Technological fundamentals of polyamide processing by injection molding at "Lamela" LLC.
Students Name: Bilynskyi Yurii Danylovych
Qualification Level: magister
Speciality: Chemical Technologies of Polymeric and Composite Materials Processing
Institute: Institute of Chemistry and Chemical Technologies
Mode of Study: full
Academic Year: 2022-2023 н.р.
Language of Defence: англійська
Abstract: Products based on polymer composites are gaining more and more popularity for industrial use in our country. The use of composite materials allows you to reduce the weight of the product without reducing its operational characteristics. Modern methods of processing make it possible to produce parts on a large scale and of high quality in compliance with all the requirements that apply to parts.[1] The most widely used in industry for the manufacture of structural parts with high technological parameters is polyamide[2], which has significant mechanical properties that in some places prevail over metal.[2] It is also characterized by a much lower specific mass than metal raw materials. However, polyamides have one significant disadvantage compared to other polymers of the polyolefin series [1] -relatively high wet absorption, which reduces the properties of the polymer. It is caused by a feature of the polymer structure, which is polar and easily e xposed to moisture. However, by using fillers and changing the polymerization components, this effect can be reduced to a minimum[3] . Among the main factors limiting the widespread introduction of polyamide in the production of polymer products is their h igh cost of about $3/kg. [4] To reduce the cost of polyamide products and modify their properties, various fillers and glass fibers are often added, which reduce the share of pure raw materials in the final product, thereby reducing the cost of the product . The most common fillers are: silicon dioxin, talc, glass fiber.[3] 10 Research object: Polyamide processing technology by injection molding on the basis of " Lamela " LLC . The subject of the research: Features of processing of polyamides by injection molding, study of the effect of moisture on product parameters, analysis of technical and mechanical parameters of the pure polymer, study of the effect of fillers on the possibility of reducing the defects of the pure polymer. Aim of the research: to deve lop an optimal technology for processing polymer raw materials ( polyamide ) into products, minimizing the negative processes that are accompanied by processing from the stage of receiving raw materials to its final packaging in the form of a finished product. The first section highlights the literature review. The advantages and disadvantages of polyamide products are indicated. Studies on the influence of moisture content on the quality of the resulting products and the influence of the nature of re-drying on the mechanical characteristics of raw materials are presented. The fields of application of polyamide products are described. The influence of thermal and hydrolytic degradation on the final parameters of the product is given. In the second section, the potential requirements for the product "Roller" are analyzed and the basic requirements for the product are established. The material for the manufacture of a unit of production is selected - PA6-L-211/311 and its parameters are indicated in comparison with possible analogues. According to the operating conditions of the finished product, the following requirements are set: - The surface of the products should not contain swellings, cracks and sinks, for which possible defects that arise in the manufacture of products by injection molding were described and ways to eliminate defects were given; - The hardness of the product should be at least 100 units; - Destructive tensile stress must be at least 75 MPa; - The product must be resistant to organic substances; 11 The characteristics and structure of the selected polymer as a raw material and the characteristics of the product are described. Possible methods of polyamide processing (injection molding, extrusion, blow molding and rotational molding) are described Only the injection molding method is suitable to fulfill the requirements, since other methods do not allow to form a product of complex structure and are not cost -effective for the formation of products of small mass and large quantities. A technological scheme for the manufacture of a typical product "Roller" was developed, taking into account the peculiarities of processing (sensitivity of raw materials to moisture and non-use of production waste in the technological process). For the manufacture of a given number of products 50 thousand units, the material flows and losses of raw materials at each stage of production are calculated and the corresponding calculations are given. For the production of 50,000 units of products per year weighing 273.6 g, taking into account the consumption coefficient, which includes the peculiarities of the processing method and the peculiarities of the raw materials and which is 1.1923, 16.31 tons/year of raw materials are required to obtain 13.68 tons of finished products. The main and auxiliary technological equipment for the manufacture of the product "Roller" was selected. Calculations of the characteristics of the equipment and its quantity for the manufacture of the entire range of products were carried out. The injection molding machine SSB SUN -200?48 with the required characteristics was selected. In the third section, the design parameters of the form and signs for the formation of the product "Roller" are calculated. Designed a typical product "Roller" taking into account all the necessary requirements and set tolerances for each size. The type and design of the casting mold for industrial production of the product is selected. The type of gating system is substantiated, the optimal cooling system is calculated, which will provide appropriate heat removal without delaying the process 12 and creating product defects. A cylindrical ejection system was chosen to automate the process of removing the product from the mold. The centering elements of the mold for high-quality closure are provided. The principle of operation of the mold is described with the corresponding elements. The fourth section analyzes possible markets for manufactured products, the competitive ability of products and the resource market. Labour cos ts for production workers, as well as energy, marketing and depreciation costs are calculated. A plan for production and sales of products was drawn up. The required amount of investment for the implementation of production is calculated. The cost of a typ ical product "Roller" is determined. In this abstract, the master’s qualification work was briefly described, the task of which was to develop the technological basis for the processing of polyamide by injection molding on the basis of Lamela LLC. The desi gn was carried out for a typical product "Roller" made of polyamide PA6 -L-211/311. The master’s thesis consists of an introduction, 4 chapters, conclusions, a list of used literature containing 16 titles, and appendices. The main content is presented on 103 pages of printed text containing 25 figures and 24 tables. Key words : polyamide , injection molding, drying, processing, mold for injection molding, plasticization, properties, modification, composites. List of used sources and literature: 1) H.F. Mark, Encyclopedia of Polymer Science and Technology, Third edition, Wiley-Interscience, 2004 - 9523 c.; 2) Stanyl, General Information, DSM, Heerlen, the Netherlands, 1995. 3) P. Schrijver-Rzymelka, Kunststoffe 89(7), 87–90 (1999) 4) Plast. Technol. Monthly. 46 (Oct. 2000).