MATL07005 2009 Polymer Processing

General Details

Full Title
Polymer Processing
Transcript Title
Polymer Processing
Code
MATL07005
Attendance
N/A %
Subject Area
MATL - Materials
Department
MENG - Mech. and Electronic Eng.
Level
07 - NFQ Level 7
Credit
05 - 05 Credits
Duration
Semester
Fee
Start Term
2009 - Full Academic Year 2009-10
End Term
9999 - The End of Time
Author(s)
Donal Lyons, Michael Moffatt, Stephen Reid, Declan Sheridan
Description

This module will provide the student with a comprehensive knowledge of the principles of operation, construction and layout of equipment used in the melt processing of polymeric materials.
The student will study the relationship between materials, products and process variables.

Learning Outcomes

On completion of this module the learner will/should be able to;

1.

Demonstrate a knowledge, understanding and practical experience of the operation of the injection moulding process

2.

Demonstrate a knowledge, understanding and practical experience of the operation of the extrusion process including sheet and profile production

3.

Demonstrate a basic knowledge, understanding and practical experience of the operation of a blow moulding machine

4.

Demonstrate a knowledge, understanding and practical experience of the operation of the vacuum forming process

5.

Demonstrate a knowledge and understanding of the dependence of moulding systems and conditions on materials properties

6.

Demonstrate a thorough knowledge of the effect that material properties have on melt processing conditions

7.

Demonstrate a knowledge of the equipment required for making compounds

Indicative Syllabus

Mixing and Compounding: Introduction to basic principles of mixing, choice and comparison of mixing and compounding systems for specific materials and applications

Extrusion: Basic screw types for single screw extruders, vented extruders. Overview of the main extrusion processes of; tube, wire coating, sheet and film. Design of mixing heads for single screw extrusion. Coextrusion process. Comparison with twin screw extrusion. Introduction to screw and die characteristics. Fault diagnosis of common processing problems. Basic screw and die design considerations.

Injection Moulding: Construction of machines and types available, hydraulic, electric and hybrid systems. Multi shot systems and micro machines. Types of mould locking systems and tie bar less machines. Screw designs. Moulding cycle Overview of injection moulding non standard materials such as elastomers and thermosets. The effects of moulding conditions and process variables on products, e.g. shrinkage and orientation. Systematic approach to correction of moulding faults. The Economics of Injection Moulding: The moulding cycle and the derivation of typical costings for moulded components. Heating and cooling requirements Machine Safety: Requirements and types of safety mechanisms.

Blow Moulding: Principles of injection and extrusion blow moulding. Parison formation Blowing systems The effect of material properties on the product, also the effect of processing on the product.

Vacuum Forming; Positive, negative, drape, air slip, snap back, and plug assist. Mould design, draft angles and venting for vacuum forming etc. Choice of mould making materials. Manual, semi-automatic and fully automatic machines

Rotational Moulding : Principles, equipment and processing. Material selection. Practical Content Determination of the optimum moulding area diagram for a range of engineering materials Optimise vacuum forming parameters Effect of extrusion variable on the dimensions of an extruded profile. Use of parison programming on the material distribution of a blow moulded bottle.

Practical Content

Determination of the optimum moulding area diagram for a range of engineering materials.

Optimise vacuum forming parameters.

Effect of extrusion variable on the dimensions of an extruded profile.

Use of parison programming on the material distribution of a blow moulded bottle.

Coursework & Assessment Breakdown

Coursework & Continuous Assessment
40 %
End of Semester / Year Formal Exam
60 %

Coursework Assessment

Title Type Form Percent Week Learning Outcomes Assessed
1 Continuous Assessment Continuous Assessment UNKNOWN 20 % OnGoing 1,2,3,4,5,6,7
2 Practical Evaluation Practical / Oral Continuous Assessment UNKNOWN 20 % OnGoing 1,2,3,4,5,6,7
             

End of Semester / Year Assessment

Title Type Form Percent Week Learning Outcomes Assessed
1 Final Exam Written Examination Final Exam UNKNOWN 60 % End of Term 1,2,3,4,5,6,7
             
             

Part Time Mode Workload


Type Location Description Hours Frequency Avg Workload
Lecture Distance Learning Suite Online lecture 1.5 Weekly 1.50
Independent Learning UNKNOWN Preparation for weekly class 1 Weekly 1.00
Independent Learning UNKNOWN Completion of weekly assignment / CA 1.5 Weekly 1.50
Independent Learning UNKNOWN Reading assignments 2 Weekly 2.00
Group Learning Not Specified Practical 8 Twice Per Semester 1.07
Total Part Time Average Weekly Learner Contact Time 2.57 Hours

Module Resources

Non ISBN Literary Resources

Injection Moulding Machines, Johannaber, Hanser ,1994

Injection Moulding the complete moulding operation, Rosato, Chapman & Hall, 1995

Plastics Extrusion Technology, Hensen, Hanser, 1997

Polymer Extrusion, Polymer Processing Technology, Rauwendaal, Oxford University Press, 2001

Extrusion Processing Data, Alberto Naranjo C., Maria del Pilar Noriega E., Juan Diego Sierra M., Juan Rodrigo Sanz., Hanser, 2001

Blow Moulding Handbook: Technology, Peformance, Markets, Econmics, Rosato.D & Rosato D, Hanser, 1989

Materials and Processes in Manufacturing, E. Paul Degarmo, Wiley (9thEd), 2003  

Other Resources

Plastic and rubber weekly journal

Newscientist journal

Polymer journal, Kunstoffe, Modern Plastics,