IEM 3303-MFG PROCESSES-SEC TH ACE

Homework # 4
1.

Which, if any, of the metal casting processes cannot be used to mold/cast glass? Why is it that glass cannot be molded by theses metal casting methods?
Explain.
____ If stated Yes and explained a process
Casting is not much used in glass working except for these kinds of special jobs. Not only is cooling and cracking a problem, but also
molten glass is relatively viscous at normal working temperatures, and does not flow through small orifices or into small sections as
well as molten metals or heated thermoplastics.
o
Sand Casting
o
Shell Molding
o
Lost Waxing
o
Slush Casting
o
Die Casting (can be used for Glass for special Case)
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2.
Which, if any, metal casting/molding methods can be used for glass?
____ If stated Yes and explained a process
Glass spinning is similar to centrifugal casting of metals, and is also known by that name in glass working. It is used to produce
funnel-shaped components such as the back sections of cathode ray tubes for televisions and computer monitors. A gob of molten
glass is dropped into a conical mold made of steel. The mold is rotated so that centrifugal force causes the glass to flow upward and
spread itself on the mold surface. The faceplate (i.e., the front viewing screen) is later assembled to the funnel using a sealing glass
of low melting point. Permanent Molding Can also be used for Glass Molding.
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3.
Are there any glass molding methods that are unique to glass? If so, list them and explain the process(es).
____ If stated Yes and explained a process
Blowing Process-When the molten glass reaches between 1050 and 1200 degrees Celsius it is said to be in its plastic stage, and it
is during this phase that press-and-blow formation begins. A shearing blade is used to cut and shape the glass into a cylindrical
shape, called a gob. The cut gob falls, and using gravitational force, rolls through the appropriate passage to reach the molds. A metal
plunger presses the gob into the blank mold, where it assumes the molds shape and is then termed a parison. Next, the parison is
moved into a final mold, where it is blown into the mold to assume its final dimensions. This process is typically used for widemouthed glass containers, but can also be used to manufacture thin-necked bottles.
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4. Which, if any, of the metal casting processes cannot be used to mold/cast plastics? Why is it that plastics cannot be
molded
by
theses
metal
casting
methods?
Explain.
____ If stated Yes and explained a process
Sand Casting Sand casting is not much used for plastics except for some special jobs. Its because of the surface tension. Surface
Tension of Metals are significantly larger than Plastics. Note that In solid state Hardness and surface tension are approximately equal.
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5. Which, if any, metal casting processes can be used for plastic?

____ If stated Yes and explained a process
Extrusion is one of the fundamental shaping processes, for metals and ceramics as well as polymers. Extrusion is a compression
process in which material is forced to flow through a die orifice to provide long continuous product whose cross-sectional shape is
determined by the shape of the orifice. In polymer extrusion, feedstock in pellet or powder form is fed into an extrusion barrel where
it is heated and melted and forced to flow through a die opening by means of a rotating screw, as illustrated in Figure 13.4. The two
main components of the extruder are the barrel and the screw.
Injection molding - Granular plastic is fed by gravity from a hopper into a heated barrel. As the granules are slowly pushed forward
by a screw-type plunger, the plastic is forced into a heated chamber called the barrel where it is melted. As the plunger advances, the
melted plastic is forced through a nozzle that seats against the mold sprue opening, allowing it to enter the mold cavity through a
gate and runner system. The mold remains at a set temperature so the plastic can solidify almost as soon as the mold is filled.
Slush Casting - In slush casting, a liquid plastisol is poured into the cavity of a heated split mold, so that a skin forms at the surface
of the mold. The process is also referred to as Shell casting

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Question 6
____ If stated Yes and explained a process
Structural foam Molding is a low pressure injection molding process where an inert gas is introduced into melted polymer for the
purpose of reducing density and weight of the finished product while increasing the strength. The lower pressure and forces involved
allow more economical molding equipment and tooling to be utilized resulting the mass production of very large or parts or multiple
parts being produced on a single machine in a single cycle at a lower cost than conventional injection molding. The structural foam
molding process utilizes a molten resin that has been injected with nitrogen gas or a chemical blowing agent. This mixture is injected
into the mold, where the gas expands and fills the mold with foam. As the foam flows through the mold, the surface cells collapse.
Solid skins are formed against the walls of the mold, while the core of the part remains structurally foamed. Because the outer skin is
solid and the center of the wall is foam, the part weight is reduced up to 20%.
Rotational Molding - Hollow molds packed with powdered or liquid plastic are secured to pipe-like spokes that extend from a central
hub. The molds rotate on separate axes at once. The hub swings the whole mold to a closed furnace room causing the powder to melt
and stick to the insides of the mold. As the molds turn slowly, the tools move into a cooling room. Here, sprayed water make to cool
the plastic to harden into a hollow part. In this type of plastic molding, tooling costs are low and piece prices are high.
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