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

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

2 Outline About BITS Pilani Different Quality Tests in Rotational Moulding Service Capabilities for Rotational Moulding Industry. Conclusions

3 BITS Pilani-Four Accredited Campuses Pilani Campus (1964) Dubai Campus (2000) Goa Campus(2004) Hyderabad Campus(2008)

4 University Industry Linkage Practice School Programmes Committed to University Industry Collaboration Since its inception (1964) Theory learnt in classroom Practice in Industry As on today, Collaboration with 300+ industries

5 University Industry Linkage Work-Integrated Learning and Collaborative Programmes [20,000 students on roll 30,000 students graduated] 33 Organizations 24 Degree Programmes

6 Testing in Rotational Moulding 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

7 Testing of Raw Material (Pellets): Density Melt Flow Index (MFI) Shape, Size Colour of Pellets Tensile Strength / Modulus Flexural Modulus Heat Distortion Temperature (HDT) Environmental Stress Cracking Resistance (ESCR)

8 Powder Characterization Dry Flow Test Bulk Density Test Sieve Analysis - Particle Size Distribution Microscopic View for Characterization of Powder.

9 Testing of form features of the product: Dimensions of Product Profile Angularity Depth Wall Thickness Distribution Shrinkage and Warpage

10 Mechanical Properties of the product: Density of part Tensile Strength and Modulus Flexural Strength and Modulus Low Temperature Impact Strength HDT ESCR Gel Cure Test (XLPE), etc.

11 Long Term and Advanced Testing 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

12 Density 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.

13 Effect of Density on Different Properties # Property Tensile Strength HDT Stiffness Shrinkage Hardness Barrier Properties Chemical Resistance Impact Strength ESCR Optical Properties Ductility Density #: Ref: R.J. Crawford, Rotational Moulding, Rapra Review Report, 71

14 Testing of Density Ref: ASTM D-792 or ISO 1183 method D.

15 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 with conditions redefined for use in rotational moulding

16 Melt Flow Index (MFI) Schematic Ref: ASTM D Dynisco MFI in Our Lab

17 Effect of MFI on Different Properties # Flow Properties e.g. Viscosity Property Impact Strength Tensile Strength ESCR Weatheribility Chemical Resistance Ductility MFI #: Ref: R.J. Crawford, Rotational Moulding, Rapra Review Report, 71

18 ESCR Ref: ASTM D-1693

19 Testing of Tensile Properties UTM in Lab (Load Cell 0-10 KN) Ref: ASTM D 638 Typical Stress-Strain Plot

20 Testing of Flexural Properties Schematic of Flexural Testing Ref: ASTM D 790 Lab Testing Set Up

21 Typical Flexural Curves Ref: ASTM D 790

22 Schematic of Low Temp. Impact Test Ref: ARM Low Temperature Impact Test

23 HDT: Schematic and Set Up Schematic of Flexural Testing Lab Set Up for HDT Ref: ASTM D 648

24 Geometry and Form Testing: Coordinate Measuring Machine (CMM) Testing of product for Dimensions, Profile, Depth, Angularity, etc.

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

26 Conclusion: Our Service Capabilities Test Standard Density ASTM D 1505/D-4883/D-792 or ISO 1183 method D. Dry Flow and Bulk Density MFI ASTM D ASTM with conditions redefined for use in rotational moulding 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

27 Thanks The best Research will give the best Teaching and the best Teaching will give the best Research Dr. APJ Abdul Kalam.