Testing for Rotational Moulding (RM) and Service...

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BITS Pilani K K Birla Goa Campus Testing for Rotational Moulding (RM) and Service Capabilities of BITS Dr. Sachin Waigaonkar

Transcript of Testing for Rotational Moulding (RM) and Service...

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BITS Pilani K K Birla Goa Campus

Testing for Rotational Moulding (RM) and Service Capabilities of BITS

Dr. Sachin Waigaonkar

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BITS Pilani, K K Birla Goa Campus

• About BITS Pilani

• Different Quality Tests in Rotational Moulding

• Service Capabilities for Rotational Moulding

Industry.

• Conclusions

Outline

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BITS Pilani, K K Birla Goa Campus

BITS Pilani-Four Accredited Campuses

Pilani Campus (1964)

Goa Campus(2004) Hyderabad Campus(2008)

Dubai Campus (2000)

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BITS Pilani, K K Birla Goa Campus

Theory learnt in classroom

Practice in Industry

Committed to University – Industry Collaboration Since its inception (1964)

As on today, Collaboration with 300+ industries

University – Industry Linkage

Practice School Programmes

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BITS Pilani, K K Birla Goa Campus

Work-Integrated Learning and Collaborative Programmes

University – Industry Linkage

[20,000 students on roll | 30,000 students graduated] 33 Organizations | 24 Degree Programmes

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BITS Pilani, K K Birla Goa Campus

• Testing of Raw Materials:

Testing of Pellets and

Testing of Powder

• Testing of Product.( Fit, Form and Function)

• Long Term Testing of RM Products.

• Advanced Tests for Material Development

Testing in Rotational Moulding

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BITS Pilani, K K Birla Goa Campus

• Density

• Melt Flow Index (MFI)

• Shape, Size Colour of Pellets

• Tensile Strength / Modulus

• Flexural Modulus

• Heat Distortion Temperature (HDT)

• Environmental Stress Cracking

Resistance (ESCR)

Testing of Raw Material (Pellets):

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BITS Pilani, K K Birla Goa Campus

• Dry Flow Test

• Bulk Density Test

• Sieve Analysis - Particle Size Distribution

• Microscopic View for Characterization of

Powder.

Powder Characterization

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BITS Pilani, K K Birla Goa Campus

• Dimensions of Product

• Profile

• Angularity

• Depth

• Wall Thickness Distribution

• Shrinkage and Warpage

Testing of form features of the product:

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BITS Pilani, K K Birla Goa Campus

• Density of part

• Tensile Strength and Modulus

• Flexural Strength and Modulus

• Low Temperature Impact Strength

• HDT

• ESCR

• Gel Cure Test (XLPE), etc.

Mechanical Properties of the product:

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BITS Pilani, K K Birla Goa Campus

• Colour Testing in Light booth

• Weatherability using Xenon Arc Lamp

• Differential Scanning Calorimetry (DSC)

• Dynamic Mechanical Testing Creep Testing using DMA

• Thermal Gravimetric Analysis (TGA)

• Scanning Electron Microscopy (SEM)

• Compounding Studies using Torque Rheometer.

• Rheological Studies using Parallel Plate rheometry

A few important tests are discussed here

Long Term and Advanced Testing

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BITS Pilani, K K Birla Goa Campus

• The specific gravity or density is a property

measured to:

Identify a material,

Follow physical changes in a sample,

Indicate degree of uniformity among different

sampling units or specimens.

To calculate strength-weight and cost-weight ratios.

Density

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BITS Pilani, K K Birla Goa Campus

Effect of Density on Different Properties #

Density

Property

• Tensile Strength • HDT • Stiffness • Shrinkage • Hardness • Barrier

Properties • Chemical

Resistance

• Impact Strength

• ESCR • Optical

Properties • Ductility

#: Ref: R.J. Crawford, Rotational Moulding, Rapra Review Report, 71

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BITS Pilani, K K Birla Goa Campus

Testing of Density

•Ref: ASTM D-792 or ISO 1183 method D.

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BITS Pilani, K K Birla Goa Campus

Testing of Powder: Dry Flow and Bulk Density

Ref: Association of Rotational Molders, Test Method for Flowability and Apparent Density of Polyethylene Powders, Version 2.1 – November 2011, pp-2-8, ASTM 1895-69 with conditions redefined for use in rotational moulding

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BITS Pilani, K K Birla Goa Campus

Melt Flow Index (MFI)

Schematic Dynisco MFI in Our Lab

Ref: ASTM D -1238

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BITS Pilani, K K Birla Goa Campus

Effect of MFI on Different Properties #

MFI

Property

• Flow Properties e.g. Viscosity

• Impact Strength • Tensile Strength • ESCR • Weatheribility • Chemical

Resistance • Ductility

#: Ref: R.J. Crawford, Rotational Moulding, Rapra Review Report, 71

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BITS Pilani, K K Birla Goa Campus

ESCR

Ref: ASTM D-1693

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BITS Pilani, K K Birla Goa Campus

Testing of Tensile Properties

UTM in Lab (Load Cell 0-10 KN) Typical Stress-Strain Plot

Ref: ASTM D 638

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BITS Pilani, K K Birla Goa Campus

Testing of Flexural Properties

Schematic of Flexural Testing Lab Testing Set Up

Ref: ASTM D 790

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BITS Pilani, K K Birla Goa Campus

Typical Flexural Curves

Ref: ASTM D 790

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BITS Pilani, K K Birla Goa Campus

Schematic of Low Temp. Impact Test

Ref: ARM Low Temperature Impact Test

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BITS Pilani, K K Birla Goa Campus

HDT: Schematic and Set Up

Schematic of Flexural Testing Lab Set Up for HDT

Ref: ASTM D 648

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BITS Pilani, K K Birla Goa Campus

Geometry and Form Testing: Coordinate

Measuring Machine (CMM)

Testing of product for Dimensions, Profile, Depth, Angularity, etc.

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BITS Pilani, K K Birla Goa Campus

• Dynamic Mechanical Analyzer (DMA): TA Instruments USA

• Differential Scanning Calorimetry (DSC).

• Thermo gravimetric Analysis (TGA)

• Scanning Electron Microscope

• Templogger

• Injection Moulding Machine: Ferromatic Millerkon -50 T

• Compression Moulding Press-32 T

• 3-D printer for Rapid Prototyping: Make Stratasys

• ROTOSIM.

• Pro-E, ANSYS and other CAE tools.

Other Facilities at BITS GOA ( will be replaced with Photos)

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BITS Pilani, K K Birla Goa Campus

Test Standard

Density ASTM D 1505/D-4883/D-792 or ISO 1183 method D.

Dry Flow and Bulk Density ASTM 1895-69 with conditions redefined for use in rotational moulding

MFI ASTM D -1238

ESCR ASTM D-1693

Tensile Strength and Modulus ASTM D 638 Type I to IV

Flexural Strength and Modulus ASTM D 790

Low Temperature Dart Impact ARM International

HDT ASTM D 648

Conclusion: Our Service Capabilities

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BITS Pilani, K K Birla Goa Campus

“The best Research will give the best Teaching and the best Teaching will give the best Research” Dr. APJ Abdul Kalam.

Thanks