കേരള PSC ലെക്ചറർ ഇൻ പോളിമർ ടെക്നോളജി സിലബസ് 2023, ഡൗൺലോഡ് PDF

കേരള PSC ലെക്ചറർ ഇൻ പോളിമർ ടെക്നോളജി സിലബസ്

കേരള PSC ലെക്ചറർ ഇൻ പോളിമർ ടെക്നോളജി സിലബസ്: കേരള പബ്ലിക് സർവീസ് കമ്മീഷൻ ഔദ്യോഗിക വെബ്‌സൈറ്റിൽ കേരള PSC ലെക്ചറർ ഇൻ പോളിമർ ടെക്നോളജി സിലബസ് പ്രസിദ്ധീകരിച്ചു. പരീക്ഷയ്ക്കുള്ള തയ്യാറെടുപ്പുകൾ ആരംഭിക്കാൻ  സമയമായി. പരീക്ഷയിൽ വിജയിക്കുന്നതിന്, സിലബസിനെക്കുറിച്ച് വ്യക്തമായ ധാരണ ഉണ്ടായിരിക്കണം, അതിനാൽ കേരള PSC ലെക്ചറർ ഇൻ പോളിമർ ടെക്നോളജി സിലബസ് വിശദമായി വായിച്ച് മനസിലാക്കുക. ചുവടെ നൽകിയിരിക്കുന്നു ലിങ്ക് ഉപയോഗിച്ച് നിങ്ങൾക്ക് ലെക്ചറർ ഇൻ പോളിമർ ടെക്നോളജി സിലബസ് PDF രൂപത്തിൽ ഡൗൺലോഡ് ചെയ്യാവുന്നതാണ്.

കേരള PSC ലെക്ചറർ ഇൻ പോളിമർ ടെക്നോളജി സിലബസ് 2023 അവലോകനം

ചുവടെ നൽകിയിരിക്കുന്ന പട്ടികയിൽ കേരള PSC ലെക്ചറർ ഇൻ പോളിമർ ടെക്നോളജി സിലബസ് സംബന്ധമായ എല്ലാ പ്രധാനപ്പെട്ട വിവരങ്ങളും ലഭിക്കും.

ലെക്ചറർ ഇൻ പോളിമർ ടെക്നോളജി പരീക്ഷ പാറ്റേൺ

കേരള PSC ലെക്ചറർ ഇൻ പോളിമർ ടെക്നോളജി പരീക്ഷ പാറ്റേൺ ചുവടെ ചേർക്കുന്നു.

• ഒബ്ജക്ടീവ് അടിസ്ഥാനത്തിലുള്ള പരീക്ഷയാണിത്.
• ആകെ 1.30 മണിക്കൂറാണ് പരീക്ഷാ ദൈർഘ്യം.
• ആകെ മാർക്ക് 100.
• ഓരോ ശരിയായ ഉത്തരത്തിനും 1 മാർക്ക് നൽകും.
• ഓരോ തെറ്റായ ഉത്തരത്തിനും 1/3 മാർക്ക് കുറയ്ക്കുന്നു.

ലെക്ചറർ ഇൻ പോളിമർ ടെക്നോളജി കേരള PSC സിലബസ് PDF ഡൗൺലോഡ്

കേരള PSC ലെക്ചറർ ഇൻ പോളിമർ ടെക്നോളജി സിലബസ് PDF ഡൗൺലോഡ് ചെയ്യാൻ, താഴെ നൽകിയിരിക്കുന്ന ലിങ്കിൽ ക്ലിക്ക് ചെയ്യുക.

കേരള PSC ലെക്ചറർ ഇൻ പോളിമർ ടെക്നോളജി സിലബസ് PDF ഡൗൺലോഡ്

ലെക്ചറർ ഇൻ പോളിമർ ടെക്നോളജി സിലബസ് 2023

ലെക്ചറർ ഇൻ പോളിമർ ടെക്നോളജി തസ്തികയുടെ വിശദമായ സിലബസ് ചുവടെ ചേർക്കുന്നു.

Module I (a): Technical Mathematics – 10 Marks

I. Matrices – Identification of Matrices, matrix operations, adjoint and inverse.

II. Determinants – Evaluation of second and third order, minors and cofactors, solutions of simultaneous linear equation in three unknowns using Cramer’s rule.

III. Binomial Series – Expansions using Binomial theorem.

IV. Trigonometric functions – Signs of functions in each quadrant. Trigonometric values of angles, properties of trigonometric functions, applications of the identities sin (A ± B), cos (A ± B), and tan (A ± B).

V. Coordinate geometry – Equations to a straight line – slope-intercept form, intercept form, Angle between two lines, condition for two lines to be perpendicular, parallel.

VI. Differentiation – Limits and continuity, derivatives of functions, equation to tangents, and normals. Maxima and minima of functions of one variable.

VII. Integration of functions – Integration of different types of functions.

VIII. Applications of integration – Area bounded by a curve and X or Y axis, solutions of differential equations using the method of variable separable, solutions of linear differential equations of the first order.

Module II: Polymer Science & Speciality Polymers – 18 Marks

• History and Classification of Polymers: History of polymers – special characteristics and general applications of polymers – elastomers, plastics, fibers, surface coatings, and adhesives. Science of micro and macromolecules, the definition of monometers, oligomers, polymer, macromolecules, and micro molecules with examples of each.
• Degree of polymerization (D P), the relationship between DP and MW, worked out examples, Classification of polymers – Natural, synthetic and derived, thermoplastics, thermos sets, crystalline and amorphous, organic and inorganic, homo chain and hetero chain. Homo and copolymers; linear branched and cross-linked; block and graft copolymers, alternating and random copolymers. Stereo regularity of polymers – optical and geometrical isomerism with reference to isoprene, butadiene, and chloroprene, isotactic, syndiotactic, and atactic configuration with reference to polypropylene, the effect of stereo regularities on properties.
• Functionality and Polymer Formation: Definition of functionality – mono, di, and polyfunctional monomers with examples, Effect of unsaturation in the functionality of monomers like ethylene, styrene, acrylonitrile, and acetylene. The functionality of phenol, dicarboxylic acid, diamine, and diol. Average functionality principle of polymerization.
• Polymerization Reaction and Techniques: Types of polymerization reaction – chain and step polymers with examples – steps in chain polymerization – initiation, propagation, and termination. Mechanism of free radical, ionic, and coordination polymerization. Living polymer, initiators catalyst, inhibitors, and chain transfer agents with examples. Step growth polymerization, ring scission polymerization, and interfacial polymerization with examples. Polymerization techniques – bulk solution, suspension, and emulsion polymerization. Role of ZN catalyst.
• The reaction of polymers: Difference between the reaction of polymers and simple molecules. The behavior of functional groups in polymers, reactions like hydrolysis, acidolysis, aminolysis, addition substitution, and the reaction of groups like hydroxyl, aldehyde, ketone, carboxylic, and cyclization reaction.
• Molecular Weight and its Determination: Mw, Mn – their derivation. Z-average molecular weight, simple problems on DP and molecular weight. Polydispersity and MWD of polymers and its significance. Experimental determination of MW and MWD – end group analysis vapor phase osmometry light scattering, viscometery and GPC – their principles.
• State of Phase and Aggregates of Polymers: Glass transition temperature, melt temperature, and flow temperature – methods of determination. Crystallinity, crystllisabilty, and determination by X-ray diffraction method. Amorphous and crystalline nature of plastic, elastomers, and fibers.
• Identification of Polymers: Purpose of identification – Physical and chemical methods. Thermal analysis – TGA, DSC, and DTA. Spectroscopy, NMR, and IR.
• Polymer Degradation: Types of degradation – chain and random – examples. Thermal, mechanical, high energy radiation, oxidative degradation. Ozone degradation. Advantages and disadvantages of degradation. Factors affecting thermal stability – polymer stabilization. Various additives – antioxidant, antiozonent and light stabilizers. Mechanism of stabilization. Methods to study polymer degradation – TGA, DSC, DTA, and IR.
• Polymer Modifications: Physical and chemical methods of polymer modifications. Physical methods – blends, alloys, and composites. Chemical methods – co-polymerization, grafting, crosslinking, and interpenetrating networks.
• Specialty Polymers: High-temperature and fire-resistant polymers – polymers for high-temperature resistance – Fluoropolymers. Aromatic polymers, Polyphenylene sulfide, polysulphones, polyesters, polyamides, polyketones, and Heterocyclic polymers. Polymers with electrical and electronic properties. Conducting polymers. Conducting mechanisms, polyacetylene, poly para phenylene, polypyrrole, organometallic polymers, photo conducting polymers, polymers in non-linear optics, polymers with piezoelectric and pyroelectric properties, photoresists for semiconductor fabrication – liquid crystalline polymers. Ionic polymers, synthesis, physical properties and applications, Ion-exchange, Hydrophilicity, ionomer based on polyethylene, elastomeric ionomers. Ionomers based on polystyrene, ionomers based on PTFE, ionomers with polyaromatic backbones, polyelectrolytes for ion exchange, and polyelectrolytes based on carboxylates. Polymer concrete, polymer-impregnated concrete ultra-high modulus fibers, polymers for biomedical applications, polymeric binders for rocket propellants, and polymer-supported reagents. Optical fiber telecommunication cables.

Module III: Rubber Technology (Natural and Synthetic Rubber) (18 Marks)

• History & Development of Natural Rubber: As an important industrial raw material – major sources – propagation of Hevea brasiliensis, different clones, extraction of Latex – methods of extraction of latex – tapping, standard of tappability for seedling and budded trees. Tapping knives, tapping task, tapping rest. Different systems and their intensity, intensive tapping, ladder tapping, slaughter & puncture tapping. Factors affecting tapping efficiency. Rain guarding, yield stimulation.
• Preservation and Concentration of NR latex: Definition of Latex – composition, and function of non-rubber constituents, colloidal nature of latex, micro-organisms in latex and their role in destabilization, need for preservation of latex, short and long term preservation – NH3 as ideal preservative, secondary preservatives – LATZ type, pre-coagulation and use of anticoagulants – examples. Coagulation and Methods of Coagulation of Latex
• The concentration of Latex: Need for the concentration of Latex – Latex concentration methods – creaming, centrifuging, evaporation, and electro-decantation.
  Marketable Forms of Dry Rubber: R.S.S., crepe block rubber – processing of field latex into R.S.S., ADS, different grades, current market status, and future prospects. Production requirements – Green book.
• Crepe Rubbers: Different grades and their processing. Application of each grade, current market status, and future prospects. Production requirements.
  ISNR: Different grades, manufacturing details, production requirements, quality enhancement, current status, and future prospects.
• Specialty Rubbers: Importance of specialty rubbers in the rubber industry – features, production methods, chemical aspects, applications, and current status of the following specialty rubbers – SP rubber, CV, and LV rubber. OENR, tyre rubber, powdered natural rubber, Hevea plus MG, DPNR, Latex black master batch, epoxidized NR, cyclized NR, chlorinated NR.
• Reclaim Rubber: Reclaim rubber – definition, objectives of reclaiming – raw materials for reclaim production – reclaiming agents and their specific functions – Manufacturing of reclaim by various methods – comparison of different processes – types of reclaim rubber and their specifications, processing advantages of reclaiming rubber – applications.
• Brief History of SR ­ Classification: Rubber elasticity & characteristics of elastomers Monomers – Preparation and properties of the monomers – styrene, butadiene, isoprene, Isobutylene, ethylene, propylene – the structure of Diene monomers – ethylidene 2 Norbornene, (ENB) Dicyclopentadiene (DCPD), 1, 4, Hexadiene used in Ethylene propylene Rubbers – Detailed study of SBR, PBD, IR, EPDM, & IIR.
• Special Purpose ­ SR: Detailed study of – NBR, CR, CSM, PU, Polysulphide & Silicone Rubbers. Study of – fluro carbon rubbers, Acrylic Rubbers & Epichorohydrin rubbers, and polypropylene rubbers. Ethylene – Acrylic rubbers, chlorinated polyethylene rubbers, carboxylated SBR, NBR, Butadiene hydroxyl terminated SBR, NBR, and Butadiene – Halobutyl rubbers
• Thermo Plastic Elastomers: Thermoplastic elastomers, definition, advantages, modification of elastomers to thermoplastic elastomers. Study of thermoplastic SBR, Ethylene, Vinyl acetate, and Thermo polyurethane.
• Blends: Definitions – Advantages, procedure, blending for specific properties, study of NR, PBD, NR-SBR-PBD, NR-EVA, NBR-PVC, NR-HSR.
• Principles of Compounding: Rubber compounding – definition and objectives formulation of the recipe and its significance – the role of the recipe in rubber product manufacturing – Method of representing the relative proportions of ingredients in a recipe (PHR) – the importance of compounding.
• Compounding Ingredients and their Classification: Different class of compounding ingredients, base polymer, curing system, vulcanizing agents, accelerators, activators, and their function in a compound – the role of other ingredients like filler, plasticizers, softener, and other special additives in a recipe, selection procedure of ingredients – Compatibility and solubility parameter concept.
• Theory of Vulcanization: Vulcanization – Changes in elastomers due to vulcanization, Sulphur vulcanization – theory of sulphur vulcanization – Different types of cross-links formed and their effect on vulcanisate properties.
• Classification of Vulcanization System: Low sulphur vulcanization system – C.V, E. V, and S.E.V system – comparison – Non-sulphur vulcanization system – sulphur chloride – organic peroxide – metal oxides – resin – dioxime – isocyanates, etc with example. Curing system for olefin and non-olefin rubbers. Preparation, Properties & Application of Compounding Ingredients: Fillers – definition and objectives – classification of fillers – Non-black fillers preparation, properties, and application of non-black fillers such as silica, silicates, clays, whiting, lithopone, barites, talc, zinc oxide, MgO, TiO2.
• Fibrous fillers: Asbestos, cellulose fiber, flocks, wood flour, organic fillers – cork, glue, cyclized NR, hevea-plus, HSR, phenolic resin. Carbon Black: Different grades and methods of manufacture – furnace process – thermal process channel process – lamp black process – Different grades – SAF, ISAF, HAF, FEF,
  GPF, SRF, MT, conducting black – etc. ASTM D 1765, colour coding and international reference black – properties of carbon black – particle size, structure – physical nature of particle size, chemical nature of particle size, particle porosity – determination of particle size and structure – application of carbon black.
• Antioxidants and Antiozonents: Functions, types staining and non-staining. Mechanism of degradation – factors affecting degradation. Retarders – functions.
• Plasticizers: Softeners and extenders – Plasticizer function – classification of plasticizers.
• Special Purpose Ingredients: Blowing agents, flame retardants, abrasives, antistatic agents, integral bonding additives, stiffening agents coupling agents, deodorants, etc. Cure characteristics & Measurements: Define cure time – cure index, vulcanization time, scorch and scorch time, heat history of compounds, optimum cure, state of cure, methods to avoid scorch reversion cure, marching cure, and plateau. Define over cure and under cure, illustrate with cure graph – discuss the various cure graphs by changing the compounding ingredients such as accelerator, and vulcanizing agents – determination of viscosity using Mooney
  viscometer.
• Rheometers: MDR, ODR – determination of cure characteristics using Rheometers. Assessment of State of Cure: Define rate of cure – cross-link density – practical assessment of the state of cure. Calculation of cure in thick articles.
• Vulcanization methods: Brief introduction of processing methods for product manufacture – flow chart.
• Compounding for Vulcanizate Properties: General principles of compounding vulcanization properties. Comparison of raw elastomeric properties factors to be considered for designing a rubber compound with examples – Effect of particle size and structure of fillers on processing and vulcanizate properties – compounding to meet processing requirement viscosity control, control of nerve, adhesion to mill rolls, tack, scorch, calendering and extrusion – continuous vulcanization.
• Calculation of Specific Gravity and Volume Costs: With worked-out examples. Compounding for Vulcanizate Properties: Such as hardness and modulus with worked-out examples. Tensile properties, T.S. elasticity, etc. – Resistance to abrasion and tear – resistance to cyclic stressing – flex cracking – cut growth and fatigue – low temp flexibility – electrical properties – resistance to gas permeation – bonding to a non-rubber substrate like metals. Stabilizing agents – stabilization against – heat, flame, liquids, light, oxygen ozone, and atmospheric exposure.

Module IV: Rubber Products – 18 Marks

• Moulded Products: Compound design – Automobile bushes – Door mats – Tea-mats, Paperweights, IB caps, Door bushes, Nipples, Hot water bags, Chemistry of hard rubber products (Ebonite). Method of production and compound design for battery boxes – Finishing of rubber mouldings.
  Expanded Products: Types of blowing agent and their comparison – compounding and moulding of cellular rubber products, MC, Hawaii sponge.
  Extruded Products: Automobile treads, channels, inner tubes, LPG tubes, etc – compound design, typical formulations, Methods of manufacture.
  Calendered Products: Supported and unsupported sheeting, Hospital sheeting, Profile calendered products – design criteria, compound design, typical formulations.
• Footwear: Components of footwear, materials, methods of manufacture, special purpose footwear, and their applications.
• Miscellaneous Products: Oil seal, Gaskets – Compound design, Manufacture, and Typical formulations.
• Sports Goods: Play balls, Tennis balls, Golf balls – components, compound design, method of manufacture, typical formulations.
• Rubber to Metal Bonded Products: Principle of bonding rubber to metal and textile fibers, production of rubber covered rolls – metal preparation – compound preparation, assembling curing, finishing – tank lining – production method, compounding, compound design. Production of typewriter rolls, rice polisher, and textile roller.
• Rubber Coated Textile: Rexene, Tarpaulin, and other rubber coated textile, rubber lining, spreading, design principles of spreading, compounding and typical formulations. Adhesive treatment for Nylon 6, Nylon 66, Polyester-adhesive composition and their preparations.
• Beltings: Conveyor belts, Transmission and V-belts, components manufacturing techniques, Batch and continuous curing, compounding, typical formulations, and specification tests for VBelts.
• Hoses: Classification according to manufacture and end use. Components. Moulded hose, Mandrel cured hose, braided hose, Knit hose, Woven hose, Spiral reinforced hose, Circular woven hose, Handmade hose, Radiator hose, Garden hose, Petrol hose, Sandblasting hose, Typical formulations, method of manufacture.
• Cables: Classification, power cables and their components, manufacturing methods, curing, compound design, typical formulations, and specification tests.
  Latex Products
• Dipped Goods: Introduction to various dipped goods – dipping processes. Methods of dipping – straight dipping, coagulant dipping, dipping with porous mould dipping with heated formers – merits and demerits of each – relation between the thickness of deposits and a number of dips in each case – after treatments of latex deposits – drying, surface treatment, bleaching, chlorination, vulcanization, and stripping- compounding of latex for the manufacture of various types of dipped goods and some typical dipping compounds. Manufacture of important dipped goods like gloves, balloons, nipples, rubber bands, and condoms, etc. some common defects and their remedies – examination gloves – methods of manufacture, machinery, powder-free
  dusting, recent developments.
• Production by Casting: General principle, the process of casting – production of hollow and solid articles by casting – preparation of moulds for latex casting, products by casting technic.
• Latex Foams: Foam manufacturing industry in India – introduction to various latex foam products, manufacture of latex foam – Dunlop and Talalay process, different steps – deammoniation, compounding, mechanical froathing, gelling, vulcanization, etc. Gelling – various gelling systems – a comparative study. Some typical latex compounds for foam production. Common defects and causes. Fibre Foam (Latex Treated Coir) and Carpet Backing: Characterization of fibre foam – constituents, production of coir foam – various steps – advantages of carpet backing. Methods of applying latex to carpet backs, carpet backing formulation.
• Latex Extrusion: General principles of latex extrusion – important latex products made by extrusion. Manufacture of latex thread – details of processes and equipment, quality control tests for latex thread comparison of latex thread with dry rubber thread. Applications of latex thread, latex rubber tubing details of processes and equipment, application of rubber tubing. Common defects and causes.
• Latex Adhesives: Introduction – comparison with solvent-based adhesives compounding of latex for the preparation of adhesives, types of adhesives – paper and leather adhesives – method of preparation and their characteristics – Adhesives for metals, ceramics, and glass. Rubber to textile bonding adhesives – nature of adhesives and typical formulation of RFL adhesives – adhesives for treatment of tyre cord – composition and properties.
• Latex Impregnation & Spreading: General principles, differences, fabric proofing coating, advantages of spreading, machinery for spreading, compound for sheet, catheters.

TYRE AND TUBES

• Introduction: History on the design and development of tyres – a survey of tyre manufacturing industries – consumption pattern – statistics – in India and abroad.
• Automobile tyres: Introduction – pneumatic tyre and its functions – Basic tyre construction – tyre sizing – aspect ration and its significance – General system for indicating tyre dimensions – different tyre components of a tyre, its geometry – functions.
• Raw Materials Used for Tyre Manufacturing: Tyre cords – reinforcing materials – their advantages and disadvantages – compounding ingredients.
• Production of Tyre Components: Compounds formulation and production of different components of tyre – tread, sidewall, bead unit, chafer, flipper, clinch strip, inner liner – production carcass plies – pre-treatment of tyre cords fabric processing, calendaring, bias cutting into plies.
• Tyre Building: Both bias and radial tyres building – building of green tyres for bias, bias-belted, and radial tyres – green tyre treatment – tyre curing methods – curing bags, bladder, diaphragms – auto form press, BOM press, PCI – advantages of PCI – typical formulation for curing bags – the brief idea of a tubeless tyre.
• Automobile inner tubes: Function – different steps involved in the production of inner tubes – compounding formulation – tube curing – inspection and packaging.

PRODUCTION OF TWO-WHEELER AND AUTO TYRES

• Solid Tyre: Comparison with pneumatic tyre – advantages and disadvantages. Re­treading Materials: Introduction – necessity and importance of re-treading – Preoperations – conventional and pre-cured tread. Different sizes of tread – dimensions – retreading process – hot and cold – machinery used for re-treading typical compounds for tread in hot and cold process.
• Cycle tyre and tubes: Cycle tyre components and their production – cycle tyre building – collapsible drum method and monoband method – curing of cycle tyre – BOM presses – cycle tube – methods of production – mould curing and mandrel curing. A typical formulation for cycle tyre and tube components.

Module V: Fibres, Plastics & Composites – 18 Marks

• Natural Fibres: Introduction – definition of fibres – the importance of fibres in modern life – Structural variations – fiber, fiber forming plastics, elastomers, natural fibres – source, production details, process properties and application of natural fibers like cotton, linen, jute coir, and sisal. Commercial importance of other natural fibers such as sisal, flax Animal fiber – brief description on silk, wool, and other animal hairs. Mineral fibers – Asbestos
• Man­made Fibers: Production properties and application of commercially available forms of glass fibres, production process and application of derived fibres – viscose rayon, Carbon fiber – Production, composition, structure, and properties of carbon fibre. Production process – wet spinning, dry spinning, melt spinning, properties, and application of Nylon 6, Nylon 66, Polyester, Acrylic Aramid, and Polyolefin fibers. Basic terms used in fiber science such as Denier, Tex, Tenacity, Filament, Yarn, Strand, Cord, Warp, Weft, and Twist.
• Composites and their Constituents: Polymer composites, history of composite, manufacture of resins like polyester, epoxy, polyurethanes, MF, PF, UF, etc. Catalyst – initiators – accelerators – Fillers, metal oxides, metallic powders, mineral fillers and mold release agent, thermoplastic resins – PP, PE, ABS, Rule of mixtures.
• Composite Moulds and Process: Open moulding process – contact moulding, Spray lay up, Wet lay up, Prepregs, Vacuum bag moulding, Pressure bag moulding, etc – Filament winding, Pultrusion, Centrifugal casting. Process machinery and suitability of hot press moulding – SMC and DMC, Cold press
  moulding, Resin injection / Resin transfer moulding, Pre-form moulding and vacuum injection moulding, designing of FRP moulds and products – selection of materials, process and design aspects like section thickness, flanges, corners, and inserts. Materials for FRP moulds viz plaster of Paris, Wood, steel, FRP – cost calculation of composite products. Selection of resin and reinforcement for individual products like pedal Boats, Tennis rackets, Helmets, Automobile bodies, Roofing sheets, Bath tubs, Water tanks – automobile part like Bumper, Dashboards, Steering Wheels. Polymer hybrid composite materials (PHBCM) – processes application and design of nanocomposites – casting and coating. Short fibre composites.
• Plastic Technology: History of plastics – the importance of plastics in modern life – advantages over other conventional materials, statistics, eco-friendly plastics – classification based on the thermal response, origin and structure, Tg, Tm, and Tf of plastics. Plastic Compounding, Plastic Compounding Equipment, and Additives used in
• Plastics: Fillers, Stabilisers, Coupling agents, Lubricants, Plasticizers, Antidegradents, Blowing agents, Cross-linking agents and typical formulations. Commodity Plastics: Industrial production – Different grades – application of PE – LDPE, HDPE, UHMWPE, PP-PS, PVC-PMMA, PMA
• Engineering Plastics: Polymerisation different grades – application of the following engineering plastics polyamides, polyacetals, Polycarbonates, polyester, thermoplastic, polyurethane, etc.
• Specialty Plastics: PTFE, PC TFE, PPO, PPS
• Miscellaneous Plastics: Shellac, casein, bitumine plastics, CI resin & cellulose plastics.
• Thermosetting Plastics: Raw materials – industrial production, resin manufacturing, moulding powder, properties and applications of MF, UF, PF EPOXY, ALKYL, SILICON, Thermosetting PU & UP RESIN.
• Important Plastic Products: General idea about plastic product design – processing limitation – steps involved in plastic product design – functional, aesthetic design of products – comparison of the plastic product with other conventional products – environmental impact of
  plastic products.
• Moulded Products: General features of IM products – products based on HDPE, PP, and other Polyolefines – Bucket, mug, bottle caps, chair, etc – products based on PVC, PS, Nylon, and polyester – Material selection procedure for product manufacturing by IM – moulded part
  design.
• Blow Moulded and Thermoformed Products: Blow moulded products based on HDPE, PP, and other plastics – processing details, production of PVC bottle, specification test on bottles, Blow moulding of pet bottles, thermoformed products based on polyolefins and other plastics – manufacturing of disposable glasses, egg cartons etc – rotational moulding – production of water tank from PP.
• Extruded and Calendered Products: PVC pipe, production line of PVC pipe, classification of PVC pipes, specification test on PVC pipes, design features of PVC pipes, rigid and flexible PVC pipes – typical formulation, extruded products based on polyethylene and PP – extruded products based on engineering plastics, melt fracture – Calendared products based on PVC and their applications, configurations and cooling methods.
• Miscellaneous Plastic Products and Finishing: Production of plastic gears – advantages and disadvantages of moulded and cut gears – casting of PMMA, powder coated products, cellular plastics, PU foam – rigid PU foam – compression moulded and transfer moulded products with examples – finishing and machining of plastic products – jointing and assembling of plastic products – decorating of plastic products.

Module VI: Polymer Processing and Testing – 18 Marks

• Compounding Equipment: Principles of mixing – types of mixing, dispersive & distributive mixing – batch and continuous mixing – mastication and mechanism of mixing – two roll mixing – Banbury mixing – master batching – mixing variables – material feeding and discharge, rotor speed, fill factor, ram pressure, batch temperature, mixing sequences – upside down mixing batch and continuous mixers – open two roll mill – types – machine details, roll
  size, capacity, drive system, friction ratio, temperature control, and safety devices, material for construction accessories, advantages and limitations – internal mixers, types – Banbury and intermix – important parts, working principle, capacity, drive system, temperature control, pressure control – fill factor and its significance, comparison with open two roll mill.
• Design Elements: Rotor and chamber design, ram, and door configurations, rotor and temperature control.
• Mixing Variables: Feed rate, discharge, rotor speed, fill factor ram pressure, batch temperature, and mixing sequences.
• Continuous Mixers: Types of blenders single screw continuous mixers – double R mixer, MVX mixer – Farrell continuous mixer and transfer mixer co-rotating disc type mixers.
• Kneaders and Blenders: Development in mixing technology. Moulding – compression – transfer – and injection moulding. Blank preparation – blank heating – water bath and ovens – high frequency and microwave heating – heat transfer – methods of heat transfer – Heating medium for presses comparison of
  electrical heating and steam heating. Vulcanization methods are other than moulding – Radiation vulcanization method – Batch vulcanization methods – autoclave – hot air oven – gas curing – peachy process – advantages and disadvantages. Continuous vulcanization method – High pressure steam – hot air tunnel molten salt bath – fluidized bed – continuous drum cure microwave curing. Examples of products vulcanized by each method.
  Moulding Techniques: Compression mould – the importance of flash positive, semi-positive type types compression mould – injection moulding – different types – RIM, RRIM, examples of compression moulded and injection moulded products – comparison of injection moulding with compression moulding, advantages, injection moulding cycle. Transfer moulding process – comparison of compression and transfer moulding – advantages – examples of products –
  troubleshooting.
• Casting: Principle of casting – material for casting – mould pattern – ejection techniques.
• Rotational moulding: Principle and process.
• Thermo Forming: Different methods – pressure forming, vacuum.
• Extrusion Technology: Pipe extrusion, sheet forming process, split film extrusion, blow film extrusion, extrusion blow moulding, different methods, parision programming, wire coating.
• Calendaring Technology: Production of supported and unsupported sheeting, textile coating – skim coating or topping, fractioning, spreading – advantages and disadvantages – comparison of calendaring and spreading, profile calendaring, advantages – major applications.
• Extruders: Types – screw and ram extruder, hot feed and cold feed extruder – cross head (Thead extruder), dual extruders, vented extruders, and twin-screw extruders – extrusion technology – important parts of extruders – screw, barrel. Feed hopper, die, head, screen pack, adapter, breaker plate, temperature control, compression ratio, size and capacity, L/D ratio of different extruders, drive system, comparison of rubber and plastic extruders – types of extruders and their functions – strainer, vented typed – design factors – screw and barrel design for controlling compression ratio, temperature control and methods of increasing the extrusion.
• Calendars: Calendars – various configurations 3 rolls, 4 rolls, vertical, inverted L, Z, etc – Calendaring Technology – Parts and their specifications – Temperature control for rolls – Roll, deflection, and method of correction – Roll cambering, roll bending, roll crossing.
• Introduction and Material Testing: Importance of quality assurance and Testing – quality – definition. Modern quality concepts, the importance of quality control in the polymer industry.
• Standards and specifications. Different standard organization. Procedure for accreditation of ISI certification. Role of standard organization in quality assurance and customer satisfaction. Importance of calibration of equipment in quality control & testing. Raw material testing – Testing of Additives – % purity of DPG, MBT, ZnO, moisture content of clay, silica, particle size determination of C-black by iodine / N2 adsorption number or microscopic method – Thermal properties, thermal conductivity, flammability, Vicat softening temperature, M. P., brittleness, sp. Heat, HDT – Electrical properties – Dielectric strength, dielectric constant, arc resistance – optical properties – Refractive index, stress optical sensitivity.
• Specification test for ISNR and Latex Concentrate: Significance, principle, and method of tests for ISNR – dirt content, volatile matter, ash content, N2 content, Po and PRI, ASHT and Colour – Technical specifications of ISNR as per BIS – Specification test for concentrated latex – Significance, principle, and methods of the following test – KOH No, VFA number mechanical stability time, Mg content, sludge and coagulum content, sp gravity, viscosity, TSC, DRC, Alkalinity, etc. Technical specifications for conc. Latex as per BIS.
• Physical Properties: Method of testing, specimen standards – the principle of conditioning – equipment used – the significance of following tests relevant to plastics and rubbers – TS, tear strength, tension set and compression set, hardness, abrasion resistance, resilience, flex cracking, impact strength, creep and cold flow, fatigue failure. Importance of processability tests – principle, method of testing, equipment used for a cure – characteristic study – illustration with graphs and advantages of cure meters – different types of cure meters – Mooney viscometer, Rheometer, recent developments in Rheometer – Determination of melt flow index, bulk factor and shrinkage of plastic materials. Polymer Product Testing: Tyre testing – Non-destructive and destructive testing of tyre – high way testing Endurance tests, plunger test – tube testing – Testing of cycle tyre and tube – cord strength, casing strength (carcass strength), joint adhesion strength, etc. Testing of dry rubber products – Importance of product testing – IS specifications and specific test procedures of cycle tyres and tubes, M. C. soles, Hawai V-straps, tread rubber, ebonite, LPG tubings, Conveyor beltings – Testing of latex products – ASTM/IS specifications and specific test procedures of latex foam, surgical gloves, electricians glove, examination glove, and condoms – Testing of Plastic product – PVC pipe – blood bag – water tank, disposable syringes – helmet – Impact test – Charpy and Izod.

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