Polymer Processing

ME 4210: Manufacturing Processes & Engineering 1

Ramesh Singh
 Outline

• Polymer Basics
• Injection Molding
– Process description
– Analysis
• Compression Molding
• Blow Molding

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 Polymer Basics

• Definition
– poly = many
– mer = basic recurring molecule
– Polymers are long chain of recurring basic molecules

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 Polymer Properties

• Low density
• Low electrical and thermal conductivity
• Low strength and stiffness
• High strength-to-weight ratio
• Good resistance to chemicals
• Wide choice of colors and transparencies
• Ease of manufacturing
• Relatively low cost

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Polymers: Mechanical Properties

metal
Stress

polymer

Strain

Comparison of metal and polymer

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 Polymer - Classification
• Thermoplastics
– Molded and remolded by heating
– posses linear and branched chains
– PMMA, polycarbonate (PC), polyethylene (PE), PVC etc.

linear chain

branched
• Thermosets chain
– Solidify by being chemically cured during which long
macromolecules cross-link with each other and cannot be remolded
– Epoxy, polyester, polyimides etc.

Cross linked chain

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 Thermoplastics vs. Thermosets

• Thermoplastics
– Little cross linking
– Ductile
– Soften with heat

• Thermosets
– Large cross linking
– Hard and brittle
– Do not soften with heat

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 Polymer - Classification

• Elastomers
– Undergo large extension without fracture and recover
quickly after the load is removed (lightly cross-linked
which permits almost full extension of molecules)

– Rubber, Silicone etc.

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 Thermoplastics

Characteristics Applications

• Mechanical properties vary with temperature • Bottles

• Exhibit creep behavior • Cable
• Molecules oriented in direction of elongation insulators
• Hygroscopy (water absorption) in some • Tape
thermoplastics • Blender bowls
• High coefficient of friction • Medical
syringes
• Textiles

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 Thermosets

Characteristics Applications

• High thermal stability and insulating properties • Glues

• High rigidity and dimensional stability • Automobile
• Resistance to creep and deformation under body parts
load • Matrix for
• Light-weight composites in
boat hulls and
tanks

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 Elastomers

Characteristics Applications

• Recover large deformation • Tires

• High friction and nonskid surfaces • Hoses
• Corrosion resistance • Footwear
• Electrical insulation • Linings
• Shock and vibration insulation • Gaskets
• Seals

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 Polymer - Classification

• Based on degree of crystallinity:

1. Amorphous

2. Semicrystalline

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 Polymer - Classification

• Amorphous
– Molecular chains intertwine with each other with
irregular packing

– Amorphous polymers exhibit a distinct change in

mechanical properties across narrow range of
temperatures

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 Polymer - Classification

• Semi-crystalline
– Some molecular chains are packed in an orderly
manner and some in an irregular manner

– The degree of crystallinity greatly influences the

mechanical and physical properties

– With increase in degree of crystallinity, polymers

become stiffer, harder, less ductile, denser and more
resistant to heat

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 Properties – Amorphous Vs. Semi-crystalline

Amorphous

Semi-crystalline
Specific Volume

glassy

1. Glassy
2. Glass transition
glass trans. temp 3. Leathery
melting temp.
4. Rubbery
5. Viscous
Temperature ME 4210: Manufacturing Processes & Engineering 15
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Injection Molding Machine

ME 4210: Manufacturing Processes & Engineering 16

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Injection Molding Schematic

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Mold Schematic

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 Process

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 Process

• Pellets placed in hopper

• Pellets fall into barrel through throat
• Pellets packed to form solid bed
– air forced out through hopper
• Pellets melted by mechanical shear between
barrel and screw

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 Mold

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Injection Molded Parts

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Injection Molding

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 Process Characteristics

• Utilizes a ram or screw-type plunger to force

molten plastic material into a mold cavity
• Produces a solid or open-ended shape
conforming to the mold cavity
• Uses thermoplastic or thermoset materials
• Produces a parting line and sprue and gate
marks
• Ejector pin marks are usually present

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 Process Capabilities

• Cycle time 10-60 s

• Economical for high production runs > 10,000
• Maximum section = 13 mm
• Minimum section = 0.4 mm for thermoplastics, 1 mm for
thermosets
• Size = 10 g -25 kg for thermoplastics, 6 kg max. for
thermosets
• Tolerance (typical)
– ±0.1 mm
• Surface roughness is a function of die condtion
– 0.2-0.8 μm is obtainable

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 Injection Molding

• Advantages
– Very complex shape and intricate details possible
– Highly automatic process
– Fast cycle time
– Widest choice of materials

• Limitations
– It has high capital cost
– Economical for large numbers of parts
– Large pressures in mold (20,000 psi)
– Complicated runner and gating system

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 Extrusion

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 Analysis of Injection Molding

• Motivation
– To compute flow rate of melt in the extruder

• Assumptions
– Newtonian fluid
– Separate into drag and pressure flows
– No slip at walls
– Incompressible
– Laminar flow
– End and side effects are negligible

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 Drag and Pressure Flow

• Drag Flow is due to the interaction of the rotating screw and

stationary barrel.
• Pressure Flow due to the pressure gradient which is built up
along the screw.

Drag and pressure flow

ME 4210: Manufacturing Processes & Engineering 29

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 Drag Flow

• For the small element of fluid ABCD the volume flow rate dQ is given
by:
dQ = V. dy . dx
• If the velocity gradient is assumed to be linear,
V = Vd ( y / H )

Hence, Qd = (1/2) T H Vd

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 Pressure Flow

High Pressure Low Pressure F3

A B
F1 F2
dy y
y H C D
z F4

Free body diagram of the fluid element

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 Pressure Flow

• Let P be the pressure and τ be the shear stress acting on the fluid
element ABCD. Hence, the forces acting on that element are:

(t+ dt) dzdx

A B
(P + dP)dydx Pdydx

C D
(t) dzdx
Force balance yields,

-dτ

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 Pressure Flow

Integrating the above equation to give the shear stress at any distance y
from the centerline,
+y

- -
0

Substituting and Integrating from base to a distance y from center,

- -
-

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 Pressure Flow

Now, the volume flow rate is given by:

dQ = V T dy
Substituting for V and integrating to get the pressure flow, Qp

Q = Qd + Qp

Q = (1/2) T H Vd

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 Pressure Flow

We are interested in the fluid flow in the extruder as it is dragged

along by the relative movement of the screw and barrel.

Details of extruder screw

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 Pressure Flow

For the case shown in extruder, where the fluid element is between the
two flights, assuming e is small, T is approximated by:
Vd = Vbarrel.cosφ
Vd =pDN.cosφ
T = πD tanφcosφ
where,
and

In terms of extruder geometry,

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 Flow in Round Runner or Die

High Pressure Low Pressure

τ+ dτ
p + dp p
dr
r D
τ

Free body diagram of the fluid element

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 Flow in Round Runner or Die

Equilibrium equation will yield,

Integrating and applying boundary conditions total flow is,

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 Example

You are extruding a polymer material through a steel die.

The density of the polymer is 980 kg/m3. At processing
temperature, its viscosity (µ) is 103 N-s/m2. The internal
diameter (D) of the barrel of the machine’s extruder is 28
mm, with a flight width (T) of 21 mm, and a flight depth (H)
of 4 mm. The helix angle of the screw (φ) is 15 degrees.
The screw is 1.25 m in axial length. The die is a cylinder 5
mm in diameter and 40 mm long. You may assume the
barrel rotates and the screw is stationary. Determine the
RPM of the screw to make product at a linear velocity of
10 cm/s?

ME 4210: Manufacturing Processes & Engineering 39

Ramesh Singh
 Solution
The melt enters the die from the extruder hence for steady state the
flow rate should be the same and the pressure drop should also be
the same:
Qextruder = Qdie
ΔPextruder= ΔPdie
Given:
Vdie = 10 cm/s H = 4 mm Lextruder = 1.25 m
Ddie = 5 mm Dbarrel = 28 mm Ldie = 40 mm

Qdie = Adie. vdie

= π/4. (5 x 10-3)2. (0.1)
= 1.963 x 10-6

ME 4210: Manufacturing Processes & Engineering 40

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 Solution
From round die analysis,

Qdie= h

p (2.5 ´10-3 ) 4 DP
= 1.96 ´10-6
8(103 )(40 ´10-3 )

ΔP = 5.12 MPa

Using the extruder flow,

Qextruder= (1/2) T H Vd

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 Solution
dP DP
=
dz Lextruder
The picture can't be displayed.

sin j
Solving for Vd (velocity in the barrel channel),

Vd = 0.0467 m/s

Vd = Vbarrel.cosφ

Vbarrel=
pDN
60
N = 33.01 rpm

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Compression Molding

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 Process Characteristics

• Uses thermoset preforms or granules

• Materials are usually preheated
• Material must be accurately measured to
maintain uniform size or to avoid excess flash
• Metallic inserts may be molded into the product
• Shape must not have undercuts
• Requires no sprues, gates, or runners

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 Process Capabilities

• Cycle time 20-600 s

• Production runs > 1,000 may be 100 for small parts
• Maximum section = 25 mm
• Minimum section = 0.25 mm
• Size = 10 g -15 kg
• Allowance
– ±0.1 mm
• Surface roughness is a function of die condition
– 0.2-0.8 μm is obtainable

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 Compression Molding

• Advantages
– It has lower mold pressures (1000 psi)
– Minimum damage to reinforcing fibers (in composites)
– Large parts are possible

• Limitations
– Very complex shape and intricate details not possible
– Requires more labor
– longer cycle than injection molding
– Each charge is loaded by hand
– Air entrapment possible

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Ramesh Singh
Blow Molding

ME 4210: Manufacturing Processes & Engineering 47

Ramesh Singh
 Process Characteristics

• Inflates a softened parison tube to the contour of

a mold cavity
• Uses thermoplastics
• Forms thin-walled hollow products
• Parting lines are present
• Wall thickness can be increased by increasing
the parison tube wall thickness
• Flash is present but is minimal

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 Process Capabilities

• Production rates 100-2500 pieces/hr

• Production runs can be as high as 10,000,000
• Maximum section = 6 mm
• Minimum section = 0.25 mm
• Size = 10 g -15 kg
• Tolerance (typical)
– ±0.1 mm
• Surface roughness is a function of pressure

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 Blow Molding

• Advantages
– It can make hollow parts (especially bottles)
– Stretching action improves mechanical properties
– Has a fast cycle
– Not labor intensive

• Limitations
– It has no direct control over wall thickness
– Cannot mold small details with high precision
– Requires a polymer with high melt strength

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 Summary

• Polymer properties
• Injection molding basics
• Analysis of polymer flow
• Compression molding
• Blow molding

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