Determination Of Effects On Different Compositions Of Polymer Blend Through Extrusion Process And The Mechanical Properties Of An ABS- PVC-LD PE.

DETERMINATION OF EFFECTS ON DIFFERENT COMPOSITIONS OF POLYMER BLEND THROUGH EXTRUSION PROCESS AND THE MECHANICAL

PROPERTIES OF AN ABS-PVC-LD PE

MUHAMMAD IZHAR BIN ABDUL RAOB

I approve that we have read this thesis thoroughly and through I/ our opinion, this thesis is good enough from the aspect of scope and quality to be awarded for Bachelor of

Mechanical Engineering (Material & Structure).

Signature :

Supervisor : Miss Nortazi binti Sanusi Date :

DETERMINATION OF EFFECTS ON DIFFERENT COMPOSITIONS OF POLYMER BLEND THROUGH EXTRUSION PROCESS AND THE MECHANICAL

PROPERTIES OF AN ABS-PVC-LD PE

MUHAMMAD IZHAR BIN ABDUL RAOB

This report is written in order to fulfill the terms in achieving the award for Bachelor of Mechanical Engineering (Material & Structure)

Faculty of Mechanical Engineering Universiti Teknikal Malaysia Melaka

“I admit that this report is all done by me except for the summary and the article which I have stated the source for each of them”

Signature :

Author : Muhammad Izhar Bin Abdul Raob Date : 27th March 2008

ACKNOWLEDGEMENT

First of all I would like to thank my supervisor, Miss Nortazi binti Sanusi and Co-Supervisor Mr. Wan Mohd Farid Bin Wan Ahmad for their guidance and support for me in completing this thesis on time. I really appreciate your flexibility.

Secondly I would like to dedicate this acknowledgement to Mr. Hisyam Bin Ibrahim, the technician from manufacturing department who has helped a lot during the Polymer Lab session from the extrusion process until the specimen cutting process and Mr. Rashdan Bin Seman from Faculty of Mechanical who always help me whenever I need guidance during the experiment..

Not to be forgotten, my beloved family who always understand the situation, my friend who involves directly and indirectly. I appreciate every second you poured. Your kindness means so much to me and I will use it to lead me to success. Hopefully, this report will give act as a useful source to other students in coming years.

ABSTRAK

Proses penyemperitan ialah satu proses dimana satu daya dikenakan pada bahan termoplastik sehinggalah ia keluar pada acuan. Dalam proses penyemperitan, bahan plastik diletakkan didalam bekas untuk dilakukan proses peleburan didalam silinder penyemperitan, putaran skru melalui acuan dan akan dapat diketahui bentuk yang akan dihasilkan berdasarkan acuan. Proses ini dilakukan untuk membuat paip, pembuluh, batng bulat, helaian, batang segi empat, gelongsor rumah dan pelbagai bentuk lagi. Proses Penekanan Panas adalah satu proses pembuatan dimana ia digunakan untuk mengurangkan keadaan berliang pada material and mempengaruhi ketumpatan untuk banyak bahan. Ini akan memperbaiki sifat-sifat mekanikal, keupayaan kerja dan ketumpatan setiap bahan. Acuan untuk mesin ini adalah dalam lingkungan 2 mm sehingga 3 mm. Untuk projek ini proses penyemperitan dan proses penekanan panas akan memberikan suhu kepada bahan dan kita akan lihat ia akan mergubahkan sifat-sifat mekanikal bahan untuk semua komposisi yang diberikan. Untuk kes ini proses pencampuran ini boleh memperbaiki komposisi untuk semua gabungan-gabungan polimer. Proses penyemperitan untuk kombinasi bahan campuran ABS dengan PVC telah menunjukkan nilai ricihan yang tertinggi berbading bahan yang lain. Kombinasi yang berbeza menunjukkan ia mengikat lebih baik antara satu sama lain berbanding bahan utama. Ini kerana proses penyemperitan boleh mengawal keadaan suhu dan kelajuan suhu cairan berdasarkan pada bahan yang digunakan. Pada eksperimen ini bahan utama ABS merupakan bahan yang paling bagus sifat-sifat mekanikalnya berbanding kombinasi yang lain.

ABSTRACT

Extrusion is a process for making continuous forms by forcing a thermoplastic material in the plastic state through a die. In Extrusion, plastics are fed through a hopper to a heated plasticizing cylinder where they are melted, then driven by rotating screws through a shaped die that determines the shapes of the extruded part. The process is used for the fabrication of pipe, flexible tubing, rods, sheets, tubes, house siding and other shapes. Hot isostatic pressing is a manufacturing process used to reduce the porosity of material and influence the density of many materials. This improves the mechanical properties, workability and density of the material. The mold for hot isostatic press is 2 mm thickness and 3 mm thickness. For this project the extrusion process and hot isostatic press would give a temperature to the material and we can see it will change the mechanical properties for the all composition material. In this case the mixing process it can improve all the composition of the combination polymers. The extrusion process for this combination material the ABS blends with PVC make a higher torque compare to other material. The different composition makes it better bonding compare to main material. It’s because of the extrusion process can set the parameter for the speed and temperature melting point based on material. This experiment for the main material ABS is the good mechanical properties compare to the others combination.

ix

CONTENT

CHAPTER TITLE PAGE

DECLARE ii

DEDICATION iii

ACKNOWLEDGEMENT iv

ABSTRAK v

ABSTRACT vi

TABLE OF CONTENT ix LIST OF TABLE xi LIST OF FIGURE xiii LIST OF SYMBOL xvii LIST OF APPENDIX xviii

CHAPTER I INTRODUCTION

1.1 Background 1

1.2 Objective 2

1.3 Scope 2

1.4 Application 3

1.5 Problem Statement 4

CHAPTER II LITERATURE REVIEW

2.1 Raw Material 5

2.2 Helpful data For Test With Extruder Sensor 10

2.3 Extrusion Process 11

2.4 Thermo Haake Function 12

x

CHAPTER TITLE PAGE

2.6 Material Composition 13

2.7 Mechanical Testing 16

CHAPTER III METHODOLOGY

3.1 Processing flow 19

3.2 Material 20

3.3 Extruder 21

3.4 Crusher 22

3.5 Hot Isostatic Press 22

3.6 Sample Cutter 25

3.7 Tensile Test 26

CHAPTER IV RESULT AND DISCUSSION

4.1 Torque Versus Time 28

4.2 Stress Versus Strain 29 4.3 Young’s Modulus Versus Time 35

4.4 Extension Versus Load 41

4.5 Ultimate Tensile Test 47 CHAPTER V CONCLUSION AND SUGGESTION

6.1 Conclusion 51

6.2 Suggestion 53

REFERENCES 54

BIBILIOGRAPHY 55

xi

LIST OF TABLE

NO. TITLE PAGE

2.1 Some typical properties of ABS plastics 6 (Source: Smith, 2004)

2.2 Properties of Rigid PVC 8

(Source: Smith, 2004)

2.3 Properties of low-density polyethylene 10 (Source: Smith, 2004)

2.4 Extruder Test 10

(Source: Thermo Haake Laboratory Information

2.5 Extruder Test 11

(Source: Thermo Haake Laboratory Information)

2.6 The chemical structure and description of 15 silane coupling agents used

(Source: Chotirat et al .2007)

2.7 Mechanical properties of ABS/ wood composites 17 containing different woodsaw dust contents.

(Source: Chotirat et al. 2007)

3.1 Pellets Characterizing 20

xii

3.2 Specimen Hot Isostatic Press 23

(Source: Thermo Haake Laboratory Information) 3.3 Specimen Dimensions for thickness, T mm (in) 26

(Source: ASTM standard D638) 4.1 Data from Extrusion 29

4.2 Data refer to ABS graph 31

4.3 Data refer to ABS + PVC graph 32

4.4 Data refer to ABS + LD PE graph 33

4.5 Data refer to ABS + PVC + LD PE graph 34

4.6 Data refer to ABS graph 37

4.7 Data refer to ABS + PVC graph 38

4.8 Data refer to ABS + LD PE graph 39

4.9 Data refer to ABS + PVC + LD PE graph 40

4.10 Data refer to Average Test for ABS 42

4.11 Data refer to Average Test for ABS + PVC 43

4.12 Data refer to Average Test for ABS + LD PE 44

4.13 Data refer to Average Test for ABS + PVC + LD PE 45

xiii

LIST OF FIGURE

NO. TITLE PAGE

2.1 Chemical Structural Units ABS 6 (Source: Smith, 2004)

2.2 Percent rubber versus some properties of ABS 7 (Source: Smith, 2004)

2.3 Chemical Structural Units PVC 7 (Source: Smith, 2004)

2.4 Chemical Structural Units Polyethylene 9 (Source: Smith, 2004)

2.5 Chain structure of different types of polyethylene 9 (Source: Smith, 2004)

2.6 Screw design of conventional single screw extruder 12 (Young, 2004)

2.7 Influence of silane coupling agent type and content 15 on tensile modulus for ABS/wood saw dust

composites (solid lines: 9.1 wt% saw dust, and dashed lines: 33.3 wt% saw dust).

xiv 2.8 Effect of silane coupling agent type and content 16

on tensile strength for ABS/wood saw dust composites (solidlines: 9.1 wt % saw dust and dashed lines: 33.3 wt% saw dust).

(Source: Chotirat et al .2007)

3.1 Example Pellets 20

(Source: http://www.davis-standard.com/)

3.2 Polylab Extruder Os 21

(Source: Thermo Haake Laboratory Information)

3.3 Crusher Machine 22

(Source: Manufacturing Polymer Lab UTeM)

3.4 Hot Isostatic Press 22 (Source: Manufacturing Polymer Lab UTeM)

3.5 Mould for hot isostatic Press (3mm) 23 (Source: Manufacturing Polymer Lab UTeM)

3.6: Mould for hot isostatic Press (3mm) 24 (Source: Manufacturing Polymer Lab UTeM)

3.7 WD – 40 24

(Source: Manufacturing Polymer Lab UTeM

3.8 Sample Cutter 25

(Source: Manufacturing Polymer Lab UTeM)

3.9 Sample Specimen 25

xv

3.10 Type I dimension for Dog Bone 26

(Source: ASTM standard D638)

3.11 Instron 5585 26

(Source: Instron 5585 Machine)

4.1 Graph Torque Vs Time 28

4.2 Graph ABS 30

(Stress Vs Strain)

4.3 Graph ABS + PVC 31

(Stress Vs Strain)

4.4 Graph ABS + LD PE 32

(Stress Vs Strain)

4.5 Test Specimen after Tensile Strength for 33 ABS + PVC + LD PE

(Stress Vs Strain)

4.6 Graph Stress versus Strain (Comparison) 34

4.7 Graph ABS 36

(Young’s Modulus Vs Time)

4.8 Graph ABS + PVC 37

(Young’s Modulus Vs Time)

4.9 Graph ABS + LD PE 38

(Young’s Modulus Vs Time)

4.10 Graph ABS + PVC + LD PE 39

xvi

4.11 Graph Young’s Modulus versus Time 40

4.12 Graph Extension Vs Load for ABS 42 4.13 Graph Extension Vs Load for ABS + PVC 43 4.14 Graph Extension Vs Load for ABS + LD PE 44 4.15 Graph Extension Vs Load for ABS + PVC + LD PE 45 4.16 Graph Extension versus Load (Comparison) 46 4.17 Chart Ultimate tensile Strength 48 4.18 Test Specimen after Tensile Strength for ABS 48 4.19 Test Specimen after Tensile Strength for ABS + PVC 49 4.20 Test Specimen after Tensile Strength for ABS + LD PE 49 4.21 Test Specimen after Tensile Strength for 49

xvii

LIST OF SYMBOL

σ = Stress, N/m2

F = Force, N

A = Area, m2 ε = Strain

li = _{instantaneous length, m}

lo = _{original length, m}

∆l = _{amount of elongation, m}

E = modulus of elasticity, psi or Pa m = mass, kg

ρ = density, kg/m3 v = volume, m3

xviii

LIST OF APPENDIX

NO. TITLE PAGE

A Procedure of POLYLAB EXTRUDER OS 55 B Procedure for Instron Machine 58 C Sample calculation for Hot Isostatic Press Mold 63

1

CHAPTER I

INTRODUCTION

1.1Background

Engineering polymers comprise a special high performance segment of synthetic plastics material. They may be shaped into mechanically functional, semi-precision parts or structural components. The term mechanically functional implies that the parts will continue to function even if they are subjected to factors such as mechanical testing. As substitutes for metal in the construction of mechanical apparatus, engineering plastics offer advantages such as corrosion resistance, lightness and economy. Replacement of metal by plastics improves the cost of metal and their fabrication increases.

Plastic application in transportation, a major growth opportunity, has been greatly accelerated by the current awareness of the interplay of vehicle weight and fuel requirement. The ability to replace metals in many areas has resulted growth in engineering thermoplastics. A significant driving force behind the growth in engineering thermoplastics is the continuing expansion of electrical markets. In addition the same requirement is driving the automotive market segment. Original equipment manufacturers strive towards lower production cost, style flexibility, lower maintenance and more efficient, lower polluting vehicles that utilize better performing materials under the hood and in exterior components. The consumption

2 of engineering plastics increased from 10 million to more than 15 billion pounds from 1953 to 1999. Engineering polymers are the fastest growing segment of the plastics industry with an anticipated growth rate from 12 to 15%. (Clara and Charles, 2000)

1.2Objective

To analyze and determine whether extrusion process has a statistically significant effect with different composition and to study mechanical properties obtained from the applied test. In this experiment we should have the procedure to follow from extrusion process then goes to crusher machine followed by hot isostatic press and sample cutter for dog bone and lastly do the tensile test to measure the mechanical properties of the material test.

1.3Scope

Scope for this case study is to analyze and evaluate the extrusion process manufacturing on some given mechanical properties for ABS-PVC–LD PE with a given composition. The analysis will be done at different temperature, dimension and the different combination of the polymer. The combinations that have been decided is ABS (Acrylonitrile-butadiene-styrene) + LD PE (Low-density polyethylene, PVC (Polyvinyl chloride) + ABS (Acrylonitrile-butadiene-styrene) and ABS (Acrylonitrile-butadiene-styrene) + PVC (Polyvinyl chloride) + LD-PE (Low-density polyethylene).

This experiment are very important for analysis in order to decide if the polymer combination has a effect in this extrusion process and shows different mechanical properties in combination of these types of polymer. In this experiment five specimens as required in standard material (ASTM D638) will be tested with different dimension.

3 ABS (Acrylonitrile-butadiene-styrene) have been choose as the one main for this extrusion process because of the highest melting point compare with the PVC (Polyvinyl chloride) and LD PE (Low-density polyethylene). Then, the changing for the mechanical properties of this type of combination and know about the strength of the material with the tensile testing.

1.4Application

Polymer blend are defined as a mixture of polymeric materials and consist of at least two polymers. The main reason for blending is for economy. The performance of an engineering resin can be extended by mixing with a lower cost polymer. In this way, the new material can be developed. In addition industrial polymer scrap may also be recycled.

The polymer blend currently dominates the market like ABS (Acrylonitrile-butadiene-styrene). ABS blend process has a good mechanical strength, with their useful mechanical properties being due to the contributing properties of each of their components.

Acrylonitrile provides chemical resistance, heat resistance and toughness, while butadiene provides impact strength and styrene provides rigidity and easy processing. ABS blends are used for piping, electrical and automotive engineering. Some examples commercially important polymer blends are ABS/PVC and ABS/PET, as mentioned by Stuart, (2002).

4 1.5Problem Statement

The major problem confronting scientists when designing testing techniques for fiber was the design of a technique able to operate for all different types of fibers. The two basic problems were differences in diameter and problem regarding the gripping of the fiber to the testing apparatus. Typically glass, Kevlar, carbon and ceramic fibers have similar small diameter (6μm to 12μm). However, boron and Sic fibers have larger diameters (100μm to 140μm) and high modulus (400 GPa). Hence they cannot sustain bending loads without failure.

In contrast, polymer fibers with diameters between 30μm to 40μm and modulus between 50 GPa and 100GPa, can be deformed without damage. Additionally, it should be noted that testing techniques based on axial tension may only provide adequate amounts of information for isotropic fibers like glass and boron. For anisotropic fibers like carbon, Kevlar and polyethylene, simple axial tests are far from sufficient in providing information about their transverse properties and poison’s ratio. For this purpose, estimating techniques using indirect measurement from the axial testing are usually used.

5

CHAPTER II

LITERATURE REVIEW

2.1 Raw Material

In this experiment the ABS (Acrylonitrile-butadiene-styrene), LD PE (Low-density polyethylene) and PVC (Polyvinyl chloride) as a raw material. Then, this material will be mixing and will blend with the extrusion machine to see the mechanical properties for this combination ABS (Acrylonitrile-butadiene-styrene) + LD PE (Low-density polyethylene, ABS + PVC (Acrylonitrile-butadiene-styrene) and ABS (Acrylonitrile-butadiene-styrene) + PVC (Polyvinyl chloride) + LD PE (Low-density polyethylene).

2.1.1 ABS (Acrylonitrile-butadiene-styrene)

ABS is the name given to a family of thermoplastic. The acronym is derived from the three monomers used to produce ABS: acrylonitrile, butadiene and styrene. ABS materials are noted for their engineering properties such as good impact and mechanical strength combined with ease of processing. The ABS contains the following three chemical structural unit’s polyacrylonitrile, polybutadiene and polystyrene. (Smith, 2004)

6

Figure 2.1: Chemical Structural Units ABS (Source: Smith, 2004)

Structure and properties of ABS is useful in engineering properties exhibited by ABS due to contributing properties of each of its components. Acrylonitrile contributes heat and chemical resistance and toughness, butadiene provides impact strength and low-property retention and styrene provides surface gloss, rigidity and ease of processing. This information refers from Smith (2004).

Table 2.1: Some typical properties of ABS plastics (Source: Smith, 2004)

High Impact Medium Impact Low Impact Impact Strength (Izod)

Ft. Ib/in J/m 7-12 375-640 4-7 215-375 2-4 105-320 Tensile Strength:

X 1000 psi (MPa) 4.8-6.0 33-41 6.0 7.0 6.0-7.5 41-52

Elongation (%) 15-70 10-50 5-30

CHAPTER I

INTRODUCTION

1.1Background

Engineering polymers comprise a special high performance segment of synthetic plastics material. They may be shaped into mechanically functional, semi-precision parts or structural components. The term mechanically functional implies that the parts will continue to function even if they are subjected to factors such as mechanical testing. As substitutes for metal in the construction of mechanical apparatus, engineering plastics offer advantages such as corrosion resistance, lightness and economy. Replacement of metal by plastics improves the cost of metal and their fabrication increases.

Plastic application in transportation, a major growth opportunity, has been greatly accelerated by the current awareness of the interplay of vehicle weight and fuel requirement. The ability to replace metals in many areas has resulted growth in engineering thermoplastics. A significant driving force behind the growth in engineering thermoplastics is the continuing expansion of electrical markets. In addition the same requirement is driving the automotive market segment. Original equipment manufacturers strive towards lower production cost, style flexibility, lower maintenance and more efficient, lower polluting vehicles that utilize better performing materials under the hood and in exterior components. The consumption

of engineering plastics increased from 10 million to more than 15 billion pounds from 1953 to 1999. Engineering polymers are the fastest growing segment of the plastics industry with an anticipated growth rate from 12 to 15%. (Clara and Charles, 2000)

1.2Objective

To analyze and determine whether extrusion process has a statistically significant effect with different composition and to study mechanical properties obtained from the applied test. In this experiment we should have the procedure to follow from extrusion process then goes to crusher machine followed by hot isostatic press and sample cutter for dog bone and lastly do the tensile test to measure the mechanical properties of the material test.

1.3Scope

Scope for this case study is to analyze and evaluate the extrusion process manufacturing on some given mechanical properties for ABS-PVC–LD PE with a given composition. The analysis will be done at different temperature, dimension and the different combination of the polymer. The combinations that have been decided is ABS (Acrylonitrile-butadiene-styrene) + LD PE (Low-density polyethylene, PVC (Polyvinyl chloride) + ABS (Acrylonitrile-butadiene-styrene) and ABS (Acrylonitrile-butadiene-styrene) + PVC (Polyvinyl chloride) + LD-PE (Low-density polyethylene).

This experiment are very important for analysis in order to decide if the polymer combination has a effect in this extrusion process and shows different mechanical properties in combination of these types of polymer. In this experiment five specimens as required in standard material (ASTM D638) will be tested with different dimension.

ABS (Acrylonitrile-butadiene-styrene) have been choose as the one main for this extrusion process because of the highest melting point compare with the PVC (Polyvinyl chloride) and LD PE (Low-density polyethylene). Then, the changing for the mechanical properties of this type of combination and know about the strength of the material with the tensile testing.

1.4Application

Polymer blend are defined as a mixture of polymeric materials and consist of at least two polymers. The main reason for blending is for economy. The performance of an engineering resin can be extended by mixing with a lower cost polymer. In this way, the new material can be developed. In addition industrial polymer scrap may also be recycled.

The polymer blend currently dominates the market like ABS (Acrylonitrile-butadiene-styrene). ABS blend process has a good mechanical strength, with their useful mechanical properties being due to the contributing properties of each of their components.

Acrylonitrile provides chemical resistance, heat resistance and toughness, while butadiene provides impact strength and styrene provides rigidity and easy processing. ABS blends are used for piping, electrical and automotive engineering. Some examples commercially important polymer blends are ABS/PVC and ABS/PET, as mentioned by Stuart, (2002).

1.5Problem Statement

The major problem confronting scientists when designing testing techniques for fiber was the design of a technique able to operate for all different types of fibers. The two basic problems were differences in diameter and problem regarding the gripping of the fiber to the testing apparatus. Typically glass, Kevlar, carbon and ceramic fibers have similar small diameter (6μm to 12μm). However, boron and Sic fibers have larger diameters (100μm to 140μm) and high modulus (400 GPa). Hence they cannot sustain bending loads without failure.

In contrast, polymer fibers with diameters between 30μm to 40μm and modulus between 50 GPa and 100GPa, can be deformed without damage. Additionally, it should be noted that testing techniques based on axial tension may only provide adequate amounts of information for isotropic fibers like glass and boron. For anisotropic fibers like carbon, Kevlar and polyethylene, simple axial tests are far from sufficient in providing information about their transverse properties and poison’s ratio. For this purpose, estimating techniques using indirect measurement from the axial testing are usually used.

CHAPTER II

LITERATURE REVIEW

2.1 Raw Material

In this experiment the ABS (Acrylonitrile-butadiene-styrene), LD PE (Low-density polyethylene) and PVC (Polyvinyl chloride) as a raw material. Then, this material will be mixing and will blend with the extrusion machine to see the mechanical properties for this combination ABS (Acrylonitrile-butadiene-styrene) + LD PE (Low-density polyethylene, ABS + PVC (Acrylonitrile-butadiene-styrene) and ABS (Acrylonitrile-butadiene-styrene) + PVC (Polyvinyl chloride) + LD PE (Low-density polyethylene).

2.1.1 ABS (Acrylonitrile-butadiene-styrene)

ABS is the name given to a family of thermoplastic. The acronym is derived from the three monomers used to produce ABS: acrylonitrile, butadiene and styrene. ABS materials are noted for their engineering properties such as good impact and mechanical strength combined with ease of processing. The ABS contains the following three chemical structural unit’s polyacrylonitrile, polybutadiene and polystyrene. (Smith, 2004)

Figure 2.1: Chemical Structural Units ABS (Source: Smith, 2004)

Structure and properties of ABS is useful in engineering properties exhibited by ABS due to contributing properties of each of its components. Acrylonitrile contributes heat and chemical resistance and toughness, butadiene provides impact strength and low-property retention and styrene provides surface gloss, rigidity and ease of processing. This information refers from Smith (2004).

Table 2.1: Some typical properties of ABS plastics (Source: Smith, 2004)

High Impact Medium Impact Low Impact Impact Strength (Izod)

Ft. Ib/in J/m

7-12 375-640

4-7 215-375

2-4 105-320 Tensile Strength:

X 1000 psi (MPa)

4.8-6.0 33-41

6.0 7.0

6.0-7.5 41-52

Elongation (%) 15-70 10-50 5-30