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Dt Unit 1.4 > Polymer Forming Processes > Flashcards

Polymer Forming Processes Flashcards

1
Q

What is vacuum forming commonly used to make?

A

Box inserts, yoghurt pots, coffee cups

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2
Q

What is the bed of a vacuum forming machine called?

A

Platen

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3
Q

What is the use of the vacuum pump in vacuum forming?

A

To suck polymer onto mould

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4
Q

What scale of production would regular vacuum forming be used for and why?

A

Small scale/batch production because it’s a slow process

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5
Q

What is thermoforming mainly used for?

A

Used to mould additional detail into the surface of a polymer

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6
Q

What are two products which use thermoforming?

A

Baths, fruit punnets

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7
Q

What is the difference between vacuum forming and thermo forming?

A

There is an additional mould that is pressed into the surface of the polymer sheet

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8
Q

What is the use of the vacuum in thermoforming

A

To suck the polymer onto the mould below

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9
Q

What is the main use for calendering?

A

Smoothing and rolling out materials and making sheet and film stock forms of polymers

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10
Q

What consistency must the thermoplastic pellets be heated to in order for them to be able to be pushed through the heated rollers?

A

Dough-like

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11
Q

What is line bending used for?

A

To create bends in sheet thermoplastics

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12
Q

What are three products which use laminating in production?

A

Boats, yachts, kayaks, cars for theme park rides, scenery props

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13
Q

During process of lamination what would the mould which is in the shape of the product be made from?

A

Timber, plywood or manufactured board

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14
Q

During lamination what would the mould be coated with to prevent the polymer from sticking?

A

Release agents such as wax or pvc

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15
Q

During lamination a gel coat is applied. What is this coat generally made up from?

A

Polyester resin mixed with a colour pigment and/or additives ( for example to prevent UV degradation)

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16
Q

In lamination of CFRP what is the place overnight in which curing takes place?

A

Autoclave

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17
Q

In lamination what type of matting is placed on the former?

A

Fibreglass matting

18
Q

What is injection moulding generally used to make?

A

Complex items made from thermoplastics

19
Q

What classification of polymer is vacuum forming used for?

A

Thermoplastics

20
Q

What is the maximum thickness of polymer which vacuum forming can process?

A

6mm

21
Q

What is the main benefit of thermoforming?

A

You can add additional detail due to the positive mould

22
Q

What scale of production is thermoforming used in?

A

Industrial production

23
Q

What scale of production is calendering used for?

A

Industrial production method used in continuous production

24
Q

What scale of production is line bending used in and why?

A

Small scale or limited batch production because it’s slow and labour intensive

25
Q

In injection moulding, what two elements are used to move the polymer granules through the heaters?

A

Archimedean screw thread connected to hydraulic motor

26
Q

In injection moulding, how is the polymer injected into the moulds?

A

Hydraulic ram forces screw thread forward so that polymer is forced into mould

27
Q

What is blow moulding commonly used to produce?

A

Bottles and hollow products

28
Q

What are the most common polymers used in BLOW MOULDING?

A

PET, LPDE, HDPE, PP

29
Q

What scale of production is BLOW MOULDING, commonly used in and why?

A

Continuous production because of high setup costs of equipment and moulds

30
Q

What polymers are commonly used in ROTATIONAL MOULDING?

A

HDPE and PP

31
Q

What stock form of polymer is used in ROTATIONAL MOULDING?

A

polymer powder or granules

32
Q

In ROTATIONAL MOULDING, how many rotations per minuet does the rotation speed stay below?

A

20 rpm

33
Q

In ROTATIONAL MOULDING, what temperature is the oven set between?

A

260-370 degrees

34
Q

What scale of production is ROTATIONAL MOULDING most commonly used for and why?

A

Large scale batch or mass production because setup costs are high

35
Q

In EXTRUSION, what stock form of polymer is used?

A

Polymer granules

36
Q

What is the difference between EXTRUSION and INJECTION MOULDING?

A

INJECTION MOULDING, uses moulds and EXTRUSION uses dies

37
Q

What is EXTRUSION commonly used to make?

A

Used to coat electrical wire for insulation, solid rod, hollow tube, angle sections

38
Q

what scale of production is EXTRUSION used in?

A

Continuous production

39
Q

what classification of polymer is used in COMPRESSION MOULDING?

A

thermoset polymers

40
Q

In COMPRESSION MOULDING, why does the mould remain closed after hydraulic pressure is applied?

A

To allow time for the cross linking takes place and thermoset cures

41
Q

What urea formaldehyde products are made using COMPRESSION MOULDING?

A

Electrical light fittings, switches, electrical plugs

42
Q

What melamine formaldehyde products are made using COMPRESSION MOULDING?

A

polymer plates, mugs and bowls

Dt Unit 1.4 (8 decks)

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