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Traditional Manufacturing Processes Casting Forming Sheet metal processing Cutting Joining Powder- and Ceramics Processing Plastics processing Surface treatment
Powder Metallurgy, Manufacturing with Ceramics Fine powder (plastic, ceramic, metal) Join powder particles (heat to just below melting point) balls used in ball-point pens gears, cams cutting tools (inserts) porous metal filters oil-impregnated bearings piston rings in engines  Shape by compacting in a die
P-M: (1) Powder Production Atomization : Spray liquid metal using high-pressure water, inert gas Chemical method : Pass CO or H 2  gas over powdered Metal oxide (reduction) Electrochemical action : Solution of metal salt   Current   Metal deposits on cathode water atomizer air atomizer
P-M: (2) Powder Blending, (3) Powder Compaction ,[object Object],[object Object],[object Object],Compaction: produces green mold
P-M: (4) Sintering, (5) Finishing Green compact    heated in oven to 70% ~ 90% of melting point    Diffusion weld Sintering: 3-stage Sintering furnace: burn off lubricant    sinter    cool down Finishing: ,[object Object],[object Object],[object Object]
Manufacturing with Glass (and Ceramics) Glass Sheet making : Rolling operation using molten glass Lenses, Headlamps manufacture : Molding process  Glass tubes and rods : Drawing process using molten glass
Bottle manufacture Blow molding source:  http://www.pct.edu/prep/bm.htm
Traditional Manufacturing Processes Casting Forming Sheet metal processing Cutting Joining Powder- and Ceramics Processing Plastics processing Surface treatment
Plastics History
General properties : more durable, harder, tough, light. Typical uses : automobile parts, construction materials. Plastic types: Thermosets Examples : Unsaturated Polyesters : lacquers, varnishes, boat hulls, furniture Epoxies and Resins : glues, coating of electrical circuits, composites: fiberglass in helicopter blades, boats, …
Plastic types: Elastomers General properties : these are thermosets, and have rubber-like properties. Typical uses : medical masks, gloves, rubber-substitutes Examples : Polyurethanes : mattress, cushion, insulation, toys Silicones : surgical gloves, oxygen masks in medical applications joint seals
General properties : low melting point, softer, flexible. Typical uses : bottles, food wrappers, toys, … Examples : Polyethylene:  packaging, electrical insulation, milk and water bottles, packaging film   Polypropylene:  carpet fibers, automotive bumpers, microwave containers, prosthetics Polyvinyl chloride (PVC ): electrical cables cover, credit cards, car instrument panels Polystyrene:  disposable spoons, forks, Styrofoam™ Acrylics (PMMA : polymethyl methacrylate): paints, fake fur, plexiglass Polyamide (nylon):  textiles and fabrics, gears, bushing and washers, bearings PET ( polyethylene terephthalate): bottles for acidic foods like juices, food trays PTFE  (polytetrafluoroethylene): non-stick coating, Gore-Tex™ (raincoats), dental floss Plastic types: Thermoplastics
Plastics Processing: Extrusion
Plastics Processing: Blow molding - similar to glass blow-molding -
Plastics  Processing :  Thermoforming   Sheet of plastic    Heated (soft)    Molded using a shaped die
Vacuum thermoforming
Plastics Processing:   Compression and Transfer Molding   ,[object Object],[object Object],[object Object],[object Object],dishes, handles for cooking pots skis, housing for high-voltage switches some rubber parts like shoe soles and even composites such as fiber-reinforced parts
Plastics Processing:   Compression and Transfer Molding   compression molding transfer molding (more complex shapes)
Plastics Processing:   Injection Molding   - Probably the most common, most important, most economical process
Plastics Processing:   Injection Molding   Cycle of operation for injection molding  [source: www.offshoresolutions.com]  AVI [source: ylmf.com.hk]
Injection Molding: geometry of the mold   Basic components: mold pieces (define the geometry of the part), AND sprue ,  gates ,  runners ,  vents ,  ejection pins, cooling system
Injection Molding: 2-piece and 3-piece molds
Injection Molding: molds with moving cores and side-action cams   - If the geometry of the part has undercuts [definition ?]
Injection Molding: designing injection molds 1.  molding directions     number of inserts/cams required, if any 2.  parting lines   3.  parting planes     by extending the parting line outwards 4.  gating design     where to locate the gate(s) ? 5.  multiple cavity   mold    fix relative positions of the multiple parts 6.  runners:  flow of plastic into the cavity 7.  sprue   located:   8.  functional parts of the mold   -  ejection system : to eject the molded part -  systems to eject the solidified runners   -  alignment rods:  to keep all mold components aligned
Injection Molding: designing injection molds 1.  molding directions     number of inserts/cams required, if any 2.  parting lines   3.  parting planes     by extending the parting line outwards 4.  gating design     where to locate the gate(s) ? 5.  multiple cavity   mold    fix relative positions of the multiple parts 6.  runners:  flow of plastic into the cavity 7.  sprue   located:   8.  functional parts of the mold   -  ejection system : to eject the molded part -  systems to eject the solidified runners   -  alignment rods:  to keep all mold components aligned cup parting line parting plane gate
Designing injection molds: mold in action [source: Lec notes, Prof T. Gutosky, MIT]
Designing injection molds: typical features [source: www.idsa-mp.org]
Designing injection molds: typical features
Considerations in design of injection molded parts   The two biggest  geometric concerns (i) proper flow of plastic to all parts of the mold cavity before solidification (ii) shrinking of the plastic resulting in sink holes  Guideline (1)   maintain uniform cross-section thickness throughout the part  How: use of ribs/gussets [source: GE plastics: Injection Molding Design Guidelines]
Considerations in design of injection molded parts   Guideline (2)   avoid thick cross-sections [source: GE plastics: Injection Molding Design Guidelines]
Considerations in design of injection molded parts   Guideline (3)   gate location determines weld lines weld lines * Source:  http://www.idsa-mp.org/proc/plastic/injection/injection_design_7.htm
A Typical Plastics Molding Factory   Website:  http://www.ylmf.com.hk - Tooling plant (produces and tests the injection mold) - Molding plant (uses the mold to produce parts, assembles products, …)
Summary   Topics covered: Powder metallurgy and Plastics processing Further reading: Chapters 17, 19, Kalpakjian & Schmid

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3 plastics

  • 1. Traditional Manufacturing Processes Casting Forming Sheet metal processing Cutting Joining Powder- and Ceramics Processing Plastics processing Surface treatment
  • 2. Powder Metallurgy, Manufacturing with Ceramics Fine powder (plastic, ceramic, metal) Join powder particles (heat to just below melting point) balls used in ball-point pens gears, cams cutting tools (inserts) porous metal filters oil-impregnated bearings piston rings in engines Shape by compacting in a die
  • 3. P-M: (1) Powder Production Atomization : Spray liquid metal using high-pressure water, inert gas Chemical method : Pass CO or H 2 gas over powdered Metal oxide (reduction) Electrochemical action : Solution of metal salt  Current  Metal deposits on cathode water atomizer air atomizer
  • 4.
  • 5.
  • 6. Manufacturing with Glass (and Ceramics) Glass Sheet making : Rolling operation using molten glass Lenses, Headlamps manufacture : Molding process Glass tubes and rods : Drawing process using molten glass
  • 7. Bottle manufacture Blow molding source: http://www.pct.edu/prep/bm.htm
  • 8. Traditional Manufacturing Processes Casting Forming Sheet metal processing Cutting Joining Powder- and Ceramics Processing Plastics processing Surface treatment
  • 10. General properties : more durable, harder, tough, light. Typical uses : automobile parts, construction materials. Plastic types: Thermosets Examples : Unsaturated Polyesters : lacquers, varnishes, boat hulls, furniture Epoxies and Resins : glues, coating of electrical circuits, composites: fiberglass in helicopter blades, boats, …
  • 11. Plastic types: Elastomers General properties : these are thermosets, and have rubber-like properties. Typical uses : medical masks, gloves, rubber-substitutes Examples : Polyurethanes : mattress, cushion, insulation, toys Silicones : surgical gloves, oxygen masks in medical applications joint seals
  • 12. General properties : low melting point, softer, flexible. Typical uses : bottles, food wrappers, toys, … Examples : Polyethylene: packaging, electrical insulation, milk and water bottles, packaging film Polypropylene: carpet fibers, automotive bumpers, microwave containers, prosthetics Polyvinyl chloride (PVC ): electrical cables cover, credit cards, car instrument panels Polystyrene: disposable spoons, forks, Styrofoam™ Acrylics (PMMA : polymethyl methacrylate): paints, fake fur, plexiglass Polyamide (nylon): textiles and fabrics, gears, bushing and washers, bearings PET ( polyethylene terephthalate): bottles for acidic foods like juices, food trays PTFE (polytetrafluoroethylene): non-stick coating, Gore-Tex™ (raincoats), dental floss Plastic types: Thermoplastics
  • 14. Plastics Processing: Blow molding - similar to glass blow-molding -
  • 15. Plastics Processing : Thermoforming Sheet of plastic  Heated (soft)  Molded using a shaped die
  • 17.
  • 18. Plastics Processing: Compression and Transfer Molding compression molding transfer molding (more complex shapes)
  • 19. Plastics Processing: Injection Molding - Probably the most common, most important, most economical process
  • 20. Plastics Processing: Injection Molding Cycle of operation for injection molding [source: www.offshoresolutions.com] AVI [source: ylmf.com.hk]
  • 21. Injection Molding: geometry of the mold Basic components: mold pieces (define the geometry of the part), AND sprue , gates , runners , vents , ejection pins, cooling system
  • 22. Injection Molding: 2-piece and 3-piece molds
  • 23. Injection Molding: molds with moving cores and side-action cams - If the geometry of the part has undercuts [definition ?]
  • 24. Injection Molding: designing injection molds 1. molding directions  number of inserts/cams required, if any 2. parting lines 3. parting planes  by extending the parting line outwards 4. gating design  where to locate the gate(s) ? 5. multiple cavity mold  fix relative positions of the multiple parts 6. runners: flow of plastic into the cavity 7. sprue located: 8. functional parts of the mold - ejection system : to eject the molded part - systems to eject the solidified runners - alignment rods: to keep all mold components aligned
  • 25. Injection Molding: designing injection molds 1. molding directions  number of inserts/cams required, if any 2. parting lines 3. parting planes  by extending the parting line outwards 4. gating design  where to locate the gate(s) ? 5. multiple cavity mold  fix relative positions of the multiple parts 6. runners: flow of plastic into the cavity 7. sprue located: 8. functional parts of the mold - ejection system : to eject the molded part - systems to eject the solidified runners - alignment rods: to keep all mold components aligned cup parting line parting plane gate
  • 26. Designing injection molds: mold in action [source: Lec notes, Prof T. Gutosky, MIT]
  • 27. Designing injection molds: typical features [source: www.idsa-mp.org]
  • 28. Designing injection molds: typical features
  • 29. Considerations in design of injection molded parts The two biggest geometric concerns (i) proper flow of plastic to all parts of the mold cavity before solidification (ii) shrinking of the plastic resulting in sink holes Guideline (1) maintain uniform cross-section thickness throughout the part How: use of ribs/gussets [source: GE plastics: Injection Molding Design Guidelines]
  • 30. Considerations in design of injection molded parts Guideline (2) avoid thick cross-sections [source: GE plastics: Injection Molding Design Guidelines]
  • 31. Considerations in design of injection molded parts Guideline (3) gate location determines weld lines weld lines * Source: http://www.idsa-mp.org/proc/plastic/injection/injection_design_7.htm
  • 32. A Typical Plastics Molding Factory Website: http://www.ylmf.com.hk - Tooling plant (produces and tests the injection mold) - Molding plant (uses the mold to produce parts, assembles products, …)
  • 33. Summary Topics covered: Powder metallurgy and Plastics processing Further reading: Chapters 17, 19, Kalpakjian & Schmid