-
Browse Book Series
- Adhesion and Adhesives: Fundamental and Applied Aspects
- Advances in Additive Manufacturing Technologies
- Advances in Antenna, Microwave and Communication Engineering
- Advances in Biofeedstocks and Biofuels
- Advances in Cyber Security
- Advances in Data Engineering and Machine Learning
- Advances in E-Mobility
- Advances in Hydrogen Production and Storage
- Advances in Intelligent and Scientific Computing (AISC)
- Advances in Learning Analytics for Intelligent Cloud-IoT Systems
- Advances in Membrane Processes
- Advances in Nanotechnology and Applications
- Advances in Natural Gas Engineering
- Advances in Pipes and Pipelines
- Advances in Production Engineering
- Advances in Solar Cell Materials and Storage
- Applied Functional Materials
- Artificial Intelligence and Soft Computing for Industrial Transformation
- Astrobiology Perspectives on Life in the Universe
- Bioprocessing in Food Science
- Computational Intelligence and Biomedical Engineering
- Concise Introductions to AI and Data Science
- Cyber Systems and Quantum Engineering
- Decentralized Systems and Next-Generation Internet
- Diatoms: Biology and Applications
- Digital Convergence in Engineering Systems
- Emerging Trends in Medicinal and Pharmaceutical Chemistry
- Engineering Systems Design for Sustainable Development
- Fintech in a Sustainable Digital Society
- Industry 5.0 Transformation Applications
- Infectious and Rare Diseases
- Innovations in Materials and Manufacturing
- Machine Learning in Biomedical Science and Healthcare Informatics
- Materials Degradation and Failure
- Mathematics and Computer Science
- Next-Generation Computing and Communication Engineering
- Performability Engineering Series
- Rotating Machinery Fundamentals and Advances
- Studies in Computational Intelligence and Smart Technologies
- Sustainable Computing and Optimization
Browse Subject Areas
For Authors
Submit a ProposalThe Basics of Troubleshooting in Plastics Processing
 | An Introductory Practical Guide By Muralisrinivasan Natamai Subramanian Copyright: 2011 | Status: Published ISBN: 9780470626061 | Hardcover | 245 pages Price: $131 USD  |
One Line Description
Provides a condensed practical guide that gives the reader a broad introduction to properties of thermoplastics plastics, additives, the major processes (extrusion, injection molding, rotational molding, blow molding, and thermoforming), as well as troubleshooting.
Audience
The book is aimed at people in industry and manufacturing such as operators, processors, engineers, chemists.
The book is also ideal for technical seminars in industry or courses in engineering and technology schools that teach polymers or plastics technology both at the graduate and post graduate levels.
The book is aimed at people in industry and manufacturing such as operators, processors, engineers, chemists.
The book is also ideal for technical seminars in industry or courses in engineering and technology schools that teach polymers or plastics technology both at the graduate and post graduate levels.
Description
The Basics of Troubleshooting in Plastics Processing is a condensed practical guide that gives the reader a broad introduction to properties of thermoplastics plastics, additives, the major processes (extrusion, injection molding, rotational molding, blow molding, and thermoforming), as well as troubleshooting. The main goal is to provide the plastics processor with an improved understanding of the basics by explaining the science behind the technology. Machine details are minimized as the emphasis is on processing problems and the defects in an effort to focus on basic root causes to problems and how to solve them..
The book’s framework is troubleshooting in plastics processing because of the importance it has to the eventual production of high quality end products. Each chapter contains both practical and detailed technical information.
This basic guide provides state-of-the-art information on:
• Processing problems and defects during manufacturing
• Plastics materials, their properties and characterization
• The plastics processing techniques
• Plastics additives
• Troubleshooting of the 5 main plastics processes
• References for further reading
Back to Top
The Basics of Troubleshooting in Plastics Processing is a condensed practical guide that gives the reader a broad introduction to properties of thermoplastics plastics, additives, the major processes (extrusion, injection molding, rotational molding, blow molding, and thermoforming), as well as troubleshooting. The main goal is to provide the plastics processor with an improved understanding of the basics by explaining the science behind the technology. Machine details are minimized as the emphasis is on processing problems and the defects in an effort to focus on basic root causes to problems and how to solve them..
The book’s framework is troubleshooting in plastics processing because of the importance it has to the eventual production of high quality end products. Each chapter contains both practical and detailed technical information.
This basic guide provides state-of-the-art information on:
• Processing problems and defects during manufacturing
• Plastics materials, their properties and characterization
• The plastics processing techniques
• Plastics additives
• Troubleshooting of the 5 main plastics processes
• References for further reading
Back to Top
Author / Editor Details
Muralisrinivasan Subramanian is a plastics technology consultant specializing in materials, additives, and processing equipment, including troubleshooting.
The author obtained his B.Sc in Chemistry from the Madurai Kamaraj University and his M.Sc (1988) in Polymer Technology from Bharathiar University. He received his Post Graduate Diploma in Plastics Processing Technology from CIPET, Chennai. He has also completed his Doctor of Philosophy in Polymer Science from Madurai Kamaraj University.
He worked in the plastic process industry, mainly in R & D, for 13 years before turning to consultancy and building up an international client base. Muralisrinivasan teaches plastics processing seminars as well as being a Board of Studies Expert member of Colleges in India dealing with curriculum of technology subjects.
He authored Update on troubleshooting in Thermoforming in 2010 (iSmithersRapra).
Muralisrinivasan Subramanian is a plastics technology consultant specializing in materials, additives, and processing equipment, including troubleshooting.
The author obtained his B.Sc in Chemistry from the Madurai Kamaraj University and his M.Sc (1988) in Polymer Technology from Bharathiar University. He received his Post Graduate Diploma in Plastics Processing Technology from CIPET, Chennai. He has also completed his Doctor of Philosophy in Polymer Science from Madurai Kamaraj University.
He worked in the plastic process industry, mainly in R & D, for 13 years before turning to consultancy and building up an international client base. Muralisrinivasan teaches plastics processing seminars as well as being a Board of Studies Expert member of Colleges in India dealing with curriculum of technology subjects.
He authored Update on troubleshooting in Thermoforming in 2010 (iSmithersRapra).
Back to Top
Table of Contents
Preface
1. Introduction
1.1 Market Trends
1.2 Importance of Plastics
1.2.1 Plastics vs Metal
1.2.2 Plastics vs Paper and Paper Board
1.3 Plastics Processing
1.4 Fundamentals References
2. Plastics Materials
2.1 Properties and Processing
2.1.1 Molecular Weight
2.1.2 Molecular Weight Distribution (MWD)
2.1.3 Flow Properties
2.1.4 Degree of Crystallinity
2.1.5 Surface Quality
2.1.6 Viscosity
2.2 Polyethylene
2.3 Polypropylene (PP)
2.4 Polystyrene
2.5 Polyvinylchloride (PVC)
2.6 Engineering Plastics
2.6.1 Acrylonitrile Butadiene Styrene (ABS)
2.6.2 Polymethylmethacrylate (PMMA)
2.6.3 Nylon
2.6.4 Polyethyleneterephthalate (PET)
2.6.5 Polycarbonate (PC)
2.6.6 Polyether Ether Ketone (PEEK)
2.6.7 Polytetrafluuoroethylene (PTFE)
2.6.8 Polyacetal (POM)
2.6.9 Polyvinylidene Fluoride (PVDF)
2.6.10 Polyphenylene Sulfi de (PPS)
2.7 Advantages
2.8 Fundamentals References 3
3. Plastics Additives
3.1 Antioxidants
3.2 Anti-block Agents
3.3 Antistatic Agent
3.4 Clarifying Agents
3.5 Slip Additives
3.6 Processing Aids
3.7 Antifogging Agents
3.8 Antiblocking Agents
3.9 Heat Stabilizers
3.10 Lubricants
3.11 Plasticizers
3.12 Coupling Agents or Surface Modifi ers
3.13 Release Agents
3.14 Flame Retardants
3.15 Pigments
3.16 Light Stabilizers
3.17 Impact Modifi ers
3.18 Blowing Agents
3.19 Nucleating Agents
3.20 Biocides
3.21 Fillers
3.22 Fundamentals References
4. Plastics Processing
4.1 Focus on Plastics Processing
4.2 Injection Molding
4.2.1 Injection Molding --Machine
4.2.1.1 Ram Injection Molding Machine
4.2.1.2 Screw Injection Molding Machine
4.2.2 Injection Unit
4.2.2.1 Barrel
4.2.2.2 Screw
4.2.2.3 Clamping Unit
4.2.2.4 Hydraulic Unit
4.2.3 Mold
4.2.3.1Runner
4.2.3.2 Gate
4.2.3.3 Sprue
4.2.3.4 Cavity
4.2.3.5 Nozzle
4.2.3.6 Vent
4.2.3.7 Ejection System
4.2.4 Injection Molding and Parameters
4.2.4.1 Temperature
4.2.4.2 Pressure
4.2.4.3 Time
4.2.4.4 Cooling
4.2.4.5 Velocity
4.2.4.6 Part Design
4.2.5 Injection Molding --Processing
4.2.6 Process Variables
4.2.6.1 Cushion
4.2.6.2 Shot Size
4.2.7 Advantages
4.2.8 Shortcomings
4.3 Extrusion
4.3.1 Extrusion --Basic Requirements
4.3.2 Extruder
4.3.2.1 Single Screw Extruder
4.3.2.2 Twin Screw Extruder
4.3.2.3 Feeder
4.3.2.4 Screw
4.3.2.5 Die
4.3.3 Polymer Melt
4.3.4 Extrudate Swell
4.3.5 Extrusion and Process Parameters
4.3.6 Extrusion --Processing
4.3.7 Advantages
4.3.8 Shortcomings
4.4 Blow Molding
4.4.1 Blow Molding and Process Parameters
4.4.2 Extrusion Blow Molding
4.4.3 Injection Stretch Blow Molding
4.4.4 Advantages
4.4.5 Shortcomings
4.5 Thermoforming
4.5.1 Thermoforming and Parameters
4.5.2 Processing
4.5.3 Mold
4.5.4 Advantages
4.5.5 Shortcomings
4.6 Rotational Molding
4.6.1 Rotational Molding and Parameters
4.6.2 Mold
4.6.3 Processing
4.6.4 Pigmentation
4.6.5 Advantages
4.6.6 Shortcomings
4.7 Fundamentals
4.7.1 Injection Molding
4.7.2 Extrusion
4.7.3 Blow Molding
4.7.4 Thermoforming
4.7.5 Rotational Molding References
5. Troubleshooting --Problems and Solutions
5.1 Troubleshooting --Requirements
5.2 Injection Molding --Troubleshooting
5.2.1 Part Sticking in Cavits
5.2.2 Part Sticking in Core
5.2.3 Discoloration
5.2.4 Burnt Marks (Diesel Effect)
5.2.5 Part Sticks During Ejection
5.2.6 Jetting
5.2.7 Dimensions Out of Specification
5.2.8 Bubbles
5.2.9 Internal Voids
5.2.10 Flash (Over Substrate or on Periphery of Part)
5.2.11 Poor Weld Line
5.2.12 Low Gloss/Gloss Difference
5.2.13 Overmold Breaks/Impinges Through Hollow Substrate
5.2.14 Warpage or Warped Parts
5.2.15 Splay Marks/Delamination
5.2.16 Flow Marks, Folds and Back Fills
5.2.17 Ejector Pin Marks
5.2.18 Sink Marks
5.2.19 Shrinkage
5.2.20 Silver Streak
5.2.21 Short Shots
5.2.22 Brittle Part
5.2.23 Poor Plasticizing
5.2.24 Crack During Mold Release
5.2.25 Nozzle Drool
5.2.26 Short Shots no Burn Marks
5.2.27 Surface Ripples, and Pit Marks
5.2.28 Pellets not Melted
5.2.29 Air Entrapment in the Mold
5.2.30 Gate Blush
5.3 Troubleshooting --Extrusion
5.3.1 Bridging -- at the Throat of the Feed Hopper
5.3.2 Brittle/Braking/Tearing
5.3.3 Contamination/Black Specks and Spots
5.3.4 Die Lines
5.3.5 Entrapped Gasses/Air Bubbles
5.3.6 Excessive Die Swell
5.3.7 Material Accumulation at Die
5.3.8 Low Gloss
5.3.9 Material Non-Homogeneous
5.3.10 Variable Thickness
5.3.11 Variable Output/Surging
5.3.12 Plate-Out on Die Lip
5.4 Troubleshooting --Blow molding
5.4.1 Extrusion Blow Molding
5.4.1.1 Curling
5.4.1.2 Hooking
5.4.1.3 Inconsistent Tail Length
5.4.1.4 Blowouts or Pin Holes
5.4.1.5 Poor Wall Thickness Distribution
5.4.1.6 Asymmetric Part
5.4.1.7 Poor Weld
5.4.1.8 Poor Parting Line
5.4.1.9 Contamination in Parts
5.4.1.10 Flashing Tear
5.4.1.11 Holes in Pinch-Offs
5.4.1.12 Blowouts
5.4.2 Injection Blow Molding
5.4.2.1 Poor Gates (Fish Eyes, Flash, Tails, etc.)
5.4.2.2 Poor Gates
5.4.2.3 Rocker Bottoms
5.4.2.4 Incomplete Thread
5.4.2.5 Pig Tails
5.4.2.6 Short Shots
5.4.2.7 Parison Flashing
5.4.2.8 Neck Folds --Shoulder Cuts
5.4.2.9 Plastic Sticking to Core Rods
5.5 Troubleshooting --Thermoforming
5.5.1 Blisters or Bubbles
5.5.2 Incomplete Forming or Poor Detail
5.5.3 Sheet Scorched
5.5.4 Changing in Color Intensity or Blushing
5.5.5 Whitening of Sheet
5.5.6 Webbing, Bridging or Wrinkling
5.5.7 Nipples on Mold Side of Formed Sheet
5.5.8 Too Much Sag
5.5.9 Sag Variation between Sheet Blanks
5.5.10 Chill Marks or Mark-off Lines on Part
5.5.11 Bad Surface Marking
5.5.12 Shiny Streaks on Part
5.5.13 Excessive Post Shrinkage or Distortion of Part Removing from the Mold
5.5.14 Part Warpage
5.5.15 Poor Wall Thickness or Excessive Thinning in Some Areas
5.5.16 Non-Uniform Pre-stretch Bubble
5.5.17 Shrink Marks on Part, Especially in Corner Areas (Inside Radius of Molds)
5.5.18 Too Thin Corners in Deep Draws
5.5.19 Part Sticking to Mold
5.5.20 Sheet Sticking to Plug Assist
5.5.21 Tearing of Part When Forming
5.5.22 Cracking in Corners During Service
5.6 Troubleshooting --Rotational molding
5.6.1 Bubbles on Outer Wall
5.6.2 Discolored Part
5.6.3 Flash Excessive
5.6.4 Long Oven Cycle
5.6.5 Low Density Less Than Estimated
5.6.6 Poor Mold Filling
5.6.7 Poor Properties
5.6.8 Rough Inner Surface
5.6.9 Surface Pitting
5.6.10 Uneven Wall Thickness
5.6.11 Warpage
5.7 Fundamentals References
6. Future Trends
6.1 Productivity
6.1.1 Reactive Approach
6.1.2 Proactive Approach
6.2 Automotive Applications 6.3 Medical Applications 6.4 Environmental Issues 6.5 Fundamentals References
Index.
Back to Top
Preface
1. Introduction
1.1 Market Trends
1.2 Importance of Plastics
1.2.1 Plastics vs Metal
1.2.2 Plastics vs Paper and Paper Board
1.3 Plastics Processing
1.4 Fundamentals References
2. Plastics Materials
2.1 Properties and Processing
2.1.1 Molecular Weight
2.1.2 Molecular Weight Distribution (MWD)
2.1.3 Flow Properties
2.1.4 Degree of Crystallinity
2.1.5 Surface Quality
2.1.6 Viscosity
2.2 Polyethylene
2.3 Polypropylene (PP)
2.4 Polystyrene
2.5 Polyvinylchloride (PVC)
2.6 Engineering Plastics
2.6.1 Acrylonitrile Butadiene Styrene (ABS)
2.6.2 Polymethylmethacrylate (PMMA)
2.6.3 Nylon
2.6.4 Polyethyleneterephthalate (PET)
2.6.5 Polycarbonate (PC)
2.6.6 Polyether Ether Ketone (PEEK)
2.6.7 Polytetrafluuoroethylene (PTFE)
2.6.8 Polyacetal (POM)
2.6.9 Polyvinylidene Fluoride (PVDF)
2.6.10 Polyphenylene Sulfi de (PPS)
2.7 Advantages
2.8 Fundamentals References 3
3. Plastics Additives
3.1 Antioxidants
3.2 Anti-block Agents
3.3 Antistatic Agent
3.4 Clarifying Agents
3.5 Slip Additives
3.6 Processing Aids
3.7 Antifogging Agents
3.8 Antiblocking Agents
3.9 Heat Stabilizers
3.10 Lubricants
3.11 Plasticizers
3.12 Coupling Agents or Surface Modifi ers
3.13 Release Agents
3.14 Flame Retardants
3.15 Pigments
3.16 Light Stabilizers
3.17 Impact Modifi ers
3.18 Blowing Agents
3.19 Nucleating Agents
3.20 Biocides
3.21 Fillers
3.22 Fundamentals References
4. Plastics Processing
4.1 Focus on Plastics Processing
4.2 Injection Molding
4.2.1 Injection Molding --Machine
4.2.1.1 Ram Injection Molding Machine
4.2.1.2 Screw Injection Molding Machine
4.2.2 Injection Unit
4.2.2.1 Barrel
4.2.2.2 Screw
4.2.2.3 Clamping Unit
4.2.2.4 Hydraulic Unit
4.2.3 Mold
4.2.3.1Runner
4.2.3.2 Gate
4.2.3.3 Sprue
4.2.3.4 Cavity
4.2.3.5 Nozzle
4.2.3.6 Vent
4.2.3.7 Ejection System
4.2.4 Injection Molding and Parameters
4.2.4.1 Temperature
4.2.4.2 Pressure
4.2.4.3 Time
4.2.4.4 Cooling
4.2.4.5 Velocity
4.2.4.6 Part Design
4.2.5 Injection Molding --Processing
4.2.6 Process Variables
4.2.6.1 Cushion
4.2.6.2 Shot Size
4.2.7 Advantages
4.2.8 Shortcomings
4.3 Extrusion
4.3.1 Extrusion --Basic Requirements
4.3.2 Extruder
4.3.2.1 Single Screw Extruder
4.3.2.2 Twin Screw Extruder
4.3.2.3 Feeder
4.3.2.4 Screw
4.3.2.5 Die
4.3.3 Polymer Melt
4.3.4 Extrudate Swell
4.3.5 Extrusion and Process Parameters
4.3.6 Extrusion --Processing
4.3.7 Advantages
4.3.8 Shortcomings
4.4 Blow Molding
4.4.1 Blow Molding and Process Parameters
4.4.2 Extrusion Blow Molding
4.4.3 Injection Stretch Blow Molding
4.4.4 Advantages
4.4.5 Shortcomings
4.5 Thermoforming
4.5.1 Thermoforming and Parameters
4.5.2 Processing
4.5.3 Mold
4.5.4 Advantages
4.5.5 Shortcomings
4.6 Rotational Molding
4.6.1 Rotational Molding and Parameters
4.6.2 Mold
4.6.3 Processing
4.6.4 Pigmentation
4.6.5 Advantages
4.6.6 Shortcomings
4.7 Fundamentals
4.7.1 Injection Molding
4.7.2 Extrusion
4.7.3 Blow Molding
4.7.4 Thermoforming
4.7.5 Rotational Molding References
5. Troubleshooting --Problems and Solutions
5.1 Troubleshooting --Requirements
5.2 Injection Molding --Troubleshooting
5.2.1 Part Sticking in Cavits
5.2.2 Part Sticking in Core
5.2.3 Discoloration
5.2.4 Burnt Marks (Diesel Effect)
5.2.5 Part Sticks During Ejection
5.2.6 Jetting
5.2.7 Dimensions Out of Specification
5.2.8 Bubbles
5.2.9 Internal Voids
5.2.10 Flash (Over Substrate or on Periphery of Part)
5.2.11 Poor Weld Line
5.2.12 Low Gloss/Gloss Difference
5.2.13 Overmold Breaks/Impinges Through Hollow Substrate
5.2.14 Warpage or Warped Parts
5.2.15 Splay Marks/Delamination
5.2.16 Flow Marks, Folds and Back Fills
5.2.17 Ejector Pin Marks
5.2.18 Sink Marks
5.2.19 Shrinkage
5.2.20 Silver Streak
5.2.21 Short Shots
5.2.22 Brittle Part
5.2.23 Poor Plasticizing
5.2.24 Crack During Mold Release
5.2.25 Nozzle Drool
5.2.26 Short Shots no Burn Marks
5.2.27 Surface Ripples, and Pit Marks
5.2.28 Pellets not Melted
5.2.29 Air Entrapment in the Mold
5.2.30 Gate Blush
5.3 Troubleshooting --Extrusion
5.3.1 Bridging -- at the Throat of the Feed Hopper
5.3.2 Brittle/Braking/Tearing
5.3.3 Contamination/Black Specks and Spots
5.3.4 Die Lines
5.3.5 Entrapped Gasses/Air Bubbles
5.3.6 Excessive Die Swell
5.3.7 Material Accumulation at Die
5.3.8 Low Gloss
5.3.9 Material Non-Homogeneous
5.3.10 Variable Thickness
5.3.11 Variable Output/Surging
5.3.12 Plate-Out on Die Lip
5.4 Troubleshooting --Blow molding
5.4.1 Extrusion Blow Molding
5.4.1.1 Curling
5.4.1.2 Hooking
5.4.1.3 Inconsistent Tail Length
5.4.1.4 Blowouts or Pin Holes
5.4.1.5 Poor Wall Thickness Distribution
5.4.1.6 Asymmetric Part
5.4.1.7 Poor Weld
5.4.1.8 Poor Parting Line
5.4.1.9 Contamination in Parts
5.4.1.10 Flashing Tear
5.4.1.11 Holes in Pinch-Offs
5.4.1.12 Blowouts
5.4.2 Injection Blow Molding
5.4.2.1 Poor Gates (Fish Eyes, Flash, Tails, etc.)
5.4.2.2 Poor Gates
5.4.2.3 Rocker Bottoms
5.4.2.4 Incomplete Thread
5.4.2.5 Pig Tails
5.4.2.6 Short Shots
5.4.2.7 Parison Flashing
5.4.2.8 Neck Folds --Shoulder Cuts
5.4.2.9 Plastic Sticking to Core Rods
5.5 Troubleshooting --Thermoforming
5.5.1 Blisters or Bubbles
5.5.2 Incomplete Forming or Poor Detail
5.5.3 Sheet Scorched
5.5.4 Changing in Color Intensity or Blushing
5.5.5 Whitening of Sheet
5.5.6 Webbing, Bridging or Wrinkling
5.5.7 Nipples on Mold Side of Formed Sheet
5.5.8 Too Much Sag
5.5.9 Sag Variation between Sheet Blanks
5.5.10 Chill Marks or Mark-off Lines on Part
5.5.11 Bad Surface Marking
5.5.12 Shiny Streaks on Part
5.5.13 Excessive Post Shrinkage or Distortion of Part Removing from the Mold
5.5.14 Part Warpage
5.5.15 Poor Wall Thickness or Excessive Thinning in Some Areas
5.5.16 Non-Uniform Pre-stretch Bubble
5.5.17 Shrink Marks on Part, Especially in Corner Areas (Inside Radius of Molds)
5.5.18 Too Thin Corners in Deep Draws
5.5.19 Part Sticking to Mold
5.5.20 Sheet Sticking to Plug Assist
5.5.21 Tearing of Part When Forming
5.5.22 Cracking in Corners During Service
5.6 Troubleshooting --Rotational molding
5.6.1 Bubbles on Outer Wall
5.6.2 Discolored Part
5.6.3 Flash Excessive
5.6.4 Long Oven Cycle
5.6.5 Low Density Less Than Estimated
5.6.6 Poor Mold Filling
5.6.7 Poor Properties
5.6.8 Rough Inner Surface
5.6.9 Surface Pitting
5.6.10 Uneven Wall Thickness
5.6.11 Warpage
5.7 Fundamentals References
6. Future Trends
6.1 Productivity
6.1.1 Reactive Approach
6.1.2 Proactive Approach
6.2 Automotive Applications 6.3 Medical Applications 6.4 Environmental Issues 6.5 Fundamentals References
Index.
Back to Top
BISAC SUBJECT HEADINGS
TEC040000: Technology & Engineering / Technical & Manufacturing Industries & Trades
TEC055000: Technology & Engineering / Textiles & Polymers
BIC CODES
TDCP: Plastics and Polymers Technology
Back to Top