polymer processing

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The pipe sector is one of the most challenging construction sectors today. Economic pressures have led to fewer construction projects in many major markets, while specifiers have been increasingly expected to balance higher performance with reduced cost. Today's plastics provide the opportunity to overcome these challenges. The economic and environmental benefits achieved by plastic pipe are an outcome of features including: Zero corrosion — Plastics resist corrosion from water and many chemicals, reducing wear and tear and increasing longevity. Increased flexibility — Easy to install, even at low temperatures. Durable and tough material — Plastic pipes give a high resistance to fracture and fatigue Leak-free joint fusion — Buttwelding, socket welding, electro-fusion fittings Light weight materials — The light weight of plastic contributes to reducing man hours and the need for heavy equipment, such as cranes. Plastics are also easier to transport and store. Easier installatio

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The second step in validating an injection mold according to injection mold validation flow chart is dry cycle mold . The steps before are: 1. Mold certification Purpose: The purpose of the dry cycle mold is to evaluate the mold mechanical actions for any gross problems prior to injecting plastic into the mold. The machine operator at the mold builder or molder should know how to adjust the settings on the injection unit to cycle the mold without injecting plastic into the tool. If at anytime during the dry cycle procedure there is a possibility that damage is being done to the tool or if the mold is not operating as designed, pull the mold from the press and have it examined by an experienced mold builder. This stage is often carried out prior to the customer being invited to the mold builder for the debug. If there are any machine/mold operation issues it is preferable for the mold builder to remedy this before customer attendance, saving unnecessary travel. If there is a serious

Mandrel and die dimensions are estimated based on container dimensional data, container symmetry, blow-up ratio, targeted container weight, neck finish requirements and the type of material (degree of parison swell) that will be used to produce the container. An initial blow-up ratio must be calculated using the container design dimensions and the required parison diameter. The required parison diameter will depend on the relative size of the container, the container design (handle or no handle) and the container neck finish requirements. Initial blow-up ratios may be calculated using the following equation. Blow up ratio = Bd / Nd where: Bd = Bottle diameter, in Nd = Minimum neck diameter, in The blow-up ratio is compared with the maximum recommended blow-up ratio of the selected material. Blow up ratios of 2 or 3 to 1 are considered normal when molding commodity resins such as polyethylene. A blow-up ratio as high as 4:1 is a practical upper limit. The blow up ratio for large contai

A fault with the dryer will lead to hydrolysis of the material in the barrel of the machine. This will cause lowered I.V. of the material. Lowered I.V. is the major cause of bad quality in preforms and bottles. More than 60% of all PET processing related faults can be traced back to the dryer . Maintaining the dryer in optimum condition will allow the molding machine to perform at maximum efficiency and quality. Check the basics! Airflow - The most important parameter, there should be nothing causing a restriction in the process and regeneration air flow. Temperature - Process Temperature should be in the region of 145~170 º C Depending on the resin supplier and the drying time. Also check the Regeneration Temperature which should be around 200~230 º C depending on the maker. Time - Calculate (or measure) the time the material is in the hopper, this should be at least 3½ hours. Dewpoint - Correct dewpoint may vary according to the manufacturer of the dryer, consult the maker's

What Is It? A simple calculation that tells you the consumption of poly(ethylene terephthalate), PET by an injection molding machine. The Calculation Is... kg / hr = W x C x S Where; W = Weight of the container in kg. (e.g. 45 grams = 0.045 kg) C = Number of injection cavities S = Number of injection cycles per hour (shots) (3,600 / Cycle Time (sec) for one set of preforms) Example A machine with a cycle time of 14 seconds making a 35 gram bottle W = 0.035 C = 8 S = (3,600 / 14) = 257.1 kg / hr = 0.035 x 8 x 257.1 = 72 kg / hr

The first step in validating an injection mold according to injection mold validation flow chart is mold certification . Purpose: The purpose of the mold certification is to ensure the mold is built according to specification before the mold validation procedures begin, e.g., critical dimensions on the first mold set are cut "Steel Safe" , core/cavity stack up dimensions are correct, cavity to cavity spacing is correct, cooling circuit layout, etc. The tool builder is required to provide verification of all critical metal tolerances on core and cavity ‘fits’ to be +/- 0,005 mm. The critical part dimension metal tolerances must be less than 10% of the plastics part dimension tolerances. In many cases, it will be necessary to go tighter than 10%. The mold certification should be performed at the tool builder while the mold is being fabricated to expedite any needed adjustments to the mold. Mold certification needs to be agreed upon when the mold order is placed. A copy of t

Free magazines, eBooks, publications, newsletter review from the polymer processing industry. Celebrating over 50 years of service to the composites industry worldwide. For over 50 years Reinforced Plastics has been the first choice of moulders, fabricators and end-users as a comprehensive source of impartial and informed comment on the global composites industry. Their unique partnership with all the main industry players enables them to empower their readers with up-to-the-minute news on all aspects of the industry. They are totally committed to being the best in the business and maintaining the support of their readers and advertisers in the continuing challenges of their industry. Geographic Eligibility : Select International Offered Free by : Elsevier Limited Request Free!

Free magazines, eBooks, publications, newsletter review from the polymer processing industry. Modern Plastics Worldwide is the only plastics publication dedicated to covering global business management issues, key technologies, and the latest manufacturing management trends for the international plastics industry. Topics range across all processes, including injection, extrusion, blowmolding, thermoforming, blown film, cast film, and compounding. Modern Plastics Worldwide also covers the latest technology developments in materials, design, equipment, processing, and applications from a business strategy perspective, marketing information on new markets, industry trends, economic influences, forecasts and more. Geographic Eligibility : USA, Canada, Mexico, Selected International (Print or Digital version) Request Free! Canon Plastics Group - the Voice of an Industry Canon Communications LLC is a strategic partner to the plastics industry. Both of our publications, Injection Molding Ma

Free magazines, eBooks, publications, newsletter review from the polymer processing industry. IMM is the only publication devoted exclusively to the injection molding marketplace, consisting of custom and captive molders, contract manufacturers, OEM companies, part designers, moldmakers, and key members of the supply channel. Readers prefer IMM's editorial content as it provides them with "how-to" advice that contributes to their success. Geographic Eligibility : USA, Canada, Mexico (Print Edition Only), Selected International (Digital Edition Only) Request Free! Canon Plastics Group - the Voice of an Industry Canon Communications LLC is a strategic partner to the plastics industry. Both of our publications, Injection Molding Magazine and Modern Plastics Worldwide , address the plastics industry from a unique viewpoint. Each one offers in-depth coverage of its subject matter that a generalist publication just can’t accomplish. Each viewpoint helps readers stay on top of

To validate an injection mold, there are numerous items one must take into consideration before the mold is completed and work is ready to begin. First, it is advisable to hold a mold design review meeting with all involved parties prior to tool manufacture. Invite the mold builder, hot runner supplier, steel supplier, press supplier, resin supplier, and a strategic molder for the design review. Involving everyone early on in the process and keeping them informed throughout the building of the mold avoids needless complications. Once all the suppliers have been identified it is vital that they are all given training on the injection mold validation procedure , IMVP. The training should be done well in advance of the first mold qualification, if you have a pilot tool stage this is an ideal time. It could be done whilst the production tools are being manufactured. It is strongly advised the tool builder is made aware of the requirements of mold certification (steel measurements) before

The following steps are required in validating a injection mold according to injection mold validation flow chart. 1. Mold certification 2. Dry cycle mold 3. Process stability test 4. Gage repeatability & reproducibility (R&R) test 5. Mold viscosity test 6. Balance of fill analysis 7. Gate freeze test 8. Commissioning (multi-cavity analysis) 9. Design of experiments 10. Qualification (process capability study) 11. Mold metal Adjustments - centering process 12. Verification (30-day run)

Companies from the world’s plastics and rubber industry put their faith in K 2010 in Düsseldorf. Some 3,000 exhibitors will step out at the No. 1 event for the industry from 27 October to 3 November 2010. No other trade fair in the industry compares with K 2010 for the panorama it will provide on offerings from all over the globe. The extensive palette on display is once again assured by exhibitors’ international reach. Companies from every continent have signed up to showcase their innovations in the following categories: - Raw materials, auxiliaries, - Semi-finished products, technical parts and reinforced plastics, - Machinery and equipment for the plastics and rubber industry. Once again, suppliers from Germany, Italy, Austria, Switzerland and the USA as well as Asian manufacturers from China, Taiwan and India will be out in force. Among them will be not only the global market leaders but also a wealth of exciting newcomers.

Safety is everyone's responsibility in the workplace. Safety is most often related to good maintenance practice and good housekeeping. Safety needs to be an attitude that is always present in your daily activities. Employees should not be hesitant to voice safety concerns in the workplace. Management is just as committed to safety as the operators on the floor; the primary difference is that the operators are usually the closest to unsafe conditions; keep management advised of unsafe conditions. The following list includes items which should be maintained to assure a safe working environment: 1. Floor and machine should be kept free of oil. 2. Floor and machine should be kept free of pellets. 3. Never reach over or under machine guards. 4. Never climb between the tie bars when hydraulic pumps are running. 5. Never disconnect or by-pass safety switches on guards. 6. In order to prevent mechanical hazards such as limbs being drawn into or trapped in the machinery, operators shoul

Acetaldehyde A.A. is an organic chemical compound with the formula CH 3 CHO . Is a colorless gas at room temperature and has a strong fruity smell. It occurs naturally in many fruits and other foodstuffs is used as a flavor enhancer for certain products and is produced by plants as part of their normal metabolism. Acetaldehyde is also generated during the production and injection processing of poly(ethylene terephthalate), PET material. It can cause an off-taste in bottled water. Generally, most acetaldehyde problems originate in the barrel during the injection process. All PET resins have some residual acetaldehyde after being manufactured, the quantity will vary according to the grade. Acetaldehyde is only generated while the PET resin is in its melt condition, therefore it can only be controlled by adjustments in the barrel (90%) and hot runner (10%) of the machine. The generation of acetaldehyde is not linked to moisture content of the material, although in the process of be

Poly(ethylene terephthalate), PET resins have several basic differences follow this notes and find the one which is the best for your application. 1. Intrinsic Viscosity, I.V. - ranging from 0.72 up to 0.85 for injection stretch blow molding. 2. Polymer Type - Homopolymer or Copolymer 3. Residual Acetaldehyde A.A Level - Normal or Reduced 4. Cosmetic Grades - Able to resist crystallization. 1. Intrinsic Viscosity, I.V. PET material for bottles is available in I.V. levels from 0.72 up to 0.85. Lower I.V. is more suited to fine details but will give lower strength in the final container and will have more tendency to flash. High I.V. material will give a stronger bottle but it may be impossible to form fine details in the preform or bottle. Low I.V. materials tend to be better if you need to blow an intricate shape but will result in a container having less strength and will become more difficult to control in the stretch blow process. A higher I.V. material will give better overall

Weld Line - The point on a part where two plastic flow fronts meet during injection. Witness Line - A visible line on part due to two molding surfaces coming together. Witness lines always occur at parting lines.

Variation - A change in the value of a measured characteristic. Vent - A shallow channel in the mold to allow air to escape from the cavity during injection. Virgin Material - Plastic material that has not been subject to use or processing other than that required for its initial manufacture. Viscosity - Internal friction or resistance to flow of a melt or liquid. The constant ratio of shearing stress to shearing rate. It is a measure of the materials resistance to flow.

Ultimate strength - Term used to describe the maximum unit stress a material can withstand before breaking when subjected to a load in compression, tension or shear. Undercut - An indentation or protuberance on a part that impedes the removal of core and/or cavity.

Tensile strength - The resistance of a material to longitudinal tension stress. Thermal conductivity - Ability of a material to conduct heat. Thermal degradation - Deterioration of material by heat. Thermal diffusivity - The ability of a material to transfer heat per unit time and area. Thermoplastic - Capable of being repeatedly softened by heat and hardened by cooling. Thermoset - A material that will undergo or has undergone a chemical reaction by the action of heat, catalysts, ultraviolet light,etc. Three-plate mold - Mold with two parting lines, one for part and the other to free trapped cold runner. Two-plate mold - Mold with one parting line used to free both part and runner.

Shear - An action resulting from applied forces which cause or tends to cause two contiguous parts of a body to slide relative to each other in a direction parallel to their place of contact. Shear heating - Frictional heat generated within a plastic due to shear forces either in the extruder or in the runner system during injection. Shot - The yield of parts from a mold after one complete molding cycles, including scrap. Shot capacity - The maximum amount of material that the injection units ram or plunger can push out in one forward stroke. Shot size - The amount of plastic required to fill the mold. Shrinkage - The decrease in dimensions a plastic undergoes from molten state to a solid state. Shrinkage is compensated for by packing pressure, but some material shrinkage occurs after gate is frozen and for as much as 24 hours after it is molded. Sink Mark - An imperfection or depression in the surface of a part, generally cause by non-uniform shrinkage. SPC - Statistical Proce

Recovery - The injection unit building up (plasticizing) for a next shot. Regrind - A thermoplastic from one process or cycle (scrap, runners, etc.) ground up to be used for a future molding cycle. Resin - Any of a class of solid or semi-solid organic products of natural or synthetic origin. Most resins are polymers. Runner - Channel in mold that connects sprue to gate. Runnerless molds - Molds which are designed so that the runner is heated and stays molten. Runner is not ejected with part each shot.

Parting line - Line, visible on the mold part, where mold separates to release the molded part from the cavity. Pearlescent pigments - A class of pigments consisting of particles that are essentially transparent crystals of a high refractive index. The optical effect is one on partial reflection from the two sides of each flake. When reflections from parallel plates reinforce each other, the result is a silvery luster, iridescent effects and metallic sheen resembling natural pearl. PET - Polyethylene Terephthalate, known as a thermoplastic polyester. Has the unusual ability to exist in either an amorphous or highly crystalline state. Plasticize - To soften a material and make it plastic or moldable, either by means of an extruder or by heat or both. Platen - The plates on which the mold assembly is mounted. Large metal blocks on clamping ends of molding machine used to support mold. Polycarbonate resins - Polymers derived from the direct reaction between aromatic and aliphatic di

Olefins - A group of unsaturated hydrocarbons and named after the corresponding paraffins by the addition of ene or ylene to the stem. Examples are polyethylene, polypropylene, etc. Orientation - The alignment of crystalline structure in polymeric materials so as to produce a highly aligned molecular structure.

Nozzle - The hollowed metal cone nose screwed into the extrusion end of the extruder screw that mates with the mold via the mold's nozzle bushing. The nozzle allows transfer of the molten plastic from the extruder to the mold runner system and cavities.

Matte finish - A surface which displays no gloss when observed at any angle. Mean - See Average Melt Flow Index - The amount, in grams, of a thermoplastic resin which can be forced through a 0.0825 inch orifice when subject to 2,160 grams force for ten minutes at 230°C, per ATSM D1238 Metallizing - Applying a thin coating of metal to a non-metallic surface. Metering Zone - The final zone of an injection barrel or screw, at which the melt is advanced at a uniform rate to the screw tip. Mold - The cavity or matrix of cavities into which plastic melt is placed and takes form. Mold Components - Parts that make up a mold and determine how a mold will be operated. Mold Frame - Series of metal plates which support mold components. Multi-cavity Mold - A mold with two or more cavities.

L/D ratio - Length to diameter ratio of an extruder screw. LDPE - Low Density Polyethylene Lead In - Initial clearance through an initial angle or chamfer that helps align two close mating parts. Linear Molecule - A long chain molecule of two-dimensional structure which may contain side chains or branches. lLDPE - Linear Low Density Polyethylene Lubricants - Prevent materials form sticking or improve processability.

Knockout - Any part or mechanism of a mold used to eject the molded article. Knockout bar - A bar that ejects the molded article from the mold. It is usually activated automatically while the mold is opening.

Jetting - A turbulent flow in the resin melt caused by an undersized gate or where a thin section becomes thicker. Can also occur when gating into and along a thick section.

Impact strength - The ability of a material to withstand shock loading. Inert additive - A material added to a plastic compound, such as a filler, which may alter the properties of the finished article but which does not react chemically with any other constituents of the composition. Injection pressure - Pressure exerted on plastic to fill, pack, and hold mold. Comprised of Boost and Hold pressure. Injection ram - The ram which applies pressure to the plunger in the process of injection molding. In-mold decorating - The process of applying labels or decorations to plastic articles simultaneously with the molding operation. Interference fit - The mating of two points, lines, or surfaces, the dimensions of which cause negative clearance between them.

Hardness - The resistance of a material to compression or indentation. Among the testing methods Brinell, Rockwell, and Shore HDPE - High density polyethylene Heat deflection or distortion point - The temperature at which a standard test bar deflects 0.010 inches under a stated load of either 66 or 264 psi. Indication of maximum temperature that you can eject a part from a mold. Hold (2nd Stage Pressure) - Sufficient pressure applied to cavity that doesn't allow plastic to flow into or out of the cavity until the gate is frozen. Hopper - Feed reservoir into which material is loaded from which it falls into a mold machine's injection unit. Hot runner mold - Type of runnerless mold. Runner is not ejected with part each cycle

Gate - An orifice through which the molten resin enters the cavity. Gate blush - A blemish or disturbance in the gate area of an injection molded article. It occurs when the melt fractures in leaving the gate due to relaxation of elastic forces. Gel permeation chromatography - A device used to determine the molecular weight distribution of a polymer. GPC - An abbreviation for Gel Permeation Chromatography. Guide pins - Devices to maintain proper alignment for molds.

Feed zone - Zone on injection screw directly below hopper. Plastic is pre-heated in this zone, not melted. Filler - A substance added to the plastic to make it less costly. Some fillers also improve mechanical properties. Finish - The ultimate surface of a plastic part. Flash - The thin, surplus web of material which is forced into crevices between mating surfaces during a molding operation, and which remains attached to the molded article. Flow lines - Wavy surface appearance caused by improper flow of the resin into the mold. Fluorescent - Organic dyes or pigments which may be blended into inks to provide a luminescent or fluorescent appearance typical of the "neon" colors. Frictional heating - See Shear Heating

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Ejection - That part of the molding cycle in which the finished part is removed from the mold mechanically. Ejection system - System used to eject the molded part from the mold after it cures. Ejector plate - A plate which backs up the ejector pins and holds the ejector assembly together. Elastic deformation - The part of the deformation of as part under load which is recoverable when the load is removed. Elasticity - The property of a substance which enables it to return to its original shape and size after removal of a deforming force. Elongation - Lengthwise stretching of a material usually denoted as a % of original length. Environmental stress cracking (ESC) - The susceptibility of a plastic to crack or craze under the influence of certain chemicals, stresses, or other agents. Ethylene plastics - Plastics based on polymers or co-polymers of ethylene. EVA (Ethylene-Vinyl Acetate) - Co-polymers from these two monomers retain many of the properties of ethylene, but have consi

Daylight opening - Clearance between the two platens of the press in the open position. Decompression - See Suckback Degradation - A deleterious change in the chemical structure of a plastic. Degating - The removal of material left on a plastic part formed by the opening through which material was injected into the mold cavity. Degree of polymerization - The average number of monomer units per polymer molecule, a measure of molecular weight. In most plastics, the molecular weight must reach several thousand to attain worthwhile physical properties. Density - Mass per unit volume of a substance, exposed in units such as grams per cubic centimeter, pounds per cubic foot or pounds per gallon. Desiccant - A substance capable of absorbing water vapor from air or other gaseous material, used to maintain low humidity in a storage or test vessel. Draft - The degree of taper of a side wall or the angle of clearance designed to facilitate ejection of parts from the mold. Dry coloring -

CAD - Computer Aided Design. Use of computer to draw/design parts. Cap - Closure Capacity - The rated amount of volume (# parts) produced by a mold/molding machine per year. Capper - Machine that applies a closure to a bottle on a packing line. Cavitation - The number of molding stations within a mold. Cavity - Mold component(s) which form the exterior or external surfaces of a part. Centerline - A line drawn down on part drawing that represents the geometrical center of the part in that axis. Charge - The amount of material volume or weight required for the injection unit to plasticize for each molding cycle. Chemical resistance - Ability of a material to retain utility and appearance following contact with chemical agents. Child resistant closure (CRC) - A closure that requires dissimilar motions which may make removal by a child difficult. Subject to government regulations. Clamp speed - Speed at which the mold platens will open and close; controlled by operator settings.

Back draft - A slight undercut or tapered area in a mold tending to prevent removal of the molded part. Back plate - A plate used as a support for the cavity blocks, guide pins, bushing, etc. Sometimes called support plate. Back pressure - Pressure exerted by the injection unit's cylinder against the screw as it recovers or plasticates. Used to increase the melt homogeneity. Increases melt temperature. Baffle - A plug or other device inserted in a flow channel to divert cooling medium to a desired path. Balanced runner - A runner system designed to place all cavities at the same distance from the sprue. Ball check valve - An anti-back flow valve which prevents the plastic melt from flowing back over the screw during injection. Band heaters - Electrical heaters surrounding the barrel and nozzle of the injection unit. Bar chart - Histogram Barrel (extruder) - Hollow tube in which plastic is gradually heated and melted. Inside the barrel is a helical screw which compresses an

ABS (Acrylonitrile-butadiene-styrene) - Blends of copolymers or styrene-acrylonitrile copolymer with butadiene-acrylonitrile rubber. Accumulator - Auxiliary cylinder and piston (plunger) mounted on injection molding machine. It is used to provide extremely fast molding cycles through accumulation of molten plastic from the main extruder (reducing plastication time) and forces the plastic into the mold during filling at high speed and pressure (reducing fill time). Acetal resins - The molecular structure of the polymer is that of linear acetal, consisting of unbranched polyoxmethylene chains. Achromatic color - A neutral color (white, gray or black) that has no hue. Acrylic - Polymethylmethacralate Additives - Used to enhance processing, performance, appearance, and/or economics of the basic plastic formulation. Aesthetics - The sum total of the visual response (color, shape, feel, etc.) to the appearance of a part. Amorphous phase - Devoid of crystallinity; no definite order. Th

Material Dynamic viscosity, Pa·s Air (temp. 20 0 C) 10 -5 Water (temp. 20 0 C) 10 -3 Mercury (temp. 20 0 C) 1,5·10 -3 Aluminum (temp. 700 0 C) 1,1·10 -3 Zinc (temp. 700 0 C) 1,7·10 -3 Iron (temp. 1400 0 C) 6·10 -3 Blood (temp. 37 0 C) 10 -2 Oil 10 -2 -10 0 Honey 10 1 Melted polymers 10 2 -10 4 Cake 10 3 -10 5 Cheese 10 7 -10 8 asphalt 10 8 Melted glass (temp. 500 0 C) 10 12 Glass 10 40

Reifenhäuser supplied in 2005 a 35 m high 3-layer blown film line . Essential components of the new wide film extrusion line are: - gravimetric dosing system for each extruder, - 2 extruders, 150 mm screw diameter, - 1 extruder, 200 mm screw diameter, - 3-layer blown film die with internal bubble cooling and 2200 mm die diameter ensuring a high production capacity, - high-performance air ring KRF 2200, - film guiding system with 4 ultrasonic sensing arms, collapsing assembly and side gusseting unit, - 8-ply folding station for C-type folding enabling simple handling of the oversized film widths in greenhouse construction, - fully automatic short-length winder FAC 4200 with bobbin magazine, adjustable for winding different film lengths and to cope with extremely short reel changing cycles, - REIcofol automation system for process control, including film measuring station and indication of side gusseting depth. The new 3-layer blown film line is designed for an extremely high producti

All you have to do is one click on the picture and then experiment with available options Polyethylene, PE Polypropylene, PP Polyvinyl chloride, PVC

Polypropylene is thermoplastic polymer consisting mainly of propylene come from a low pressure process based on catalysts and have generally linear polymer chain. There are three general types of polypropylene: homopolymer , random copolymer and impact or block copolymer . Random copolymer is produced by statistical insertion of units mainly ethylene . Through this, the glass transition temperature and melting point are lower than in homopolymer . Additionally we receive better mechanical properties in the temperature below zero (e.g. impact) and optical (transparency). Processing of random copolymer by injection molding considering properties mentioned above characterizes lower temperature (lower cycle time) and pressure. Application, e.g. thin wall and transparent products on the other hang thick wall, because of lower crystallization ratio (amorphous structure).

The story of Ponar Zywiec The successor of the machine factory with more than 100 years of traditions in construction of different kinds of machines, among them also machines with hydraulic drive, has specialized in construction of injection moulding machines and hydraulic presses for plastics and rubbers for above 30 years.