Moulding. Second Edition. Crawford. Roy J. 4CC%SMITHERS. A Smithers Group Company

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1 Practical Guide to Rotational Moulding Second Edition Roy J. Crawford Mark P. Kearns 4CC%SMITHERS %))J R A P R A A Smithers Group Company Shawbury, Shrewsbury, Shropshire, SY4 4NR, United Kingdom Telephone: +44 (0) Fax: +44 (0)

2 (T,s Preface ix 1. Introduction to the Rotational Moulding Process Introduction The Rotational Moulding Process Overview of Rotational Moulding Special Nature of Rotational Moulding Advantages of Rotational Moulding Disadvantages of Rotational Moulding Common Applications for Rotomoulded Products Material Handling Products Industrial Products Environmental Products Leisure Products Marine Products Road Signage Moulds Introduction Mould Materials Sheet Steel Aluminium The Aluminium Casting Process Electroformed Nickel Comparison between Mould Materials 26 in

3 Practical Guide to Rotational Moulding 2.7 Mould Design Mould Frame Moulded-in Inserts Moulded-in Structural Components Temporary Inserts Threads Mould Clamps Mould Guides and Hinges Automatic Mould Movement Mould Venting Automatic Venting Mould Surface Finish Mould Outer Surface - Heat Transfer Enhancement Mould Shielding (Internal) Mould Shielding (External) Mould Release Mould Preparation for Release Agent Reactive Systems Spray-on Zinc Stearates Silicones Disiloxanes Conventional Systems Permanent Systems Hybrid Release Systems Moulding Aids Airflow Amplification Rotational Moulding Machinery Introduction Types of Rotational Moulding Machines Carousel Machines Shuttle Machines Clamshell Machines Rock and Roll Machines 79 IV

4 Contents Other Types of Machines Hot Oil Rotational Moulding machines Mould Swing Mould Speed Speed Ratio Oven Air Flow Amplification Cooling Material Feed Systems Developments in Machine Control Internal Air Temperature Measurement in Rotational Moulding Preparation of Rotolog for Moulding Trials Monitoring Pressure inside a Mould Materials for Rotational Moulding Introduction Ill 4.2 Typical Characteristics of Rotationally Moulded Plastics Materials Used in Rotational Moulding Polyethylene Low-density Polyethylene High-density Polyethylene Medium-density Polyethylene Linear Low-density Polyethylene Metallocene Polyethylene Ethylene-vinyl Acetate Ethylene-butyl Acrylate Polypropylene Polyamides (Nylons) Nylon Nylon 11 and Nylon Reaction Injection Moulding Nylon Amorphous Materials Polyvinyl Chloride Fluoropolymers 125 v

5 Grinding/Pulverising Practical Guide to Rotational Moulding 4.8 Other Plastics Additives Used in Rotational Moulding Materials Fillers Plasticisers Lubricants Stabilisers Anti-oxidants Ultraviolet Stabilisers Flame Retardants Crosslinking Agents Foaming or Blowing Agents Chemical Blowing Agent Technology Pigments Powders for Rotational Moulding Introduction Particle Size Distribution Dry Flow Bulk Density Factors Affecting Powder Quality Gap Size Number of Mill Teeth Grinding Temperature Other Techniques for Analysing Powders for Rotational Moulding Powder Shape and Size Melting Parameters Micropelletising Colouring of Plastics for Rotational Moulding Types of Pigments Pigment Selection Criteria Design for Functionality Introduction Preliminary Design Considerations Material 168 VI

6 Contents 5.4 Number of Parts Size of Moulds Part Complexity Wall Thickness Distribution Tolerances and Shrinkage Shrinkage Guidelines Control of Shrinkage Effect of Release Point on Shrinkage Other Factors Affecting Shrinkage Warpage Control of Warpage Residual Stress Short-term Effects of Residual Stresses Long-term Effects of Residual Stresses Cures for Residual Stress Problems Stiffening of Parts Double Walled Parts Corner Radii Draft Angles Surface Quality Surface Texture Graphics and Surface Decoration Painting Hot Stamping Adhesives In-mould Decoration Post Moulding Decoration Design of Foamed Sections Solid/Foam Cross-sections Solid/Foam/Solid Cross-sections The Future for Rotational Moulding Materials Moulds 207 VII

7 Practical Guide to Rotational Moulding 6.3 Moulding Equipment The Challenges The Role that the Moulder Must Play The Role that the Suppliers Must Play 213 Abbreviations and Acronyms 215 Index 217 viii

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