PA4102 Manufacture of Plastics Products Syllabus:

PA4102 Manufacture of Plastics Products Syllabus – Anna University PG Syllabus Regulation 2021

COURSE OBJECTIVES:

 To understand the functions of each of these additives, technical requirements, types & mechanism, and their effective evaluation are dealt with in this subject.
 To select suitable plastics material compounding and mixing techniques like two roll milling, internal blender, single / twin screw extruder, etc.
 To learn the fundamentals of compression moulding & transfer moulding.
 To impact knowledge on basic processing of thermoplastics.
 To analyze the various processing techniques of plastics materials

UNIT I COMPOUNDING OF THERMOPLASTICS

Compounding-Importance, ingredients, master batch, equipments- Twin screw extrusion, compression moulding and compounding lines -compounding of polyolefins, polystyrene and styrene copolymers, engineering polymers, natural fiber filled plastics, post compounding operations.

UNIT II INJECTION MOULDING AND EXTRUSION PROCESS

Injection Moulding: processing outline- Types-effect of processing parameters on moulding quality, Troubleshooting. Basic principles of extrusion–Types of extruders, general features of extruders. Melt fracture &Bambooing. Production of blown film, cast film/slot film, BO film, coextruded film. Tube/pipesizing take off equipment, extrusion coating, wire & cable covering–pretreatment of conductor, cooling, constructional features of dies for the above processes and trouble shooting. Applications of extrusion and new developments.

UNIT III BLOW MOULDING, COMPRESSION & TRANSFER MOULDING PROCESS

Basic principles of blow moulding–Injection Blow moulding, extrusion blow moulding, Parison programming, Advantage & disadvantage of blow moulding. Basic principles of compression and transfer moulding-Bulk factor-Curing time-Mould temperature and Pressure requirements-Preforms and preheating-Techniques of preheating- Machines used-Types of compression mould-Common moulding faults and their correction. Advantages of transfer moulding over compression moulding Equipment used-Moulding faults–causes and remedies.

UNIT IV THERMOFORMING, CALENDERING AND ROTO MOULDINGPROCESS

Basic principles–Raw materials & types of thermoforming processes, Thermoforming moulds processing parameters—faults, causes and remedies. Calendaring-Principle and process description, types of calendar units 2, 3 and 4 rolled calendars, Design of calendar roll, Heating and temp control, roll crown, roll crossing and roll bending, materials for calendaring, calendaring sheets and films, embossing, coating and lamination by calendar. Rotational moulding – Introduction-principle-process machinery used-materials-moulds process parameters-merits & demerits of roto moulding.

UNIT V SELECTIVE LASER SINTERING (SLS) PROCESS

Principle, process, Indirect and direct SLS- powder structures, materials, post processing, surface deviation and accuracy. Applications; Laser Engineered Net Shaping (LENS): Processes, materials, products, advantages, limitations and applications. Other Additive Manufacturing Systems: Shape Deposition Manufacturing (SDM), Ballastic Particle Manufacturing (BPM), Selective Laser Melting, Electron Beam Melting;

TOTAL: 45 PERIODS

COURSE OUTCOMES:

At the end of the course, students will be able to
CO1 Acquire knowledge of processing of plastic materials by injection moulding, extrusion, and blow moulding.
CO2 Understand processing techniques like compression molding and transfer moulding of thermoset plastics.
CO3 Acquire the knowledge of processing of plastics materials
CO4 Gain knowledge on extrusion & Laser sintering technique
CO5 Acquire knowledge on thermoforming, calendaring & roto moulding process.

REFERENCES:

1. Fisher, Edwin George., and E. C. Whitfield. Extrusion of Plastics: [by] E.G. Fisher, Assisted by E.C. Whitfield. 1976.
2. Hornsby, P R. “Plastics Extrusion Technology. Edited by Friedhelm Henson, Carl Hanser Verlag, Munich, 1988.
3. Donald V. Rossato, Injection Moulding Hanbook, International Thomson Publishing Co., 1995.
4. M.S. Welling, Injection Moulding Technology, VDI–VerlagGmbh, 1981.
5. Seymour S. Schwartz & Sidney H. Goodman, Plastics Materials and process, Van Nostr and Reinhold Company, New York, 1982.
6. Innovation in Polymer Processing By Stevenson., 1996.
7. Extrusion The definitive Processing Guide and Hand Book By Giles, H.H & Others., 2004.
8. Iyesew, A.I., Compression Molding
9. Bruins Basic Principle of Rotational Molding
10. Brycle, D.M, Basic Principle of Thermoforming