Plastics Processing Techniques detailed Syllabus for Plastic Engineering (PS), I – scheme has been taken from the MSBTE official website and presented for the diploma students. For Subject Code, Subject Name, Lectures, Tutorial, Practical/Drawing, Credits, Theory (Max & Min) Marks, Practical (Max & Min) Marks, Total Marks, and other information, do visit full semester subjects post given below.
For all other Diploma in Plastic Engineering (PS) Syllabus for 3rd Sem I – Scheme MSBTE, do visit Diploma in Plastic Engineering (PS) Syllabus for 3rd Sem I – Scheme MSBTE Subjects. The detailed Syllabus for plastics processing techniques is as follows.
Rationale:
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Competency:
The aim of this course is to help the student to attain the following industry identified competency through various teaching learning experiences:
- Maintain various types of Plastic Extrusion Plants.
Course Outcomes:
The theory, practical experiences and relevant soft skills associated with this course are to be taught and implemented, so that the student demonstrates the following industry oriented COs associated with the above mentioned competency:
- Operate relevant extrusion process for the given application.
- Troubleshoot blow molding process for manufacturing a plastic product.
- Execute joining and welding process for plastic products.
- Decorate the plastic product using relevant techniques.
- Manufacture different types of foams by using relevant technique.
Suggested Exercises:
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Major Equipment/Instruments Required
The major equipment with broad specification mentioned here will usher in uniformity in conduct of experiments, as well as aid to procure equipment by authorities concerned.
Equipment Name with Broad Specifications
- Extrusion Machine with Auxiliary Equipment and dies such as Pipe die, blown film die. pelletizer die (45 mm diameter screw.
- Blow moulding machine with auxiliary equipments and one liter bottle blow mould (45 mm diameter screw.
- Soft mild steel file
- Hot plate welding machine [Plate size 6×6, Overall size 1 lwxl 1Dx5H, Power 120/240V, 1100W. Max. Temp. 1000F(537C)J
- Ultrasonic welding machine (Ultraweld 1200 watt / 20 KHZ, Welding pressure adjustable up to 6 bar, Weld time, Hold time settable in the steps of 100 milliseconds., Microprocessor based controller., Digital counter up to 100,000 countsresettable., Electrical Input: Voltage: 230 +/- 5 V AC single Phase. Current: 12 Amps. Max., Power 3 KW. .
- Corona discharge equipment (0 5 kw to 3 kw – 220 kw volt single phase / 415 volt 3 phase.
- Flame treatment equipment (blow pump 4 liter.
- Screen printing table, screen frame with mesh size of 90, 120 and 180
- Injection moulding machine (80 ton. capacity.
Unit 1
Extrusion
Total Teaching Hours – 16
Distribution of Theory Marks
R Level – 04
U Level – 06
A Level – 12
Total Marks – 22
Unit Outcomes (UOs) (in cognitive domain)
- Describe constructional features of the given extruder.
- Distinguish between the given single screw and twin screw extruder on the basis of benefits
- Describe the given Pipe manufacturing extruder and its parts.
- Describe common causes and their remedial measures for defects in the given extruded products.
- Suggest operating parameters for a given process line and justify.
Topics and Sub-topics
- Extrusion: Principle, definition, materials and applications.
- Single screw extruder: constructional features and functions of different parts such as hopper, barrel, screw, drive system, heating and cooling systems, zones of extruder, thrust bearing, breaker plate and screen pack.
- Twin screw extruder: types-co-rotating, counter-rotating, its comparison, advantages over single screw, intermeshing and non intermeshing.
- Pipe extrusion: Process plant layout and auxiliary equipments such as sizing device, cooling trough, takeoff unit, cutter and coiler.
- Blown film extrusion: process plant layout and auxiliary equipments such as venture ring support, bubble blowing unit, cooling unit, bubble collapsing plates, winder unit, co extrusion -2and3 layer
- Sheet extrusion: process layout and auxiliary equipments such as cooling unit, stripping roll-unit, gauging heads, cut-out unit, sheet stacker and coiler.
- Wire and cable Coating: Materials, process.
- Extruder pelletizer: Equipment, process
- Trouble shooting in extrusion i.e. defects, causes and remedies.
Unit 2
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Unit 3
Fabrication with Plastics
Total Teaching Hours – 10
Distribution of Theory Marks
R Level – 02
U Level – 06
A Level – 06
Total Marks – 14
Unit Outcomes (UOs) (in cognitive domain)
- Describe purpose of finishing operation in the given application.
- Explain bonding method by adhesives and solvent cements in the given situation.
- Select different solvents for bonding purpose in the given situation.
- Explain significance of ultrasonic welding in plastic industries for the given situation.
- Justify the selection of joining and welding techniques in the given situation.
Topics and Sub-topics
- Finishing: Process and purpose.
- Joining Techniques: Solvent cementing and adhesive bonding.
- Welding Techniques: High frequency welding, thermal sealing of film and sheet, hot gas welding, hot plate welding, induction welding, spin or friction welding, ultrasonic assembly.
Unit 4
Decorating Plastics
Total Teaching Hours – 08
Distribution of Theory Marks
R Level – 02
U Level – 04
A Level – 06
Total Marks – 12
Unit Outcomes (UOs) (in cognitive domain)
- Explain need of surface treatment for plastics in the given situation.
- Describe various decorating techniques for plastics in the given situation.
- Explain importance of decorating techniques in the given situation.
- Explain in the given situation process of screen printing and vacuum metalizing.
- Justify the parameters for selecting decorating technique for the given plastic product.
Topics and Sub-topics
- Surface treatment: Need, methods- washing, solvent cleaning, flame treatment, corona discharge.
- Decorating techniques: paint and coating, printing, laser marking, dyeing, electroless plating, electrolytic plating, vacuum metallizing, flocking, dip coating, in mold decorations
Unit 5
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Suggested Student Activities:
Other than the classroom and laboratory learning, following are the suggested student-related co-curricular activities which can be undertaken to accelerate the attainment of the various outcomes in this course:
- Collect different thermoplastic and thermosetting materials from the surrounding area, prepare a report and make a class presentation.
- Download from internet, mechanisms and best practices for reduction, reuse and recycle of rejected plastics products, make a PPT.
- Prepare a report on information of plastic machinery manufacturers and suppliers (grades, rates, minimum quantity, bulk discounts, sizes of machines and specifications.).
- Collect information of different plastic products produced from extrusion processing from surrounding industries (BIS standard, size, materials, and dimensions) and prepare report.
- Prepare a report of best practices and standard operating procedures for plastic processing machines from internet and make class presentation.
- Visit an existing plastic product manufacturing unit and collect information of registration procedure, plant layout, machinery specifications and price, electrical load, manpower requirement, rate list, annual turnover, major clients and terms and conditions. Make a report of it.
Suggested Special Instructional Strategies:
These are sample strategies, which the teacher can use to accelerate the attainment of the various learning outcomes in this course:
- Massive open online courses (MOOCs) may be used to teach various topics/sub topics.
- ‘L’ in item No. 4 does not mean only the traditional lecture method, but different types of teaching methods and media that are to be employed to develop the outcomes.
- About 15-20 % of the topics/sub-topics which is relatively simpler or descriptive in nature is to be given to the students for self-directed learning and assess the development of the COs through classroom presentations (see implementation guideline for details).
- With respect to item No. 10, teachers need to ensure to create opportunities and provisions for co-curricular activities.
- Guide students in undertaking micro-projects.
- Demonstrate the process to students thoroughly before they start doing the practice.
- Encourage students to refer different websites to have through understanding of the subject.
- Observe continuously, monitor the performance of students in Laboratory and provide feedback.
- Guide students for information search.
- Arrange visits to industrial fairs.
- Conduct brainstorming sessions on reducing wastage and defects.
- Invite industry experts for guest lectures.
- Assign micro projects to group of 4 to 5 students and let them prepare and present the project through PPT. Group shall submit a report which is limited to 5 pages.
Suggested Micro-Projects
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Suggested Learning Resources:
- SP1 Plastics Engineering Handbook Berins, M. L. Kluwer Academic Publishers, Boston, 2000, ISBN: 97814615 7606 8
- Polymer Extrusion Rauwendaal, C. Carl Hanser Verlag GmbH , Kolbergerstrasse, 2014, ISBN: 9781569905166
- Extrusion: The Definitive Processing Guide and Handbook (Plastics Design Library. Giles Jr, H. William Andrew, Norwich, 2004 ISBN :9780815514732
- Decorating Plastics Margolis Hanser Gardner Pubns, Cincinnati 1987, ISBN: 9781569900581
- Blow moulding Handbook Rosato, D. Hanser Publishers, Cincinnati 1989 ISBN: 9783446150713
- Handbook of Polymeric Foam and Foam Technology Klempner, D. Carl Hanser Verlag GmbH & Co., Kolbergerstrasse, 2004 ISBN: 9783446218314
- Plastic Processing Strong, B. Prentice Hall, New Jersey 1999 ISBN-13: 9780130216267
Websites
- http://www.technologystudent.com/equipl/plasextrul .html
- http://www.bpf.co.uk/plastipedia/processes/Injection_Blow_Moulding.aspx
- http://www.plasticsdecorating.com/
- https://www.dukane.com/us/PPL_WhatisPW.htm
- https://www.youtube.com/watch?v=HUa4OAAtjfk
- http://www.motan-colortronic.com/solutions/extrusion/wire-and-cable-coating.html
For detail Syllabus of all other subjects of Plastic Engineering, I – scheme do visit Plastic Engineering 3rd Sem Syllabus for I – scheme.
For all Plastic Engineering results, visit MSBTE Plastic Engineering all semester results direct links.