UNIVERSITY DEPARTMENTS
ANNA UNIVERSITY CHENNAI : : CHENNAI 600 025
REGULATIONS - 2009
CURRICULUM I TO IV SEMESTERS (FULL TIME)
M.TECH. PLASTIC TECHNOLOGY
SEMESTER I
SL. COURSE
NO
CODE
THEORY
1.
PT9111
2.
PT9112
3.
PT9113
4.
PT9114
5.
PT9115
6.
PT9116
PRACTICAL
7.
PT9117
8.
PT9118
9.
PT9119
SL. COURSE
NO
CODE
THEORY
1.
PT9121
2.
PT9122
3.
PT9123
4.
E1
5.
E2
PRACTICAL
7.
PT9126
PT9127
PT9128
SL. COURSE
NO
CODE
THEORY
1.
E3
2.
E4
PRACTICAL
3.
PT9131
4.
PT9132
COURSE TITLE
L
T
P
C
Plastic Materials
Plastics Processing Technology
Plastics Mould & Product Design
Plastics Mould Manufacturing Technology
Additives and Compounding
Mathematics for Plastics Technology
3
3
3
4
3
3
0
0
0
0
0
0
0
0
0
0
0
0
3
3
3
4
3
3
Plastics Processing Laboratory – I
Plastics Product/Tool Design Laboratory
Seminar
TOTAL CREDITS
0
0
0
19
0
0
0
0
6
12
2
20
2
4
25
L
T
P
C
Plastics Testing Technology
Plastics Composite Technology
Industrial Economics and Costing
Elective – I
Elective - II
4
3
3
3
3
0
0
0
0
0
0
0
0
0
0
4
3
3
3
3
Plastics Testing Laboratory – I
Plastics Processing Laboratory – II
Seminar
TOTAL CREDITS
0
0
0
16
0
0
0
0
6
12
2
20
2
4
22
L
T
P
C
Elective – III
Elective – IV
3
3
0
0
0
0
3
3
Plastics Testing Laboratory – II
Project Work Phase – I
0
0
6
0
0
0
12
20
32
4
10
SEMESTER II
COURSE TITLE
SEMESTER III
COURSE TITLE
TOTAL CREDITS
1
SEMESTER IV
SL. COURSE
NO
CODE
PRACTICAL
1.
PT9141
COURSE TITLE
Project Work Phase – II
TOTAL CREDITS
L
T P
0 0
0 0
40
40
C
12
12
LIST OF ELECTIVES
ELECTIVE I
SL.
NO
1.
2.
3.
4.
COURSE
CODE
PT9151
PT9152
PT9153
PT9154
COURSE TITLE
Plastics Characterization Techniques
Biodegradable Plastics
Advanced Plastics Processing Technology
Polymeric Nanocomposites
L
T P
3
3
3
3
0
0
0
0
L
T P
3
3
3
3
0
0
0
0
L
T P
3
3
3
3
0
0
0
0
L
T P
3
3
3
0
0
0
0
0
0
0
C
3
3
3
3
ELECTIVE II
SL.
NO
1.
2.
3.
4.
COURSE
CODE
PT9161
PT9162
PT9163
PT9164
COURSE TITLE
Plastics Waste Management
Quality Management
CAD/CAM/CAE Application in Tool Design
Bio-Medical Plastics
0
0
0
0
C
3
3
3
3
ELECTIVE III
SL.
NO
1.
2.
3.
4.
COURSE
CODE
PT9171
PT9172
PT9173
PT9174
COURSE TITLE
Polymer Blends & Alloys
Advanced Tool Design
Thermoplastic Elastomers
Coating Science & Technology
0
0
0
0
C
3
3
3
3
ELECTIVE IV
SL.
NO
1.
2.
3.
COURSE
CODE
PT9181
PT9182
PT9183
COURSE TITLE
Advanced Mould Manufacturing Technology
Secondary Processing Techniques
Plastics Packaging Technology
2
0
0
0
C
3
3
3
PT 9111
PLASTIC MATERIALS
UNIT I POLYMER CHEMISTRY
3 0 0 3
9
Introduction to polymer – Polymerization – Chain polymerization – Step polymerization.
Polymerization techniques – Bulk polymerization – Solution polymerization – Suspension
polymerization – Emulsion Polymerization. Molecular weight and its distribution.
UNIT II COMMODITY PLASTICS
9
Sources and Manufacture of raw materials - Methods of manufacture of Polymer, General
Properties and applications of Polyethylene - Polypropylene and their copolymers - Vinyl Polymers
and Co-polymers - Polystyrene and Copolymers - Acrylic and copolymers - Cellulose Polymers.
UNIT III
ENGINEERING PLASTICS
9
Sources and Manufacture of raw materials, Methods of Manufacture of Polymer, General
Properties and applications of Acrylonitrile Butadiene Styrene - Polyamides (PA-6, PA-66, PA-6,10,
PA-11 & 12) - Polycarbonates - Polyacetal & Copolymers - Thermoplastic Polyesters (PET & PBT)
- Polyphenylene oxide - Polysulfones - Fluoro polymers (PVF, PVDF, PTFE, PCTFE) Thermoplastic Polyurethane.
UNIT IV
SPECIALITY PLASTICS
9
Sources and Manufacture of raw materials, Methods of manufacture of Polymer, General
properties and applications of Polyphenyline Sulphide - Polyphenylene ether - Polyetherether
ketone - Polyimide and related polymers - Liquid Crystal Polymers - Conductive Polymers – Plastic
alloys and blends.
UNIT V THERMOSETTING PLASTICS AND BIO-DEGRADABLE PLASTICS
9
Sources and Manufacture of raw materials, Methods of manufacture of resin - Additives - Curing
and cross linking agents - General properties and applications of Phenol Formaldehyde - Urea
Formaldehyde - Melamine Formaldehyde - Unsaturated Polyesters - Epoxy resins - Polyurethane
and Silicones.
Overview of Recycling - Recycling of Polymers - Over view of plastics degradation - Natural Biodegradable Polymers - Synthetic Bio-degradable Polymers - Water soluble Polymers.
TOTAL : 45
REFERENCES
1. Fred W. Billmeyer, JR., Text Book of Polymer Science, John Wiley & Sons, Singapore, 1994.
2. J. A. Brydson, Plastics Materials, Butterworth Heinemann Oxford, 1999.
3.
4
5.
6.
Charles A. Harper, Modern Plastics Hand Book, McGraw-Hill, New York, 1999.
J. S. Anand, Applications of Plastics, CIPET, Chennai - 1997.
H. Domininghaus, Plastics for Engineers, Hanser Publishers, Munich - 1988.
Nabil Mustafa, Plastics Waste Management, Marcel Dekker Inc., New York, 1993.
Back to Index
PT 9112
PLASTICS PROCESSING TECHNOLOGY
3 0 0 3
UNIT I
INTRODUCTION & INJECTION MOULDING
9
Basic principles – Classification of processing methods – Effect of polymer properties on
processing behaviour.
Injection Moulding – Definition of terms – Specification – Types of machines used – Part & their
functions – Cycle time – Process variables & its effect on Moulding quality – Cavity pressure profile
– Factor influencing moulding shrinkage, annealing – Frozen-in – Stresses – Types of clamping
systems and their merits & demerits – Start up and shut down procedures – Processing
3
parameters and special precaution to be taken while processing of Engineering plastics such as
Nylon, Acetal, PC, etc., - Common moulding defects, causes and remedies.
UNIT II
COMPRESSION MOULDING
9
Introduction – principles – definition of Terms – Compression moulding process – specifications –
machine used – Bulk factor – flow – cure relationship – ageing of compound – cup flow and spiral
flow tests & its significance – cycle time - Preforming, preheating – Methods, machine used, merits
& demerits - Influence of process variables such as temperature, pressure, part size &
configuration on quality and cycle time - Compression moulding of Thermoplastics – cold forming –
sintering - Optimising process parameters & Trouble shooting - Merits & Demerits of Compression
moulding - Finishing operation.
UNIT III
TRANSFER MOULDING & THERMOSET INJECTION MOULDING
9
Transfer Moulding - Principles – Types of process – machine used – pot transfer, plunger transfer
& screw transfer moulding techniques – moulding cycle – specification – merits and demerits of
transfer moulding – Theoretical calculation of pressures – line pressure, Injection ram pressure –
trouble shooting.
Thermoset Injection Moulding – Process – Machinery part & their functions – Process parameters
– Merits & Demerits – Quality control in Injection Moulding, statistical process control techniques.
UNIT IV
EXTRUSION
9
Introduction – principles – classification of extruders – single screw extruder – specification – screw
nomenclature – types of screws – L/D ratio, compression ratio-back pressure – factors governing
back pressure – output and factors affecting output-heating & cooling systems – breaker plate –
screen pack & its functions – screw & hopper cooling-die entry effects and die exit instabilities –
shark skin, melt fracture & bambooing.
Twin screw extruder – principle – types – process – merits & demerits - Vented barrel extruder –
hopper loading devices - Drying equipments - Process, machinery – down stream equipments –
dies for producing products such as – film – blow film, cast film – Sheets - Tubes / pipes,
corrugated pipes - Mono filaments - Box strapping - Coating / Lamination
UNIT V
BLOW MOULDING
9
Introduction – Principle – Processes – Extrusion Blow Moulding – Injection Blow Moulding –
Process control – Parison programming – Moulds – Machine used – Constructional features –
Material and design factors affecting bottle performance – Trouble shooting – Stretch Blow
moulding – Process outline.
REFERENCES
TOTAL : 45
1. Denold V. Rosato, Injection Moulding Handbook, International Thomson Publishing Co., 1995.
2. M.S. Welling, Injection Moulding Technology, VDI-Verlag GmbH, 1981.
3. Seymour S. Schwartz & Sidney H. Goodman, Plastics materials and Processes, Van Nostrand
Reinhold Company, New York, 1982.
4. A.S. Athalya, Injection Moulding, Multi-tech Publishing Co., New Delhi, 1997.
5. Irvin Rubin, Injection Moulding Theory and Practice, A. Wiley Interscience Publication, 1972.
6. Lee, Blow Moulding Design Guide, Hanser Publishers, Munich, 1998.
7. Friedhelm Hensen, Plastics Extrusion Technology, Hanser Publishers Vienna, New York, 1988.
Back to Index
4
PT 9113
PLASTICS MOULD & PRODUCT DESIGN
UNIT I INJECTION MOULD DESIGN
3 0 0 3
9
Introduction: Concept of design – mould design principles – layout of impression - mould venting
- mould alignment – mould location – mould clamping.
Selection of machines: Specifications of machines – types of machines - shot capacity – shot
weight - plasticizing capacity – nozzle details – minimum daylight – maximum daylight – projected
area – Injection pressure – Locking force – shut height - ejection arrangement – dry cycle time –
methodical approach to mould design - deciding number of impressions – determination of
economical no. of cavities.
Parting line/Parting surface: Types of parting surface - plain – stepped – irregular – local
stepped and profile parting surface – complex edge form.
Ejection system: Types of ejection – pin ejection – stepped pin - part pin –“D” pin – blade ejection
– sleeve ejection – stripper ejection – air ejection – double ejection – delayed ejection - calculation
of ejection force required.
Mould temperature control: Types of cooling – Bolster cooling – integral cooling core/cavity –
Insert cooling-core/cavity – Baffle cooling – Bubbler cooling – Deep chamber design - spiral cooling
– cooling through heat pipes – capillary tubes- heat rods – mould temperature – melt temperature
– heat removal rate – calculation of cooling time.
UNIT II
9
Feed system: Sprue, runner and gate – determination of runner-gate - size and cross sectionlayout of runners – balancing of runners – types of gates – application of gates to various
products/materials – gate balancing.
Types of moulds: Two plate mould – single impression – multi impression – three plate mould –
multi day-light mould – stack mould – runnerless mould – hot runner and insulated runner mould split moulds – external undercut – internal undercut –finger cam, dog leg cam and cam track
actuation – spring - hydraulic actuation - split cavities – split cores – threaded inserts – internal and
external – standard mould bases – Calculation of strength of cavities – strength of guide pillar and
support pillar requirements - Mould design check list.
Blow Mould Design & Extrusion Die Design
Types of blow moulds – extrusion – injection and stretch blow moulds – blow ratio – parison design
– pinch off design – parting line – clamping force – mould venting, mould cooling – mould
alignment – mould clamping. Extrusion Die Design: Basic concepts
UNIT III
COMPRESSION & TRANSFER MOULD DESIGN
9
Types of compression mould - open flash - semi-positive type - positive - displacement moulds types of loading chambers - bulk factor - flash thickness - pot design – depth of loading chamber
calculation - projected area - compression pressure - clamping force – deciding no. of impression
by technological method - heating system - types of heaters - heat losses - heat requirement &
heater capacity- advantages and disadvantages of compression mould.
Types of transfer moulds - integral pot transfer mould – Top & Bottom plunger design - auxiliary
ram transfer mould - transfer pot design - projected area - transfer pressure - clamping force pressure pad design - design of sprue runner and gate – calculations - advantages and
disadvantages of transfer mould.
5
UNIT IV
PLASTICS PRODUCT DESIGN
9
Concepts – size, shape and function – form and function – Aesthetics, Ergonomics – Shrinkage,
Flash lines. Undercuts – External & Internal - Wall thickness – variances in wall thickness –
suggested wall thickness for thermoplastics and thermosetting materials – steps in product design
- emphasize on designing with engineering plastics - Taper or draft - Fits & Tolerances – Designing
with plastics for load bearing applications like gears, bearing, etc.
Design of radii, fillets, ribs and bosses - Design for flow and shape -Moulded Holes – through holes
– blind holes – threaded holes – side holes – holes parallel to draw – nearness of holes to each
other and side wall – moulding holes not parallel to draw – drilled and tapped holes – moulded
threads – moulded lettering – surface treatment.
UNIT V
9
Types of Inserts – Materials – selection of metal for inserts – minimum wall thickness of material
around inserts – anchorage – relieving moulding stresses around inserts – location of inserts in the
part – moulded in inserts – pressed in inserts -Design of integral hinges, hinges and snap fits for
boxes and assembly of moulded parts - Designed mismatch for part assembly.
Quality and economy – tooling aspects on product design – process variables vs product design –
product design appraisal - Product design limitations – shrinkage vs tolerance – end use
requirements with case studies – product design tips - prototype development – rapid prototyping
techniques – stereo lithography.
TOTAL : 45
REFERENCES
1. R.G.W. PYE, Injection Mould Design for Thermoplastic, Affiliater East-West Press P. Ltd., New
Delhi, 1989.
2. Fischer (EG), Blow moulding of plastics, Newnus Butter Worths, London, 1976.
3. MV Soshi, Dies for Plastics Extrusion, S.G. Wasant for Macmillan India Ltd., Madras, 1992.
4. DYM, Injection Mould Design, Van Nostrand Reinhold Company, New York, 1987.
5. Neil L. Hancox, Design Data for Reinforced Plastics, Chapman & Hall, London, 1994.
6. Beck, Plastic Product Design, Yan Nostrand Reinhold Company, London, 1970.
7. Norman Lee, Blow Mould Design, Hanser Publishers, Munich, 1998.
PT 9114
UNIT I
Back to Index
PLASTICS MOULD MANUFACTURING TECHNOLOGY
MATERIAL FOR MOULDS
4 0 04
12
Selection of steels – Properties of steels – common steels used for moulds – strength of materials,
calculation of wall thickness for cavity – Insert size – Life of mould
Non-ferrous metals for mould construction: Application – Zinc base alloys – Aluminium alloys –
Beryllium copper
Non-metallic materials for mould construction: Advantages and its applications – epoxies polyester – silicon
UNIT II SURFACE TREATMENT OF MOULD MATERIALS
12
Introduction – Heat treatment process – case hardening – through hardening – nitriding – tips on
successful heat treatment – vacuum hardening – cryogenic heat treatment – Hard chrome plating –
Nickel plating – chemical etching – Mould Polishing techniques
6
UNIT III
MOULD MAKING TECHNIQUES
12
Pantograph engraving – Hydro copying – Jig boring – CNC machines – CNC Lathe – CNC Milling
– CNC EDM – Advantages and its Applications – Assembly of moulds – Rapid prototyping
UNIT IV
INSPECTION AND QUALITY CONTROL OF MOULDS
12
Introduction to Tool Room measuring instruments – Vernier – Micrometer – Height Gauge – Slip
Gauge – Dial Gauge – Measuring tapers and angles – CMM.
UNIT V
MOULD ESTIMATION, REPAIR AND PROTECTION
12
Procedure for estimating mould cost – General outline – Cost calculation – Basic moulds – Cavity
– Basic functional components – Special functions etc.
Introduction – Mould Repair and maintenance – scheduling mould maintenance – advantages –
storage – corrosion protection – wear and lubrication – special consideration.
TOTAL : 60
REFERENCES
1. Cyril Donaldson George H. Lecain V C Goold, Tool Design, TATA McGraw-Hill, 1998.
2. Richard R. Kibbe John E. Neele, Roland O Meyer, Warran T. White, Machine Tool Practices,
Prentice Hall of India Pvt. Ltd., 1999.
3. Irwin Rubin, Injection Moulded Theory and Practice, Wisely Interscience Publication, 1972.
4. Society of Plastics Industry, Plastics Engineering Hand Book, Van Nostrand Reinhold
Company, 1960.
5. Dominick V. Rosato, Donald V. Rosato, Injection Moulding Hand Book, CBC Publishers &
Distributors, 1987.
Back to Index
PT1115
UNIT I
ADDITIVES AND COMPOUNDING
INTRODUCTION TO ADDITIVES
3 0 0 3
9
Introduction - Technological Requirements - Classification - Chemistry and Mechanism - Selection
Criteria - General effect on Properties - Evaluation and functions of additives.
UNIT II
ADDITIVES
9
Antioxidants - Stabilizers (Heat & UV) - Plasticizers - Fillers and reinforcements - Impact Modifiers Lubricants - Slip and Anti-block agents - Processing aids - Blowing agents - Flame Retardants Anti-static & Conductive additives - Nucliating agents - Colourants - Additives for Recycling.
UNIT III
COMPOUNDING TECHNIQUES
9
Selection of Polymers and Compounding ingredients - General objectives - possibilities and
limitations of mixing and compounding - Methods of incorporation of additives into polymer
materials.
UNIT IV
COMPOUNDING EQUIPMENTS
9
Mixing and mixing equipments. Principles - Operating characteristics - Machine construction Specifications - Process control systems and working details of Batch mixers and continuous
7
mixers - High speed mixer - Two roll mill - Banbury Mixer - Ribbon blender - Planetary mixers Single Screw extruder - Twin Screw extruder.
UNIT V
END USE MARKET FOR PLASTICS
9
Principles of Material selection including consideration of conventional materials competitive with
plastics - Case studies on material suitability (e.g., Plastic Gears, Feeding Bottle, Bowels for micro
wave ovens). Survey and uses of plastics with reasons for their importance in major industries
like, Agriculture, Packaging, Building, Transport, Electrical, Electronics and Telecommunications,
Medical and Furniture.
TOTAL : 45
REFERENCES
1. R. Gachter and H. Muller, Plastics Additives Hand Book, Hanser Publishers, Munich, 1993.
2. John Murphy, The Additives for Plastics Hand Book, Elsevier Advanced Technology, Oxford,
1996.
3. Jesse Edenbaum, Plastics Additives and Modifiers Hand Book, Chapman & Hall, London,
1996.
4. Ica Manas - Zloczower and Zehev Tadmor, Mixing and Compounding of Polymers, Hanser
Publications, Munich, 1995.
5. Nicholas P. Cheremisionoff, Polymer Mixing and Extrusion Technology, Marcel Dekker Inc.,
New York, 1995.
6. J. A. Brydson, Plastics Materials, Butterworth Heinemann, Oxford, 1999.
Back to Index
PT9116
MATHEMATICS FOR PLASTIC TECHNOLOGY
UNIT – I
30 03
9
Numerical Solutions of Ordinary Differential Equations: Engineering application: motion in a
viscous fluid, Numerical solution of first –order ordinary differential equations
UNIT – II
9
Partial Differential Equations : Linear and quasilinear first order partial differential equations,
second order linear equations in two variables and their classifications, Cauchy, Dirichlet and
Newman problems, Green functions, Solutions of Laplace, wave.
UNIT- III
9
Vector and tensor analysis, Matrices and Determinants, Laplace and Fourier transforms.
Introduction to numeric use of the above techniques in plastics engineering and calculations.
UNIT – IV
9
Probability: Random experiment, classical and statistical definition of probability,. Distribution
Functions:- Binomial, Normal, Poisson, Uniform, Mean, Variance, Moment dispersion, Kertosis,
Median, Mode, Least square method of curve fitting, Regression Analysis, correlation co-efficient.
UNIT – V
9
Statistics: Sampling theory, populations, Sampling errors and bias, Sampling methods: random,
multistage, sampling distribution. Estimation and testing of hypothesis – theory of estimation, point
8
estimates, consistent and uniased estimates. Methods of point estimation – method of maximum
likelihood, interval estimation, Null hypothesis
TOTAL 45
REFERENCES
1.
2.
3.
4.
5.
6.
Krayszig, “Advanced Engineering Mathematics”
Bali.N.P- A Texk book of Engg. Mathematics – Laxmi Publication 2008
Glyn James. Advanced Modern Engineering Mathematics – Pearson Edn - 2008
Raman “Higher Engg. Mathematics –Tata Mcgrawhill -2008
Kandasamy & Others – Engg. Mathematics – S. Chand 2008
Jain & Iyengar – Advanced Engg. Mathematics- Dorling Kindersley 2007
Back to Index
9
PT9117
1.
2.
3.
4.
5.
6.
7
8.
PLASTICS PROCESSING LABORATORY - I
0 0 6 2
Injection Moulding (Hand Operated)
Injection Moulding (Semi-Automatic)
Injection Moulding (Automatic)
Extrusion Processes
Compression Moulding (Hand Operated)
Compression Moulding (Semi Automatic)
Blow Moulding (Hand Operated)
Scrap Grinding
TOTAL : 90
Laboratory Requirements
1.
2.
3.
4.
5.
6.
Injection moulding machine (conventional)
Plastic tube extrusion machine
Plastic film extrusion machine
Compression moulding machine
Blow moulding machine (conventional)
Scrap grinding machine
-
2 Nos.
1 No.
1 No.
2 Nos.
1 No.
2 Nos.
REFERENCES
1.
2.
3.
4.
A.S. Athaly, Injection Moulding Practice, Multi-Tech. Publishing Co., New Delhi, 1997.
Irvin Rubin, Injection Moulding Theory and Practice, A. Wiley interscience Publication. 1972.
Lee, Blow Moulding Design Guide, Hausar Publishers, Munich, 1998.
Friedhelm Hensen, Plastics Extrusion Technology, Hansar Publishers, Vienna, 1988.
Back to Index
10
PT9118
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
PLASTICS PRODUCT/TOOL DESIGN LABORATORY
0 0 12 6
Part Drawing from product
Design of Mould elements
Two plate Mould Design (Injection) – Single impression
Two plate Mould Design – Multi impression
Three plate Mould Design (Injection) – Multi impression
Split Mould Design (Injection)
Compression Mould Design
Transfer Mould Design
Mould Design for Industrial Components
Blow Mould Design
Extrusion Die Design
TOTAL : 180
LABORATORY REQUIREMENTS
1.
2.
Drafting machine
Computer system with Auto cad software
-
30 Nos.
15 Nos.
REFERENCES
1.
2.
3.
R.G.W. PYE, Injection Mould Design for Thermoplastic, Affiliater East-West Press P. Ltd.,
New Delhi, 1989.
M.V. Joshi, Dies for Plastics Extrusion, S.G. Wasant for Macmillan India Ltd., Madras, 1992.
Norman Lee, Blow Mould Design, Hanser Publishers, Munich, 1998.
Back to Index
PT9121
PLASTICS TESTING TECHNOLOGY
4 0 0 4
UNIT I CONCEPTS OF TESTING & IDENTIFICATION OF PLASTICS
12
Basic concepts of testing - Specification and Standards - National and International Standards Test specimen preparation - Pre-conditioning and test atmosphere.
Identification of plastics by simple tests - Visual examination - Density - Melting point - Solubility
test - Flame test - Chemical tests.
UNIT II
MECHANICAL PROPERTIES
12
11
Long-term Mechanical Properties – Creep – Stress relation.
Short-term Mechanical Properties: Tensile properties - Flexural properties - Compressive
properties - Shear properties - Impact properties - Tear resistance - Hardness tests - Abrasion
resistance - Friction test.
Specific gravity - Density by Density-gradient technique - Bulk density - Particle size by sieve
analysis - Moisture analysis.
UNIT III
THERMAL PROPERTIES
12
Melt flow index - Heat deflection temperature - Vicat softening temperature - Marten's Heat
resistance test - Brittleness temperature - Specific heat - Glass transition temperature - Thermal
conductivity - Co-efficient of thermal expansion - Shrinkage - Thermal stability - Flammability.
Characterization of plastics by IR, spectroscopy, light microscopy.
characterization of plastics.
Thermal and rheological
UNIT IV
ELECTRICAL AND OPTICAL PROPERTIES
12
Dielectric strength - Dielectric constant and Dissipation factor - Insulation resistance - Volume and
Surface resistivity - Arc resistance - Antistatic tests.
Refractive index - Luminous transmittance - Clarity and Haze - Photo-elastic properties - Colour
measurements and Specular Gloss.
UNIT PERMANENCE PROPERTIES AND PRODUCT TESTING
12
Gas and Moisture Vapour Permeability - Water absorption - Chemical Resistance - Environmental
Stress Cracking Resistance - Crazing - UV Resistance - Ozone Resistance - Weathering
Resistance - Salt spray and Straining Resistance - Irradiation Effects - Microbiological attack.
Testing of Pipes and Fittings - Films & Sheets - Container - Foam - Laminates and FRP based
products - Failure Analysis.
TOTAL : 60
12
REFERENCES
1. Vishu Shah, Hand Book of Plastics Testing Technology, John Wiley & Sons Inc., New York,
1998.
2 J. S. Anand, K. Ramamurthy, K. Palanivelu & C. Brahatheeswaran, How to Identify Plastics
by Simple Methods, 1997.
3. R.P. Brown, Hand Book of Plastics Test Methods, George Godwin Ltd., London, 1981.
4 G. C. Ives, J. A. Mead, M. M. Riley, Hand Book of Plastics Test Methods, The Plastics
Institute, London, 1971.
5. Frank T. Traceski, Specifications & Standards for Plastics & Composites, ASM
International, Metals Park, OH, 1990.
6. J. Hasiam, H. A. Willis, Identification and Analysis of Plastics, London Iliffe Books Ltd., New
Jersey, 1980.
Back to Index
13
PT9122
PLASTICS COMPOSITE TECHNOLOGY
3 0 0 3
UNIT I
9
Introduction – Resins for composites – polyester resins – epoxy resin – phenolic resins – vinyl
ester resins – alkyd resins.
UNIT II
9
Reinforcements for composites – Natural fibers – jute, sisal – synthetic fibers – glass fibers – types
and different forms – carbon fibers – classification - graphite fibers – polyethylene fibers – silicon
carbide and boron fibers.
UNIT III
9
Additives for composites – catalysts – room temperature and elevated temperature – accelerators
– coupling agents – fillers – flame retardants – toughening agents – UV stabilizers.
UNIT IV
9
Processing of composites – Important processes like hand lay-up, spray-up, resin transfer
moulding, vacuum bag, pressure bag moulding, centrifugal casting, pultrusion, filament winding,
moulding compounds – SMC, DMC, BMC, TMC.
UNIT V
9
Testing Quality control & end use of plastics – Testing for mechanical, electrical, thermal, optical
and chemical properties, Determination of shelf life and gel time – Non-destructive testing
methods. Application of FRP products - in marine, chemical, railways, electrical and electronic
industry, space structures – Robotics.
TOTAL : 45
REFERENCES:
1.
2.
3.
4.
P.K. Mallic, Fiber Reinforced composites, Morcal Dekker Inc. 1988.
Sidney H. Goodman, Handbook of Thermoset Plastics, John Wiley & Sons, 1984.
T.G. Gutowski, Advanced Composites Manufacturing, John Wiley & Sons, 1997.
S.M. Lee, Reference Book for Composite Technology I, II & III, Technomic Publishing Co.,
1989.
PT9123
INDUSTRIAL ECONOMICS AND COSTING
3 0 0 3
UNIT I FUNDAMENTAL PRINCIPLES OF COST ACCOUNTING
9
Financial and Cost Accounting – Costing – Elements of Cost – Cost centres – Methods & Types of
Costing – Advantages of Cost Accounting – Preparation of cost sheet.
UNIT II
PURCHASE & STORES ORGANIZATION
14
9
Purchase of materials – Procedure for purchases – Levels of materials – Economic ordering
quantity.
Store keeper and his functions – Bincard; Priced Stores Ledger – Perpetual Inventory System –
ABC Method of stores control – Pricing of material issues (FIFO, LIFO, Average price, etc.).
UNIT III
LABOUR COSTING
9
Methods of recording attendance – Methods of remuneration – Time rate, Differential time rate,
payment by results – Different Incentive schemes (Taylors differential, Merrick, Gantt Task Bonus,
Emerson & Halsey plan).
UNIT IV
BUDGETARY CONTROL & MARGINAL COSTING
9
Budget – Budgetary control – Types of Budgets – Advantages & Difference between Budgetary
control and Standard costing – Zero base budgeting.
Marginal cost & costing – Cost volume profit Analysis – PIV Ratio – Margin of safety – Application
of Marginal costing technique – Advantages – Break Even point & Analysis – Its advantages.
UNIT V
TAX RULES & REGULATIONS
9
Brief about Income tax Rules, Customs, Excise Rules, Sales Tax & its application in industry.
TOTAL : 45
REFERENCES
1. B.M. Lall Nigam, I.C. Jain, Cost Accounting an Introduction – Prentice, Hall of India Pvt. Ltd.,
New Delhi, 2001.
2. S.P. Jain, K.L. Narang, Cost Accounting Principles and Practice, Kalyani Publishers, New
Delhi, Ed. 12, 1993.
3. B.K. Bhar, Cost Accounting Methods and Problems – Academic Publisher, Calcutta, 1991.
4. T. Horngren, M.R. Foster, M.Datar, Cost Accounting A Managerial Emphasis – Prentice, Hall of
India Pvt. Ltd., New Delhi, Ed.8, 1994.
PT9126
PLASTICS TESTING LABORATORY – I
0 0 6 2
Chemical Lab: Identification of Plastics – Viscosity and Molecular Weight Determination –
Determination of K-value for PVC.
Demonstration: Melting point – Carbon black content – Filler content – Environmental stress
cracking resistance – PH meter – Hooper Viscometer – Brookfield Viscometer.
Specimen Preparation Lab: Specimen preparation using injection moulding machine –
Compression moulding machine – Two roll mill and Contour cutter.
Demonstration: Scrap grinder – Blender
Physico-Mechanical Lab: Tensile strength – Flexural strength – Compression strength – Tear
strength – Impact strength – Hardness
Demonstration: Abrasion resistant tester – Folding endurance tester – Burst strength tester –
Density gradient column – Creep tester – Moisture vapour transmission rate – Gas permeability –
Sieve analysis.
TOTAL : 90
15
LABORATORY REQUIREMENTS
Chemical Laboratory
1.
2.
3.
4.
5.
6.
7.
Plastics Identification Kit
Viscometer
Melting point apparatus
Carbon black content tester
Environmental stress cracking resistance tester
Brookfield viscometer
PH meter
-
1 No.
1 No.
1 No.
1 No.
1 No.
1 No.
1 No.
-
1 No.
2 Nos.
1 No.
1 No.
1 No.
1 No.
-
2 Nos.
1 No.
2 Nos.
1 No.
Specimen Preparation Laboratory
8.
9.
10.
11.
12.
13.
Injection moulding machine
Compression moulding machine
Two roll mill
Contour cutter
Scrap grinder
Blender
Physico-mechanical Laboratory
14.
15.
16.
17.
Universal testing machine
Tear strength tester
Impact strength tester
Shore A – Hardness tester
16
18.
19.
20.
21.
22.
23.
24.
25.
26.
Shore D – Hardness tester
Rockwell Hardness tester
Abrasion resistance tester
Folding endurance tester
Burst strength tester
Creep tester
Humidity chamber
Gas permeability tester
Sieve analysis apparatus
-
1 No.
1 No.
1 No.
1 No.
1 No.
1 No.
1 No.
1 No.
1 No.
REFERENCES
1.
2.
3.
4.
5.
Vishu Shah, Hand Book of Plastics Testing Technology, John Wiley & Sons. Inc. New York,
1998.
R.P. Brown, Hand Book of Plastics Test Methods, George Godwin Ltd., London, 1981.
ASTM test standards for plastics Vol.8.01 to 8.04, 9.01 & 9.02, 2002.
ISO test standards, 1998.
J.S. Anand, K. Ramamurthy, K. Palanivelu & C. Brahatheeswaran, How to Identify Plastics by
Simple Methods, 1997.
PT9127
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
PLASTICS PROCESSING LABORATORY - II
0 0 12 4
Micro processor controlled Injection moulding operation
Blow Moulding Automatic
Vacuum Forming
Rotational Moulding
Coating of Plastics
Welding & Sealing of Plastics
Screen Printing
Machine Maintenance
Mould Study
FRP – Hand lay up process
Co-extrusion
TOTAL : 180
LABORATORY REQUIREMENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Micro processor controlled inj. moulding machine
Blow moulding machine (Automatic)
Vacuum forming machine
Rotational moulding machine
Plastics coating machine
Ultrasonic welding machine
Plastic sealing machine
Printing machine (on plastics)
Machine maintenance kit
Moulds maintenance kit
Moulds for plastic products
FRP hand lay up kit
Plastic co-extrusion film plant
1 No.
-
3 Nos.
1 No.
1 No.
1 No.
1 No.
1 No.
1 No.
1 No.
5 Nos.
1 No.
1 No.
1 No.
REFERENCES
1.
2.
3.
4.
A.S. Athaly, Injection Moulding Practice, Multi-Tech. Publishing Co., New Delhi, 1997.
Irvin Rubin, Injection Moulding Theory and Practice, A. Wiley interscience Publication. 1972.
Lee, Blow Moulding Design Guide, Hausar Publishers, Munich, 1998.
Friedhelm Hensen, Plastics Extrusion Technology, Hansar Publishers, Vienna, 1988.
17
PT9131
PLASTICS TESTING LABORATORY – II
0 0 12 4
Thermal and Rheological Lab: Melt flow index – Heat distortion temperature – Vicat softening
point – Oxygen index.
Demonstration: Brabender – Capillary Rheometer – Haake Viscometer – Thermal conductivity –
Marten’s heat resistance – Low temperature brittleness – Stiffness by Torsion Pendulum.
Electrical and Optical Lab: Volume and Surface resistivity – Breakdown Voltage – Comparative
tracking index – Arc resistance – Haze – Gloss – Clarity.
Demonstration: Refractive index – Microscopes – Colour Guard – Microtome cutter.
Characterization Lab: Demonstration: Thermal analysis – Thermo gravimetric analysis (TGA) –
Differential scanning calorimeter (DSC) – Weather-o-meter.
Product Testing Lab: Pipe, film – Water storage tank
TOTAL : 180
LABORATORY REQUIREMENTS
Thermal & Rheology Laboratory
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Melt flow index tester
Heat deflection temperature tester
Vicat softening point tester
Oxygen index tester
Capillary rheometer
Haake Rheocord
Thermal conductivity tester
Martiens heat resistance tester
Low temperature brittleness tester
Flammability testing apparatus
-
1 No.
1 No.
1 No.
1 No.
1 No.
1 No.
1 No.
1 No.
1 No.
1 No.
Electrical & Optical Laboratory
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Volume & Surface resistivity testing apparatus
Dielectric strength tester
Comparative tracking index tester
Arc resistance tester
Haze meter
Clarity meter
Gloss meter
Refractive index tester
Microscope
Colour measuring equipment
Microtome cutter
-
1 No.
1 No.
1 No.
1 No.
1 No.
1 No.
1 No.
1 No.
1 No.
1 No.
1 No.
-
1 No.
1 No.
2 No.
1 No.
Characterisation Laboratory
22.
23.
24.
25.
Differential Scanning Calorimeter
Thermo Gravimetric Analyser
Weather-o-meter
Gas chromotograph – FTIR
Product Testing Laboratory
18
26.
27.
28.
29.
30.
31.
Hydrostatic pressure tester
Hot water bath
Low temperature cabinet
Reversion test equipment
Hot air oven
Dart impact tester
-
1 No.
1 No.
1 No.
1 No.
1 No.
1 No.
REFERENCES
1. Vishu Shah, Hand Book of Plastics Testing Technology, John Wiley & Sons. Inc. New York,
1998.
2. R.P. Brown, Hand Book of Plastics Test Methods, George Godwin Ltd., London, 1981.
3. ASTM test standards for plastics Vol.8.01 to 8.04, 9.01 & 9.02, 2002.
4. ISO test standards, 1998.
PT9132
PROJECT WORK PHASE I
0 0 20 *
Thesis/Project work on any of the following specialised area to be carried out by each student.

Polymer Blends & Alloys, Speciality & High Performance of Polymers

Prototype Development of a machine/tool/testing equipment

Experimental Investigation on a specific aspects of plastics processing/tooling.

Development of new product designs and value analysis

Design of moulds for plastic products with innovative concepts/techniques

Studies related to process parameter optimisation in any processing technique for defect
free production

Application development for substitution of conventional materials by plastics

Developmental work in Plastics Waste Management (PWM)/Recycling
19
ELECTIVES
PT9151
PLASTICS CHARACTERISATION TECHNIQUES
UNIT I
MOLECULAR WEIGHT DETERMINATION
3 0 0 3
9
Molecular weight averages - Molecular weight determination techniques like End-group analysis,
Colliquative Properties - Ebulliometry, Osmometry and Vapour phase Osmometry, Light scattering
techniques, Solution viscometry, and Gel Permeation Chromatography.
UNIT II
SPECTROSCOPIC CHARACTERIZATION
9
Introduction to Spectroscopic techniques - Ultraviolet - Visible Spectroscopy - Infra Red and
Raman Spectroscopy - Nuclear Magnetic Resonance (NMR) Spectroscopy - Electron Spin
Resonance Spectroscopy, X -Ray Diffraction.
UNIT III
MICROSCOPIC AND CHROMATOGRAPHIC CHARACTERIZATION
9
Light Microscopy - Scanning electron microscopy - Transmission electron Microscopy and
Scanning transmission electron microscopy.
Analysis of residual monomer like VCM, Acetaldehyde, Acrylonitrile and Styrene content in
Polymers by Gas Chromatography.
UNIT IV
THERMAL CHARACTERIZATION
9
The basis of Thermal Analysis - Differential Thermal Analysis (DTA) and Differential Scanning
Calorimetry (DSC) - Thermo-mechanical Analysis (TMA) - Thermo gravimetric Analysis (TGA) Dynamic Mechanical Thermal Analysis (DMA) and Dielectrical Thermal Analysis.
UNIT V
RHEOLOGICAL CHARACTERIZATION
9
Introduction and definitions related to fluid flow - Newtonian and non-Newtonian and visco elastic
fluids. Rheological properties - viscosity, melt-flow, relationships describing temperature and shear
rate dependence on the rheological behaviour of amorphous and crystalline plastics materials,
Simple shear flow and its application for measurement of viscosity as well as normal stresses.
Simple elongation flow and its significance. Dynamic flow behaviour, time dependent fluid
responses. Viscosity measurements - capillary rheometer, viscometer, torque rheometers, cup flow
and spiral flow tests for determination of flow behaviour.
TOTAL : 45
REFERENCES
1. Fred W. Billmeyer, J. R. Text book of Polymer Science, John Wiley & Sons, Singapore, 1994.
2. Seymour/Carraher's Polymer Chemistry An Introduction, Marcel Dekker, Inc., New York, 1996.
3 Campbell and J. R. White, Polymer Characterization Physical Techniques, Chapman and Hall,
London, 1989.
4. J. Spells, Characterization of Solid Polymers, Chapman and Hall, London, 1994.
5 Charles L. Rohn, Analytical Polymer Rheology, Hanser Publishers, Munich, 1995.
6. Edith A. Turi, Thermal Characterization of Polymeric Materials, Academic Press, New York,
1981.
PT9152
BIO-DEGRADABLE PLASTICS
3 0 0 3
UNIT I
9
Introduction – Chemistry and biochemistry of polymer degradation – Enzymes chemical
degradation initiates biodegradation – Hydrolysis of synthetic biodegradable polymers.
UNIT II
9
20
Starch filled plastic – thermoplastic starch – starch based materials in the market – other additives
for biodegradation.
UNIT III
9
Photo-biodegradable plastics – need for degradable polymers – technical requirements of
degradable polymers – Agricultural plastics – Packaging plastics – Control of bio-degradation by
means of antioxidants.
UNIT IV
9
Test methods and standards for bio-degradable plastics – Criteria used in evaluation of
biodegradable plastics – Description of current test methods – Scanning test for ready
biodegradability – Test for inherent biodegradability – Test for simulation studies – Other methods
for assessing polymer biodegradability.
UNIT V
9
Recycling technology for biodegradable plastics – Conventional recycling – Degradable complicate
recycling – reprocessing polyethylene starch/film scrap – Economics in in-plant recycling.
TOTAL : 45
REFERENCES
1. G.J.L. Griffin, Chemistry and Technology of Biodegradable Polymers, Blackie Academic
Professional, 1994.
2. Gerald Scott & Dan Gilad, Degradable Polymers-Principles & Applications, Chapman & Hall,
1995.
3 Handbook of Biodegradable polymers – Abraham J. Domb, Joseph Kost & David M. Wiseman.
4 Polymer Photodegradation – Mechanism and experimental methods – Jain F. Rabek.
PT9153
ADVANCED PLASTICS PROCESSING TECHNOLOGY
UNIT I SPECIALIZED INJECTION MOULDING PROCESS - I
3 0 0 3
9
Introduction - Co-injection moulding, Two-colour injection moulding process - applications, Gas
assisted Injection Moulding - Basic processes and procedures - Moulding aspects - shrinkage and
summary. Reaction Injection Moulding (RIM) - Process - Mould - Process Controls – Merits.
UNIT II
SPECIALISED INJECTION MOULDING PROCESS – II
9
Multi-layer Moulding, Counter flow moulding, Liquid Injection Moulding processes. Structural foam
moulding - Low pressure and high pressure processes - Merits & demerits.
UNIT III
ADVANCED BLOW MOULDING - I
9
Introduction - Classification of advanced Blow moulding processes - Deep draw Double Wall Blow
Moulding Technology - Split moulds- Versatility - Applications. Press Blow Moulding Technology
Process - Applications, Three dimensional Blow Moulding Process - Applications.
UNIT IV
ADVANCED BLOW MOULDING – II
21
9
Stretch blow moulding - Injection stretch blow moulding - Extrusion stretch blow moulding Process - Merits & demerits - Applications. Multi-layer Blow Moulding - Process - Applications.
UNIT V
ADVANCED EXTRUSION PROCESSES
9
Introduction - Profile Extrusion - Material - Process - Process optimisation - Cooling Profile
applications. Process, down stream equipments - dies and application.
Multi-layer films, co-extruded sheets, Pipes, Corrugated pipes.
TOTAL : 45
REFERENCES
1.
James F. Stenvension, Innovation in Polymer Processing Moulding, Hanser Publishers, New
York, 1996.
2.
Donald V. Rosato, Injection Moulding Handbook, International Thomson Publishing Company,
1985.
3.
Friedhelm Henson, Plastics Extrusion Technology, Hanser Publishers, New York, 1988.
4.
PT9154
UNIT 1
Brunt Strong, Plastics: Materials and Processing, Prentice-Hall, New Jersey, 1996.
POLYMERIC NANOCOMPOSITES
3003
PREPARATION OF SYNTHESIS
9
Polymer Nanocomposites, Nanocomposites Preparation and Synthesis, Polymer Matrics :
Thermoplastics, Thermosets, Elastomers, Natural and Biodegradable Polymers
UNIT II
RHEOLOGY OF NANOCOMPOSITES
9
Rheology of Multiphase Systems, Rheology of Polymer / clay Nano composites, Recent studies on
Rheaology, Measure Techniques, Steady shear Rheology, Dynamic Rheology, Non Linear
Viscoelastic properties, Extensional Rheology, Rheological modeling of Nanocomposites.
UNIT III
PROCESSING OF NANOCOMPOSITES
9
Extrusion, Injection Moulding, Blow Moulding, Foaming, Rotational Moulding
UNIT IV
STRUCTURE AND PROPERTIES CHARACTERIZATION
9
Scattering Techniques, Microscopic Techniques, Spectroscopic Techniques, Spectroscopic
Techniques, Chromatography, Solid-state characterization: Mechanical Testing, Thermal
Characterization
UNIT V
APPLICATION OF POLYMER NANOCOMPOSITES
9
Thermoplastics, Thermosets, Biodegradable Polymers.
TOTAL :
22
45
REFERENCES
1.
Luigi Nicolis & Gianfranco Carotenuto “Metal -Polymers Nanocompsites” A John Wiley
& Sons, Inc Publication 2005
2.
Y.C. Ke & P. Stroeve “ Polymer-Layered Silicate and Silica Nanocomposites- Elsevier,
2005
3.
L.A. Utracki “ Clay-Containing Polymeric Nanocomposites” Rapra Technology Limited,
2004
PT9161
PLASTICS WASTE MANAGEMENT
3 0 0 3
UNIT I
9
Introduction – Sources of plastics waste – Separation technologies, viz. Sorting – Manual,
automated, Density separation, Flotation, Solvent separation, Melt filtration, Separation of resin
from fiber in waste FRP.
UNIT II
9
Plastics waste management – 4 R & I approach viz. Source reduction, Reuse, Repair, Recycling,
and Incineration with examples. Plastics recycling – Classification – Code of practice - Primary,
secondary, territory and quaternary recycling with examples – Co-extrusion and Co-injection
moulding – Waste plastics as fillers.
UNIT III
9
Mechanical recycling of commonly used plastics, such as PP, PE, PET, etc. mixed waste recycling
– co-extruded films waste, commingled waste – Extrusion flow moulding for production of plastics
lumbers, chemical recycling/feedstock recycling processes for recovery of oil, monomer and
energy – thermolytic processes. Solvolysis –process outline for PMMA, PET, etc. Fluidised bed
incinerator with energy recovery.
UNIT IV
9
Recycling of plastics by surface refurbishing – Application of a coating, polishing with examples –
Plastics ageing – Environmental ageing – Thermal ageing – Chemical degradation – Wear and
erosion. Biodegradable plastics – an over view.
UNIT V
9
Environmental issues, policies and legislation in India, Review, Tutorial section. Plastics – Energy
saving, Eco-friendly – Case studies. Life cycle analysis – a model.
TOTAL : 45
REFERENCES
1.
R. Johanner Brandrup, Recycling and recovery of plastics, Hanser Publishers, New York,
1996.
2.
Nabil Mustafa, Plastics Waste Management, Disposal Recycling and Reuse, Marcel Dekker,
Inc. New York, 1993.
3. Ehrig, Plastics Recycling, Products and Processes, Hanser Publishers, New York, 1992.
4. Gerald D. Andrews & Pallatheri M. Subramanian, Emerging Technologies in Plastics Recycling,
23
American Chemical Society, Washington, DC 1992.
24
PT9162
UNIT I
QUALITY MANAGEMENT
BASIC CONCEPTS OF QUALITY
3 0 0 3
9
Introduction to quality – Basic concepts – Definitions of Quality of Design and conformance –
Quality assurance functions – Investigational methods – Quality circle. Organization for quality
control, quality audit, costs of quality, ISO 9000 and their documentation.
UNIT II
DATA COLLECTION AND PRESENTATION
9
SQC techniques and their applications – Organising for data collection – Summarisation of data –
Presentation of data in the form of bar diagram, histogram, frequency distributions and pie
diagram.
UNIT III
MEASURES OF CENTRAL TENDENCY AND DISPERSION
9
Calculation of Mean, Median, Mode, Standard deviation and variance – Relationship of Mean,
Median & Mode – Their calculation and interpretation.
UNIT IV
PROBABILITY DISTRIBUTIONS
9
Concept of distributions – Normal, Binomial and Poisson distributions – Sampling distributions, t, f
and λ distributions – Introduction to tests to simple hypothecs.
UNIT V
INSPECTION, SAMPLING AND CORRELATION ANALYSIS
9
Variation – Process and product checks – Inspection – In process, patrol – Objections of inspection
– 100% inspection concepts of acceptance sampling – Single, double and multiple sampling – OC
curves and their characteristics. Concept of regression – Concept of correlation – Different types of
correlation – Scalter diagrams – Correlation analysis.
TOTAL : 45.
REFERENCES
1. Suddhendu Biswas, Statistics of Quality Control, Wiley Eastern Ltd., 1998.
2. Juran & Geyna, Modern Methods for Quality control and improvement, John Wiley & sons,
1986.
3. Jerry Banks, Principles of Quality Control, John Wiley & Sons, 1989.
4. A.V. Feigenbaum, Total Quality Control, Mc Graw Hill Book Company, 1986.
25
PT9163
CAD/CAM/CAE APPLICATION IN MOULD/TOOL DESIGN
3 0 0 3
UNIT I
9
Introduction- Basic concepts of Computer Aided Design – CAD and CADD system – Shape and
size description. Parametric programming - Construction of Engineering drawing – Two
dimensional drafting – 3D surface & Solid Modelling – Concepts of engineering data base –
Various techniques used to analyse the material properties.
UNIT II
9
Introduction to numerical control system – CNC machines - Types of control system for CNC
machine – CNC processing – co-ordinate system – CNC axis and motion – CNC milling – CNC
turning – CNC EDM – machining – CNC wire EDM concepts – concepts of CNC program – tool
motion – canned cycles – CNC interface with CAD-CNC stimulation softwares.
UNIT III
9
Computer Integrated Manufacturing (CIM) - Computer Aided Design & Manufacturing (CAD/CAM)
process – advanced CAD/CAM Technology – Flexible Manufacturing System (FMS).
UNIT IV
9
Rapid prototyping – Processes – Applications - Reverse Engineering – New generation cutting
tools for Mould manufacturing.
UNIT V
9
Computer Aided Engineering (CAE) – Finite Element Analysis(FEA) – Flow analysis–Thermal
analysis – Warpage Analysis – Cooling Analysis - Shrinkage Analysis - Pressure Analysis – C
Mould – Mould Flow – Analysis – Introduction and Application.
TOTAL : 45
REFERENCES
1.
Mikell P. Grooves and Emary W. Zimmers, Jr. `CAD/CAM Computer Aided Design and
Manufacturing’, Prentice Hall, Inc. 1995.
2.
Groover, M.P., `Automation, Production system and CIM’, Prentice – Hall of India, 1998.
3.
Dr.Khalil Taraman, Robert E. King, Rachel Subrin, `CAD/CAM Intergration and Innovation’ –
Computer and Development Department Marketing Services Division – Dearborn, Michigan,
1985.
4.
Peter Kennedy, `Flow analysis of injection moulds’ – Hanser Publishers, Munich Vienna, New
York, 1995.
5.
U. Rembald, B.O. Nnaji, A. Storr, `Computer Integrated Manufacturing and Engineering’,
Addison – Wesley Publishing Company, New York. 1993,
PT9164
BIO-MEDICAL PLASTICS
3003
Unit-I
9
Recent Development in the Bio-Polymer Industry: Fibre –Reinforced composites starch based
materials, Plant Produced Polymers, Microbially produced polymers, Biologically-Based resins,
Adhesives, and coatings, continuing research and development on Bio-polymers
Unit-II
9
Synthetic and Natural biomaterials used in Biomedical applications
26
i)
ii)
Polyolefin’s, Polyamides, Acrylic Polymers, Fluorocarbons, Polyesters,
Engineering Plastics.
Collagen, Polysaccarides, Proteins, etc.
Unit-III
9
Human applications of Plastics: Cardiovascular implants, Dental Implants, Role of plastics in
Ophthalmology, Hydro gels, Drug Delivery systems, Sutures, Burn Dressings and Artificial skin,
Hernia Mesh, Adhesives and Sealants, Artificial organs and devices, Blood bags, Condoms, etc.
Unit-IV
9
Blood Polymer interactions and blood compatibility, chemical and biochemical degradation of
polymers, Tissue engineering and polymers.
Unit-V
9
Testing and Evaluation: in-vitro/vivo; Standards in product development and regulations; Ethical
and sociological issues.
TOTAL 45
REFERENCES
1. Buddy D. Ratner, Allan S. Hoffman, Fredrick, J. Schoen and Jack E. Lemons (Eds),
Biomaterials, Science – An Introduction to Materials in Medicine, Academic Press, San
Diego (1996).
2. Joon B. Park and Roderic S. Lakes, Biomaterials: An Introduction, 2nd edition, Plenum Press,
New York (1992).
PT9171
UNIT I
POLYMER BLENDS & ALLOYS
3 0 0 3
9
Introduction to polymer blends & alloys – Definitions and nomenclature – reasons for making
polymer blend – how to select blend components – preparation of alloys & blends – economy of
blending.
UNIT II COMPATIBILIZATION AND REACTIVE BLENDING
9
Introduction – compatibilization mechanisms – compatibilization methods – compatibilization by
addition of copolymer reactive blending – future trends.
UNIT III
9
Rheology of polymer blends - Introduction – Miscibility and flow behaviour of polymer blends –
Immiscible blends – Flow behaviour of immiscible and miscible polymer blends. Complex flow –
processing of polymer blends – flow through a contraction.
UNIT IV
9
Techniques for studying blends and alloys – light microscopy – the microscope, micro structure –
scanning electron microscopy – specimen preparation – application to polymer blends.
27
Transmission electron microscopy - specimen preparation – application to polymer blends.
UNIT V
9
Thermal analysis - Differential thermal analysis, Differential scanning calorimeter – Gloss transition
temperature.
Other techniques: Light scattering – X-ray scattering – spectroscopy
TOTAL : 45
REFERENCES
1. L.A. Utracki, Commercial Polymer Blends, Chapman & Hall, London, 1998.
2. R.P. Singh, C.K. Das, S.K. Mustafi, Polymer Blends and Alloys an Overview, Asian Books Pvt.
Ltd., New Delhi, 2002.
3.R. Paul & Seymour Newman, Polymer Blends, Vol. 1 & 2, Academic Press, New York, 1978.
28
PT9172
UNIT I
ADVANCED TOOL DESIGN
3 0 0 3
RUNNERLESS MOULDS
9
Nozzle types – Hot runner unit moulds – Manifold Block Design – Inlet Aperture Design – The melt
flow way – Expansion problem – Types of secondary nozzles – Valve systems – Heating systems –
Hot runner unit grid – Insulated runner mould – Hot runner plate mould – Standard mould systems
- Quick mould change system.
UNIT II
AUTOMATIC UNSCREWING MOULDS
9
Component design – Single interrupted thread design – collapsible core design – Automatic
unscrewing moulds for internally threaded components – Axially fixed rotating core – withdrawing
rotating core – Layout of impression – In line layout – pitch circle layout – power and transmission
system – Archimedean screw design – Automatic unscrewing mould for externally threaded
components – Mould construction for pitch circle and in line layout – Standard unscrewing type
mould systems.
UNIT III
9
Mould design – Structural foam moulding – Gas assisted injection moulding – Low pressure and
vacuum moulding of polyurethane (RIM) casting – Resin transfer moulding insert and outset
moulding – Mould Design checklist. – Case studies.
UNIT IV
9
Design standard for inserts – Types of inserts – Selection of metal for inserts – Minimum wall
thickness of material around inserts – Anchorage – Preparation of inserts before moulding –
problem in moulding usual types of inserts – Comparison of inserts – Don’ts in insert design.
UNIT V
9
Rapid prototyping & reverse engineering – 3 D lazar deitizing – Influence of CAD/CAM/CAE in tool
design – Finite element analysis (FEA) – Gate & runner design through mould flow analysis –
Thermal analysis – Warpage & shrinkage analysis – Cooling analysis – Pressure analysis – Mould
design checklist – Case studies.
TOTAL : 45
REFERENCES
1.
James M. Margolis, Advanced Thermoset Composites, Van Nostrand Reinhold Company,
New York, 1986.
2.
John J. Morena, Advanced Composite Mould Making, Van Nostrand Reinhold Company,
New York, 1988.
3.
Bdye, Injection Mould Design, Affiliated East-West Press P.Ltd., New Delhi, 1989.
4.
Gastrow, 108-Proven Design, Hanser Publishers Munich, New York, Barelona, 1993.
5.
Belosky, Plastic Product Design, Hanser, Germany, 1995.
PT9173
THERMOPLASTIC ELASTOMERS
UNIT I
3 0 0 3
9
Introduction to Thermoplastic Elastomers (TPE) Polyolefin – based thermoplastic elastomers –
Block copolymer, Random Block polymers, Graft copolymers, Polyolefin blend TPE’s preparation,
Properties, processing and applications.
UNIT II
9
29
Polyvinylchloride based Thermoplastic Elastomers – PVC/Nitrile Rubber blends, PVC/Polyurethane
blends, PVC/Co-polyester elastomer blends.
Styrenic Thermoplastic Elastomers – Manufacture, Properties, Compounding, Processing and
Applications.
UNIT III
9
Thermoplastic Polyurethane Elastomer – Raw materials, Synthesis, Properties, Processing, Blends
and Applications.
UNIT IV
9
Polyamides based Thermoplastic Elastomers – Polyamide thermoplastic elastomers, Preparation
properties, Structure – Property relationship, Processing and applications.
Thermoplastic Polyether ester Elastomers – Synthesis, polymer structure and Morphology,
Properties, Blends and applications.
UNIT V
9
Dynamically vulcanized Thermo Plastic Elastomer Blends – Introduction - Preparation of Elastomer
– Plastic blends by dynamic vulcanization, properties and applications.
Ionomeric Thermoplastic Elastomers: Synthesis, Properties, ionic interactions in polymer blends
and applications of ionomeric elastomers.
TOTAL : 45
REFERENCES
1. G.Holden, N.R. Legge, R. Quirk, H.E. Schrolder, Thermoplastic Elastomers – 2nd Edition,
Hanser Publishers, Munich, 1996.
2. Anil K. Bhowmick, Howard L. Stephens, Hand Book of Elastomers New Developments and
Technology, Marcel Dekker, Inc., New York, 1988.
1. S.K. De, Anil K. Bhowmick, Thermoplastic Elastomers from Rubber – Plastic Blends, Ellis
Horwood, New York, 1990.
2. Benjamin M. Walker, Hand Book of Thermoplastic Elastomers, Van Mostrand Reinhold
Company, New York, 1979.
PT9174
COATINGS SCIENCE & TECHNOLOGY
UNIT – I
3003
9
Basic paint technology; Polymeric binders, Pigments and extenders additives.
UNIT – II
9
Essential concepts of paint formulation and paint properties : paint preparation (pigment
dispersion), surface preparation and paint application, paint properties and their evaluation
mechanism of film formation, factors affecting coating properties, methods used for film preparation
and their properties; barrier properties and corrosion, mechanical properties, aging properties,
rheological properties, adhesion properties and other related properties.
UNIT –III
9
30
Mathematics of paint formulation, formulations of coatings as finishes (automotive
appliances, coil, can, marine, aircraft etc) and for various substrates (Steel, timber, masonry,
plastics etc.)
UNIT –IV
9
State of the art technologies, specialty coatings (radiation durable, nonpolluting, powder, high
solids etc.)
UNIT V
9
Water – borne coatings : Water – A Fundamental Constituent of water-borne coatings, Types of
Aqueous coatings systems, Binders in water-borne coatings, Additives in water-borne coatings,
Pigments and fillers, The action of Amines and Auxiliary solvents in Aqueous, The manufacture of
water-borne coatings
TOTAL 45
REFERENCES
1.
2.
3.
4.
Outline of Paint Technology, W.M. Morgans (3rd Edition – Recently CBS Publishers.
Paints, Coatings and Solvents, Dieter Stage (Ed.) – 2nd Edition – Wernor Freitag Ltd (Eds)
Principle & Paint Formulation, R. Woodbroidge (Ed) – 1991
Doren “ Water-borne” Hanser 1994
PT9181
ADVANCED MOULD MANUFACTURING TECHNOLOGY
UNIT I
PROGRAMMING AND OPERATION OF CNC MACHINES
3 0 0 3
9
Introduction – Co-ordinate system – Dimensioning – Axes and motion nomenclature – Part
programme structure – Tool compensation – MDI – Sub-routines – Canned cycle – Machining
cycles – Programming examples for Machining centre – Turning centre – Introduction to Computer
and CAD/CAM
UNIT II
IMPORTANCE OF EDM IN MOULD MAKING
9
Brief about EDM – Electrode materials – Applications – CNC EDM – CNC wire EDM – Its
development in Mould and Die industry
UNIT III
PRODUCTIVITY SOLUTIONS FOR THE MANUFACTURING OF
MOULDS & DIES
9
CNC Tooling – Different tool materials – Applications – Different tool coatings – Endmills – Ballnose
– Selection criteria – Chip thickness with milling cutters – special tools for die and mould making –
Tool presetting – Effective and efficient process planning
UNIT IV
ADVANCED MANUFACTURING SYSTEM
9
Introduction – Mould making techniques – Electronic data processing (EDP) – Mould making using
computer integrated manufacturing – CAD for part construction – Interfaces – Softwares – CAD
mould design – Data preparation for machining operation – advantages of machining using CAM –
Reverse engineering – Rapid prototyping
31
UNIT V
DESIGN OF MODERN CNC MACHINES
9
Introduction – Machine structure – Guide ways – Feed drives – Spindles / Spindle bearings –
Measuring systems – Controls, software and User Interface – Gauging – tool monitoring system –
Ball screw and nut – Feedback element – Equipment for assembly – Troubleshooting
TOTAL : 45
.
REFERENCES
1. Cyril Donaldson George H. Lecain V.C. Goold, Tool Design, TATA McGraw-Hill, 1998.
2. Richard R. Kibbe John E Neele, Roland O Mayer, Warran White, Machine Tool Practices,
Prentice Hall of India Pvt. Ltd., 1999.
3. Stoeckhert Mennig, Mould Making Hand Book, Hansel Publishers.
PT9182
UNIT I
SECONDARY PROCESSING TECHNIQUES
CALENDERING, THERMOFORMING AND ROTOMOULDING
3 0 0 3
9
Calendering: Introduction – type of calenders – roll configuration – Definition of terms such as
calender bank – calendering process – process variable and application.
Thermoforming: Introduction – pressure forming – vacuum forming – Techniques of vacuum
forming – simple vacuum forming, drape forming, plug assisted forming, snap-back vacuum
forming – pressure snap-back forming-blow back forming – merits & demerits of vacuum forming –
vacuum forming moulds. Pressure forming – Advantages over vacuum forming – material for
thermo forming – heating systems. Matched die forming – continuous forming methods –
application.
UNIT II
9
FRP Laminates: Introduction, FRP processing methods – contact moulding – hand lay up, spray
up method – vacuum bag & pressure bag moulding, filament welding, centrifugal casting,
pultrusion, matched die moulding – Laminates, definition of terms – high, pressure laminating
process, types of machinery, impregnation systems – decorative and industrial laminates,
continuous high pressure laminating process, application.
UNIT III
9
Cellular Plastics: Introduction – process to create foam in resins – mechanical foaming, chemical
foaming, physical foaming – processes to shape and solidify foams – low pressure foam moulding,
high pressure foam moulding, RIM extrusion foaming, casting foams, steam chest moulding
structural foam moulding – applications.
UNIT IV
9
Machinery & Joining of Plastics: Introduction – Importance of machining – methods viz. cutting,
drilling, blending, filling, etc. Joining – principles – cohesion principle, adhesion principle – solvent
cementing, Dop cementing, welding of plastics – viz. high frequency welding thermal sealing, spin
welding, vibration welding, hot plate welding, ultrasonic welding, Adhesive bonding – examples:
Mechanical fasteners.
Other Secondary Processes:
plating and vacuum metallising.
Printing, painting, Hot stamping, In mould decoration, Electro
32
UNIT V
9
Casting Processes: Dipcasting, slush casting, continuous casting, cell casting, processes and
applications.
Rotational Moulding: Introduction – principle – process – machinery used – materials – moulds,
process parameters – merits & demerits of roto moulding.
Coating Processes: Roller coating, powder coating, fluidised bed coating, electrostatic spray
coating, processes and applications.
TOTAL : 45
REFERENCES
1.
2.
3.
Donal V. Rosato & Dominick V. Rosato, Plastics Processing Data Book, Van Nostrand
Reinhold, New York, 1990.
A. Brent Strong, Plastics: Materials and Processing Practice – Hall, New Jersey, 1996.
M.N. Watson, Joining Plastics in Production, The Welding Institute, Cambridge, 1988.
33
PT9183
PLASTICS PACKAGING TECHNOLOGY
3 0 0 3
UNIT I
9
Introduction to Packaging – Functions of packaging – Major packaging materials viz. Polyolefins,
Polystyrene, Polyvinylchloride, Polyesters, Polyamides (Nylons), Polycarbonate and Newer
materials such as High Nitrile polymers, Polyethylene Naphthalate (PEN), Polyetherimide (PEI)
and LCP – Properties and Applications in Packagings.
UNIT II
CONVERSION TECHNOLOGY-I
9
Extrusion – Blown film, cast film, sheet, multi-layer film and sheet, lamination, stretch and shrink
wrap and heat sealing – Injection moulding for manufacturing of packaging products – Influence of
process variables and its effects. Blow moulding – Extrusion blow moulding, Die shaping,
Programmed parison, Injection blow moulding and Stretch blow moulding
UNIT III
CONVERSION TECHNOLOGY-II
9
Thermoforming – Vacuum forming, Drape forming, Snap-back vacuum forming, Plug-assisted
vacuum forming, Pressure forming, Matched mould forming, Scrap less thermoforming, Skin pack
and blister packs, Thermoform/fill/seal systems (TFFS). Advantages and disadvantages of
thermoforming.
Printing – Surface treatment, Printing on films and containers viz. Flexographic printing,
Rotogravier printing, Pad printing, Hot stamping, Reverse printing.
UNIT IV
PERFORMANCE EVALUATION OF PACKAGING PRODUCTS
9
Mechanical properties – Tensile properties, Impact properties, Tear strength, Burst strength,
Stiffness, Crease or flex resistance, Co-efficient of friction, Blocking, Orientation and shrinkage.
Optical Properties – Clarity, Haze and gloss
Barrier Properties – Oxygen transmission, Water vapour transmission rate – Migration.
UNIT V
ENVIRONMENTAL CONSIDERATION
9
Plastic waste – Classification, Segregation, Sorting and Waste Management viz. source reduction,
reuse/repair, recycling related to packaging films and constrainers.
Pollutants an outline – Chloro Fluoro Carbon (CFC), Dioxin
Life cycle assessment: A case study
TOTAL : 45
REFERENCES
1. Gordon L. Robertson, Food Packaging Principles and Practice, Marcel Dekker, Inc., New York
1993.
2. Louis T. Manzione, Plastic Packaging of Microelectronic Devices, Van Nostrand Reinhold, New
York, 1990.
34