5.

What are the primary and secondary pr

metal powders ?
6. Explain the following powder meta llurg
.
(a) Blendmgorm 1xmg
. .
oceses, Used t
.
Y p1 oces
(b) B . ses :
vvo~l<SHop

or Pr0
. ces
lEclf~

8i
\\
ne
~
~
,, ~
.........- ,a
c-f
~ ...
A V'l'ER
•• ' f
', I

· nqu etr
(c) Presintering. ing or c0111
:b h •s· . '
7. Descn et e mtenng process in detail.
Pilctin g

8. Explain the utility and applications of s econdary

Processe .
metallurgy.
9. What important consideration s should be ma d ein d .
s •n Po
ll'o,,
PLAS TICS AND THEIR
metal Iurgy products ? es1gning th
. e~~
10. Wnte short notes on the following with r e tierence to ~

(a ) Injection moulding (b) H . POWdermetaJI PROC ESSIN G

ot isostatic . Utgy;
(cl Osprey process (d) C Pressing
eracon proces 8 .
(e) Centrifugal compacting. ·

11. What are 'cermets'? Give a few exam pl f :

es O useful applications~ 22.1 INTRODUCTION
powder metallurgy.
In general terms, the word Plastic has been used in the past for
12. What are cemented carbides? How a re th
13 Wh ey processed ?. all those materials which could be readily moulded by heating or pressure
. at are the advantages of powder metallurgy .
14. What th di processes? or both. But, the modern application s have changed this concept and ll
. are e sadvantages and limitation s of powder.metallurgy1 have limited the area <>f this word to cover only those Synthetic Organic i\
Materials which become Plastic when heated and can be formed into
different shapes under pressure. After having been processed and
finished, they are observed to be fairly hard and rigid. Various useful
articles ~an be produced from them rapidly, accurately and with excellent
s~ace finish. They are marked by their extreme lightness in weight, I

high corrosion resistance and good dielectric strength. Also they can be I
produced in different colours or as transparent . Plastics are also known I
as 'Synthetic Resins'.
In scientific terms t hese organic compounds are called polymers.
Th t · ·
, e erm polymer has its. base in Greek terminology , where 'poly'means I:
many' and 'mers' means 'parts'. Thus, the term Polvmer stands to 111·
II
represent a substance built up of several repeatina ~nits each unit
?eing known as a Manomer. Thousands of such u;zits or ·Munomers
Join .together in a polymerisati on reaction to form a Poly mer. There
are some n a tural polymers like st arch. r esi ns. shellac, ceJiulose,
Proteins, etc., but our studies in this chapter will mostly confine to the
synth et ic polymers only, beca use th e.r find a wide application in
engineering work.
(587)
 I
'f
,11
I
&.,,c::
All the 1
\.:LASSIFICATION Wo~ks
liop
y~
ft~ , ..rS ~NO ,n ,.. . PROCESSING
-e,
p astics are broadly cla . 589
l. Thermosetti ssified into t . ,t>'s,,..,
by heat, effectin ng Plastics. Tllos Wo 1nain usifUL coMMON PROP_ERTIES OF PLASTICS
setting Plasti!t ~~n:ielversible chemic:t:istics Whi:oup,~11. zz.A 11 wing useful properties are common with most of th .
permanent sha e 1er Words, We c· ange, are Elre h11 "''~: 'f}le fo o e Plastics
reheating. The:ar:':;:l:ated and presse~:~:y that ~~ed'lli:~~ Lightness in weight
2._ Thermoplastics T~w~ as Heat-settingc:n'l'not be ~0~cq%e ~ ~: Good resistance to most of the chemicals
an d agian by l t• · ose plastic , 1 r he-. eneii ~ Good corrosion resistance.
heated d iea mg are called Th s w lich can b • ..,.osek ., 3. l .
I I an reshaped b ennopl e Soft ... J_ High electrical insu ation.
hand Th Y pressing . astics. Th ened ':l
· . ey are also know many tunes. 0 . us, the Qgai1 S. Easy to shape and mould.
shaped into bars tub _ n as Cold-setting 1\f n cooling, th y can~ Can be made transparent or coloured.
, e.s, sheets, films, and llla ateriaJs. They hecoll!e 6.
22.3 POLYMER ADDIT ny other sh ey can~ 7. Non-resonant.
IONS apes. B. Good resistance to peeling.
. Oneormoreofthe . ' - -'--1 d t fh t
either before or d .· following materials a 9. Non-con uc ance o ea .
plastics : ui mg [Link] t re added to the P, 10. Resistance to moisture and greases.
0 make them 01
, :Ymers,
I. Catalysts or A Processable 22.5 THERMOSETTING COMPOUNDS (PLASTICS)
Hardeners The cceJerators Th .: The common Thermosetting Compounds are the following :
che ·ca1 • Y are the cataJ • ey are al k ·
m1 reactions during 1 ysts which are added t so . nown as LPhenol Formaldehyde. It is widely known by its trade name
. 2. Fillers. These po Ymerisation of plastics o accelerate the Bakelite, after the name of its inventor Dr. L. Bakelite. It is the most
dilute them in ord are the materials add . , , • ·1 widely used plastic. It is made by the reaction of Phenol with
their bulk and th er to reduce their consu e? to synthetic resins to Formaldehyde. It has high strength, hardness, stability. rigidity and
when they are'fi us, r~duce the material mptwn. They also increase can be easily cast or laminated. It has high resistance to heat. electricity
and thermal ~ely distributed help . _cost. Many of them; specially and water. It is generally produced in dark colour shades. It is adversely
. · resistanc f h ' In 1ncreasin t h ·
include clay tal e o t e plastics M t . g s rengt , stiffness affected by the attack of strong acids and alkalies. Some of its typical
calciUJn ca b' c, Wpod flour, mic · a enals added for this purpose uses include handles, radio cabinets, plugs, knobs, dials. bottle caps.
M r _onate,
3 • odifiers Th asbestos, glass fi~ quartz, alumina, carbo,n, black,
1 res, etc pulleys, wheels, tooling and forming dies, telephone handsets and
.
the properties ofb. ese are the chemical8 . . ,, . electrical components like switches, etc. These plastics are also called
properties as ase resin. Some ofth added to plastics for changing Pbenolics.
Pl .w:U. em help in improving mec11anical 2. Urea Formaldehyde. It is obtained by the condensation of Urea

l
4
• ast1eisers Th, and Aqueous Formaldehyde. It is widely used as an adhesive and binding
t J1e re::;ins at for . • ey are the che . .
finished ~t ming temperatu 01Jcals [Link] for either softe111118 material, s uch as in foundry t·ores and plywood manufactW"e. It has
age and to .
0
re or to · 1 good colourabilitv ii\ light colours and can be easilv mouJded. It cannot I.
Plasticise · Illlpa,-t fl .b . . tmproue their toug/uie~s attic
r 1s normal! ex1 llity t 0 U1 . A be cast and can ~ithstru\d temperatures upto 77" oclv. It is widely used
5 s . . . Ya fluid ofl . eir finished productli,
· tab1hsers Tl . add . .llgh molecuJa r we1g •J · ~or cabinets, toilet seats, table ware, buttons. doclt cases, dials for
detc · t· · 1e1r · . Jtwns t 1t. · · instruments, electric switches and plugs. It is also known as an Amino
nora wn due to th .
6 I . . e [Link],on of h o P1a.-.,t,n; help iJJ prevo{l tlnH nesin.
· _mt~ators. They he) . . ~at and light. .
Polymensatton. H o 18 · [Link] In 1n1tiat; . · 3. Phen~ Fvrfural. It has good [Link] at low ,noulding
2 2 01 ng or starting th~ reaction, i.e., ten1puratures. and set:'.\ quiduy a t [Link]>ect temper;ture. Like Phenol
7. Dyes and Pigine t Y used for th ·
. . n s. 1'J 1s purpose. Por11ialclehy(Je, its produds a n i a lso availab! , , Lu· k shades of colour.
impart different colours and 8 h 18Y are the .0 1 . dded W
ades to ) ~- ourtng agents. a
P ast1cs.
r· - .-

It ha s go od re sis
fa br ica ted . A few
. .
hn m
.
br nd er m res mo
ad he siv es .
. .d b
ta nc e to m oi stu

gs , el ec [Link] l pa
. rts an d in
1 a ra s1. ve w l
.
.
.

re pr es en ta tiv e
st
re an d ele ctr ici

ru
ex am pl es of its
m en t ca bi ne ts
WORkSlioWl

ty a

It .
nd can
Product
1e e ls an d la m in . is alsos are h •1
ae
lEc11

_,be,

Use
'

d
e<\si,
.
pV'
511cS,.
7 ·
NDTH~R
\"
poly es e · .
ta~ we [Link] ot he r re sin s.
pROCESSING

po ., es tert,s- rs
h
1 ey
re de riv ed fro
T ~h a ha ve good m Polymeric Esters and, hence,
Th ey can be cast,
er y rap idl
co lou rab
.
nity and can be eas
compress1o .
n moulded or
ily
tng var . as pde uld d an d cu re v y at low tem pe ratures. They
4. M el am in e Fo n1she 8 1 bIe-,,,force d Jll 0 e , .
na m es hk . rm al de hy de . It
is av ail ab le un d ani rel•• e .,ceHent un us ua1 pr op ert ies like hig h d.1e\ectric
e...
. str
ength,
e M elm_ac, Ca tli. M 1 . .,e sofll bT ty h' h i'm pa ct
n, . e ~n tm e an d Pl erv
. bll• • en si . on al st a i 1 ig res ist an ce , low mm· sture
by th e co nd en sa
tw n po ly me ns at wn ari
as ko n, etc. lt'i s ou
s.t~ade bl·ah d1tll nd he at res1s · t ne e up o 204oc They are mostl
' t .
of m el am in e an " t' on a · y used m
It i_s pr oc es se d by . h
e1t er co mp re ss . d fo-..- obtain~ sbsorP l d a\astic pa rts · re gn a t·mg ma ·
ter ial s, binders for
low pre
io n or tra ns fe r , un p A few typ ica l us es ssure
di ele ctr ic str en
gt h, hi gh re sis ta mould•[Link] hyd reinfor
h _e. \am ce ~n d rn ou lde d pa rts . . ht s an of the se plast1-cs are ·
nc e to he at an d m
str en gt h an d is ex
tre me ly ha rd . It
ha
d sh oc k
s go od co lo ur ab ili 0
d as high g:• car
ina
bo d
~es
ies
.
. cr af t pa rts , sk y
air hg
arc hit ec tur al sheets.
Oi l-m od ifi ed Po
to m oi stu re , is qu
ite sta bl e an d ca ty g'ood r -~veran A}kY d s. Th ey ar e a lso kn ow n as lye ste rs,
It is wi de ly us ed n wi th sta nd tem
pe
, . es1stance
ra tu re s up~ 8°
[Link] use in d . sy nt he tic en am els an d lac qu ers.. TbevJ are als•o use d lil .
fo r mou_lde~ pa rts . tan ce s are reqmr
in clu de tel ep ho ne . So me o~ its rep 3 'fh~Y _a wh er e hi
gh . al an d he at
res1s ed. sueh
se ts, c1 rcm t br ea resentati~e_,Il~ ftuc
~ sohd forIIl bile ig ~lectn.c
an d la m p re fle cto
rs. M ixe d wi th ot
ke rs , sw itc h pa ne 9
ls, lighting fixture as in auto mo ni tio n pa rts . .
an d ad he siv e. he r re sin s, it is
als o us~cf~~ c~atin; 9 po ly ur et ha ne Th ey ar e foa m type p lastics us ed mainly for
. . . tra ns po s. t for in su lat io n kin g material
5. Ep ox id es or Ep cushions lll rta tio n se a s , an d as pac
ox y Re sin s. Th ei .. • for 'electronic eq U1. t
is Ar al di te . Th ey r m os t po pu lar tr. pm en .
ar e ob tai ne d by ~1~variety
re ac tio n of Bi sp co nd en sa tio n polym 22.~ THERMOPLAS
he no l an d Ep ic hl eri~q,J~?t in ~he TICS
an d mo uld ing . Th or oh yd ri n. Th ey
ey ha ve good ch ar e used/or,~asting
sh rin ka ge , ve ry em ica l an d ele ctr CELLULOSE OERIV
good ad he sio n to ica l res~~}.wce, low . ATiVES :
m et al an d gl as .
aff ec ted by mo st
or ga ni c so lv en ts. s etc ., an~ _are not 1. Ce llu lo se Ni.
tr at e. i,:- ob
It tam ed by treatin g cellulose w i~ ~
we ar an d im pa ct.
Th ey ar e qu ite ex
Th ey als o ha ve go
od resi~~ance ~ mixture of Ni tri-c . d Su lp hu ric _.-,.ci.d It has hi gh colo urabilitY , [Link]
.t
an . tan ce go · . b t
liq ui d form for us pe ns iv e an d ar e tou h
ghness, goo d c e mical res1s od resi...<:.tance to. mo ist ur e, u
e in ca sti ng , lam us ua lly av~lablem . · • . pe
of th e re pr es en tat in ati ng an d re in fo is highly in fla mm ed .
fo r fo un tam -p en bo die s, s cta cle
iv e pr od uc ts in clu rc ed mouldii;ig:"Somc ab le. It 18 us .
lw us in gs for Elec de .
to ol s an d d1es,J1-• fra me s, toi let art icl es , tab le te ba lls an d toy -m .aking.
trical Parts, En am gs an d fixt
. ure . s.d ~1 s b . d bv
tre ati ng Cellulos .th
Laminates. els , Ca st an d M
oulded Parts an 2. Ce llu lo se A c~ ta te . It is o tru ne - e w1 d
Acetic Ac id. It ha . [Link] be In jec tio n an
str en gt
6. Si lic on es . Th s hi gh d d ha s be tte r h, c~ . . . st
ey ca rry an un us Compressio .
n mo u lded '. ex tru e , sta bility ag ain . he at, is
W he re as , on on e ua l co mb in ati on •erti es. r t an d ha s a ten de nc tu re It
on th e ot he r ha nd
ha nd th ey po sse
ss th e sta bi lit y of
of prop . ts
·
. 1ghter th an ce ll l
u ose n1trabe colou y to a bsorb roo1s ·
th ey ha ve th e ve ino rg rod
an ic P TbeY uc ' is a go od in su lat or an d red . Us ed for coa n.,, ph otogr a phic
ti 2S
l ca n re sis t hi gh tem rsa til ity of or ga ni
c produc~s. tric film s, packaging, buttons 01 can t ~ t art icl es rad io pa ne ls, toys ' d tru de d
pe ra tu re s up to 26 , e an ex
str en gt h at hi gh 0°C an d po ss es '
tem pe ra tu re s. Th s ex ce lle nt die}ec
ed sheets. tu be s an d tods etc .
mo ul de d. In liq ey ca n be co mp re · B I I
ui d fo rm th ey ar ss ed an d rel"nforcare . 3. Ce llu l~ se Ac eta te u tv ,·a te Ob tai ne d
by tre at·in g Cellulose
r,J ..
,,i'1;/}
i
al so us ed as re
lu br ic at in g oil s
le as e ag en ts in
an d gr ea se s op er
e us ed as wa te r
sh ell m ou ld in g
ati
re pe lla nt s. TheYd ill
. Th ey ar e useTh \ ~e~de~cy' good st ab
eY
W1 th Ac etic Ac id a~~t
!/
Bu tor ic A. cid . lt

ex
ag
tru
ain
de
st he at an
.
ha s low _mo is
d lig ht, hi gh t~ ug
. t re ab so rp tio
u
hn ~: •
ca
tap
n
.

es
be
n
. I' I

I
ar e als o us e d m · pa · t ng be tw 1nJection moulded d. Us ed ,
m s, coa t·mg s, lam · · ee n 10 °c an d 260 C. tioll •1 ls radio ca bin ets , fo~ co ati ng s, i_ ns ul a:i ;et s, etc.
0

he at in g ap pa rtu . . .m ate s, fo am pr od uc ts, induc ha nd les , ste er in gw ~~ ' pip es an d tu bi ng . h .

s an d Je t en gm dill It is th e lig ht es t . .
ga sk et s fo r pr ov
id in g hi gh he at
e pa rts . 1n ru bb er
form, th ey ar 0 use 4. Et hy l .ce lll ~t P°an "" of all cellulose de
n~adtives·,
ce , go od electrical pr op •
re sis tan ce , in ex 811 d has good chelll1cal ert ies . s ur fac e ba r ness
in su la tio ns . tru sio n worlt
I •
A
 592
Wo~ICSt-fo~
. and stre ngt h. Use d as a
form ing dies h
' ose noz zles
bas e 11
and
or
mou
coa
lded
ting
~1a teria Js fl
~ i
' ··" :', / , . .
"';ncsANO
THEIR PROCESSING
,•
~r=
' or jigg ' ·,,:"
.ariJwali ;• ,. ,•.·.1 f
has att
5. Cel lop han e. It
t·
is av ·1 bl . arti cles
ai a e in ext rud ed she t
rac Ive app eara nce and h
.

fo11:n,
· 'filtt
•,,,
i; d
~r, P .
used for ram coat s, hoses and
,rbeY 3ret0 ys elec trica l plug b • · . stan t hnm
·
tubing; floor
.
~m m~
s, wire insulatio.n ' , , . . ;~et y gla,s d ,.,:/~','~~.-
ka . as goo d resi stan e kets, ' . gs fuel tanlu ; · · d... . : ia1r
and solv ents . Use d for pac ging , cur ta · ce to . · llt ~1 ve resi th' ~ smuiar
gas ., · of safety glas s, a ras1 .· ,) ,
. ins, dra pe rs and· llloistUre ~R.""' Jletpro 1 nam e m 1s group· is, [Link],... :.:,_ ·
6. Cel lulo se Pro pio i t b
nat e It s s a Je and t . Wrap p· •'lit btJ , ·t ms. The mos t pop u ar · . ~n~ e
fior moi stur e abs t. • ,oug h, h · 111g, otber I e . . . . . . "
orp ion and can be . pVC~- , n~,.
lded asJo wten e. It 1s_qmt e popu lar by itsb -~~
eas lly mou ( [Link] Flu o~o e~h ylen max imu m chemical resistance -
tem per atu res upt o 930 c.
U
c~n With:eo~
sed for tele pho nes , f~ It Of all the plas tics , it offe rs , (an _,
flas hlig ht case s. Unta1n·pe laoQ , t1;.
fe O0 · tem pera ture s upto 28,8 C, cann ot be d1~olved ~µ any solye
o .
nt.
lls
, ani . hsta nd c~nV eI}tie na1-
SYNTH ETIC RESINS : not bT mou lded. thro ugh
·, iii I ;~!s. ~qt abso rb moi stur e '. can ugh powder metallurgy me_thods. ft'
ked thro
I. Pol yet hyl ene s Th h eth~ ds-b ut can be wor
low friction and very low adhe
sion to othei.
ver y high :as•liigh 'electrical resi stan ce:,
• ey ave st 1.,. ·
.:a:: :u:a~~~
and l s • resi anc e to a tubes. It is--
so ven t , can be mad e fle
·bl forms like rods, shee ts. and
r.~ ;•J~ c~: ~~ sub~t/lflces. It is ava ilab le in rs and chemi~aI
electrical insu lato
~~ ~:: ~:~ ::i: ;.~ ~rb es
an~
d elec tn·c a1 1~~test of aJJ used for grea sele ss bea ring s, gask ets, - :·•
be inje ctio n and com s~rp tian , ver y goo properti corl~ainers. _ . . . by its trad e nam e Nylon... ltis
ld d is pop ular ly kno wn
. pres s1o n mo nd extr ude d It ·.> es,can ,.,, :6'. P~l yin ide'. It
m · l ~ e a for , .
y. Can be mo ~~
ngth , toug hne ss and elas ticit ·sha pes. Powder
con tain ers for che . Ica s,_ cor rosi on res ista nt coat1··;1 -."1~ used_
f .

a :qlafe_ria1 of high sti:e

insu lato rs.e xtru de insu on on wir es fab . . . _. . .~gs , electrical d into rod s, tub es and oth er usa ble
d lati a~d ·ext rude iator. ,
and t b. ' rics , developingtrays, pipes for this plastic. It is a good insu
u mg. · m.,,~thll iirgy, met hod s can also be used .
for mak ing
. ,,. I' .• ,,.
. Its specific uses are as fibre
2.. Pol ysty rene. I tha shi ghr e. t
moi stur e and el_ i ctrticity, andlia'sgood wea r resi stan c,e gear s, wire insu latio n ~d co~ ~-
col SIS anc e to cou plin gs,
~ be ~bta ined clea r or in an td heafhigh yarii"rcir 'd oth, bea'ri~gs and ul l kn b its. trade names
_Y our , has goo d resi stan ce . ' 7• Me th y I M eth acr yI ate. It is pop ar y own y
dim ensi ona l stab ility t emp era ture upto 82°C, and can uidl iig)r ligh l ~
' can wit hsta nd mar ked 'by, its: clea r colo ur-r
t
. cas , mou lded and extr ude
be d
sion '[Link] Lucite and Ple xig lass . It is at tem. pei:a [Link]!s [Link]
. · It c_an also be com pres be form ed easi ly
tr~s mis sion capa bjlit y, It can raft part s, such as canopy and [Link].t:...
is used for high freq uen par ts, toys , pack agihg; battery f~r airc "·
msu lat1 0n l20°C . It is w·idely · used
boxes, radi o Par ts and t bcyl , ., t es
·
and vari ous surg ical inst ruw
[Link]. ·
a e-w are rans pare nt bow ls, con tact l~ns
3 · Acr ylic Re · · h· h ,.; ,, . . ,, .
any Iour, hav e sins d
. The y hav
e ig tran spa ren cy ' can· ' · to oe made ID
22 . 7 ELASTOMERS .
co · ] ·
goo hstren gth ' d ie ectn c pro per ties , resis'tanc e ing
moi stu re, exc elle nt 1· -· · con side rabl y elon gate d by load
d
mou ld e , extr ude d ig d
t tran sm· 1tt·mg pow er, can be cast ,' injection Such Pol yme rs, whk h can be r orig inal shap e and size
st retc h form ed into she ets. A few iypic~ ng back to thei
at room tem pera ture and spri r$ $ ~1°[ a.'-
app lica tion s incl ud ~n coati~gs and ed Ela ~tom ~rs. ';l'he~e po1y~e
_rent she ets, tub es, plat es, ~P 0 n_ removal of load, are call thes e ) ><lly mer:ns \&' -
adh esiv es, lam inat e: :~~ spa lay case s, Iens ~r•~a)ves t~latively loose bond. The deg ree of a
el' stid ty in
ma. llen gth
, P teal inst rum ents , disp eve n [Link] t~p, tim es th:e,ir, orig
and helm ets.
' l ;, ' high that., th~){ .f:{lfl "~t l'8t ffi~ ns Ylhe n. the, loads: •ar.e.. ·
al\~ .lii~iH t'1~Y - rf.:li:~iu.
[Link] qrie,1uaJ d~n sio
1

4. ~in yl Res ins. A lar f1,11l~ ~ tllID (y ~ vism us ftuid,.

'
nu_mber of Vin yl and Po) yvin relll OVifl~( .N ~(H ('II &~.lu«:
...wni~ I\ i$ l\Q<l.<i~fr~m:..
are ava ~l~b le. The y can b;e injei :titJR , ~~ / i-.i.
w.~l~ [Link] wn &la sio mer, ,!f:he, .-j
cant)cj i~,~~ ~~~ Jr,O~l -
eas d~ cas t, cale nde red , tree ~
~o~ pess 10n mou lded and extr ber . ••,
m diff eren t vari etie s, S~ch
oil resi stan t, elec trica l res~
_u~ed into vari ous
ngid , flexible ' wat er and
. 1stan t h
sha pes
che
. The
mic ~
y are,
resi$
P
O ,di
J~ I
~'
ftW9
I 01 ~ilJ. i1)8'1"\dutPWM ~t~ . \\i~W t\~Q .f:\~
is ~~f U<t('tfi//~/~ft,'{i.,'M·•.f~l,i
~Opf~~' ~
p ~ ~~ ~ Qt'Ul.e oa~ rub

:ver y,us
·
eful
. ,'
.in.
h
,na
·.,
tur.
' •,'
alif
I
orm
; li'! Gd.,

t if,,i
1

ofte ' eat resi stan t or a com bina tjvo •Nat\ll'lll '.Rubbal\ ailthough eo.t d:•:;
resin.s, can P~ ~~.
or mo re of t h ese. The y are ,j.., ul.,,n llsol
form s n blen ded with oth er i,..0 ..., a - . wu.. t;,, . _.... u..,sallmc<1
in diff eren t colo urs and . s and smaJI soJ'd 1 pl~
'as shee t s, 1·1qu1d · ,
~
rr 594
WORl(s~ ' / ~
.
It carries fairly high strength and is less prone to tearing a ~~.~
~. ,,.o ftfE• ,t()CESSING 595
·I
It It l·s however adversely affected by many solvents and nd crat1., , ed An example of Compression Moa,.u__ .

Guide.
I
· fotfll• isus · -...isshow n 1n.
•
varieties '
of Synthetic Rubber have been developed gasoi- Wh" 1ne. Sei,,~i'
t\l~

. ·
comparable in the mherent properties to the natur
• lch ' 1 al ,re
. are %i1. · f.11• 22• · 1
\ · very h'a1hrubb er b.." •~
! possess greater stabihty ·
· of d"1mens10ns an d exhibit Pins
. . . h h ig re.81 •l
. stance
to oils and oxidation. That 1s w Y t ey find Wider ~ l~wrlere,? ,
than natural rubber. A few popular Synthetic Rubbers :PPhcati0118 m

~~= ' re descn ~ .. '

. ~ock Out iip~~er!
Synthetic Rubbers. There is a large variety of S . 1u l Pins (bJ
· · . Ynther
Rubbers in common use. A part1cu1ar van~ty, with trade lllarkca;
is compounded with natural rubber for use m the manufacture o'r . , mould before compression (b) Mould closed
,~, ' Another variety Thiokol has high resistance to oils, paints g/tt
..es.
(a)Open . . 1 f .
Fig. 22.1. Pnnc1p e o compression mou ng.
ldi

itr;I I , . . .
and sun. It is widely use d fi?r msu 1at10n coatmgs, soles and he~ls of
shoes, oil hoses, gaskets, diaphragms and coated fabrics. It can.'6e
• s0111e
1

22 10
TRANSFER MOULDING
i;ii,1, easily moulded through usual plastic moulding methods. Another · . 1 known as Extrusion Moulding or Gate Moulding. It
lt,1s a so dified form of Compression Moulding. In this, the heat
1, t variety, called Neoprene, is heat, oil and light resistant and i's ~sed··
j\'. ' is actually a moe applied to the compound separately outside the mould,
in shoe-making, insulation, belts , tyres and tubes , hoses, printingrblli dpressure ar th uld de
rubbe~;ht F an th latter becomes fluid it is transferred to e mo · un r
'i and as binder in abrasive wheels. Butyl, another synthet~c and when e · finall This uld ·
· through a sprue and gate, where 1t cures · y. mo lS
good strength, good abrasion resistance and other properties comparablt
. .,,di. pretlissureb t the operation is easier and enables trouble free production
to natural rubber. It is widely used for belts, steam hoses an:d 1~n1er., cos er, u ld. td· 11 b" ted
tubes. ofintricate parts with thin sections as the mou is n~ 11:c Y su '}eC ·
\ ' to the compression force. An example is illustrated m Fig. 22.2.
•:l 22.8 ,PlASTIC PROCESSING METHODS
.
The followmg methods are common l y emp 1oye d for processing
~
I
~Plunger Plunger
plastics into various usable articles :
f •I: 1. Compression moulding 2. Transfer moulding
Sprue
!" Preform

1t
i :t i
i. .:-j , .\·.·,
.1
}I
3. Injection moulding
5. Casting
7. Calendering.

22. 9 COMPRESSION MOULDING

-
-·
4. Extrusion
6. Slush moulding

. sties
!~ rl llii\1 . tastic Pla Before applying Af\er applying
,'I
w ,t 1
\'! [~~I ~; .,.
1
Most of the Thermosetting Plastics and a few .
T. 'hennop f'
··stso P
lacin~ a
d Pressure Pressure
. . ! 'r . can be moulded through this process. The process col::;IA punch, [Link] Fig. _ _An example of transfer moulding.
,r L, ,ii :r correct amount of plastic compound in a he~ted mou · .red shape ~n 22
11
22 2
· ,1 Force, compresses the compound from top mto the requi h cheJ1l 1cal · l~JECTION MOULDING
1
· density, The mould is kept closed for sufficient time to allow :fllci••dY . , . It is '•r . Pl tics The process
I' change (polymerisation) to complete, so that the product is s for faster '\ 1t/
111strate[ ~ouu~1only used for Thermoplas 1ic . 0 :m ~und is first
\ hardened. Although loose compound can be used, bu\et, ,.u,d
I ~l•dtodriv'" Fig. 22.3. The powdered_ plas~c ; . per,.\V!.lenlh•
·;, :r production a previously shaped cold compressed Tab L "1 ,, dra e off n101sture and then fed into t e Pfo..;n into the
; i ~ wn back, some of the powder drops
 596 . , ' / /
~ ', ;·,;,-, ,,,~~~~~ .~. ~ ,tt4£IR,PIQCESSING
C:liaid:6er!~ffer 1clo'~ · ' 'tile 'iii ' ·1J·i-i:.•e' I ' '' . . ~ ,,~ It~?,, . o tha shape . ", ~ 7
·-' •, · ' · ' ;T' ',.. .. J~g ' .,. ' ·' Q~ ,µ , H ran~ ,l~ mq,ved ,,-. , \ ~ l ,d esit~oft ,.,. · ,
I I pressure behmd the powder. This compresses th .. .forwa,r~l/1() oodl~gt. bl cooled h ' '1· .~ei~M~ilqW:-~~W'~J'~· -· . '
Iii it forward through the thin space left around the 01 ateriJ1 ·a\1,
Knockout Mould
eh n c0r1~~aoct.!
hro ,,
58
11
~ 1
~~~r-, : · "
' ' .r.,!f{;'{~';'.9fµ~~.-~(~~~t~ndc~/dl~~~
, , ., . .. . [Link]
. . eatedi1:. . 9t ' tb~[Link]'1be1t .·, 1 i,•:•- : · '-i , .- .,., , 1 .·. . · ··•, · Ya
_ ort~1-,,, 'oil\~ . 11 1 '
• :,,, • ·•" : '," ., ..
. 't Cl) Heatmg · ' Powct
• , , _ C r 'd •.
• • · · • 1
Pins Hopper. r- erect , -.-., . cto. ~ STING :; ,,
~ . :~ ~n ~1 ~ \ Resin ;.V . '
f=~~~'
· --.• ~ '. ·:
z-•'
-~:;:::;:;:::::::==ir~ · -
.,.,_ ___.,
·.l.
1
13 CA . ' . .
22, . ocessing method mvolves only heating d ,, .:. ,
.. '. ,
'fb15 pr_t is similar to the Metal Ca 8 ti..,,..,,:J>[Link]>an ,r.~o pressure is
. .. .

l=~~---·- o/:'f~P~H➔i'~l4;~ . fbllS, 1 , . . 6

~-f ' ·--- 'll'"'ll~- wl!\lally-hm.-.-J
use_d. soch as P?e-~,oh~;s, ,~t~lJ.f~t~rh·~.'. s~h~?nes, ~~lies and epoxies~-:i
,est11~: .- ' , eUulose denv,a }v~sr, V: 1ch c~n be .considerably·80a ·, ed .
' ll· ot11e_ c .. . ,, .. -, '• 't ' / , / Th '·pz•·. ' . '"•, . . . [Link] for
'• als,_·o,_ S,., .d ,, n·r··c'··'used
, for
. cas . in . ,_ g.. . . . e, . astics~·are· ,i;, neated , ti) a. su1a ·t· b\ e
Mouldea·, !
_p4 rt . . ,
· ; ,
tbf'jq,
"pour,
1
:;~tu~e
-~n~ ~ p~u.r _e ~ ?~t~J~~-
te!llP, •·· fass : plaster. ; wooH or metaL ,A catalyst is added t
~?~~,1.r{,~~~Wf are
made ot lead,
Fig. 22.3. Principle of injection mo~ldi~g· . ·,~'.i,J;. ·(1~:befm.'Jised__·,_plas_~ic_~. he~17"p:~li,n_~eri'sation
··,· .. ,v,,\,,,, · unPJ!{, 'i )the ·111c>Ulds 'are ·ope'ried and castings knocked out A few
t1 fr.'d ue ~u;i;;g -i~_.. an~
The material,_being_in contact with th~ heated surf~c~:s ~(([); ;01 ti :h~'r'd-e Ts~r
such cast proqucts are sheets, films,ie~ellery, dies, ~unches
and th.e .c-Jr..mnber and ·at the· same time being under, co~~;lie~p. 1
exr{gs:'two or more plasti,cs ~an be po~r~d t<:>g~~~~r..i~~he same mould
I H, sDoft~ns ~~ i_s fo~teqh·.in~~t~ebwather'Cooled moul_d t~roughth&,ii,ti ano~t 1n di~~re~t, colour sha?es. The pro~ess lS ch~ap, but slow . It is,
1 .~ :.1, urmg ue-atmg mt e Cllkllll: er t e,t~mperature ofthe ·mat~t;i~l~iesI :er~:~rquite .s~ita~l~ .f?.~/ 1:IlfJLproductlo!l onJ.l-. 1r·--· --- .
to .between l.'J.7PC and 274PC •. After the plastic has bae-n,coo1'~ 1 tlr,t n~ls · ,· ·--

\~ ·\ \\ [Link] .harden:e.d inuthe mould, the mould is ·openM~'i-\lll'e1q 22'.14·5,t~~~'. :~OULD~~\_ · ,

[Link] P8:rl knocked_ ~ut. · It is· a faster. pr.o cess and, ~u.i~~-G ~~~~:to1m · frte'~embles Casting in·•t hat ,no pressure is attlied_The ~rocess
. _, ) ~ \ '

l\ l~.1
·'I
.~
A
large-q~antlty prodoctw;o:. ' ' '

22.12 EXTRUSION
· • ·
' ' . j' / :q:r;·it?J:1N/1u
I ' . ... ; consists of prep~ng 'a Slurry\of'!',hermoplastic
~_,-. ',:i~lW?,J1/;lf:l thesan,i~1iP.,to a preheated mould. (?n account of the ~at of'the ~ul~ a
... ·, ·.' ; ,i Hnn:;.. uniform layer of resin sets all along the st¢ace o~ he mould ~avn.y ..
res~ an~ then
pouring

tt .l It is also known as Extrusion Mouldin:g·.. Pr!ac,tjf~Hi!},\1 Exces~:Sl!:fl"I)', if any, is th;en·poure~ out. Additionalleat-is provided for
1 1

i~ Thermopla,sticmaterial s can be extruded ihto vhti~~s ~.~ apesi'i\~tt,S, curink',q{tre~in ;set in the mould. followed by ha~,;iin.g_!>f_UJ.e product
l~ \' rods, she~ts, films~.pipes, ropei; an~{ other profiles. Thei/no{ff//!:~.f:{~frt,hcs , bychiliing and removi0:g the same .
:I ' · .. l · · }],owing e from [Link]. Flexible tov.s and
·ti '-.
tl 1. are, gene~all~•-not s~itable for extrusion. Pf. section~_..v1~.~ -l °"tf~edi~g
Extr~sion. f'roces~ in shown jn Fig. 22.4.:The proce~~ co~~~t{' ,~! ,; :i ·· · artbitfih1c_ialfl"owers, etc., .....e .prodJ :U.·e:ed·.. ·, ,,
~ .
- - -tr'!- - - - •··
'rl kl 1 . .. . . ,, 1« '" y ~ Process.
· -~1 :. ~
;: ,;c:,[Link]!\,..,,
Y

,:·-J~tii',. . . . 3 '

~!. iU~:.
I
i_::. ,r !!;'¾~~lE~[Link] , , , , , . . \ _~!i>' _', . . . ,,
lllaki Process 1s vastly used for ., ,..: . . . ,1 • : : • ~:,t- '·
I
I ll'[Link]'
,.~~J !~t,~Hi~~s~~~~~~~~;;~ ln'tR~f~~s, t icFilmsandSheets.
.' d . ' I .. R·U bt,eti-'': . .• ~ I
Paste'Hf~l . .. ~•.' a 'h eate·
'., \ Droce's' h' , I,~ ., ' '
' I,; dou~ .Y: . .1 • • . ,-&.,.t: i<1_:..\.. 0- ·- •,.·,, n· 1•
r } ___......__, \ ., th toughP astic ·
. , , \d .
[Link] is passe , , ' .. i i ;.1'. , , , . ; . . ' . r •!••fl'
, ,i '1 ' .• , ..
11·' 1'• 1
·· , ,i, " -· I ,' 'Fee'dsc1:ew . .. ,I'.",', I \ ' Whel'tl itlj: ,series' of
hot' roifers, '
I t .. Heating Jacket \ ' . t ' ~' M of thin sh !!queezed into the 'fornf .'
, .ll ,' 1 Fig. 22.4. The extrusion m'o{dding process. ,, 1 .;,:,·.~eali~( <IS show,- ~et ~f uniform 'thickness 11 ' ,,, ,, ''Ci>'nveyor , , , 'T .b:miffl
. • ,y,;bet n,f11 1 '~it l&i,y .,,nFi l r B •it ' .. , . ,, ,. 111
t '
thepoWdefeclplasticfr otntheHonnerhrtotheh eated'Ch1, ' I tt'.,;[Link]#i,Hl CL,,tel\ ,llc\,,,1 g, 22 16, Thelastlro}ll•' ,) .·_ . I:'
1
'ff\"!Ol
, 1 , , ,,, , ,t , ' . . (' t ·[Link].
t ,' , tl'/! ,'I
•, • , , . Yr 'r~ a ~ ,Y 11if!l • llll}· ~....,.ed• a: d .
~
, , ,. , . 1
1 scr~tlJ_\. ~fi~led ~eed ~crew,· caJ'.ri~s thts·,foate~i.~ _fo~~•. , $·i~~·fi r:1,"
118 ang loll. n 1s called' the t
1
'\Fig:
22.5. The calende11nJ pro
~~ ut t~~?~~ll ~~~}e'afecl ~rifice•.~~ ~?~!~i~:~~t~~~re! ~fi\1I>, ll ·d ~
 THEIR PRU~t.»INb
22.16 PLASTIC FABRICATING METHODS ..,,.'1Qfl~_, . ,''41)
-~ . S99
Several techniques have been developed for fab . I f'P'" h space between the sheet and the mo ld
Of t e. ng examples are 1·11ustrated in u . A few t .
. 00 t Fig. 22 7 Atl Y1>1ca1
·
to convert them mto usabl e fiorms. Sorne popular t rtcati
h . 0 nor,, 31t forJlll h d h . . . a)onlyvacu
ec n1q 1 00J11 d wing the eate s eet into the mould At (h) h \lJ:n
t ~ fonneu
l'l\i,
are the following : Ues of lhllti vile for ra d h . .
. ,, 5ed · down the heate s eet, fonrung it Partially , "iollOWed b-.
1. Blow moulding 2. Forming methods ~
1s ,, esses
00 \d pr cuum through the mould to complete the fornf ,. Y
J1l the va h h ing. nt(c )
22.17 BLOW MOULDING oiling . used to push t e eated sheet into the mould fo\lowft.1 b
r plug IS .
Cored · . ressure through the plug to complete the fanning 1\1'\Arati·
I y=
It is used for producing narrow neck plastic container l' . g air p 11 h . -r- on.
Jyill . the mould a ow t e air to escape.
3PP h \es 1n
and similar other articles. An example showing the Pro~ tk~botu~ oolief o . M ld Air exhaust
screwed neck plastic · 1·11 us t ra t e d m
· bottle 1s · F'1g. 22.6. In th·Uct,on of ~ Heater ou

heated closed end The~opI a~t1c . Tube. 1s . p l aced in the mould

is Proee 1 n _L,}L.,__
cl) •
I
andss!

n.,··:,
pressure is applied to inflate 1t to acquire the shape of mould .air
After the plastic is cooled the mould is opened and the producttakcaVJ~.
Airhlow enoul
Clan>P t:::t I~~~
I - ~ ~r

I ~t:m;a,a

·i I
II
I I
I ~ i r exhaust (bl
(a)
kl
' ,:~ I M :+
Fig. 22.7. Vacuum forming methods.
~~~~~ Threads
on neck 3. Snap Back Formi~g.
It is also a Vacuum Forming
method. In this method the
Bottle heated plastic sheet fitted at th e
top of the Vacuum Box is pulledvacuum
to a certain depth in the cavity box
l Vacuum
by pulling the vacuum. Male Formed sheet Pu;i
,:1\
,, Blowing started Completed plug is then moved down until
. it reaches a . predetermined
Blown hottle
Fig. 22.8. Snap back forming.
Fig. 22.6. Making a plastic bottle. position. Vacuum is then pulled
i'i._rl through the male plug to form
~l; Ii t. 22.18 VARIOUS FORMING METHODS · . ets into the plastic sheet around the

~l\l ' \.·

h. ·
. lastlc s e ~ontours of the plug, as shown
,h?I ;--~
The common methods of forming or shaping
useful shapes are the following: ·
P
thods of foTlll1~
in Fig. 22.8.
th· .4· Pressure Forming. In
Ii.!1,1,,,ir::·!.' 1. Drape Forming. It is the simplest of all me the contou~ 0
is Process the heated plastic
and consists of Draping the heated plastic sheet 0 ;~rg we sheet ·
male Form, followed by applying pressure and coo 10 . · formed bY ~
sh ls fonned into the required
. . 1Y d 11yet 11d1 ~ I\Jle between a pair of Male and
2. Vacuum Forming. Intncate shapes a re. cas1t draP" e111ctle l)·
011 22_9 N ies, as shown in Fig. Clamp
:1pplieation of prt>.<;s11rP or vacuum on t hC.' Pl a s~tic ·shee t overthe .iJlat~1' •I 0
. the shee · drll w11111 . Pt0c· uac1,um is used in this
~ Fig, n.9. Press~~-
mould. The operation com;ists of stretch mg d then
cavity to form a seal. heating it by suitable means an ~
 c$~0
· It· · ·1
. . ~~
qi~.~ · ' sflcs,.N~
'""•-••oc•ss1NG
· 60
5. Draw FormIDl{, . 1s s1m1 ar to the Deep D . · ~:)fia~ . r} .. ·
. lth h. 1
r. ,:.-.._ ._ ·t · l .. h· . .,(·· h 1 t •[Link].\i;,.l:. k ' f 1 · . rawin. . 1uunatmg,a . oug insomecasesth
' m.e1;ais.. . il t lS, 3 ea eu uiun . 0 p asbc sheet is pla' Ad €_ Proce ed 1Jl a . fi r"ing· [Link]'u!': ,F · •, ; /' . er~?J?lastic res·
: ' ' . . f ' f{i' ltf. D p e!IS T}le rein O \.,
Ct:: ove ,, . '8& 'fllt seu are g1ass tibr' ••.' I f ins are
I \ ' ¥icldifirmlY by niean!rn ·a , 0 . . own late. A [Link] .i ,·' t aclll ·•· al' osed- . , er and oth~t 'fib~~s. Th . " 1 es'. cotton, asbesto
·.intb'[Link] die-cavity 'to draw the•fua. terial into the die a . ds ~res~~cfll.l'
·t....•- •..1 . Fl .. . . ·r . .. .. , .b t •
~sdl h, }\eJllP'. paP s or mat, etc. The\:o~m eylare used ~n Varioµs
n around1 .:'..."Wll
[Link] .. b' r1refortn . , . on y used resins h'·
ron:~
uuu . y,. angel [Link], tnay e rimmed sep ,.,edot , t' • , ., ·s furnaces aha silicones
. aratel ,., . f~li.:.t' P. • . are P enolics
. · , ti~ Y or Wfthl "WU
5 epo,oe ' · Igtnents are added to .'
same operation. '·:t i: ·· · " · ... · · ,·, , . n!i~ti
yestef • .. ·. • -shades. ·Fillers like day · cal• · •. :· obtain
, . . , • .. . . • • pO1 :1 . t 'colour
., ·.,,1 J !!1 ·,1 ·~ . . . . . , c1um carbonate a"b st0
.• ',•)·6. Plug-and ·R1ng ,Fbrnung-. It 1s a cotnbinatit>ii• r· '(· 1'1i1~ differe(l . ·uinsilicate,areusedfor·obtaihing·bettersurfa·· fi : s e s
Draw ,For;ming-·met:hods.•. In, this,.the heated · plastic ·Sh O /tfJt~Jt~ ,Jnd aJtJ!illn~ . 'erties reducing shnnkage and lowering cos:\t~;be~r
over a Draw Ring whi ch forces the sheet,on the Fonn ,~~-rts~t1~lte11 physical Pr f~he se~eral methods ~s~d..fo.r low.pre88ve 1 ~ ~[Link]
0 O
the mould mounted at ~he. bot,to,x:n of a Ram is forced int [Link]'i nany
• l h fc . . fi 1· h . . .
arc a few ta t [Link]. It is the simplest of ~h
o e clam
1 Con c . . .. . i , • • • . •
all h a · ".
e met ads, In this
s h eet to compete t e ornung. to ma s ape. ~
... r.h)•~s layers of. rein~orcing
,. ,: 4.r .
. I' •' material .are .coated wi'th cat l -' .
a yse~ resm
·· :., -·: · ·· · · : · ·p!f~ · / ·:d'one ov·e r the other o.n a preJ)ared form. In order to atcelerate
22.19 lAMl ~...·..ATIJ~G P.:.f... PtASTI .·_. ~~ . · ··· ..... · .-·:. :...,.!').
,[Link] .. . . · · · .1 . -1 · · · 1·d ·
- -·11 'i~i;.:Mc~~s, p~icula~ y m arge m_ou ~i the resin and reinfo~cement
. There ~ 'e~ o·,~ iftar~'meth:ods«?fifaniinating''pl~~.tics :
1
· ro~&ri~ '~f~
~p.~~!ed m~te~~ of be1~g ,coated by hand operation. The
1. High. 'l're~l ur~.~mtrJ.C~._tin:g ... : ; 'rJ~i/tis'tne1i allowed to_be cured _by,.... ~at or .at room t~mperature. The
2. Loiif 1'ressufe I:aminiiti1fof Reinforced Plast~~' Moulding_. ; , main adva~.tages of this proce~s are lo~ cost, simple operation, no size
., ., ;,
11
!firt\itf6f products, ·readiness to ~dopt chang~s in design and minimum
22.20 HIGH PRESSURE LAMINATING equipment required. ' · · · ·
This process in;~lves· join,i ng ·of layers of hbrous [Link]~fo~~:g 2. Pressure Bag Moulding. In this method the resin impregnated
materials with thernwsett(ng resin binders by the' appHcatid'n·lif heat ~or~p1ete'1~·;pfaced in the mould. A tailored to .size rubber bag covers
and pressure both. The pressure usually ranges between 8(}(kg/cm2~ the work piece from above. To the top of the mould is secured a pressure
240 kg/cm2'.. Thelayers ·~e generally of sonie fibrous .materiallilc~1Jiap~. 'pMe11~ of ~team pressure·is applied between the ·bag and the plate to
cotton ~ [Link] mat~ asbes~ ~glass, nylon or wood verieer.)Larni;.a~~ inflate the bag against the work-piece. Its main advantages include
with ~~f-8~ .s,·3:r.~ made .by 1;1srng graphite', mica arid ialulnina, ·~y lformation of cylindrical shapes, dense and voidTess ·produ~ts,
etc. The. [Link] commonly used .are . phenoL formald'[Link];Jiutell, undercuts·[Link] made cores and inserts can be used and the advantage::-
meJamines; silicones, epc:ixies.~r their combinations. .. . :: ;:; oiH uq •'ld 'ot:contatit>moulding ar~ still retained. · .
. . . . :.. ~by
The process consists of preparing varnish solution:from,res"> . . ,~i:~~'.:~acuum
Ba·g Moulding. In this~.the resin im~regnated ~atei;ial
dissolving them in suitable solvents, followed .by impregn:ating,[Link]~:
the fibrous sheets . with·. this,.varnish [Link]"'e sheets ,are then,.,~n , ' inth~ith~~ 0 a
/J~~
~l~ced over the form mould, followed a covering P~""ld;!
f ri!m
~x
· · ' .. ~ · · fotlll of cell~ph~ne or po~yvinyl. Exhaust ports are proVI .

=
tnmmed to size ~.d heated and pressed•b<>tween metal .plates iiw·· eiia·bl:ili·h~ld ,through which vacuum 1s drawn from under the~- Thls
th 1 · · · · _,, ' · p 'ib~~~
e ~ated sh~ts. [Link] are made by ro,lling (he impregnate ,ti IY'f
rnatenal ar~und ·~ndr~ls and_ heating ,~iJ): they ~r~ 1 c~n~l;l., ~q~~/
e.s t · · ·
lgai\i't '' a~mo~pheric pressure t ·
to act on the bag to orce .
·fi the lay-v.p
.
~n~a~ir~ ,forru_. The main advantages of this methQCi, ~ ~ess
made by rolling and;heatmg the impregnated material inside C~lf ~ d bX ~ll'irtij;tJ es,s voids, better surface finish ~high~r g;l~ lm\ding · :
~ou_lds, foll_owed bf ,grin~~n~. to size. ¥o1J:~4~A i,hl}M~- 0
flP,~~H9 .~~.e1•!
l.:ikln~ _the advanta~es of [Link], · · . . O
cuttmg _the unpre?~~d she'e tt to requir~~ 1~pf\P~s .~nQ ~1z.;s,/Al1 ·/'k
by heating and P~lll~:Qg ~ us:u~. 1 Q\~t~~18· !~Qcl~ve . FQrm1•ng It ; .., "' [Link] e>f ~e. ~bo .. ;.e -~~ ·
:·,.: . ;, 1 , ., ,i•• ' ,, ' ,, la; , Y\I , ~•th · · • · ""' "" · , me ~. a,Ltr
2 :~:' . , . . ·.T•<)'.,,-:: ..: :·:~ '.'' ·'. :; ., . •, .,;j ,l:•l...l, I P~~g-µQ·ll" ~r [Link]~e pres.s¥,re qag or va~um bag ~~ge ~ave ,to
2.21, ~~'.:.'11E~~J-. ~•N~'ffNG "i:, . . .. ,.... , .... :•! , 1 ,6_ i. 0 ~ 1~~ an '. ~ ~Qv~nng qm be placed Ul a st~a,m oi.·.hot a,u: a_u · ,.1 •
.id~ ~htfrs,,W!~
··It fs aiso-~owii"'~ ~ihf~r~~ ·PI1t,ii,c~~ 'J~•ng,
In thi~ t;:;i:~
'IJflf "~ \~er . · ' - · ·
'"',;~tf~c .' ~a&ec\ pres~\,\re av.~. ad.d,[Link] •[Link],V•. · ~u}ping.
pressurei. of only upto 32 kg/cm2 are appi1e<i. :M;tiy
thermosettt11I. . - ·i il',,,c\ip;e~o'lal ancU\JW ~•~Qaod vo~Mre:e
 602 ~ "'< ,,_."'5,_~o
'No~si.o,·- .
/ flllll,OOCESSING

5. Vacuum Injection Process. It con . ~ ~·· Of PLASTICS

reinforcing material between two matching sists of h 1 3 J()INIMG th
s and / dillg 11 22•
2 tics can be joined by e following four methods .
resin up, from a container placed at the bottomlllothUld
, rou l rawi Q, plaS Th 1 ti Pl
material, by drawmg the varnum through the t 0 g l lhe r . Ilg ~ some ennop as c astics like acry}j · st
6. Matched Dies. Reinforced plastic m f
~lloutct. einrol'tii
1
1
· cellulosics a nd a few vinyls can be joined by::•
pol~ Yrenea,
dd~ngs are als Or · 50 [vent · mentang 'Nith a
in rigid or flexible punches and dies. Mostly stoul
ee 1e 8 10 th Od Of · · · ·
. Another me Jommg plastics is by usin
d ~ an adhesive.
),' I
small production they can be made from reinfo d are used bl'lli~ 2· 'fhiS method can be used for all plastics
rce Plastics al,' Utf~
theOl with metals and other materials. ' an so for joining
l'·
\
22.22 MACHINING Of PLASTICS so.
I
I
The common methods of producing plastic . J\}l the plastics, except a few inflammable ones c~be . .
3 ' d.. _J~ed
I·
a~e MouJdi'n1 · by Welding.h The common welding processes use
and Forming, as described above. However ' Mach~a1:s •ning f ld' h ior JO\ntng
stock may be more economical when only a few part s are req rom standari plastics are ot gas we mg, eated tool welding, friction welding .
. · · ' t· h t·
of the techmques used for metal machining are e ll uir~[Link] and induc ion ea mg.
fa_steners like bolts, screws, nuts and n·vets
machining of plastics, but the following special p qua Y _apphcable~
roperties. of PIastics. 4_ Various engineering
. . . . . can be used for fastenmg plastic parts together. Also, peening
require special cons1derat10 ns m machining them.
1. They cannot conduct the heat away but are ' .1 ·,
heat. Thus, the heat localises in th~ tool.
2. They are generally soft and yield readily.
eas1 Y,affectedby
. and press fitting, etc., can be used.
22.24 A FEW IMPORTANT DESIGN RULES
The following are the Important Rules to be followed for designing
I
3. ?\fa~y of them contain abrasive fillers, partic~iarly the plastic moulded parts. It will be observed that a large number of them
lammated plastics. · ', · areconunon with the rules followt.,,d for designing sand. die and pt:rmanem
4. Some of the plastics are quite brittle and at the s~e time mould castings.
soft. ·· 1. A13 far as possible, try to locate the partingsurfaceofthemould
Coolants, which do not discolour the plastic and ,do not offer in one plane.
difficulties. can be used . Most commonlv used roolants are ,wateror 2. Try to avoid undercuts.
soluble oil and water. Acrylics and Poly~tyren e can be machin~d~ a 3. Provide due allowance for shrinkage after moulding.

~-
tolerance of± .025 mm, but they have to be annealed before machrnrng .
. · t 00I ano 4. Try to avoid tolerances closer than 0.127 mm, if ~hie. as
Th ermoplasti cs become soft and gummy and clog to the this will lead to higher costs.
Thermosett ing plastics char at higher temperature s. It is nec~s_sarY, 5· Holes located normal to the parting surfaces are produced easily
therefore, to keep the temperature as low as possible by providing a
. edge and smooth faces to the cuttir.g tool. In gener ' ano
. and more economically than obliquely located holes.
keen cuttmg
be used for plastics as used for machining copperroto 6· Adraft of upto 1° on surfaces is normally needed to enable e~
tool angles can 1

5
brass. Twist drills with 0° rake give best results. Surface i>t:e~s:utfor , removal of products from the moulds.
100 metres per minute arc very commqn in machining plasticS,cxactlt I 7· If any lettering or other details are to be produced 00 the
those plastics which contain abrasive fillers these figures fe ptastiCS \ surface, they should be located on a surface at right angles \0
halved. Best sawing results are obtained by using a band saW-
0
J
carbid1 lbe directio~ of opening or closing of mould.
""-~-able
with abrasive filler best results arc obtained by using cemeti: 0 sed for &. Lon r
g cored holes should be avoided, as ,ar as r-- · . ul·
or cemented oxide tools. Sharp tools with light cuts should bronie a11d 9· As f . · - t 0 have c1rc ar
ar as possible, try to design proJections
pl~tics which are brittle. Czttting speeds and feed~ used fo\astiO" .
for machining lam1na ted p [Link] .
mild steel are equally suitable