© Pearson & GNU Su-Jin Kim Plastics Manufacturing Processes Plastics & FRP Associate Professor Su-Jin KimSu-Jin Kim School of Mechanical Engineering Gyeongsang.
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© Pearson & GNU Su-Jin Kim© Pearson & GNU Su-Jin Kim
PlasticsPlasticsManufacturing ProcessesManufacturing Processes
Manufacturing ProcessesManufacturing Processes
Plastics & FRPPlastics & FRP
Associate Professor Su-Jin Kim
School of Mechanical EngineeringGyeongsang National University
© Pearson & GNU Su-Jin Kim© Pearson & GNU Su-Jin Kim
PlasticsPlasticsManufacturing ProcessesManufacturing Processes
Contents
1. Plastic Process• Extrusion ( 압출 )• Injection molding ( 사출금형 )• Blow molding• Thermo forming
2. Composite ( 복합재료 / 강화플라스틱 )• Composite process
3. Rapid prototyping ( 쾌속조형 )
© Pearson & GNU Su-Jin Kim© Pearson & GNU Su-Jin Kim
PlasticsPlasticsManufacturing ProcessesManufacturing Processes
Processing of Plastics
1. Extrusion ( 압출 )2. Injection molding ( 사출 )3. Blow molding4. Thermo forming
© Pearson & GNU Su-Jin Kim© Pearson & GNU Su-Jin Kim
PlasticsPlasticsManufacturing ProcessesManufacturing Processes
Extrusion
• The molten plastic is forced through a die and cooled.• Long products with constant cross-section are extruded.• High production rates, low tooling cost.
http://kr.youtube.com/watch?v=Ct34UCjOr-c&feature=related
Throat
Barrel
Gear reducer Box
Thermocouples
Feed section
Barrel heater/cooler
Barrel liner
Melt thermocouple
Melt section
Adapter
Breaker plate
Melt-pumping section Screw
Die
Wire filter screen
Hopper
Motor
© 갈창우 , GNU
© Pearson & GNU Su-Jin Kim© Pearson & GNU Su-Jin Kim
PlasticsPlasticsManufacturing ProcessesManufacturing Processes
Injection molding
http://ma.gnu.ac.kr/vod/Plastic/Plastic_Injection.wmvhttp://ma.gnu.ac.kr/vod/Plastic/Plastic_Injection_Molding.MP4http://kr.youtube.com/watch?v=bit-D1NnfjI&NR=1http://kr.youtube.com/watch?v=NedTUB7YQE0&feature=related
Hopper
Barrel
Mold
• Plastics are melted in a heated cylinder and forced into a mold by hydraulic plunger of rotating screw.
• Complex shape and good dimensional accuracy can be achieved, as in die casting.
© Pearson & GNU Su-Jin Kim© Pearson & GNU Su-Jin Kim
PlasticsPlasticsManufacturing ProcessesManufacturing Processes
Injection molding
• Die structureSLIDE CORE
EJECTION PLATE EJECTION PIN RETURN PIN
GUARD BUSH
GUARD PIN
ROCKET RING
SPRUE BUSHINGANGULAR PIN
CORE
돌출판 돌출핀Injection Mold http://ma.gnu.ac.kr/vod/Plastic/Injection_Mold.wmvJY-Solutec http://www.jysolutec.com
© Pearson & GNU Su-Jin Kim© Pearson & GNU Su-Jin Kim
PlasticsPlasticsManufacturing ProcessesManufacturing Processes
Injection molding
Vacuum Cleaner: Hand grip
Blower: Housing
http://www.tsmould.com/cyberpr01.htm
© Pearson & GNU Su-Jin Kim© Pearson & GNU Su-Jin Kim
PlasticsPlasticsManufacturing ProcessesManufacturing Processes
Design for Injection Molding
• Parting line is flat or simple-curved surface• Flow path ratio (length/thickness < 200)• Clamping force = Pressure x Area• Draft angle 1~2˚ • Shrinkage PE(1.5~6), PP(1~3), PS(.2~.6), PVC(0.1~0.5)• Reinforcements (ribs and bosses)• Defects : Sink mark, Weld line, Air traps, Deflection
© Pearson & GNU Su-Jin Kim© Pearson & GNU Su-Jin Kim
PlasticsPlasticsManufacturing ProcessesManufacturing Processes
Injection Molding
• MIT Lecture Node
• http://ocw.mit.edu/courses/mechanical-engineering/2-008-design-and-manufacturing-ii-spring-2004/lecture-notes/04_polymer_1_6_f.pdf
• http://ocw.mit.edu/courses/mechanical-engineering/2-008-design-and-manufacturing-ii-spring-2004/lecture-notes/05polymer_2_6f1.pdf
© Pearson & GNU Su-Jin Kim© Pearson & GNU Su-Jin Kim
PlasticsPlasticsManufacturing ProcessesManufacturing Processes
Blow molding
http://www.youtube.com/watch?v=vSabFFQUr9E&p=9B6D9EAE75875D9Dhttp://kr.youtube.com/watch?v=grIPNOHkdOc&feature=relatedhttp://kr.youtube.com/watch?v=3haIAsECzRchttp://www.youtube.com/watch?v=oR0gMKN58kY&p=9B6D9EAE75875D9D
• Blow up a plastic balloon to fill the mold.• Hollow thin-wall parts; beverage and food containers.
© Pearson & GNU Su-Jin Kim© Pearson & GNU Su-Jin Kim
PlasticsPlasticsManufacturing ProcessesManufacturing Processes
Blown film
• A thin-walled tube is extruded and expanded into a balloon shape by blowing air until the desired film thickness is reached.
http://kr.youtube.com/watch?v=W0QbPtYXsRs&NR=1
© Pearson & GNU Su-Jin Kim© Pearson & GNU Su-Jin Kim
PlasticsPlasticsManufacturing ProcessesManufacturing Processes
Thermo (Vacuum) forming
http://kr.youtube.com/watch?v=deeENCiuKWMhttp://kr.youtube.com/watch?v=YCGEKT3iHMs&feature=relatedhttp://www.metacafe.com/watch/1685267/thermoforming_machine_by_europack1_gmail_com/
• The thermoplastic sheet is heated by an oven until it is softened, pressed into the mold using vacuum pressure, and held until it cools.
• Medium production rates, low tooling cost.
© Pearson & GNU Su-Jin Kim© Pearson & GNU Su-Jin Kim
PlasticsPlasticsManufacturing ProcessesManufacturing Processes
Economics of Processing Plastics
• Design and manufacturing decisions are based on costs of equipment, tooling and production volume.
10 102 103 104 105 106 107 Number of parts
Machining
Extrusion
Injection molding
Blow molding
Thermo forming
Pro
duc
tion
rate
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