PA4005 Secondary Processing Operations Syllabus:

PA4005 Secondary Processing Operations Syllabus – Anna University PG Syllabus Regulation 2021

OBJECTIVES:

 To know about the different secondary processing methods like calendaring, thermoforming, and rotomoulding.
 To gain knowledge about the processing of FRP laminates.
 Acquire knowledge about different types of foaming.
 To understand the various machining and joining methods for plastics products.
 To study about different coating processes

UNIT I CALENDERING, THERMOFORMING AND ROTOMOULDING

Calendering: Introduction–type of calendars–roll configuration–Definition of terms such as calendar bank–calendering process–process variable and application. Thermoforming: Introduction–pressure forming–vacuum forming–Techniques of vacuum forming–simple vacuum forming, drape forming, plug assisted forming, snapback vacuum forming– pressure snap-back forming-blowback forming–merits & demerits of vacuum forming – vacuum forming moulds. Pressure forms–Advantages over vacuum forming–material for thermoforming–heating systems. Matched deforming–continuous forming methods – application.

UNIT II FRP LAMINATES

Introduction, FRP processing methods – contact moulding – hand layup, spray up method– vacuum bag & pressure bag moulding, filament welding, centrifugal casting, pultrusion, matched die moulding – Laminates, definition of terms – high, pressure laminating process, types of machinery, impregnation systems – decorative and industrial laminates, continuous high pressure laminating process, application.

UNIT III CELLULAR PLASTICS

Introduction–process to create foam in resins – mechanical foaming, chemical foaming, physical foaming–processes to shape and solidify foams–low pressure foam moulding, high pressure foam moulding, RIM extrusion foaming, casting foams, steam chest moulding structural foam moulding – applications.

UNIT IV MACHINING & JOINING OF PLASTICS

Introduction–Importance of machining–methods viz. cutting, drilling, blending, filling, etc. Joining– principles–cohesion principle, adhesion principle–solvent cementing, Dop cementing, welding of plastics–viz. high frequency welding thermal sealing, spin welding, vibration welding, hot plate welding, ultrasonic welding, Adhesive bonding–examples: Mechanical fasteners. Other Secondary Processes: Printing, painting, hot stamping, in mould decoration, Electroplating and vacuum metallising.

UNIT V CASTING PROCESSES AND ROTATIONAL MOULDING

Dip casting, slush casting, continuous casting, cell casting, processes and applications. Introduction– principle–process–machinery used–materials–moulds, process parameters–merits & demerits of roto moulding. Coating Processes: Roller coating, powder coating, fluidised bed coating, electrostatic spray coating, processes and applications.

TOTAL: 45 PERIODS

OUTCOMES:

At the end of the course, students will be able to
 Gain knowledge of various secondary processing techniques and their importance with industrial relevance
 Select a specific processing technique as per the requirement.
 Learn different FRP processing methods and foaming methods
 Choose suitable machining and joining methods for plastic products.
 Understand different coating processes and applications

REFERENCES

1. A. Brent Strong, Plastics: Materials and Processing Practice – Hall, New Jersey, 1996.
2. Bruins, Paul F., ed. Basic principles of rotational molding. CRC Press, 1972.
3. Crawford, Roy James, and James L. Throne. Rotational molding technology. William Andrew, 2001.
4. Wagner, John R, Eldridge M. Mount, and Harold F. Giles. Extrusion: The Definitive Processing Guide and Handbook, Second Edition. Kidlington, Oxford: William Andrew, 2014.
5. Bown, John. Injection Moulding of Plastic Components: A Guide to Efficiency, Fault Diagnosis and Cure. London: McGraw-Hill, 1979.
6. Injection Moulding Technology. Düsseldorf: Published by Verein Deutscher Ingenieure, 1981.
7. M.N. Watson, Joining Plastics in Production, the Welding Institute, Cambridge, 1988.
8. Strong, A B. Plastics: Materials and Processing. Upper Saddle River, N.J: Pearson Prentice Hall, 2006
9. Bebb, R H. Plastics Mould Design: Vol. 1. London: Iliffe for the Plastics Institute, 1962.
10. Rauwendaal, Chris. Polymer Extrusion. Munich: Hanser Publishers, 2014.
11. Throne, James L. Understanding thermoforming. OH: Hanser Gardner Publications, 2008.