Injection molding, blow molding, extrusion and thermoforming. Effects of thermoplastic melt characteristics on product design and part quality. Effects of machine design, set-up, and operation on part cost and profitability. Overview of processing machinery including take-off and sizing equipment.

Prerequisites & Corequisites: Prerequisite: IME 2500.

Credits: 3 hours

Lecture Hours - Laboratory Hours: (2 to 3)

1. Knowledge of the elements of plastication.  (IME 2500 - Plastics Properties and Processing)
2. Basic understanding of extrusion, injection molding, and blow molding. (IME 2500)
3. Ability to correctly differentiate independent and dependent process and product variables.  (IME 2500)

At the end of the semester the student should be able to:

1. Understand the physical and chemical bases for plastication. (b & A)
2. Understand the integrated systems within injection, extrusion, and blow molding. (a & K)
3. Understand the role of different types of auxiliary equipment as related to plastics processing. (a & K)
4. Identify the root causes of molding defects (faults) and how they can be corrected. (f & E)
5. Know the importance of molding safety as it relates to mechanical and electrical safeguarding of manufacturing personnel. (i & F)
6. Function as a member of a team to set up production equipment and collect process data. (e, c, D, & B)
7. Collect and distill a large amount of technical information into a usable document. (g & G)

Lower case letters in the parentheses at the end of each objective refer to the TAC of ABET 2001 criteria, upper case letters are EAC of ABET 2000

The student should be able to:

Objective 1

1. List the most critical elements of plastication. [4]
2. Correctly identify stable plastication from a normal shear rate curve. [3, 4]

Objective 2

1. Correctly identify key components, and their function, within injection, extrusion, and blow molding systems. [4, 5]
2. Set up and operate injection molding and extrusion production equipment. [1]

Objective 3

1. Set up and operate auxiliary equipment as an integral part of the primary processing system. [1]

Objective 4

1. Correctly identify the root cause of a given molding fault, and at least one probable corrective action solely from the observation of a molded product. [6]
2. Conduct experimentation to assess the effectiveness of appropriate corrective actions for molding fault discovered during production in the laboratory. [1]

Objective 5

1. Demonstrate the safe operation of processing equipment by producing sample parts without causing injury to anyone present. [1]
2. Demonstrate safe mold, die, and equipment set of procedures, as outlined in the appropriate operations manuals and procedure sheets. [1]

Objective 6

1. Participate as an equal team member in the process of setting up equipment, gathering data and shutting down production. [1, 7]

Objective 7

1. Use a comprehensive array of references drawn from sources, both inside and outside, current university library holdings to collect thorough information on a technical topic. [2]
2. Present detailed written technical information, so that a professional from the plastics industry could use it to improve some element of thermoplastics processing. [2]
   

Numbers in brackets refer to the method of evaluation as listed in the previous section.

Engelmann, P. V. (2000). Production thermoplastics processing. (Lecture/lab manual).

Richardson, P. N. (1974). Introduction to extrusion. Brookfield, CT: Society of Plastics Engineers.

Paul Engelmann, Ed.D.
Departmental Chair
Industrial and Manufacturing Engineering
Western Michigan University
F-259 Parkview Campus
Kalamazoo, Michigan 49008-5336
Phone: (269) 276-3350
Email: paul.engelmann@wmich.edu