6 Tao Quang Bang, Hoang Van Thanh STUDY OF DESIGNING AND MANUFACTURING SIMILI FILM COATING MACHINE Tao Quang Bang, Hoang Van Thanh The University of Danang, University of Science and Technology; hvtha[.]
6 Tao Quang Bang, Hoang Van Thanh STUDY OF DESIGNING AND MANUFACTURING SIMILI FILM-COATING MACHINE Tao Quang Bang, Hoang Van Thanh The University of Danang, University of Science and Technology; hvthanh@dut.udn.vn; hoangvanthanh_03c1b@yahoo.com Abstract - The purpose of this paper is to present research results of designing and manufacturing of simili film coating machine on plastic profile to produce wood simili products Based on advantages and disadvantages of the products which have been used widely in the market recently, the researchers decided to choose a method of using simili film coating on plastic materials to make new products that can replace others made from wood The study designed 3D drawing of Coating machine system thanks to Solidworks software, including four main units such as stock feeding unit, coating unit, cutting and heating unit, glue providing and glue drying unit The system was fabricated successfully on CNC machine Experimental coating process was carried out at QuangThanh Plastic Company, HoaKhanh industrial Zone, Danang City and the experimental result shows that recommended coating temperature is about 1220C These wood simili products initially showed their effectiveness of coated-surface quality and easier pressing roller adjustment Vietnam as shown in Figure The uPVC material contains no contaminants, no heavy metals like lead, cadimi, andharmless substances such as canxi, zinc [1]-[2] uPVC profile is hard plastic slat manufactured on twinscrew extruder including PVC plastic (K65 – K66), thermostabilizer, lubrication, bulking agent, annealing color, UV ray resistance Key words - Simili film; plastics profile; CAD/CAM/CNC; coating; heat treatment Introduction Wood is raw material widely used in industry, agriculture, transport, architecture, construction and mine ores Nowadays, many consumers have chosen products made from wood for their families because these wood products have some advantages such as heat and electricity insulation, good moisture proof, small heat of expansion, hardness, high durability and high aesthetic value However, wood source in Vietnam as well as in the world is becoming more and more exhausted since so many natural forests have been destroyed by illegal wood exploitation Therefore, research and application of a new material to replace natural wood are extremely essential in conserving ecological environment One of the materials used to replace natural wood is uPVC plastic The uPVC material has many advantages such as no warping, no shrinkage, high flame resistance, no oxidization, no limit of age or no discoloration in any radiant conditions of sun and acid rains in comparison with wood material Besides, this material has much lower cost than the products made from wood material As a result, windows, doors, baffles, ceilings made from uPVC material have been widely used all over the world In the world, many companies manufactured equipment to produce wood replacement products, such as spray system, coating machine However, this production is very bulky and heavy Moreover, it is difficult to adjust coating temperature, pressing rollers position and it costs a lot of money This leads the researchers to redesign and manufacture simili film coating machine so that the coating quality may be enhanced and the cost will be reduced More importantly, it is easier to operate the coating machine system Experimental Set-up and Method 2.1 Materials The material used in this study is plastic uPVC slat obtained from QuangThanh Plastic Company, Da Nang, Figure uPVC plastic profile 2.2 Simili and glue Simili coated on plastic uPVC profile is provided by Phu Lam Plastic Industrial Stock Company, Vietnam as shown in Figure The simili has advantages as follows: moisture resistance is high, it is easy to clean surface, and there will be no discoloration Glue employed in the paper is Nanpao, Taiwan as shown in Figure 3, [3] Figure Simili film Figure Nanpao glue ISSN 1859-1531 - THE UNIVERSITY OF DANANG, JOURNAL OF SCIENCE AND TECHNOLOGY, NO 12(97).2015, VOL 2.3 Designing and Manufacturing Tool SolidWorks R2011 was used to design simili film coating machine All of components were fabricated by CNC machine as shown in Figure and Figure Technical requirements were inspected by metrologies system as shown in Figure Fabrication and inspection were carried out at Institute of Mechanical Technology and Automation, Danang University of Technology, The University of Danang [6]-[9] In order to define coating temperature, the study explored glass transition temperature and melting point of PVC plastic [1] Results and Discussion The authors researched and designed a simili film coating system by SolidWorks software as shown in Figure The system manufactured includes main four units: stock feeding unit, coating unit, cutting unit, and heating and glue providing unit as shown in Figure The simili film coating machine utilizes coating simili film on uPVC profile at QuangThanh plastic company, HoaKhanh industrial Zone, Da Nang city, Vietnam The results show that the quality of the coated surface is high and the models of each product are various, and importantly, these products meet the needs of the consumers as shown in Figure Figure CNC Milling Machine Figure 3D Simulation on SolidWorks Figure CNC turning Machine Figure Experiment of Coating machine Figure Coordinate Measuring Machine 2.4 Experimental Method Thanks to plastic uPVC profile, the study calculated and designed different impression rollers which pressed simili film on the plastic uPVC profile Pressing force of rollers is then defined and motor power was also determined Furthermore, the authors computed and designed clamping unit and cutting unit of plastic uPVC profile [4]-[5]-[8] Figure Simili coated uPVC plastic profile uPVC profile produced from twin screw extruder is cleaned, brushed oil-paint, added thermal prior to moving to coating system The simili film is simultaneously fed with uPVC profile through the glue providing system, thermal addition, and drying fan The simili film is then coated on uPVC profile owing to the shaped rollers system arranged logically If the consumers have any requirements about the Tao Quang Bang, Hoang Van Thanh length of products, this system is automatically controlled to define the length and carry out cutting process Experimental result shows that recommended coating temperature is about 1220C When pressing force is increased, it will enhance the quality of coated uPVC profile On the other hand, if uPVC profile is changed with different shapes, it is necessary to adjust pressing rollers position as well as select different rollers shaped with uPVC profile Conclusion This paper has introduced a new method to plastic companies in order that they can manufacture high-grade interior products of diverse designs from wood replacement plastic material with high quality The study has made a significant contribution to reducing the customers’ needs for natural wood which costs a lot to decorate their houses Simili film coating machine on plastic profile will be considered as the one that can produce wood replacement articles which are popularly used in Vietnam and all over the world Acknowledgment The authors would express their acknowledgement to QuangThanh Plastic Company and Chip Viet Technology Solutions Co., LTD of providing equipment and financial support for manufacturing the machine REFERENCES [1] Van der Vegt A K., "From polymers to plastics", DUP Blue print, 2002 [2] Hoang Van Thanh, "Injection Molding Technology of Optical Elements in LED Illumination", LAP Lambert Academic Publishing, 2013 [3] GhoshP., "Adhesives and coatings Technology", Tata McGraw-Hill, 2008 [4] KarwaR., "Machine Design", Laxmi Publication (P) LTD, 2006 [5] BhandariV B., "Design of Machine Elements", Tata McGraw-Hill, 2008 [6] NarayanaK L., RamanaS V., KrishnaP V., "Production Technology", Second Edition, I K International Publishing House Pvt Ltd., 2010 [7] Nguyễn Văn Khôi, "Keo dán hóa học cơng nghệ", Nhà xuất Viện Khoa học Công nghệ Việt Nam, Hà Nội, 2006 [8] Nguyễn Trọng Hiệp, Nguyễn Văn Lẫm, "Thiết kế chi tiết máy", Nhà xuất Giáo dục, 1998 [9] Trần Văn Địch, Nguyễn Trọng Bình, Nguyễn Thế Đạt, Nguyễn Viết Tiếp, Trần Xuân Việt, "Công nghệ chế tạo máy", Nhà xuất Khoa học Kỹ thuật, 2003 (The Board of Editors received the paper on 06/03/2015, its review was completed on 06/11/2015) ... UNIVERSITY OF DANANG, JOURNAL OF SCIENCE AND TECHNOLOGY, NO 12(97).2015, VOL 2.3 Designing and Manufacturing Tool SolidWorks R2011 was used to design simili film coating machine All of components... Figure CNC turning Machine Figure Experiment of Coating machine Figure Coordinate Measuring Machine 2.4 Experimental Method Thanks to plastic uPVC profile, the study calculated and designed different... unit, coating unit, cutting unit, and heating and glue providing unit as shown in Figure The simili film coating machine utilizes coating simili film on uPVC profile at QuangThanh plastic company,