MUHAMMAD FAUZAN BIN AZAHAR 03PMK11F1021 MOHD HAZIQ 03PMK11F1018 WAN MUHAMMAD EZRIZAM 03PMK11F1020

Introduction
y Plastic formation process-manufacture of bottles and

hollow-shaped parts y Competitive with other processes, injection molding y Advantages; cycle is very short (low cost), lower mold cost than injection molding, high production rates in producing hollow parts with small or large opening

Blow molding process; general steps

y Melting the resin- done in extruder y Form the molten resin into a cylinder or tube (this

tube is called parison) y The parison is placed inside a mold, and inflated so that the plastic is pushed outward against the cavity wall y The part is allowed to cool in the mold and is then ejected y The part is trimmed

Image of parison

Image of Parison

Blowing step in the blow molding process

Blow Molding Process

y The parison can be formed by y Extrusion process y Injection molding process

Extrusion blow molding

y Parison is formed from by forcing the plastic through an

extrusion die. y Material enters the die, flow around the mandrel so that extrudate would be cylindrical y The die would have a hole at the center so that air could be blown into the cylinder y In some blow molding operations, the air is introduced from the bottom through an inlet

Extrusion blow molding

y This process can be; y continuous extrusion blow molding
y

During the process, the extrusion runs continuously, thus making a continuous parison. using multiple mold to match the mold cycle to the extrusion speed

y Intermittent extrusion blow molding y During the process, the extruder is stopped during the time that the molding occur y use either reciprocating screw or an accumulator system

Two-mold system in continuous extrusion blow molding

y In this system, one mold captures the parison

(Mold A) y While a part is cooling in Mold B

Two-mold system in continuous extrusion blow molding

Mold A then withdraws the parison from the extruder While the part is ejected from in Mold B

Two-mold system in continuous extrusion blow molding

y The part is cooling in Mold A (moved out from extruder) y Mold B is moving into position around the parison

Two-mold system in continuous extrusion blow molding

y The cycle is completed by cooling of the part in Mold A y Capture a new parison in Mold B, blow the part into the mold cavity

Parison transfer system for continuous extrusion blow molding

y System in which the parison is removed from the die and transferred to a mold, thus give space for another parison to be formed while the first part is cooling

Advantage and disadvantages

y Disadvantages of rotating mold system-the rotating

wheel is much more complicated mechanically, cost of additional molds is quite high y Advantage of rotating mold system mold cycle that are much longer than extrusion rate can be accommodate y Continuous extrusion blow molding methods are suitable for production of small to medium size parts

Accumulator system
y The accumulator system also produce parison

intermittenly y In this system, the extrudate flow from the extruder into an external chamber or accumulator y At the appropriate moment in the cycle, a ram in the chamber injects the resin through a die to form parison y The accumulator is heated to maintain the proper temperature of the resin

Accumulator system in intermittent extrusion blow molding

Injection Blow Molding

y The parison is formed by the injection of molten

resin into a mold cavity and around a core pin y The parison is not a finished product, but it is subjected to subsequent step to form the final shape y Second step, blowing of the intermediate part in a second mold y Because of distinct separation of the two steps, the parison made by injection molding is called a preform

Injection blow molding process

y The mold is closed y Resin is then injected to form a cylindrical part y The mold is opened, and preform is ejected

Injection blow molding process

y The preform is transferred to a blowing station while it is still hot or it

can be reheated y After the second mold is closed, air is injected into the heated preform (through a hole) y Blow the preform, against the inside walls, mold is open and the part is ejected

Injection blow molding process

y The preform can be stored until the finished blow

molded is needed y The flexibility of separating the two cycles has proven useful in manufacture of soda pop bottle

Comparison of extrusion and injection blow molding

y Extrusion blow molding
y It is best suited for bottle over 200g in weight, shorter y y y y y y

runs and quick tool changeover Machine costs are comparable to injection blow molding Tooling costs are 50% to 75% less than injection machine It requires sprue and head trimming Total cycle is shorter than injection (since the parison and blowing can be done using the same machine) Wider choice of resin Final part design flexibility

Common plastics for blow molding

y HDPE (stiff bottle, toys, cases, drum) y LDPE (flexible bottle) y PP (higher temperature bottle) y PVC (clear bottle, oil resistant containers) y PET (soda pop bottle) y Nylon (automotive coolant bottle, power steering

reservoir)