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2. MANUFACTURING OF HONEYCOMB
MATERIALS
PROCESSING ELASTOMERS
REINFORCED PLASTICS

4. Definition of Elastomers
 An elastomer is a polymer with the property of
elasticity generally having high yield strain compared
with other materials.
 Some of the material can be stretched to several time
from their original position this is due to the elastic
property of the material.

6. Schematic Drawing
Fig A is a schematic drawing of an
unstressed polymer. The dots represent
cross-links.
B is the same polymer under stress.
When the stress is removed, it will
return to the A configuration.

7. History
The origins of Kraton Polymers and its role in the
development of styrene-based thermoplastic
elastomers can be traced back to the U.S. government's
Synthetic Rubber (GR-S) program during World War II.
Between 1942 and 1945 this program developed a new
styrene butadiene synthetic rubber (SBR) and built
plants to provide a critical alternative to natural rubber
for making tires for military vehicles during the war.

8. Shell Chemical Company, who was a butadiene
supplier to the SBR plants, bought one of the
plants in Torrance, California, when the
government decided to sell its holdings in 1955.
This newly formed
Elastomers Division of Shell
Chemical evolved into what
is today Kraton Polymers.

9. PROCESSES

10. Polymerization
The beginning step for elastomers is
the polymerization of the
monomers.
Polymerization combines two or more
process gases (monomers) under
specific temperature and pressure
conditions connects the individual
monomers into the desired
polymer.
Initiating agents, chemicals may be
added to the polymer reactor to
achieve the desired chemical
properties and polymerization
dynamics.

11. Isolation & Compounding
The backbone polymers are isolated (brought out of the
emulsion), cleaned and dried.
Chemical agents may be added at
this step to isolate the polymer for
more usable form. Once the
polymer is cleaned and dried, the
polymer is shipped to compounders
for mixing.

12. Extrusion
The sheet compound is extruded into a configuration
similar to the desired finished.

13. Molding
Most of the elastomeric O-rings used in the
semiconductor industry are compression molded.
A preshaped form is inserted into a multi-section
mold and transferred to a heated press.
Under heat and pressure, the elastomer flows into
the mold cavities and chemical cross-linking takes
place.
After a period of time ranging from several seconds
to several minutes, the parts are removed from the
hot molds.

14. Flash Removal
After the parts are removed from the molds, they
contain thin "flash" as a result of the elastomer
flowing in the multi-section mold.
This "flash" is typically removed by processes.

15. Curing
• Elastomer parts are exposed to
high temperatures in carefully
controlled environments for
several hours to complete the
curing process.
• Additionally, this post-curing
step removes excess water
vapor and volatile process
additives, thereby improving
vacuum and contamination
performance.

16. Finishing and Inspection
After the parts are removed from the curing ovens, the
parts are again cleaned and inspected to ensure the
parts meet the material and dimensional
specifications.

17. Cleaning and packaging
Acceptable parts are delivered t
cleaning and packaging.
Acceptable parts are then counted and packaged,
either individually, in a heat-sealed clean inner o the
clean room forbag.

18. Types of Elastomers

19. Natural Rubber
Raw material extracted from trees.
The base of natural rubber is
latex, a milk like sap obtained
from the inner bark of
tropical tree.

20. Properties
It has good resistance to abrasion and fatigue and
high frictional properties.
But it has low resistance to oil, heat, ozone and
sunlight.

21. Applications
Typical Applications include
• Tyres
• Seals
• Shoe heels
• Coupling
• Engine mounts

22. Synthetic Elastomers
Acrylic Elastomers:
Exhibiting the attributes of high-performance
durability, These acrylic elastomers are useful in
various industries that are mentioned below
Automotive power train seals
Gaskets
EPDM(Ethylene propylene diene monomer) elastomers:
It is synthetic rubber,elastomer . Useful in
the manufacturing of rubber sheets and
various industries, have good resistance to
water-based chemicals, vegetable-based
hydraulic oils and outstanding
heat, ozone, and weather resistance.

23. Neoprene Elastomers:
It has good chemical stability maintains
flexibility over a wide temperature
range . These are used in many
industries for the manufacturing of the
following:
Car fan belts
Gaskets and laptop sleeves.
Thermoplastic elastomers:
Thermoplastic elastomer eliminate and
can be processed into products by all of
the conventional thermoplastic polymer
process[ injection molding, extrusion
,blow molding, thermoforming and
others].

24. Silicones:
Silicones have the highest useful temperature range
of all elastomers, up to 315 ̊̊̊̊̊̊̊̊̊C, but their other
properties r inferior to those of other elastomers.
Typically used in the production of seals, gaskets,
thermal insulation, high temperature electrical
switches, etc.

25. Advantages
Excellent impact resistance.
Easy color ability.
Tough yet flexible.
Low density and light weight.
Easy forming and processing.
Recyclable for in-process scrap re-use.
Excellent melt strength and process ability.
Lower shrinkage.

26. Disadvantages
High cost of raw materials.
General inability to load TPEs with low cost fillers such
as carbon.
Poor chemical and heat resistance.
High compression set and low thermal stability.
Soften or melt at elevated temperature above which
they lose their rubbery behavior.
Show creep behavior on extended use.

27. Elastomers
Heavy in weight.
Maximum elasticity.
Recyclable for in-process
scrap re-use.
Lower shrinkage.
Excellent impact
resistance .
High production cost.
Plastics
Light in weight.
Comparatively Lower
elasticity.
Recyclable for in-process
scrap re-use.
maximum shrinkage .
Lower impact resistance.
Low production cost.
Comparison Between Elastomers & Plastics

28. Applications of Elastomers in Pakistan industry
Use in the making of
power and hand tools, and
shoe midsoles in Bata &
Service industry, etc.
Daily routine things like
dishwashers, clothes dryers
& washing
m/c, refrigerators seals are
also made in Super
Asia, Pel, Waves, Orient, etc
.

29. Applications of Elastomers in Pakistan industry
It is also used for the production
of construction material like
residential glazing seals, roof
sheeting in cars, bus, trucks, etc
in Hino , Honda, Suzuki, Toyota
industries.
It is also used for the production
of tiers of vehicles in
Service, Panthers, Yokohama &
Dunlop tiers industry.

30. Applications of Elastomers in Pakistan industry
Electricity things like , low-voltage industrial wire
and cable can be made by elastomers. In Pakistan
cables, Ittefaq cables, etc.

31. HONEY COMB STRUCTURE
AMMAR QAISER CH.
BSME 01113109

32. HONEY COMB STRUCTURE
•Honeycomb structures are natural or man-made
structures that have the geometry of
to allow the minimization of thehoneycomba
amount of used material to reach minimal weight
and minimal material cost. The geometry of
honeycomb structures can vary widely but the
common feature of all such structures is an array of
hollow cells formed between thin vertical walls

34. Material use for honeycomb structure
Honeycomb provides a unique structure made from a
wide variety of materials including
thermoplastic, fiberglass, carbon, aluminum and
steel

35. Cell of honeycomb

36. Hexagonal cell
The non angled rows of honeycomb cells are always horizontally (not
vertically) aligned. Thus, each cell has two vertical walls, with "floors" and
"ceilings" composed of two angled walls.

37. Rectangular cell
Rectangular cells give easier forming in the W direction

38. Manufacturing of honey comb
There are two method for making honey comb
structure
1. HOBE (honey comb before expansion process)
2. Corrugated process

39. Expansion Process

40. Corrugated process

41. Composite Honeycomb Structure
Sandwich structure is comprised of layered composite materials formed by
bonding two or more thin facings or face sheets to a relatively thick core
material.

42. Comparison between honeycomb material and metal
Inexpensive
Light in weight
Easy to handle
Honeycomb material
expensive
Not light in weight
Not easy to handle
Metals

43. Advantages
•From a mechanical point of view:
- they are light
- they don’t curve under their own weight
- they are shock absorbers
- they accept significant distortions without breaking
•From a chemical point of view:
- they are water and corrosion resistant
- their behavior with respect to bacteria is excellent.
They resist to most acids and bases.
•From the insulation point of view:
- they are heat insulators
- they absorb vibrations
•From the implementation point of view:
- they are easy shaping
- they can be easily cut with standard tools
- they can be easily transported

44. Military Application
Honeycomb structure design is
one of the Several improvements
made in military defense to
protect against the ambush or
explosives. This will not only take
bullets but also explosions from
an improvised explosive device

45. Commercial Application
Marina city

47. Usama Umair
(BSME01113108)

48. Reinforced Plastics

49. Reinforced Plastics:
“Fiber reinforced plastics are a category of
composite plastics that specifically use
fibrous materials to mechanically enhance
the strength and elasticity of plastics.”

50. 50
Reinforcing fibers
Glass – most common and the least expensive, high strength, low stiffness and
high density. GFRP consists 30-60% glass fibers by volume.
– highest specific strength, toughest fiber, undergoes plastic
deformation before fracture, but absorbs moisture, and is expensive.
Aramids (Kevlar)
– boron fibers consist of boron deposited on tungsten fibers, high
strength and stiffness in tension and compression, resistance to high
temperature, but they are heavy and expensive.
Boron
– more expensive than glass
fibers, but lower density and higher stiffness with high strength. The composite
is called carbon-fiber reinforced plastic (CFRP).
Graphite (99% carbon) or Carbon (80-95% carbon)
The average diameter of fibers used is usually less than .0004 inch (.01 mm). The tensile
strength of a glass fiber could be as high as 650 ksi.

51. VIDEO

52. Types of Reinforce Plastic fibers
•Three main types of fibers
–Fiberglass
–Carbon fiber or Graphite
–Organic fibers, aramids (kevlar)

53. Fiberglass
• Spin molten glass
• Different types of glass can be made
– E-glass (improved electrical resistance)
– S-glass (high strength)
– C-glass (high chemical resistance)

54. Carbon or Graphite Fiber
• Made from PAN fibers, pitch or rayon
fibers
• Through heating, raw material looses
most non-carbon atoms in the chain
• Processing also aligns carbon chains
• Carbon fibers have very high modulus
(stiffness)

55. Organic Reinforcement Fibers
• Aramid fibers have greatest strength and
modulus properties of organic fibers
• Kevlar is the most commonly used aramid
fiber
• Aramids are strong and stiff but their
greatest value is in impact applications
– Front of airplane wings
– Armor applications

56. Processes Of Making Fiber Reinforced
Plastics:
F.R.P Involves Two Distinct Processes:
1. The first is the process whereby the fibrous material is
manufactured and formed.
2. The second is the process whereby fibrous materials are bonded
with the matrix during the molding process.

57. video

58. Manufacturing Methods
• Resin transfer molding
– Fiber preform is placed in the mold cavity
– Preform doesn’t move—resin is
pulled/pushed in

59. Manufacturing Methods
• Spray-up
– Fibers are chopped, coated with resin and
sprayed onto the mold

60. Vacuum Bagging
• Provides for increased part consolidation
• Reduces matched die mold costs

61. video

62. Manufacturing Methods
• Roll wrapping
– Limited to symmetrical mandrels

63. Manufacturing Methods
• Pultrusion
– High volume production
– Comparable to extrusion but the main
processing force is tension
– Profile is pulled from the machine

64. Advantages and limitations:
• Glass reinforced polymers are strongest and
most resistive to deforming forces when the
polymers fibres are parallel to the force being
exerted.
• Weakest when the fibres are perpendicular.

65. Advantages:
• Weight Saving
• Precision Engineering
• Finite Tolarance
• Simplification of parts in production and
operation.
• Cheaper
• Faster
• Easy to manufacture.

68. COMPARISON:
Fiber Reinforced
Materials
Steel
High Material Cost Low Material Cost
Low Installment Cost High installment Cost
Non Corrosive Corrosive
Light in Weight Heavy in weight
Low Maintenance High Maintenance

69. Video

70. Apps in Pakistan OF FRP:
1: Super Asia & Dawlance: In making of Washing
machine
2: Toyota, Honda & Suzuki:
car(head lights, bumpers, dash board, bonnets)

73. Dawlance, Pel &Haier:
Refrigerator: In the making of Internal Cabin
Gourmet, Pepsi & Coca-Cola:
In the Making of Pet bottles.

74. Nokia, Samsung & Motorola:
In the Making of Mobile bodies & Charger
bodies.

75. Pak electric company:
In the Making of Electric switch boards

76. Bata, Service & Stylo:
In the Making of Shoes

77. Pak Popular Pipes:
In the making of Pipes for water, Sanitary
pipes & Insulation pipes.