ENG08038 2019 Advanced Polymer Processing and Analysis
Full Title
Advanced Polymer Processing and Analysis
Transcript Title
Advanced Polymer Processing an
Code
ENG08038
Attendance
N/A %
Subject Area
ENG - Engineering
Department
MECT - Mechatronics
Level
08 - NFQ Level 8
Credit
05 - 05 Credits
Duration
Semester
Fee
€
Start Term
2019 - Full Academic Year 2019-20
End Term
9999 - The End of Time
Author(s)
Brian Golden, David Mulligan
Programme Membership
SG_EPOLY_K08 201900 Bachelor of Engineering (Honours) in Polymer Processing (Add-on)
SG_EPOLP_K08 202200 Bachelor of Engineering (Honours) in Polymer Process Engineering (Add-on)
SG_EPOLY_K08 202200 Bachelor of Engineering (Honours) in Polymer Process Engineering (Add-on)
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 students will become proficient in the application of the principles of scientific moulding and its use in injection mould design and process improvement.
Learning Outcomes
On completion of this module the learner will/should be able to;
1.
Demonstrate an understanding of the theory, concepts and methods and gain practical application in relation to the injection moulding process.
2.
Analyse key factors that affect the quality and performance of polymer extrusion process.
3.
Inform new designs based on feedback and analysis of injection mould analysis.
4.
Optimise the design and production parameters of an injection mould machine based on analysis an understanding of the historic faults.
5.
Develop a continual improvement system based on evidence to a polymer processes.
6.
Demonstrate a detailed of knowledge and understanding of mould flow analysis.
Teaching and Learning Strategies
Lectures, Tutorials, Handouts and Exercises
Visit to a moulding shop/toolroom to examine moulding machines and moulds.
Application packages, videos and multimedia presentations.
Injection moulding laboratory.
Module Assessment Strategies
End of Year Exam
Project Work
Repeat Assessments
End of Year Exam
Project Work
Indicative Syllabus
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. Nozzle shut-off 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. Heating and cooling requirements. EUROMAP specifications and standards; Machine Safety: Requirements and types of safety mechanisms.
Scientific Moulding: Scientific Moulding will involve the design of experiments work and the information flow from this to key design features and process improvements.
Injection mould design: Basic mould construction
Feed systems: Sprue, Runner and gate systems, including valve-gating. Runner profiles and freeze characteristics, Gate types, size and choice of gating position. Surface vs submarine gates. Runner balancing. Hot runner / insulated runner systems.
Cooling channel design, size and layout. Heat transfer requirements.
Venting: Role of venting, choice of vent location, problems with poor venting.
Mould Analysis:
Pressure Drops in Mould: Calculation of pressure drops across primary, secondary, and tertiary runner; Runner design, including runner balance; Pressure build-up in cavity; Design of runners for two and three plate moulds. Discuss the advantages and disadvantages of both hot runner and insulated runner moulds.
Rheology of Polymers: Newtonian and Non-Newtonian liquids pseudoplastic behaviour; Pressure-Volume-Temperature (PVT) curves ; effects of shear and shear rates on polymers; Use of viscosity and shear rates curves; Factors affecting viscosity; Applications of Rheological Data; Application of rheological properties to moulding conditions.
Plastic flow analysis package: Moulding filling application e.g. MoldFlow. Factors affecting filling, cooling characteristics, warp analysis, effects of gate position, viscosity affects.
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 | Injection Moulding | Practical | Assignment | 20 % | Week 10 | 1 |
| 2 | Mould Flow Analysis | Coursework Assessment | Project | 20 % | Week 12 | 6 |
End of Semester / Year Assessment
| Title | Type | Form | Percent | Week | Learning Outcomes Assessed | |
|---|---|---|---|---|---|---|
| 1 | Exam | Final Exam | Assessment | 60 % | End of Semester | 1,2,3,4,5 |
Full Time Mode Workload
| Type | Location | Description | Hours | Frequency | Avg Workload |
|---|---|---|---|---|---|
| Lecture | Lecture Theatre | Presentation of Module Material | 3 | Weekly | 3.00 |
| Practical / Laboratory | Engineering Laboratory | Laboratory | 2 | Weekly | 2.00 |
Total Full Time Average Weekly Learner Contact Time 5.00 Hours
Required & Recommended Book List
Required Reading
2013-09 Moulding Masterclass
ISBN 1906479119 ISBN-13 9781906479114
2013-09 Moulding Masterclass
ISBN 1906479119 ISBN-13 9781906479114
Moulding Masterclass is a compilation of technical articles by plastics injection moulding industry expert John Goff, originally written for magazine publication between October 2009 and July 2013. According to the author, injection moulding processes are frequently developed in the early stages of a product's launch and never revisited. Particularly in today's challenging economic climate where manufacturing costs need to be minimised, it is more important than ever that time is devoted to process optimisation. This collection of 32 articles takes the reader through many aspects of the injection moulding process, from the influence of screw design and speed on melt plasticization, flow and shot consistency, through injection and holding time and pressure, gate sizing, runner systems, mould cooling, clamp forces, systematic process control and more. Each discussion combines theory with recommendations and practical examples seen in diverse manufacturing environments. John Goff has almost 40 years' experience of injection moulding and has seen all sides of the process, having been a senior university lecturer, process engineering manager, consultant and trainer. He has written numerous books and articles, presenting complex technical information in a simple, coherent fashion.
Module Resources
Non ISBN Literary Resources
Injection Moulding Machines, Johannaber, Hanser, 2007
Injection Molding Handkbook: The Complete Molding Operation, Rosato, Chapman & Hall, 1995
Injection Moulding Handbook, Rosato, Springer Science & Business Media 2012
Plastics Extrusion Technology, Hensen, Hanser, 1997
Polymer Extrusion, Rauwendaal, Hanser, 2014
Extrusion Processing Data, Alberto Naranjo C., Maria del Pilar Noriega E., Juan Diego Sierra M., Juan Rodrigo Sanz., Hanser, 2001
Materials and Processes in Manufacturing, E. Paul Degarmo, Wiley, 2011
Blow Molding Handbook : Technology,Performance,Markets,Economics. The Complete Blow Molding Operation, Rosato, Rosato & DiMattia, Hanser, 2003
Injection Mold Design Engineering, David O'Kasmer, Hanser, 2016
Injection Mould Design, RWG Pye, Longman Scientific
Journal Resources
.
URL Resources
.
Other Resources
Plastic and rubber weekly journal
Newscientist journal
Polymer journal, Kunstoffe, Modern Plastics,