Page 504 - 04. Subyek Engineering Materials - Manufacturing, Engineering and Technology SI 6th Edition - Serope Kalpakjian, Stephen Schmid (2009)

Plastics and

Composite Materials:

Forming and Shaping

° This chapter describes the manufacturing processes involved in producing
polymers and composite materials for consumer and industrial products.
° Extrusion is widely used to produce rods, tubing, and pellets for further
processing and is also used to make base stock for the production of plastic
bottles, sheet, and film.
° The chapter discusses a variety of molding operations for producing discrete
parts, including injection and reaction-injection molding, transfer molding,
rotational molding, and compression molding.
° The manufacturing processes associated with shaping composite materials are
then described, including compression and vacuum molding, Contact molding,
pultrusion, and filament winding.
° The production of prepregs for these processes is also discussed.
° The chapter ends with a description of the characteristics of the machinery used,
mold design principles, and economic considerations in polymer processing.

Typical parts made: Extensive variety of consumer and industrial products with a
range of colors and characteristics.
Alternative processes: Casting, forming, powder metallurgy, and machining.

l9.l Introduction

The processing of plastics and elastomers involves operations similar to those used
in the forming and shaping of metals, described in preceding chapters. The process-
ing of rubbers and elastomers began in the 1800s with the discovery of vulcaniza-
tion by C. Goodyear in 1839. Plastics began to be developed in the 1920s, and rapid
progress in the 1940s and onward led to important advances in the design and man-
ufacture of various processing equipment to make numerous consumer and indus-
trial products in large quantities. In the 1970s, reinforced plastics began to be
introduced, leading the way for rapid progress in the use of composite materials-
Protectorm Tennis with unique properties and attendant challenges in producing them.
Racquets 5 I 5 As noted in Chapter 7, thermoplastics melt and thermosets cure at relatively
low temperatures. Hence, unlike metals, they are relatively easy to handle and

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