Chapter 14
Fabrication of Plastics,
Ceramics, and Composites
(Review)
EIN 3390 Manufacturing Processes
Spring, 2012
14.1 Introduction
Plastics, ceramics, and composites have
different structure and properties than
metals
Principles of material selection and
manufacturing are different
Provide required properties and fabrication
processes to produce desired shape in an
economical way
Large, complex shapes can be formed as a
single unit
Processes can produce a near perfect shape
and surface product
14.1 Introduction
Many of fabrication processes convert raw
materials into a finished product in a single
operation
Properties of these materials are affected by
processes used to produce shapes.
Fabrication of an acceptable product involves
selections:
◦ Appropriate material, and
◦ Companion method of processing, such that the
resulting combination provides the desired shape,
properties, precision, and finish surface.
14.2 Fabrication of Plastics
A successful plastic product is
manufactured so that it satisfies the
various mechanical and physical
property requirements
The preferred manufacturing method is
determined by the desired size, shape,
and quantity and type of polymers.
There are three main different types of
polymers: thermoplastics, thermosets,
and elastomers
14.2 Fabrication of Plastics
Thermoplastics can be heated to produce
either a soft, formable solid, or liquid. It can
be cast, injected into a mold, or forced into
or through dies to produce a desired shape.
Thermosets can’t be further deformed once
polymerization has occurred.
Elastomers are sufficiently unique.
14.2 Fabrication of Plastics
Fabrication Processes of Plastics
◦ Casting
◦ Blow Molding
◦ Compression Molding
◦ Transfer Molding
◦ Cold Molding
◦ Injection Molding
◦ Reaction Injection Molding
◦ Extrusion
◦ Thermoforming
◦ Rotational Molding
◦ Form Molding
◦ Other Plastic-Forming Processes
Casting
Simplest of the
shape-forming
processes
No fillers and no
pressure is required
Thermoplastics are
the main type of
polymer that can be
casted
◦ Acrylics, nylons, Figure 14-1 Steps in the casting of plastic parts
urethanes, and PVC using a lead shell mold.
plastisols
Some thermosets can
also be cast
Blow Molding
Thermoplastics can be converted to hollow-
shape containers such as bottles
The preform is heated and placed between
the two mold halves
The mold closes and the preform is expanded
from air or gas pressure
The mold is then cooled, halves separated,
and the product is removed
Flash, extra material, is trimmed from the
part and recycled
Blow Molding
Figure 14-2 Steps in
blow molding plastic
parts: (1) a tube of
heated plastic is
placed in the open
mold; (2) the mold
closes over the tube,
simultaneously sealing
the bottom; (3) air
expands the tube
against the sides of the
mold; and (4) after
sufficient cooling, the
mold opens to release
the product.
Blow Molding
Figure 14-2 Steps in
blow molding plastic
parts: (1) a tube of
heated plastic is
placed in the open
mold; (2) the mold
closes over the tube,
simultaneously sealing
the bottom; (3) air
expands the tube
against the sides of the
mold; and (4) after
sufficient cooling, the
mold opens to release
the product.
Injection Molding
Used for high-volume production of
complex thermoplastic parts
Granules of a raw material are fed through a
hopper into a cavity that is ahead of a
plunger
The plunger moves forward and the material
is heated
In the torpedo section, the material is mixed,
melted, and superheated
The fluid then flows through a nozzle that is
against the mold
Sprues and runners are used in the same
way as in metal casting
Injection Molding
Figure 14-5 Schematic diagram of the injection molding process. A moving
plunger advances material through a heating region (in this case, through a
heated manifold and over a heated torpedo) and further through runners
into a mold where the molten thermoplastic cools and solidifies.
Injection Molding
Figure 14-5 Schematic diagram of the injection molding process. A moving
plunger advances material through a heating region (in this case, through a
heated manifold and over a heated torpedo) and further through runners
into a mold where the molten thermoplastic cools and solidifies.
Reaction Injection Molding
Two or more liquid reactants are mixed
under pressure
The mixture then flows through a pressure-
reducing chamber and into a mold
Exothermic reaction causes the
thermosets to polymerize
Curing times are typically less than a
minute
Low processing temperatures and low
injection pressures
◦ Typical for casting large parts
Reaction Injection Molding
Figure 14-6 The reaction injection molding process. (Left) Measured
amounts of reactants are combined in the mixing head and injected into the
split mold. (Right) After sufficient curing, the mold is opened and the
component is ejected.
Extrusion
Used for long plastic products with a
uniform cross-section
Pellets or powders are fed through a
hopper and then into a chamber with a
large screw
The screw rotates and propels the
material through a preheating section
where it is heated, homogenized, and
compressed
To preserve its shape, the material is
cooled by jets of air or water spraying
Extrusion
Figure 14-7 A screw extruder producing thermoplastic product. Some units may have a
changeable die at the exit to permit production of different-shaped parts.
Thermoforming
Thermoplastic sheet material is heated
and then placed over a mold
A vacuum, pressure, or mechanical
tool is applied to draw the material
into the mold
The die can impart the dimensions and
finish or texture on the final product
Typical products are thin-walled parts,
plastic luggage, plastic trays, and panels
for light fixtures
Thermoforming
Figure 14-8 A type of thermoforming where thermoplastic sheets are shaped using a combination
of heat and vacuum.
Foam Molding
A foaming agent is mixed with a plastic
resin and releases gas when the material is
heated during molding
The materials expand to 2 to 50 times their
original size
Produces low density products
Both rigid and flexible foams can be produced
◦ Rigid type is used for structural applications such as
computer housings, packaging, and shipping
containers
◦ Flexible foams are used for cushioning
Machining of Plastics
Plastics can undergo many of the same
processes of metals
◦ Milling, sawing, drilling, and threading
General characteristics of plastics that affect
machining
◦ Poor thermal conductors
◦ Soft and may clog tooling
◦ Softening may reduce the precision of the final
dimensions of thermoplastics
◦ Thermosets can have more precise dimensions
because of its rigidity
Tooling Considerations for
Machining Plastics
High temperatures may develop at the
cutting point and cause the tools to be
hot
Carbide tools may be preferred over
high-speed tool steels if high-speed
cutting is performed
Coolants can be used to keep
temperatures down
◦ Water, soluble oil and water, weak solutions of
sodium silicate
Lasers may be used for cutting
operations
Designing for Fabrication
Materials should be selected with the
manufacturing processes in mind
The designer should be aware that
polymers can soften or burn at elevated
temperatures, have poor dimensional
stability, and properties deteriorate
with age
Many property evaluation tests are
conducted under specific test conditions
◦ Materials should be selected that take these
conditions into account
Designing for Fabrication
Each process has limitations and design
considerations
◦ Shrinkage in casting
◦ Solidification issues
◦ Part removal and ejection
◦ Surface finish
◦ Section thickness
◦ Thick corners
Design Factors Related to
Finishing
Finish and appearance of plastics is
important to consumers
Decorations or letters can be produced
on the surface of the plastic, but may
increase cost
Processes should be chosen so that
secondary machining is minimized
If parting lines will result in flash, the
parting lines should be placed in
geometrically easy locations (i.e. corners
and edges) if possible
14.4 Processing of Ceramics
Two distinct classes of processing
ceramics
◦ Glasses are manufactured by means of
molten material via viscous flow
◦ Crystalline ceramics are manufactured by
pressing moist aggregates or powder into
shape
◦ The material is then bonded together using one
of several mechanisms
Chemical reaction
Vitrification
Sintering
Fabrication Techniques for Glasses
Shaped at elevated temperatures
Sheet and plate glass is formed by
extrusion through a narrow slit and
rolling it through water-cooled rolls
Glass shapes can be made by pouring molten
material into a mold
◦ Cooling rates may be controlled
Constant cross section products can be
made through extrusion
◦ Glass fibers are made through an extrusion process
Fabrication Techniques for Glasses
Viscous masses may be
used instead of molten
glass
Figure 14-17 Viscous glass
◦ Female and male die
can be easily shaped by
members are typically used
mating male and female die ◦ Processes similar to blow
members. molding are used to make
bottles and containers
Figure 14-18 Thin-walled glass shapes can be produced by a
combination of pressing and blow molding.
Fabrication Techniques for Glasses
Heat treatments
◦ Forced cooling produces surface
compression and this glass is known as
tempered glass and is stronger and more
fracture resistant.
◦ Annealing operation can be used to relieve
unfavorable residual stresses when they
exist
Fabrication Techniques for Glasses
Glass Ceramics
◦ A unique class of material with part
crystalline and part glass
◦ Glass material is subjected to a special heat
treatment (devitrification)
Controls nucleation and growth of crystalline
component
Dual structure with good strength, toughness,
and low thermal expansion.
Typical products such as cookware and ceramic
stove tops
Fabrication of Crystalline Ceramics
Crystalline ceramics are hard, brittle
materials that have high melting points
Cannot be formed by techniques that
require plasticity or melting
Processed in the solid state
◦ Dry pressing
◦ Isostatic pressing
Clay products are ceramics blended with
water and additives
Machining of Ceramics
Most ceramics are hard and brittle, so
machining is difficult
Machining before firing is called green
machining
Machining after firing are typically
nonconventional machining processes
◦ Grinding, lapping, polishing, drilling, cutting,
ultrasonic, laser, electron beam, water-jet, and
chemical
Design Considerations
Joining of Ceramics
◦ Adhesive bonding
◦ Brazing
◦ Diffusion bonding
◦ Threaded assemblies
Most ceramics are designed to be one piece
structures
Bending and tensile loading should be
minimized during manufacture
Sharp corners and edges should be
avoided
It is costly to achieve precise dimensions and
surface finishing
HW for Chapter 14
Review Questions:
2, 23, 26, 27, 33, and 41 (page 360-361)
