processing of polymer and plastics

Department Of Mechanical Engineering

National Institute Of Technology, Durgapur
Raghvendra Kumar P andey
Under the supervision of
Prof . A.B. Puri
Prof. J. Dey

28-Jun-19 1
 Contents
Title Page number

Introduction 1

Classification on polymers 2

Polymers synthesis and types of 6

polymerization
Mechanical behavior of polymers 9

Polymer forming 11

Types of polymer forming 12

Characteristics and typical application 17

28-Jun-19 2
 Introduction
 The word polymer is originated from Greek word meros which means unit.

 Monomer = single unit and polymer =many units joined together

 Polymers are basically organic compounds but few are inorganic too.

Characteristics of polymers :-

- Low temperature stability

- Low hardness

- Low mechanical strength

- High elongation under application of stress

- Low thermal and electrical conductivities

- High sensitivity of properties to their morphology

28-Jun-19 3
Classification:-
Thermoplastic
Plastics
Thermosetting
Polymers
plastic
Elastomers

Thermoplasts
• Plastics which softens up on heating and hardens up on cooling where the softening and hardening are totally reversible
processes. Hence, Thermoplasts can be recycled.
• They consist of linear molecular chains bonded together by weak secondary bonds or by inter-winding.
• Cross-linking between molecular chains is absent.
• Thermoplasts have the property of increasing plasticity, i.e., increasing ability to deform plastically with increasing
temperature.
• E.g.: Acrylics, PVC, Nylons, Perspex glass, etc.
 Thermosetting plastics:-

• Plastics which are ‘set’ under the application of heat and/or pressure. This process is not reversible hence,
thermosets can not be recycled.
• They consist of 3-D network structures based on strong covalent bonds to form rigid solids. Linear
molecular chains bonded together by weak secondary bonds or by inter-winding.
• Characterized by high modulus / rigidity / dimensional stability when compared with Thermoplasts.
• E.g.: Epoxies, Amino resins, some polyester resins, etc.

Elastomers
• These polymers are known for their high elongations, which are reversible upon release of applied loads.
• They consist of coil-like molecular chains, which straighten up on application of load.
• Characterized by low modulus / rigidity / strength, but high toughness.
• E.g.: natural and synthetic rubber

28-Jun-19 5
 • Processing of polymers primarily limits to synthesis followed by forming.
Polymer • Polymers are synthesized by process known as polymerization.
synthesis

• Polymerization is process in which multi-functional monomers are attached to form linear/3-D macro molecular
chains.
polymerization

• Involves single kind of monomer

• Three stages i.e. initiation (e.g., benzoyl peroxide) , propagation and termination
Addition
• As molecular chain grows longer, reaction rate decreases. However the growth process is terminated either by the
polymerization combination or disproportionation process.
• E.g., polyethylene

• Involves more than one monomer

• Also known as step growth polymerization
• Unpredicted chemical formula
condensation
polymerization • Reaction time is longer as compare to addition polymerization
• E.g., Formation of a polyester from Ethylene glycol and Adipic acid

28-Jun-19 6
 Polythene:-

Combination

Disproportionation

28-Jun-19 7
 Formation of a polyester from Ethylene glycol and Adipic acid:-

Degree of polymerization
• Extant of polymerization is characterized in terms of ‘degree of polymerization’.
• It is defined as number of mer units in molecular chain or ratio of average molecular weight of polymer
to molecular weight of repeat unit.
• Average molecular weight is defined in two ways: Weight average molecular weight (based on weight
fraction) and Number average molecular weight (based on the number fraction).
• Number average molecular weight is always smaller than the weight average molecular weight.

28-Jun-19 8
 Mechanical behavior of polymers
1) Parameters like temperature, strain rate and morphology of polymers has strong influence on
mechanical behavior.

2) Mechanical property changes dramatically with temperature, going from glass like brittle at very low
temperature to rubber like behavior at high temperature.

3) Due to cross linkage, recoverable deformation up to high strain also observed in

polymers(elastomers).

4) Highly crystalline polymers behaves like brittle whereas amorphous polymers exhibit plastic
deformation.

5) Tensile modules and strength is very lower than those of metals but elongation can be up to 1000% in
some cases.

6) Unlike metals, plastics typically possesses glass transition temperature, exhibits prolonged creep, and
tend to degrade ( due to heat) rather than corrode.

7) Plastics impregnated with organic can be subjected to bacterial infestation.

28-Jun-19 9
28-Jun-19 10
 Polymer forming

 Thermoplasts usually formed above their glass transition temperature.

 Thermosets are formed in two stages – making liquid polymer and then moulding it.

 Melting of pallets Injection into the mould.

 Crystallization temperature polymer ∝ molecular weight

 Glass transition temperature range 0.5 to 0.75 of absolute melting temperature.

 Polymer melting and TG depends upon following factors:-

- chain stiffness (e.g., single vs. double bonds)

- size, shape of side groups
- size of molecule
- side branches
- cross-linking

28-Jun-19 11
Compression
moulding
1) Place the appropriate
amount of heated
polymer (say pallet) in
between the male and
female part of mould
parts.
2) Punch presses the molten
pallets causing the
viscous plastic flow to
attend the
predetermined shape.
3) If flash present, it is
trimmed.

28-Jun-19 12
Injection moulding
1. Palletized material is fed
with use of hopper into a
cylinder where material
melts due to heating
coils.
2. Molten metal is impelled
through nozzle into the
enclosed cavity.
3. Edges are trimmed if
present
4. Outstanding
characteristic of this
mounding process is
cycle time is very less.
i.e. rate of production is
very high.

28-Jun-19 13
extrusion
1. This technique is adapted
to produce continuous
length with constant
cross section.
2. Thermoplastic material is
forced through a die
orifice.
3. One of the most famous
products of extrusion
moulding is the optical
fibre cable.

28-Jun-19 14
Blow moulding
1. Using this manufacturing
process hollow parts are
made like bottle or sphere
etc.
2. Air is blown into a thin
walled plastic cylinder called
the parison. The parison is
formed by melted plastic
material being pushed
through an extruder.
3. When the parison reaches a
certain length, the two
halves of the mould close
around the parison sealing it
at the bottom.
4. Compressed air is then used
to inflate the parison to form
the shape of the cavity inside
the mould.

28-Jun-19 15
Transfer moulding
1. The molten resin is
transferred by pressure from
a melt pot into a mould
which is at a temperature
above the melt point of the
resin.
2. Durable and dimensionally
stable parts
3. Minimal release of airborne
emissions during production

4. Uniform thickness of parts

5. Prevents corrode or rust

28-Jun-19 16
Characteristics and typical application
1. Thermoplastic
Material Characteristics
• Outstanding toughness and
1. Acrylonitrile-butadiene-styrene strength
• Resistance to heat distortion
(ABS) • Soluble in some organic
solvents
2. Acrylics • Outstanding light transmission
• Resistance to weathering
3. Polyester (PET or PETE) • One of the toughest plastic film
• Excellent fatigue and tear
resistance
• Resistance to grease, acids and
oils
28-Jun-19
Applications
• Refrigerator lining
• Highway safety devices
• Lenses
• Drafting equipment's
• Transparent aircraft enclosures
• Magnetic recording tapes
• Clothing
• Automotive tire chords
• Beverages container
17
Material Characteristics Application
4. Polystyrene • Good thermal and dimensional • Wall tile
stability • Battery cases
• Relatively inexpensive • Indoor lighting panels
• Electrical resistance
5. Polyethylene • Chemically resistance and • Flexible bottle
electrically insulating • Toys
• Tough and low coefficient of • Bags
friction • Tumblers
• Poor resistance to weathering • Ice trays

Thermosetting plastics
Material Characteristics Application

1. Epoxies • Good adhesion • Protecting coating

• Corrosion resistance • With fiberglass laminates

2. Phenolic • Excellent thermal stability over • Motor housing

150 degree C • telephones

28-Jun-19 18
 conclusion
"Better things for better living... through chemistry“

Polymers are being used now smartly in electrical and electronic, packaging, automobile and
construction areas. This sector has potential to increase exponentially through proper planning
of recycling.

Any shaped product is now possible to manufacture through various moulding processes to
manufacture.

The global market for engineering plastics in terms of revenue was estimated to be worth $45.2
billion in 2011 and is expected to reach $76.8 billion by 2017.

28-Jun-19 19
28-Jun-19 20