Plastics processing I,II & III Lectures and exercises
Plastics processing I
Building on the lecture and exercise “Materials Science II”, this basic course explains the most important processing methods in plastics technology. In an introductory part, the classification of plastics, their properties and processing methods are presented, the focus is on a detailed treatment of standard and special processes in plastics technology and their areas of application.
Contents of the lecture
Extrusion is a continuous process that is used to produce films, sheets and profiles. Today, extrusion blow moulding and stretch blow moulding processes are mainly used to produce hollow bodies from thermoplastics (bottles, canisters, but also half-shells for suitcases or fuel tanks). The individual processes with their special features, possibilities and limitations are explained in detail in the lecture. The injection moulding process as a discontinuous process enables the fully automatic production of geometrically complex plastic parts in large quantities – from the smallest gear wheels or bearings to garbage cans with a capacity of several 100 liters. The machine and process sequence are explained, as are individual special processes such as thermoplastic foam injection moulding, which can be used to produce components with a foamed core. Fiber-reinforced plastics are the outstanding material, especially when high stability combined with low weight is required (car bodies, sporting goods, wind turbines). The lecture deals with the fiber and matrix materials used, areas of application for fiber-reinforced plastics and processes. In addition, the lecture looks at important further processing techniques such as thermoforming and welding and goes into the processes of elastomer processing (rubber) and polyurethane processing (reactive plastic with a particularly wide range of applications).
Übung zur Vorlesung
© DF.FotografieIKV offers practical exercises for all lecture topics in Plastics Processing I. These mainly take place in IKV’s laboratories and pilot plants and enable students to consolidate what they have learned in the lecture. In small groups, students work directly on the machines and learn about materials, processes and operating settings in detail.
Literature for the exercise:
Introduction to plastics processing
Authors: Christian Hopmann, Walter Michaeli
Edition: 7th edition 2015
ISBN: 978-3-446-44627-4
Published by HANSER-Verlag Students registered for the course can find a downloadable reprint in the RWTHmoodle learning room.
Important information at a glance
- Compulsory subject
in the Bachelor of Mechanical Engineering/Plastics and Textile Technology and
in the Bachelor of Business Administration and Engineering specialising in Mechanical Engineering/Plastics Technology - Dates
Only in the winter semester - Scope
3 SWS (L2 E1) - Credit Points
4 - Form of examination
Written exam - Lecturer
Prof. Dr.-Ing. Christian Hopmann
Plastics processing II
The most important processes presented in the lecture Plastics Processing I – extrusion and injection moulding – are discussed in more detail in this lecture and the associated series of exercises. The focus is on the technology and design of machines and tools as well as on temperature equalization processes and orientations in plastics.
Contents of the lecture
The central element of an extrusion system is the extruder or extruder screw, which has the task of conveying a homogeneous melt evenly, in sufficient quantity and at the right temperature into the die, where the material is finally formed into pipes, sheets, films or profiles. In the lecture, the processes in the screw channel are explained using melting models and approaches to the design of extruders are discussed. Other functional elements of the extrusion line – feed opening, degassing systems, drive unit, etc. – are discussed in detail. General design rules, various designs and applications are presented in a thematic block on the design of extrusion tools. The injection moulding process is presented in depth with the phases of the injection moulding cycle. An important basis for understanding the process are methods and formulas for determining and calculating process parameters such as melt temperatures, temperature profiles, injection work, speed profiles and pressure curves as well as the use of p-v-T diagrams to determine the relationship between pressure, temperature and specific volume. With a view to the products to be manufactured, the respective advantages and disadvantages of the process variants and their possible applications are also clarified. For an in-depth understanding of materials and processes, comprehensive knowledge of temperature equalization processes and molecular orientations is imparted.
Exercise accompanying the lecture
The exercises for the lecture Plastics Processing II are essentially designed as calculation and self-calculation exercises in which methods for determining, for example, screw geometries, flow processes and filling processes are explained and applied by the students. Homework accompanying the exercises gives students the opportunity to check their level of knowledge and understanding during the semester and to collect points in advance for the final exam. Literature for the exercise: Students registered for the course can download the reprint in the RWTHmoodle learning room.
© IKVImportant information at a glance
- Compulsory subject
in the Bachelor of Mechanical Engineering / Plastics and Textile Technology and
in the Bachelor of Business Administration and Engineering specialising in Mechanical Engineering/Plastics Technology - Dates
only in the summer semester - Scope
3 SWS (V2 Ü1) - Credit Points
4 - Form of examination
Written exam - Lecturer
Prof. Dr.-Ing. Christian Hopmann
Plastics processing III
The course “Plastics Processing III” deals with complex issues of plastics processing, in particular with the design and manufacture of components. Comprehensive knowledge of the properties of plastics and the various manufacturing processes is essential for this; this was taught in the previous courses “Plastics Processing I” and “Plastics Processing II” and is applied to further issues in the Master’s course “Plastics Processing III”.
Contents of the lecture
The lecture begins with a block on the design and layout of plastic components and the corresponding injection moulding tools. Special consideration is given to material-specific conditions, which have a major influence on component design and manufacture. The plastics engineering production processes are explored in depth and expanded to include upstream and downstream accompanying processes: the topics of quality assurance, recording and optimizing manufacturing processes, surface functionalization, prototype production and disposal complete the process understanding with numerous boundary conditions that are of the utmost importance in industrial production. The topic “Additive manufacturing” provides an overview of the various processes for the layered (“additive” or “generative”) construction of components. In these processes, production takes place without the use of a mould, which is particularly interesting for the manufacture of highly individualised products in small quantities. A large block on fiber-reinforced plastics provides comprehensive knowledge on this important topic.
Exercise accompanying the lecture
In the plastics processing exercise III, the main topics of the lecture are deepened and put into practice. The exercise series concludes with a block on product development, in which students analye a complex plastic component with regard to functionality, materials used, recycling options, optimization options, etc. Literature for the exercise: Students registered for the course will find a reprint for download in the RWTHmoodle learning room.
© DF.FotografieImportant information at a glance
- Compulsory subject in the
Master’s in Plastics and Textile Technology
and in the Master’s in Business Administration and Engineering specialising in Mechanical Engineering/Plastics Technology - Dates
only in the winter semester - Scope
3 SWS (V2 Ü1) - Credit Points
6 - Form of examination
Written exam - Lecturer
Prof. Dr.-Ing. Christian Hopmann